Operation And Maintenance Manual: 6060, 6060 Fs Hydraulic Shovel

EM024061-1 (en-us)

Operation and Maintenance Manual 6060, 6060 FS Hydraulic Shovel DH360148; DH360180; DH360183 - up DHN60177 - up

Language: Original Instructions

EM024061-1 (en-us)

EM024061-1

OMM 6060, 6060FS(3 847 031.02)-EN 07 / 2017

Operation and Maintenance Manual 6060, 6060 FS Hydraulic Shovel DH360148; DH360180; DH360183 - up DHN60177 - up

Language: Original Instructions

No.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known in the State of California to cause cancer, birth defects, and other reproductive harm. This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Published by:

Caterpillar Global Mining HMS GmbH Dept. Technical Publications D-44149 Dortmund, Karl-Funke-Straße 36 Tel. 49 (0) 231 922-4997 Fax 49 (0) 231 922-5005 https://mining.cat.com

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2017. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design. Printed in Germany

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The Operation and Maintenance Manual is in 6 sections; the sections are designed for different target groups: Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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TABLE OF CONTENTS TABLE OF CONTENTS 1 INTRODUCTION __________________________________________________________________ 1-1 ALL PRODUCTS FOREWORD _______________________________________________________ Literature Information ______________________________________________________________ Safety _________________________________________________________________________ Operation_______________________________________________________________________ Product Information _______________________________________________________________ Maintenance ____________________________________________________________________ Maintenance Intervals _____________________________________________________________ Product Capacity _________________________________________________________________

1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3

PREFACE _______________________________________________________________________ 1-4 About this Operation and Maintenance Manual _________________________________________ 1-4 Further machine documentation _____________________________________________________ 1-4 WARRANTY______________________________________________________________________ 1-5 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ Warnings and symbols ____________________________________________________________ Declaration of Conformity __________________________________________________________ Noise emission information _________________________________________________________ Vibration information ______________________________________________________________ Visibility Information ______________________________________________________________ Restricted Visibility _______________________________________________________________

1-6 1-6 1-6 1-7 1-7 1-7 1-8

DESIGNATED USE ________________________________________________________________ 1-9 ORGANIZATIONAL MEASURES ____________________________________________________ Selection and qualification of personnel; basic responsibilities _____________________________ Safety instructions governing specific operational phases ________________________________ Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ___________________________ Warning of special dangers ________________________________________________________ Gas, dust, steam and smoke _______________________________________________________ Hydraulic equipment _____________________________________________________________

1-10 1-11 1-11 1-12 1-13 1-13 1-14

FIRE AND EXPLOSION HAZARD ____________________________________________________ 1-15 NOTES __________________________________________________________________________ 1-2 2 OPERATION _____________________________________________________________________ 2-1 OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3 Visibility aids ____________________________________________________________________ 2-4 Operation and Maintenance Manual, where to store it in the operator’s cab ___________________ 2-4 FIRE AND EXPLOSION HAZARD _____________________________________________________ 2-5 DESCRIPTION OF THE HYDRAULIC SHOVEL __________________________________________ Hydraulic shovel layout ____________________________________________________________ Undercarriage ___________________________________________________________________ Upper structure __________________________________________________________________ Drive unit _______________________________________________________________________ Hydraulic system _________________________________________________________________

2-6 2-7 2-8 2-8 2-8 2-8

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TABLE OF CONTENTS Control and Monitoring Platform (CAMP) ______________________________________________ 2-8 Board-Control-System (BCS) _______________________________________________________ 2-9 Demand control / Zero-flow regulation ________________________________________________ 2-9 Automatic reset to idling ___________________________________________________________ 2-9 Electrical system _________________________________________________________________ 2-9 Safety films and warning messages – Overview and Description ___________________________ 2-10 ISO – compliant safety messages set ________________________________________________ 2-11 Safety messages (ISO) – Description ________________________________________________ 2-17 Additional messages (ISO) – Description _____________________________________________ 2-21 ANSI – compliant safety messages set _______________________________________________ 2-26 Safety messages (ANSI) – Description _______________________________________________ 2-32 Additional messages (ANSI) – Description ____________________________________________ 2-36 Entering and leaving the machine - Safety instructions___________________________________ 2-40 Access ladder - Lighting __________________________________________________________ 2-40 Swinging ladder - Function ________________________________________________________ 2-41 Folding ladder (optional) – Function _________________________________________________ 2-42 Emergency exit in operator’s cab and escape ladder ____________________________________ 2-43 Cab interior lighting – Switch on and off ______________________________________________ 2-44 Maintenance lights – Switch on and off _______________________________________________ 2-45 Emergency shut-off - Function _____________________________________________________ 2-46 Putting the machine back into operation, reset of emergency shut off function ________________ 2-47 Battery isolator switch - Shut off supply voltage ________________________________________ 2-48 Starter isolator switch - Shut off starter voltage _________________________________________ 2-48 Operator’s seat _________________________________________________________________ 2-49 Reducing operators exposure to vibrations ____________________________________________ 2-51 Trainer's / instructor's seat ________________________________________________________ 2-51 Windscreen washer ______________________________________________________________ 2-51 Operating hours meter (if equipped) _________________________________________________ 2-51 Fire extinguisher ________________________________________________________________ 2-52 Automatic fire-extinguishing system _________________________________________________ 2-52 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-54 Engine 1 (LH), control and monitoring ________________________________________________ 2-61 Engine 2 (RH), control and monitoring _______________________________________________ 2-63

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PUTTING THE MACHINE INTO OPERATION __________________________________________ Electrical Storm Injury Prevention ___________________________________________________ Reducing the operator's exposure to noise ____________________________________________ Refuelling _____________________________________________________________________ Diesel fuel – Recommendations ____________________________________________________ Back-up heating (option) - Fill in fuel _________________________________________________ Service Station (fast fill arm) _______________________________________________________ Emergency off switch ____________________________________________________________ Electrical system – Switch on and off ________________________________________________ Engines - Emergency shut-off ______________________________________________________ Preheating system for engine and hydraulic oil (if equipped) ______________________________ Fuel preheating system (if equipped) ________________________________________________

2-82 2-82 2-82 2-83 2-83 2-83 2-84 2-85 2-90 2-90 2-91 2-92

ENGINES - STARTING AND STOPPING ______________________________________________ Engines - Start__________________________________________________________________ Starting the left-hand engine _______________________________________________________ Starting the right-hand engine ______________________________________________________ Engines – Adjust speed___________________________________________________________

2-93 2-93 2-93 2-93 2-94

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TABLE OF CONTENTS Engines - Start at low temperatures _________________________________________________ Engines - Shut off _______________________________________________________________ Shutting off the left-hand engine ____________________________________________________ Shutting off the right-hand engine ___________________________________________________

2-94 2-95 2-95 2-95

AIR CONDITIONER (OPTIONAL) ____________________________________________________ 2-96 Back-up heating operator’s cab (optional) _____________________________________________ 2-97 Back-up heating (optional) ________________________________________________________ 2-98 OPERATIONAL PRACTICES _______________________________________________________ 2-99 Working operation - Safety instructions _______________________________________________ 2-99 Before starting work ____________________________________________________________ 2-100 Machine Operating Temperature Range _____________________________________________ 2-100 Warming up the hydraulic system __________________________________________________ 2-100 Electronic hydraulic shovel control (pilot control) – activate ______________________________ 2-101 Working operation – basics _______________________________________________________ 2-102 OPERATION TECHNIQUES _______________________________________________________ 2-108 Machine operation with backhoe attachment, Best Practices _______________________________ 108 Backhoe Operation – Restricted Operation ___________________________________________ 2-118 Machine operation with face shovel attachment - Best Practices __________________________ 2-129 Face Shovel Operation – Restricted Operation ________________________________________ 2-143 TRAVELING ____________________________________________________________________ Traveling - Safety Instructions _____________________________________________________ Before starting traveling _________________________________________________________ Traveling – Basic Movements _____________________________________________________ Counter-rotation turns / Turning on the spot __________________________________________ Track Parking Brake – set/release _________________________________________________ Traveling speed – adjust _________________________________________________________ Traveling uphill and downhill on ramps and steep slopes ________________________________ Traveling over long distances _____________________________________________________ Traveling – Best Practices ________________________________________________________ Traveling – Restricted Operation ___________________________________________________ Maximum Machine Inclinations ____________________________________________________

2-158 2-158 2-159 2-161 2-164 2-165 2-165 2-166 2-168 2-170 2-171 2-174

TRANSPORTING THE MACHINE ___________________________________________________ Transport - Safety instructions ____________________________________________________ Engine-off lowering of the attachment _______________________________________________ After daily operation ____________________________________________________________

2-175 2-175 2-176 2-177

ASSEMBLING ATTACHMENT - SAFETY INSTRUCTIONS _______________________________ Safety line on boom_____________________________________________________________ Main control valves – attach/remove the handrail ______________________________________ Securing the machine ___________________________________________________________

2-178 2-178 2-179 2-179

CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___________ 2-180 ON-BOARD CRANE (OPTIONAL) ___________________________________________________ On-board crane - Monitoring, warning and control elements _____________________________ On-board crane- Putting into operation ______________________________________________ On-board crane - Drive unit _______________________________________________________ On-Board crane – Blocking the boom in position of rest _________________________________ On-board crane - Check _________________________________________________________ Monitoring cameras – Function ____________________________________________________

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TABLE OF CONTENTS Operator Assist System (if equipped) _______________________________________________ 2-184 NOTES ________________________________________________________________________ 2-185 3 INSPECTION AND SERVICING ______________________________________________________ 3-1 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ________________________________ 3-3 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ____________________ 3-7 INSPECTION AND SERVICING PLANS - INSTRUCTIONS _________________________________ 3-9 Intervals ________________________________________________________________________ 3-9 Change of engine oil ______________________________________________________________ 3-9 Refer to chapter “Engine oil service interval table” for more information. Also refer to SEBU6250 Caterpillar Machine Fluid Recommendations. _____________________________________________ 3-9 Air-intake system _________________________________________________________________ 3-9 Oils / Greases ___________________________________________________________________ 3-9 Cleaning jobs____________________________________________________________________ 3-9 Components ____________________________________________________________________ 3-9 3500 Engine Maintenance Interval Schedule – Notes____________________________________ 3-10 Plan V ________________________________________________________________________ 3-11 Plan N ________________________________________________________________________ 3-13 Plan T and Plan W ______________________________________________________________ 3-15 Plan A – E _____________________________________________________________________ 3-19 LUBRICATING CHART – GREASE ___________________________________________________ 3-26 Lubricating chart – Grease (legend) _________________________________________________ 3-27 Refill Capacities – Grease _________________________________________________________ 3-27 INSPECTION PLAN - OIL __________________________________________________________ Inspection plan – Oil (legend) ______________________________________________________ Engine oil service interval table _____________________________________________________ Refill Capacities - Oil _____________________________________________________________ Refill Capacities – Other __________________________________________________________

3-28 3-29 3-30 3-31 3-31

LUBRICANTS / CONSUMABLES ____________________________________________________ Notes on the selection of oils and greases ____________________________________________ I. Oils for combustion engines ____________________________________________________ II. Fluids for hydraulic system ___________________________________________________ III.a Oils for pump distribution gearboxes and travel gearboxes __________________________ III.b Oils for swing gearboxes _____________________________________________________ V. Grease for bearings, slew rings and track system (Central lubrication system) ___________ Grease for idlers, track rollers and upper rollers (Lifetime lubrication) _______________________ Coolant for use on all combustion engines ____________________________________________

3-32 3-32 3-33 3-34 3-35 3-36 3-37 3-38 3-39

SERVICING WORK _______________________________________________________________ 3-40 Hose line for oil and cooling liquid changes ___________________________________________ 3-40 ENGINE ________________________________________________________________________ Engine - Safety instructions ________________________________________________________ Walk-Around Inspection __________________________________________________________ Belts - Inspect/Replace ___________________________________________________________ Fuel Injector - Inspect/Adjust _______________________________________________________ Engine Oil Sample – Obtain _______________________________________________________ Engine Valve Lash – Check/Adjust __________________________________________________ Water Pump - Inspect ____________________________________________________________ viii

3-41 3-41 3-42 3-43 3-43 3-44 3-45 3-45

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TABLE OF CONTENTS Engine oil level – Check level / top up ________________________________________________ Engine oil reservoir (if equipped) – Check oil level / top up ________________________________ Engine oil - Change ______________________________________________________________ Engine oil reservoir (if equipped) - Drain / Fill oil ________________________________________ Engine oil reservoir (if equipped) – Replace oil filters ____________________________________ Engine oil reservoir (if equipped) – Replace breather filters _______________________________ Engine oil filter – Replace _________________________________________________________ Engine crankcase breather – Clean _________________________________________________ Cold-starting fluid (ether) - Replace the pressure vessel _________________________________

3-46 3-47 3-48 3-50 3-52 3-52 3-53 3-53 3-54

COOLING SYSTEM _______________________________________________________________ Temperature ___________________________________________________________________ Cooling liquid radiators - Check / clean _______________________________________________ Cooling liquid level - Check ________________________________________________________ Cooling liquid – Top up ___________________________________________________________ Cooling liquid - Change ___________________________________________________________ Cooling liquid composition – Test ___________________________________________________ Cooling System Supplemental Coolant Additive (SCA) – Add _____________________________ Cooling System Water Temperature Regulator –Replace ________________________________ Cooling System Coolant Sample (Level 1) – Obtain _____________________________________ Cooling System Coolant Sample (Level 2) – Obtain _____________________________________

3-55 3-55 3-56 3-56 3-57 3-59 3-60 3-61 3-62 3-63 3-63

AIR-INTAKE SYSTEM _____________________________________________________________ Engine air pre cleaner - Inspect / clean _______________________________________________ Primary air filter element - Inspect / replace ___________________________________________ Secondary air filter element - Replace _______________________________________________ Air-intake lines - Inspect __________________________________________________________

3-64 3-65 3-66 3-67 3-67

FUEL SYSTEM __________________________________________________________________ Fuel system - Safety instructions ___________________________________________________ Fuel tank supply valve – Function ___________________________________________________ Fuel System – Prime _____________________________________________________________ Fuel filter – Replace _____________________________________________________________ Fuel system – Vent ______________________________________________________________ Breather filter fuel tanks - Replace __________________________________________________ Fuel tanks – Clean ______________________________________________________________ Water trap (option) - Clean / replace _________________________________________________ Hoses and Clamps - Inspect/Replace ________________________________________________

3-68 3-68 3-68 3-68 3-69 3-69 3-69 3-70 3-72 3-74

ELECTRICAL SYSTEM ____________________________________________________________ Electrical system - Safety instructions ________________________________________________ Alternator - Instructions ___________________________________________________________ Electrical circuit diagrams _________________________________________________________ Electrical system switch-cabinets ___________________________________________________ Lamps and bulbs – Replace _______________________________________________________ Xenon floodlight projector (optional) - Replace the lamp __________________________________ Lighting systems in LED technology - Instructions ______________________________________ Battery- Check the state of charge __________________________________________________ Battery - Remove and install _______________________________________________________ Battery charge inside the machine - Safety instructions __________________________________ Switchgear cabinet filter – Clean ____________________________________________________ CAN-Bus wiring connections – Inspect _______________________________________________

3-77 3-77 3-77 3-77 3-77 3-77 3-78 3-80 3-81 3-82 3-83 3-84 3-86

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TABLE OF CONTENTS HYDRAULIC SYSTEM _____________________________________________________________ 3-87 Hydraulic system - Safety instructions________________________________________________ 3-87 Hydraulic system - Depressurize ____________________________________________________ 3-87 Attachment circuits – Depressurize __________________________________________________ 3-88 Hydraulic system sections – Depressurize ____________________________________________ 3-89 Hydraulic oil level – Check ________________________________________________________ 3-89 Hydraulic Oil Analysis – Understand Particle Count Results _______________________________ 3-91 Hydraulic oil return-flow filters, Replace ______________________________________________ 3-92 Hydraulic oil return-flow filters - Replace (from machine no. 340173 / DHN60173) _____________ 3-94 Bypass valves - Clean / replace ____________________________________________________ 3-96 Hydraulic oil tank breather filters - Replace ____________________________________________ 3-97 Filters (pilot control circuit) - Check / replace __________________________________________ 3-98 Hydraulic oil filters for working hydraulics – Check / replace _______________________________ 3-99 Filters for swing pump charge circuit – Check / replace _________________________________ 3-100 Filters for swing circuits - Replace __________________________________________________ 3-101 Bearing flushing for main pumps - Replace filter _______________________________________ 3-102 Hydraulic oil – Change __________________________________________________________ 3-103 Hydraulic oil tank- Clean _________________________________________________________ 3-105 Hydraulic system – Vent _________________________________________________________ 3-107 Hydraulic oil cooler – Clean _______________________________________________________ 3-108 Electronic hydraulic shovel controls - Clean / lubricate __________________________________ 3-109 Pressure accumulator - Emergency lowering _________________________________________ 3-110 PUMP DRIVE GEARBOX _________________________________________________________ Pump drive gearbox – Check oil level / Top up with oil __________________________________ Pre-chambers – Check oil level / top up with oil _______________________________________ Pump drive gearbox oil sample - Obtain _____________________________________________ Pump drive gearbox – Change gearbox oil ___________________________________________ Pre-chambers - Change gearbox oil ________________________________________________ Pump drive gearbox breather valve - Replace ________________________________________ Pre-chamber breather valve - Replace ______________________________________________ Pump drive gearbox lube oil filters - Replace _________________________________________

3-111 3-111 3-112 3-112 3-113 3-114 3-114 3-115 3-116

SWING GEARBOX ______________________________________________________________ Swing gearbox oil sample - Obtain _________________________________________________ Swing gearbox - Check oil level / Top up with oil ______________________________________ Swing gearbox - Vent ___________________________________________________________ Swing gearbox oil – Change ______________________________________________________

3-117 3-117 3-117 3-117 3-118

TRAVEL GEARBOX (GEARBOX P/N 3683483) _______________________________________ Travel gearbox - Check oil level / Top up with oil ______________________________________ Travel gearbox - Change oil ______________________________________________________ Travel gearbox breather filter – Replace _____________________________________________ Travel gearbox oil sample – Obtain _________________________________________________

3-120 3-120 3-121 3-122 3-122

TRAVEL GEARBOX (GEARBOX P/N 3683496) ________________________________________ Travel gearbox - Check oil level / Top up with oil ______________________________________ Travel gearbox oil sample – Obtain _________________________________________________ Travel gearbox oil - Change ______________________________________________________ Travel gearbox breather filter – Replace _____________________________________________

3-123 3-123 3-124 3-125 3-126

TRAVEL GEARBOX (GEARBOX P/N 3749598) ________________________________________ 3-127 Travel gearbox - Check oil level / Top up with oil ______________________________________ 3-127 Travel gearbox oil sample – Obtain _________________________________________________ 3-128 x

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TABLE OF CONTENTS Travel gearbox oil – Change ______________________________________________________ 3-129 Travel gearbox breather filter – Replace _____________________________________________ 3-130 CRAWLER TRACKS _____________________________________________________________ Undercarriage – Check for leaks and free movement ___________________________________ Track roller - Lubricate __________________________________________________________ Track tensioning system _________________________________________________________ Pressure-accumulator inspection regulations _________________________________________ Checking the gas charging pressure in the pressure accumulator _________________________

3-131 3-131 3-132 3-133 3-134 3-134

SWING RING ___________________________________________________________________ Swing ring – Instructions _________________________________________________________ Bearing races _________________________________________________________________ Swing ring grease filling – Check __________________________________________________ Swing ring bolts – Check for tightness ______________________________________________

3-135 3-135 3-135 3-136 3-136

CENTRAL LUBRICATING SYSTEM _________________________________________________ Central lubrication system - Design _________________________________________________ Central lubrication system - Function _______________________________________________ Grease container – Fill up ________________________________________________________ Grease container breather filter - Check / replace______________________________________ Greasing pressure - Check _______________________________________________________ Grease line - Unblock ___________________________________________________________ Oil filter (hydraulic circuit grease pump) - Replace _____________________________________ Grease filter (filling the grease container) - Check / replace ______________________________ Grease filter (grease lines) - Check / replace _________________________________________

3-137 3-137 3-138 3-139 3-139 3-140 3-140 3-141 3-142 3-143

OTHER MAINTENANCE WORK ____________________________________________________ Engine – Clean ________________________________________________________________ Travel Alarm – Test _____________________________________________________________ Radiator – Clean _______________________________________________________________ Aftercooler Core - Clean/Test _____________________________________________________ Reservoirs for used grease at the A-frame - Empty ____________________________________ Air conditioning filter – Clean ______________________________________________________ Attachment - Check for cracks ____________________________________________________ Clam cylinder chamber - Check for soiling ___________________________________________ Window panes - Clean __________________________________________________________ Mirror – Clean / adjust position ____________________________________________________ Seat belt – Inspect______________________________________________________________ Seat belt – Replace _____________________________________________________________ Cameras – Check/Clean/Adjust (If equipped) _________________________________________ Horn – Inspect / Replace _________________________________________________________ Hydraulic ladder – pressure accumulator ____________________________________________ Pressure-accumulator inspection regulations _________________________________________ Pressure accumulator - Checking the gas charging pressure _____________________________

3-144 3-144 3-144 3-145 3-146 3-146 3-147 3-147 3-148 3-148 3-149 3-150 3-150 3-151 3-152 3-153 3-154 3-154

ON-BOARD CRANE, DRIVE UNIT (OPTIONAL) _______________________________________ 3-155 On-board crane - Lubricate _______________________________________________________ 3-156 On-Board crane fastening bolts - Check tightness _____________________________________ 3-156 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING _______ Putting the hydraulic shovel out of operation__________________________________________ Battery storage ________________________________________________________________ Recommissioning ______________________________________________________________

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TABLE OF CONTENTS NOTES ________________________________________________________________________ 3-159 4 REPAIR WORK ___________________________________________________________________ 4-1 REPAIR WORK - SAFETY INSTRUCTIONS_____________________________________________ 4-3 CONFINED SPACES - SAFETY INSTRUCTIONS ________________________________________ 4-4 REPAIR WORK, FIRE AND EXPLOSION HAZARD _______________________________________ 4-5 REPAIR WORK, ENGINE ___________________________________________________________ 4-6 Overhaul Considerations ___________________________________________________________ 4-6 Overhaul Recommendation _________________________________________________________ 4-7 Cleaning of Components __________________________________________________________ 4-10 HYDRAULIC SYSTEM _____________________________________________________________ 4-11 Repair instructions_______________________________________________________________ 4-11 Hydraulic hoses – Instructions _____________________________________________________ 4-11 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS _______________________________ 4-12 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS _____________________ 4-13 DISPOSAL AT THE END OF THE SERVICE LIFE _______________________________________ Dismantling and removal instructions ________________________________________________ Risk of deflagrations _____________________________________________________________ Risk of fire _____________________________________________________________________ Disposing of the machine without polluting the environment_______________________________ Further hazardous substances _____________________________________________________ Appropriate disposal of batteries ____________________________________________________

4-16 4-16 4-16 4-16 4-17 4-17 4-18

NOTES __________________________________________________________________________ 4-1 5 ANNEX__________________________________________________________________________ 5-1 BOARD-CONTROL-SYSTEM ________________________________________________________ 5-3 BCS III, what’s that? ______________________________________________________________ 5-3 The keys on the front side __________________________________________________________ 5-4 Other elements on the front side _____________________________________________________ 5-4 BCSIII, the start screen ____________________________________________________________ 5-5 Information given on the start screen, top section ________________________________________ 5-6 Information given on the start screen, central section _____________________________________ 5-7 Information given on the start screen, lower section ______________________________________ 5-8 Emergency Stop, reset function _____________________________________________________ 5-9 Swing circuit lock-out function ______________________________________________________ 5-10 Information given on the “Service” screen _____________________________________________ 5-11 Engine data screen ______________________________________________________________ 5-12 Hydraulic data screen ____________________________________________________________ 5-13 Lubrication data screen ___________________________________________________________ 5-14 Controls adjustment data screen ____________________________________________________ 5-15 View documents screen __________________________________________________________ 5-16 Signal table screen ______________________________________________________________ 5-17 Signal table screen, location _______________________________________________________ 5-18 Signal table screen, diagram _______________________________________________________ 5-19 Signal table screen, diagram configuration ____________________________________________ 5-20 Code table screen _______________________________________________________________ 5-21

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TABLE OF CONTENTS Slew brake test screen ___________________________________________________________ BCS III, interfaces _______________________________________________________________ USB interface, data storage _______________________________________________________ Saving data to a USB stick ________________________________________________________ Saving data to a USB stick, continued _______________________________________________ Saving data to a USB stick, continued _______________________________________________ BCSIII, cleaning_________________________________________________________________ BCSIII, disposal _________________________________________________________________

5-22 5-23 5-23 5-24 5-25 5-26 5-27 5-27

TROUBLESHOOTING _____________________________________________________________ Instructions on troubleshooting _____________________________________________________ Layout of the fault table ___________________________________________________________ Possible causes ________________________________________________________________ Measures______________________________________________________________________ Section _______________________________________________________________________

5-28 5-28 5-28 5-28 5-28 5-28

FAULT TABLES __________________________________________________________________ Combustion engine - Fault table ____________________________________________________ Working hydraulics – Fault table ____________________________________________________ Track drive – Fault table __________________________________________________________ Swing mechnism – Fault table _____________________________________________________ Central lubricating system – Fault table ______________________________________________

5-29 5-29 5-30 5-31 5-32 5-33

HYDRAULIC CIRCUIT DIAGRAM ____________________________________________________ 5-34 Vibration data __________________________________________________________________ 5-34 ABBREVIATIONS ________________________________________________________________ 5-35 ABBREVIATIONS _______________________________________________________________ 5-36 PRODUCT SPECIFICATION SHEET _________________________________________________ 5-37 NOTES _________________________________________________________________________ 5-39 6 INDEX __________________________________________________________________________ 6-1

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TABLE OF CONTENTS

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INTRODUCTION 1 INTRODUCTION Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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INTRODUCTION

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INTRODUCTION ALL PRODUCTS FOREWORD Literature Information This manual should be read carefully before using this product for the first time and before performing maintenance. This manual should be stored in the product literature holder or in the product literature storage area. Immediately replace this manual if lost, damaged, or unreadable. This manual may contain safety information, operation instructions, transportation information, lubrication information, and maintenance information. Some photographs or illustrations in this publication show details or attachments that can be different from your product. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your product, which are not included in this publication. Whenever a question arises regarding your product, or this publication, consult your dealer for the latest available information.

Safety The safety section, if present, lists basic safety precautions. In addition, this section identifies the text and locations of safety messages used on the product. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance, and repair on this product.

Operation The operation section, if present, is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, controls, attachment controls, transportation, and towing information (if applicable). Photographs and illustrations guide the operator through correct procedures of checking, starting, op- erating, and stopping the product. Operating techni- ques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the product and its capabilities.

Maintenance The maintenance section, if present, is a guide to equipment care. Proper maintenance and repair are essential to keep the equipment and systems operating correctly. As the owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual. The Maintenance Interval Schedule lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the "When Required" service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or "one safe source" for all maintenance procedures.

Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty, or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily.

Product Capacity Additional attachments or modifications may exceed product design capacity, which can adversely affect product performance characteristics, safety, reliability, and applicable certifications. Contact your dealer for further information.

Product Information The product information section, if present, may provide specification data, product intended use, product identification plate locations, and certification information.

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INTRODUCTION PREFACE About this Operation and Maintenance Manual These Operation and Maintenance Manual are designed to familiarize the operator with the machine and its designated use. The Operation and Maintenance Manual contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine. The Operation and Maintenance Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The Operation and Maintenance Manual must always be available in the operator’s cab of the machine. The Operation and Maintenance Manual must be read and put into practice by any person in charge of carrying out work with or on the machine, such as  operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,  maintenance (inspection, servicing, repair) and / or  transport. In addition to the Operation and Maintenance Manual and the mandatory rules and regulations for accident prevention and environmental protection in the user's country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The Operation and Maintenance Manual are directed to the mining-machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days' instruction by a qualified 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.

1 Complies with VDMA recommendation "Operation and Maintenance Manual"

1-4

The Operation and Maintenance Manual does not contain work instructions for carrying out major repairs. Such work is willingly done for you by the CGM HMS GmbH after-sales service.

Further machine documentation 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 Operation and Maintenance Manual, the spare-parts list and the „Service Manuals“ are marked with the serial number of the machine. The documentation supplied with your machine is rather comprehensive. Therefore, it has been split up in several volumes: Volume 1: the present Operation and Maintenance Manual, Volume 2: Parts Manual of the machine, Volume 3: electrical circuit diagram and key, Volume 4: documentation of other components, Volume 5: Service Manual Volume 1 Volume 6: Service Manual Volume 2 Depending on the size of your machine, the documentation can also consist of more volumes. If you cannot find the information you are looking for in the present Operation and Maintenance Manual please check also the other volumes of the documentation. The „Service Manual“ Volume 1 also provides information on how to assemble the machine, on functions of the hydraulic system, on hydraulic circuit diagrams etc. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION WARRANTY The warranty of CGM HMS GmbH presupposes among other things that the servicing works as described in the Operation and Maintenance Manual have been performed: 

Do not operate the machine  when components / assemblies are defective or missing, 

by your Cat dealer,

or 

in a workshop authorized in writing by CGM HMS GmbH or your Cat dealer,

and 

by using the original spare parts of CGM HMS GmbH.

The proper execution of the servicing works must be documented on the CGM HMS GmbH Service checklists.

if one or several of such components of which more than one are installed in the machine have been removed.

In cases of doubt seek advice from the CGM HMS GmbH Service. CGM HMS GmbH refuses to assume the guarantee for damage and consequential damage caused by an abusive utilization of the machine. Therefore: Do not operate the machine,  when several track rollers or upper rollers have been removed; 

when one or several swing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs. Such circumstances are considered by CGM HMS GmbH as "abusive utilization". Why? The machines have been designed and built on the basis of detailed calculations and so that all of the components installed absorb the occurring forces and are thus loaded to an equal extent. Example: If the machine is used for working with, for instance, one or even several track rollers removed, the forces must be absorbed by the remaining track rollers. These are then overloaded or loaded to a greater extent than calculated. The consequences are higher wear and consequential damage to the track rollers, but also to other components of the machine: chassis, travel gearbox and crawler track.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Complies with VDMA recommendation "Operation and Maintenance Manual"

Warnings and symbols The following signs are used in the Operation and Maintenance Manual to designate instructions of particular importance: Precautionary rules and measures designed to protect the machine operator and other persons from lifethreatening danger or injuries and to prevent extensive damage. Information and precautionary measures designed to prevent damage to the machine or other property.

Declaration of Conformity An EC or EU Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements for the European Union. In order to determine the details of the applicable Directives, review the complete EC or EU Declaration of Conformity provided with the machine. The extract shown below from an EC or EU Declaration of Conformity for machines that are declared compliant to "2006/42/EC" applies only to those machines originally "CE" marked by the manufacturer listed and which have not since been modified.

Content of the Original EC or EU Declaration of Conformity Manufacturer: Caterpillar Global Mining Hydraulic Mining Shovels GmbH (CGM HMS GmbH) Karl-Funke-Straße 36 D-44149 Dortmund Germany Telephone: +49 231-922-3 Telefax: +49-231-922-5300 The manufacturer certifies that the machine Category: Hydraulic excavator Type : 6060 / 6060 FS fulfills the relevant provisions of the following EC Directives: 2006/42/EC, 2000/14/EC amended by 2005/88/EC, 2002/44/EC. Harmonised standards taken into consideration: EN 474-1, EN 474-5. Authorised person for documents: Design Department Date: 14.03.2012 Signed by: Engineering Manager Factory Manager

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION Noise emission information

Visibility Information

Noise emission data are specified in acc. with ISO 6394. Time-averaged A-weighted emission sound pressure level at operator’s position with the machine running at high idle: LAeq = XX dB.

Before you start the machine, perform a walkaround inspection in order to ensure that there are no hazards around the machine. While the machine is in operation, constantly survey the area around the machine in order to identify potential hazards as hazards become visible around the machine. Your machine may be equipped with visual aids. Some examples of visual aids are Closed Circuit Television (CCTV) and mirrors. Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean. Adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual. If equipped, the Work Area Vision System shall be adjusted according to Operation and Maintenance Manual, SEBU8157, "Work Area Vision System". If equipped, the Cat Detect Object Detection shall be adjusted according to the Operation and Maintenance Manual, "Cat Detect Object Detection" for your machine. It may not be possible to provide direct visibility on large machines to all areas around the machine. Appropriate job site organization is required in order to minimize hazards that are caused by restricted visibility. Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area. Examples of job site organization include the following:  Safety instructions

Vibration information On the condition that the hydraulic shovel is used within the limits of its designated use, the installation of seats for operators in conformity with ISO 7096 ensures that the weighted vibration accelerations awz (measured in compliance with ISO 2631 Part I) fulfil the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG. The vibrations transferred are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. with the "Regulations for noise and vibration at the place of work", Section 4, as of 18.12.2008. The effective value of the weighted acceleration to which the wole body is exposed, does not exceed 0.5 m/s2. The measurement uncertainty is ±3% (tolerance of the measuring instruments).



Controlled patterns of machine movement and vehicle movement



Workers that direct safe movement of traffic



Restricted areas



Operator training



Warning symbols or warning signs on machines or on vehicles



A system of communication



Communication between workers and operators prior to approaching the machine

Modifications of the machine configuration by the user that result in a restriction of visibility shall be evaluated.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION Restricted Visibility The size and the configuration of this machine may result in areas that cannot be seen when the operator is seated. For restricted visibility areas, an appropriate job site organization must be utilized to minimize hazards of this restricted visibility. For more information regarding job site organization refer to this Operation and Maintenance Manual, “Visibility Information”. Fig. 1 and Fig. 2 provide an approximate visual indication of the areas at ground level inside a radius of 24 m (79 ft) from the operator of significant restricted visibility for machines with faceshovel and backhoe attachments. Refer to the correct illustration for your machine configuration. All restricted visibility areas less than 300 mm wide may not be shown. These illustrations do not indicate areas of restricted visibility for distances outside of the shown radius. The areas of restricted visibility shown in the illustrations are with the track and work tool of the machine in the “travel position”. This machine may be equipped with optional visibility aids that may provide visibility to some of the restricted visibility areas. Refer to this Operation and Maintenance Manual, “Mirror – Clean/Adjust” for more information on additional visibility. If your machine is equipped with cameras, refer to this Operation and Maintenance Manual, “Monitoring Cameras” for more information on additional visibility. For areas that are not covered by the optional visual aids, an appropriate job site organization must be utilized to minimize hazards of this restricted visibility. For more information regarding job site organization refer to Operation and Maintenance Manual, “Visibility Information”. When equipped with optional visual aids, the machine visibility will meet the technical requirements found in ISO5006:2006.

Fig. 1-1:

Fig. 1-1: shows the machine with faceshovel attachment. Top view of machine, ground level visibility without use of visual aids that are not standard in all markets. Note: The shaded areas indicate the approximate location of areas with significant restricted visibility.

Fig. 1-2:

Fig. 1-2: shows the machine with backhoe attachment. Top view of machine, ground level visibility without use of visual aids that are not standard in all markets. Note: The shaded areas indicate the approximate location of areas with significant restricted visibility.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION DESIGNATED USE The machine has been built in accordance with state-of-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property (acceptable risk) An acceptable risk is present, e.g.: loose material or material to be loaded may drop out of the bucket or backhoe while the attachment is being swivelled.

Using the hydraulic shovel or its attachments for purposes other than or extending beyond those stated above, e.g.:  for lifting or transporting persons,

The machine must be used only in technically perfect condition in accordance with its designated use and the instructions set out in the Operation and Maintenance Manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately. With attached shovel equipment, the machine is to be used solely for loosening and loading of:  sand, oil sand,  gravel,  blasted rock,  ore,



as a working platform,



for lifting crane loads without the equipment being approved for this purpose,



for driving in posts, sheetpiles supports, etc. without the equipment being approved for this purpose,



for moving material to the side (sweeping),



for breaking down rocks by beating with the shovel or the backhoe,



for fitting or reparing of other machines

is contrary to its designated use and considered as "unauthorized use".

 coal, and other raw materials. With attached backhoe equipment, the machine can additionally also be used for excavating and loading of excavatable soils and other raw materials. Operating the machine within the limits of the designated use also involves observing the instructions set out in the Operation and Maintenance Manual and complying with the inspection and maintenance directives.

Lifting eyes on the lower carriage - are settled for transporting with a crane only. -

must not be used for towing a machine.

Improper use may involve a life-threatening risk for operators or other personnel or may cause injury or extensive damage. The manufacturer/supplier cannot be held liable for any damage resulting from other than the designated use. The risk involved in such misuse lies with the user.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION ORGANIZATIONAL MEASURES The Operation and Maintenance Manual must always be at hand at the place of use of the machine, e.g. by stowing them in the place provided for such purpose. In addition to the Operation and Maintenance Manual, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment or traffic regulations. The Operation and Maintenance Manual must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work. Personnel entrusted with work on the machine must have read the Operation and Maintenance Manual and in particular the chapter on safety before beginning work. Reading the Operation and Maintenance Manual after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance. Check - at least from time to time - whether the personnel is carrying out the work in compliance with the Operation and Maintenance Manual and paying attention to risks and safety factors. For reasons of security, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewellery, such as rings, may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts. Use protective equipment wherever required by the circumstances or by law.

Personal protective equipment and the working clothing Depending on the cleaning, servicing and/or repair activities to be performed, the personal protective equipment and the working clothing may consist of the following items: 

fall arresters,



protective suit,



helmet,



goggles - e. g. for cleaning work - or for welding work,



protective gloves - e.g. for work on hot units - for grinding and welding work,



protective working gloves - e.g. for fitting work - for grinding and welding work,



ear protectors.

Observe all safety instructions and warnings attached to the machine. See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible. In the event of safety-relevant modifications or changes in the behavior of the machine during operation, stop the machine immediately and report the malfunction to the competent authority/person. Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements. Use only the original spare parts of CGM HMS GmbH. They are the only ones to fulfill the technical specifications of the machine. Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected. Adhere to prescribed intervals or those specified in the Operation and Maintenance Manual for routine checks and inspections. For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable. The personnel must be familiar with the location and operation of fire extinguishers. Observe all fire-warning and fire-fighting procedures.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION Selection and qualification of personnel; basic responsibilities Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed. Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair. Make sure that only authorized personnel works on or with the machine. Define the machine operator's responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety. Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person. Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. Work on chassis and brake systems must be performed by skilled personnel only, which has been specially trained for such work. Work on hydraulic systems must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Safety instructions governing specific operational phases Standard operation Avoid any operational mode that might be prejudicial to safety. Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working area and the bearing capacity of the soil. Take the necessary precautions to ensure that the machine is in a safe and reliable state. Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional. Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine's working behaviour) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it. In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified immediately.

Start the machine from the operator's seat only. During start-up and shut-down procedures always watch the indicators in accordance with the Operation and Maintenance Manual. Before setting the machine in motion, make sure that nobody is at risk. Before starting work or traveling with the machine, check that braking, signalling and lighting systems are fully functional. Before setting the machine in motion always check that the accessories have been safely stowed away. Shut the machine down until damaged or nonfunctioning visibility aid(s) is repaired (if applicable) or until appropriate job site organization is used to minimize hazards that are caused by any resulting restricted visibility. In conditions of poor visibility and after dark always switch on the lighting system. Persons accompanying the operator must be seated on the passenger seat provided for this purpose. When crossing underpasses and bridges or when passing under overhead lines always make sure that there is sufficient clearance. Always keep a distance from the working face and from slopes. Avoid any operation that might be a risk to machine stability. Never travel across slopes; always keep the atachment and the load close to the ground, especially when traveling downhill. On sloping terrain always adapt your traveling speed to the prevailing ground conditions. Before leaving the operator's seat always secure the machine against inadvertent movement and unauthorized use. Shut off the engines.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation and Maintenance Manual, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only. Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities. In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the Operation and Maintenance Manual and the information on maintenance work. Ensure that the maintenance area is adequately secured. If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by:  removing the ignition key and  attaching a warning sign (Fig. 1-3:).

Fig. 1-3:

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movements.

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To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads. The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator. For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Never use machine parts as a climbing aid Wear a safety harness when carrying out maintenance work at heights above 1 m. Wear an approved harness equipped with fall arresters and safety lines. Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice. Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use aggressive detergents. Use lint-free cleaning rags. Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switch-gear cabinets. Ensure during cleaning of the machine that the temperature sensors of the fire-warning and fire-fighting systems do not come into contact with hot cleaning agents as this might activate the fire-fighting system. Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material. This material must not be spray-washed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments. After cleaning remove all covers and tapes applied for that purpose. After cleaning, examine all fuel, lubricant, brake and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defect found must be rectified without delay. Always tighten any screwed connections that have been loosened during maintenance and repair. Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of maintenance and repair work. Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION Warning of special dangers

Gas, dust, steam and smoke

Electric energy

Always start and operate the engine in a well-vented area; If in an enclosed area, vent the exhaust to the outside; Do not modify or tamper with the exhaust system Diesel engine exhaust and some of its constituents are known to cause cancer, birth defects, and other reproductive harm Operate fuel-operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation. Observe the regulations in force at the respective site. Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire. Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system. When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the attachment must be kept well away from them. Caution, danger! Check out the prescribed safety distances. If your machine comes into contact with a live wire  do not leave the machine  drive the machine out of the hazard zone; warn others against approaching and touching the machine  have the live wire de-energized  do not leave the machine until the damaged or contacted line has been safely de-energized. The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

High-voltage system Floodlamps equipped with gaz discharge lamps require a high-voltage supply (ca. 25 kV). The high voltage is generated by a ballast unit. Switch off the electrical system of the hydraulic shovel before touching the lamp or the ballast unit.

Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.

Electrical Storm Injury Prevention When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures:  Mount the machine. 

Dismount the machine.

If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION Hydraulic equipment Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire. Depressurize all system sections and pressure pipes (hydraulic system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work. Hydraulic lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

Noise During operation, all sound baffles of the machine must be closed. Always wear the prescribed ear protectors.

Oil, grease and other chemical substances When handling oil, grease or other chemical substances, observe the product-related safety regulations (see safety specifications). Be careful when handling hot consumables (risk of burning or scalding).

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Ether The machine can be equipped with pressure vessels for cold-starting fluid (ether) installed in the engine compartment. Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the vessels against damage and high temperatures. Do not store pressure vessels with cold-starting fluid (ether) on the hydraulic shovel. Do not eat, drink or smoke when replacing pressure vessels with cold-starting fluid (ether). Observe the instructions on the pressure vessels. Provide for sufficient ventilation (see also Part 3 "Inspection and servicing"). Do not open empty cold-starting fluid pressure vessels (ether). Have the vessels disposed of properly. For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Transporting and recommissioning The machine must be loaded and transported only in accordance with the Operation and Maintenance Manual. Use only appropriate means of transport and lifting gear of adequate capacity. The recommisioning procedure must be strictly in accordance with the Operation and Maintenance Manual.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires. Pay particular attention to hazards caused by combustible and easily flammable substances. Obtain information on the safe handling of the fire extinguishers to be used. Avoid smoking and open fire on, next to and below the hydraulic shovel. Combustible and easily flammable substances or liquids increase the fire and explosion hazard. Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight. Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning. These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger. Even battery gases can ignite in open flames or fire. Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work. Apply special protection to cables, cable ducts as well as to hose and pipe lines. If necessary, also cover the ground with fireprotective blankets. The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment. Ensure sufficient ventilation. Clean the hydraulic shovel before starting a job. Do not keep any fire extinguishers that are not suitable or have not been tested. Do not extinguish flammable liquids with water. Use:  dry-powder, 

carbon-dioxide or



foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards. Call the fire brigade. Have all your welding, flame cutting and grinding work approved.

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground. Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INTRODUCTION NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... 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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION 2 OPERATION Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION OPERATION - SAFETY INSTRUCTIONS Operation and Maintenance Manual Never operate the machine before having read and understood the Operation and Maintenance Manual. Pay special attention to the "Fundamental Safety Instructions" and to all warning and instruction signs attached to the machine. Familiarize yourself with the layout, the functioning and the sense of actuation of the control elements prior to starting up the machine. Activate the control elements from the operator's seat only. Keep the Operation and Maintenance Manual with the machine at all times.

Operating personnel The operating personnel must be fully informed of the operation and application of this or comparable machines. The necessary know-how can be acquired in several days' instruction, e.g. by an CGM-HMS GmbH mechanic or by attending an CGM-HMS GmbH operator's training course.

Personal protective gear and working clothing Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation. Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in control levers being inadvertently activated.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions. Always have inspection and maintenance work carried out on schedule. Operate the machine only with the equipment and component combinations approved by CGM-HMS GmbH. Clear-cut data are given in the technical specification. Never install and commission other equipment and component combinations without CGM-HMS GmbH having first inspected and approved the project. Before starting work or traveling with the machine, check that the braking, signalling and lighting systems are fully functional. Poor visibility may result in accidents. Always clean the windows and the glass covers of all lamps before starting the machine. Check that all warning and instruction signs attached to the machine are present and legible.

Entering and leaving the machine Always face the machine when entering or leaving it. Use only the ladders, steps, platforms and grab handles provided when entering and leaving the machine. Always maintain a three point contact with the steps and grab handles.

Safety belts For machines with safety belts for operating personnel: Check the safety belts attached to the operator's seat as well as at the trainer’s seat. In the event of damage or after an accident, have them replaced immediately. Apply the safety belts before starting work.

Fig. 2-1:

Always keep ladders, steps and platforms in a non-slip, safe state and remove any oil, grease, soil, snow, ice and other foreign matter immediately.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Hazard range The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its equipment and attachments or of swinging loads.

Persons within the hazard zone Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine. Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

Marshallers The marshaller must keep outside the hazard zone. Have a marshaller to assist you:  when you have no clear overview over the hazard zone of the machine, 

when reversing,



when shunting.

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie/camera). Calls cannot be understood by the marshaller because of the noise made by the machine during operation. Keep in constant contact with the marshaller. Stop the machine immediately if you lose contact with the marshaller.

Visibility aids Your machine may be equipped with visual aids. Some examples of visual aids are cameras and mirrors. Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean. For the best visibility of the area that is close to the machine adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual. Shut the machine down until damaged or nonfunctioning visibility aid is repaired (if applicable) or until appropriate job site organization is used to minimize hazards that are caused by any resulting restricted visibility. Shut the machine down until damaged or nonfunctioning visibility aid(s) is repaired (if applicable) or until appropriate job site organization is used to minimize hazards that are caused by any resulting restricted visibility.

Operation and Maintenance Manual, where to store it in the operator’s cab One copy of the Operation and Maintenance Manual for the machine must be available in the operator’s cab during operation. Replace Operation and Maintenance Manual if lost, damaged or unreadeable. The binder with the Operation and Maintenance Manual can be stored in the tray (Fig. 2-2:).

Securing the machine Secure the machine as described under "Securing the machine" before:  mounting or dismantling the attachment, 

parking the machine after daily operation,



carrying out any servicing or repair work.

Fig. 2-2:

2-4

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires. Pay particular attention to hazards caused by combustible and easily flammable substances. Obtain information on the safe handling of the fire extinguishers to be used. Avoid smoking and open fire on, next to and below the hydraulic shovel. Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight. Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning. These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger. Clean rubber or electrical with compressed air only. Ensure sufficient ventilation. Even battery gases can ignite in open flames or fire. Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground. Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel. Clean the hydraulic shovel before starting work. Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work. If necessary, also cover the ground with fireprotective blankets. Apply special protection to cables, cable ducts as well as to hose and pipe lines. The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49 °C / 120 °F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment. Ensure sufficient ventilation. Do not keep any fire extinguishers that are not suitable or have not been tested. Do not extinguish flammable liquids with water. Use:  dry-powder, carbon-dioxide or foam extinguishing compounds. When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards. Call the fire brigade. Have all your welding, flame cutting and grinding work approved before starting work.

open or smouldering fire may occur.

2-5

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION DESCRIPTION OF THE HYDRAULIC SHOVEL

Fig. 2-3:

2-6

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Hydraulic shovel layout

40 – Energy station for on-board crane (optional)

Fig. 2-3:

44 – Grease container of central lubricating sys-

Undercarriage

tem

1 – Track drive

45 – Tool cabinet (optional)

2 – Idler

46 – Hydraulic ladder

3 – Track roller

47 – Ladder

4 – Upper roller

48 – Control cabinet

5 – Crawler track

50 – Counterweight

6 – Track tensioner

52 – 54 Ladder

7 – Swing ring 8 – Emergency ladder

Face shovel attachment

Upper structure

61 – Boom

11 – Engine

62 - TriPower linkage

12 – Radiator (engine cooling liquid)

63 – Stick

13 – Air-intake system

64 - Bottom-dump bucket

14 – Exhaust system

65 - Boom cylinder

15 – Fuel Tank

66 - Stick cylinder

16 – Engine oil reservoir (optional)

67 - Tipping cylinder

17 – Hydraulic oil reservoir

68 - Bottom-dump cylinder

18 – Hydraulic oil cooler

74 - Control valves

19 – Reservoir (engine cooling liquid)

75 - Quick-action valve

20 – Pump drive gearbox 21 – Working pump 22 – Swing pump 23 – Servo system pump 24 – Gearbox oil circulating pump 25 – Filling pump (swing circuit) 26 – Fan drive pump (engine radiator) 27 – Pump for fan drive and hydraulic oil cooling 28 – Air conditioner (inside cab) 29 – Swing gear 30 – Travel block and rotor 31 – Operator's cab

Backhoe bucket attachment 63 - Stick 65 - Boom cylinder 66 - Stick cylinder 69 - Monoblock boom 70 - Backhoe bucket 71 - Backhoe cylinder 72 - Toggle link 73 - Toggle lever 74 - Control valves 75 - Quick-action valve

32 – Control column 33 – Control-cabinet 34 – 24Volt control-cabinet 35 – Fire-extinguisher 37 – Batteries 38 - Service-station (tank lift) 39 – On-board crane (optional)

2-7

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Undercarriage The undercarriage of the hydraulic hydraulic shovel serves as a stable base and for traveling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and upper structure are connected by means of a swing ring.

Upper structure The upper structure accommodates the drive and part of the hydraulic and electrical equipment.

Drive unit The drive unit comprises diesel engines, pump drive gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Hydraulic system All working and traveling movements are performed hydraulically. The movements are controlled by servovalves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the upper structure to the undercarriage is ensured by the rotor. The hydraulic system is overload-protected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

2-8

Control and Monitoring Platform (CAMP) The electronic CAMP system ensures the control and monitoring of all electrical and hydraulical functions of the hydraulic shovel. Four interconnected electronic units ensure optimal use of the installed engine power. Microprocessors are used to adapt the power output of the hydraulic pumps optimally to actual operating conditions. The machine is thus prevented from demanding more hydraulic power than the diesel engines can provide. The desired working movements are detected by microcontrollers which permanently sense the position of hand levers and pedals. As soon as movement is detected, the corresponding signals are transmitted to the electronic units. These units activate the drive control in order to provide the hydraulic energy needed for working. Only then do they activate the electrohydraulic valves which control the execution of the working movements.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Board-Control-System (BCS) The BCS is a micro-processor-controlled system for the acquisition and processing of measuring data. It's function consists in collecting data of the hydraulic shovel operating conditions and to evaluate, store and display these data to the hydraulic shovel operator. For this purpose, the BCS is connected via a bus system to the Control and Monitoring Platform (CAMP). An interface with the outside world ensures the transfer of stored data and software updating. The measured values (actual values) from the sensors and transducers installed in the hydraulic shovel are compared to the predefined reference values. Inadmissible deviations are indicated as fault messages on a display screen. Sensor or transducer defects or defective connecting cables are detected and indicated by plain-text messages. The data from the engine electronics are acquired, processed and displayed in the same way. Critical states of operation are brought to the operator's attention by means of optical and acoustic warning signals. The display screen of the BCS is a touch-screen with a surface sensitive to the touch. This feature supports the hydraulic shovel operator or the service technician in navigating through the menus of the BCS sorftware. For further information in this respect, please refer to section 5 in this Operation and Maintenance Manual or to the brochure "Board-Control-System – Operation and Maintenance Manual"

Demand control / Zero-flow regulation In the fine-control range, swivelling of the hydraulic pumps, and thus the variation of oil flow, are proportional to control lever and pedal valve travel. This means that during the work, the pumps supply only as much hydraulic oil as required to perform the working movement. In the neutral position of the control levers, the pumps are automatically swivelled to zeroflow. These special features offer the following advantages:  reduced fuel consumption 

minimum power losses



reduced temperature of the hydraulic oil



greater service life of hydraulic pumps and diesel engines.

Automatic reset to idling If no servovalves are actuated by the control pedals or levers for more than 8 seconds (factory-set value, adjustable), the engine is automatically set back to idling speed (factory setting ca. 1000 rpm, adjustable). This feature, too, contributes to reducing the fuel consumption.

Electrical system The electrical system operates on 24 volts.

2-9

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Safety films and warning messages – Overview and Description Warning and additional messages Observe the safety films and warning and additional messages attached to the machine. There are several specific safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages. Make sure that all of the safety messages are legible. Keep all the safety films and warning messages legible and clean. Clean the safety messages if you cannot read the words. When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall. Replace warning messages and films immediately if they have become illegible or have been lost. New warning messages and films can be ordered from the CGM-HMS Spare Parts Service. The ordering part numbers are set out in the spare-parts list of the machine. Fig. 2-4: - Fig. 2-9: and Fig. 37 – Fig. 42 show the location of warning and instruction signs on the machine. Note: There could be two different sets of safety messages on the hydraulic shovel. Depending on the national regulations in the country the hydraulic shovel is working the safety messages set could be: - ISO – compliant safety messages or - ANSI – compliant safety messages.

2-10

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION ISO – compliant safety messages set

Fig. 2-4:

2-11

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-5:

2-12

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-6:

2-13

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-7:

2-14

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-8:

2-15

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-9:

2-16

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Safety messages (ISO) – Description In this section you can find a description of all safety messages and additional messages fitted to the machine (ISO compliant messages set). The number in brackets, f.ex. (27), corresponds with the number of the film shown in the safety messages overview graphics. The number corresponds also with the films item number in the spare parts manual.

Do Not Operate (27) This safety message is located in the cab on the left side window. WARNING Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. Fig. 2-10:

Hot Fluid Under Pressure (4)

Fig. 2-11:

This safety message is located on the cooling system expansion reservoir pressure cap. WARNING Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance. Refer to Operation and Maintenance Manual, “Cooling System Coolant Level - Check” for further information.

Batteries, Flammable Gas (3) This safety message is positioned on the battery cabinet. WARNING Explosion hazard-Improper jumper cable connections can cause explosions. Could cause serious injury or death. See Operation and Maintenance Manual for proper procedure for jumper cable connection. Fig. 2-12:

2-17

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Crushing Hazard (9) This safety message is located on the rear of each side of the machine. WARNING Machine swings. Crushing hazard could cause serious injury or death. Stay back.

Fig. 2-13:

Falling Hazard (13) This safety message is located on the upper structure of the machine at the handrail gates. WARNING Falling hazard. Could cause serious injury or death when falling down from great height. Use caution when performing service work on the attachment. Always wear your fall protection equipment. Read Operation and Maintenance Manual. Refer to Operation and Maintenance Manual, “Working on the attachment- Safety Instructions” for further information. Fig. 2-14:

Fire Hazard (2) This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the cab module. WARNING Fire hazard. No open fire near area while lighting burners. Could cause serious injury or death. Read Operation and Maintenance Manual. Refer to Operation and Maintenance Manual, “Fire and Explosion Hazard – Safety Instructions” for further information. Fig. 2-15:

2-18

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Head Bump Hazard (7) This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments. WARNING Head bump hazard because of low clearance. Could cause serious injury or death. Stay back and wear a hard hat.

Fig. 2-16:

Trip Hazard (8) This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments. WARNING Trip hazard because of obstacles on the floor. Could cause serious injury or death. Be careful and pay extra attention on your steps. Read Operation and Maintenance Manual. Refer to Operation and Maintenance Manual, “Fundamental Safety Instructions” for further information. Fig. 2-17:

Hot Surface (11)

Fig. 2-18:

This safety message is located in two locations. This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the oil cooler module. WARNING Components and assemblies of the hydraulic system and components in the engine compartments can be hot while engines are running or immediately after engine shutdown. Hot parts or hot components can cause burns or serious injury or death. Do not allow these parts to contact your skin, when engines are running or immediately after engine shutdown. Use protective clothing or protective equipment to protect your skin. Wait until hot components have cooled down.

2-19

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Cutting Hazard (32) This safety message is located in two locations. This message is located outside the oil cooler module and outside the counterweight near the cooling fan wheels. WARNING Severe hazard caused by self starting fan wheels. Could cause serious injury or death. Keep hands away from fan. Shut off engines and wait until hydraulic system and engine cooling system has cooled down before starting work. Read Operation and Maintenance Manual. Fig. 2-19:

Refer to Operation and Maintenance Manual, “Other Maintenance Work” for further information.

Belt Entanglement Hazard (12) This safety message is located in two locations. This safety message is located on the belt cover assembly on each engine. WARNING Entanglement hazard. Could cause serious injury or death. Do not touch while engine is running. Keep hands away. Do not operate engine with guard removed. Shut off engines before starting work.

Fig. 2-20:

Deflagration Hazard This message is located on the counterweight and on the doors in front of the cooling fan wheels. WARNING Severe hazard caused by build-up of flammable gases inside the chambers of the counterweight. In case these gases were ignited, deflagrations may occur which could cause serious injury or death. Any work on the counterweight such like welding, flame cutting, grinding, drilling, milling is prohibited. Read Operation and Maintenance Manual. Refer to Operation and Maintenance Manual, “Welding on the counterweight” for further information. Fig. 2-21:

2-20

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Additional messages (ISO) – Description

Lashing point (6) This message is located in two locations.  On the right-hand side of the carbody in the near of each of the lashing points,  On the left-hand side of the carbody in the near of each of the lashing points.

Fig. 2-22:

Battery Disconnect Switch (19) This message is located in the control cabinet on the deck of the engine module next to the battery disconnect switch.

Fig. 2-23:

Starter Disconnect Switch (21) This message is located in the control cabinet on the deck of the engine module next to the starter disconnect switch.

Fig. 2-24:

2-21

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Personal Protection Equipment (PPE) Required (10) This message is located on the upper structure of the machine at the entrance to the pump bay. Eye, ear and foot protection are mandatory beyond this place.

Fig. 2-25:

High Pressure Water Jet Prohibited (5) This message is located on electrical components in six locations. This message is located on the upper structure of the machine  at the entrance to the pump bay,  on the control cabinets in the cab module,  on the control cabinets near the doors to the engine compartments,  on the control cabinet behind the hydraulic fluid reservoir. Washing with high pressure water jet is prohibited. Read Operation and Maintenance Manual. Fig. 2-26:

Refer to Operation and Maintenance Manual, “Electrical System” and “Inspection and Servicing Safety Instructions” for further information.

Maintenance Lights Switch (24) This message is located near the maintenance light switches in three locations  inside the operator’s cab next to the door,  inside the cab module next to the door,  in the engine compartment.

Fig. 2-27:

2-22

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Emergency Stop Reset Switch (20) This message is located inside the cab module on the front side of the 24 volt control cabinet next to the emergency stop reset switch.

Fig. 2-28:

Hydraulic fluid level (14 and 15) This message is located at the hydraulic fluid reservoir near the inspection glass. Refer to Operation and Maintenance Manual, “Hydraulic System” for further information.

Fig. 2-29:

Fan rotation (35) This message is located in two locations. This message is located inside the oil cooler module and inside the counterweight near the cooling fan wheels. The message shows the direction of rotation.

Fig. 2-30:

2-23

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Engine Shut Off Switch (18) This message is located in six locations. This message is located near the engine shut off switches  on the control box at the fast fill arm,  on the left side of the upper structure near the location of the pulling rope switch,  inside the operator’s cab at the control column,  on both control cabinets near the doors to the engine compartments  on the control cabinet behind the hydraulic fluid reservoir. Fig. 2-31:

Refer to Operation and Maintenance Manual, “Emergency shut-off function” for further information.

Alternate exit (33) This message is located in the cab on the left, slidable window pane. Refer to Operation and Maintenance Manual, “Alternate exit in operator’s cab and escape ladder” for further information.

Fig. 2-32:

Seat Belt (34) This message is located in the cab on the right side of the operator’s seat. WARNING A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

Fig. 2-33:

2-24

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

CE – Sign (25) This message is located inside the cab on the left window pane (in Europe only). This message indicates that the machine has been built in compliance with European directives.

Fig. 2-34:

Ladder up switch

Fig. 2-35:

Ladder down switch

Fig. 2-36:

Machine Operation (28,29) This message is located inside the cab on the left window pane. The message shows the function of the operator controls, one message is for machines with backhoe attachment, one is for machines with shovel attachment. Refer to Operation and Maintenance Manual, “Monitoring, Warning and Control Elements” for further information. Fig. 2-37:

2-25

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION ANSI – compliant safety messages set

Fig. 2-38:

2-26

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-39:

2-27

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-40:

2-28

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-41:

2-29

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-42:

2-30

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-43:

2-31

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Safety messages (ANSI) – Description In this section you can find a description of all safety messages and additional messages fitted to the machine (ANSI compliant messages set). The number in brackets, f.ex. (27), corresponds with the number of the film shown in the safety messages overview graphics. The number corresponds also with the films item number in the spare parts manual.

Fig. 2-44:

Do Not Operate (18) This safety message is located in the cab on the left side window. WARNING Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Hot Fluid Under Pressure (16)

Fig. 2-45:

This safety message is located on the cooling system expansion reservoir pressure cap. WARNING Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance. Refer to Operation and Maintenance Manual, “Cooling System Coolant Level - Check” for further information.

Batteries, Flammable Gas (10) Fig. 2-46:

This safety message is positioned on the battery cabinet. CAUTION Explosion hazard. Battery gases can cause explosions. Could cause serious injury or death. Do not smoke. No open flames.

Crushing Hazard (2)

Fig. 2-47:

2-32

This safety message is located on all four corners of the machine. DANGER Machine swings. Crushing hazard could cause serious injury or death. Stay back.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Falling Hazard (23) This safety message is located on the upper structure of the machine at the handrail gates. CAUTION Falling hazard. Could cause serious injury or death when falling down from great height. Use caution when performing service work on the attachment. Always wear your fall protection equipment. Refer to Operation and Maintenance Manual, “Working on the attachment- Safety Instructions” for further information. Fig. 2-48:

Fire Hazard (9) This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the cab module. CAUTION Fire hazard. Oil or fuel escaping in the event of damage can produce flammable vapours. Could cause serious injury. No open flames. Do not smoke. Refer to Operation and Maintenance Manual, “Fire and Explosion Hazard – Safety Instructions” for further information. Fig. 2-49:

Head Bump Hazard (8) This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments. CAUTION Head bump hazard because of low clearance. Could cause serious injury. Stay back and wear a hard hat.

Fig. 2-50:

Trip Hazard (7) This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments. CAUTION Trip hazard because of obstacles on the floor. Could cause serious injury. Be careful and pay extra attention on your steps.

Fig. 2-51:

Refer to Operation and Maintenance Manual, “Fundamental Safety Instructions” for further information.

2-33

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Hot Surface (6)

Fig. 2-52:

This safety message is located in two locations. This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the oil cooler module. CAUTION Components and assemblies of the hydraulic system and components in the engine compartments can be hot while engines are running or immediately after engine shutdown. Hot parts or hot components can cause burns or serious injury. Do not allow these parts to contact your skin, when engines are running or immediately after engine shutdown. Use protective clothing or protective equipment to protect your skin. Wait until hot components have cooled down.

Cutting Hazard (14) This message is located outside the oil cooler module. WARNING Self-starting, rotating fan blades. Can cause serious injury or cut. Keep hands away from fan. Turn off and lock-out electrical system before servicing. Fig. 2-53:

Refer to Operation and Maintenance Manual, “Other Maintenance Work” for further information.

Cutting Hazard (15) This message is located outside the counterweight near the cooling fan wheels. WARNING Rotating fan blades. Can cause serious injury or cut. Keep hands clear. Lock-out / tag out engine before servicing. Refer to Operation and Maintenance Manual, “Other Maintenance Work” for further information. Fig. 2-54:

Belt Entanglement Hazard (28) This safety message is located in two locations. This safety message is located on the belt cover assembly on each engine. WARNING Entanglement hazard. Could cause serious injury or death. Do not touch while engine is running. Keep hands away. Do not operate engine with guard removed. Shut off engines before starting maintenance work. Fig. 2-55:

2-34

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Head Bump Hazard (17) This safety message is located under the upper structure near to the fast fill arm / servicestation. CAUTION Head bump hazard when the servicestation is moving downwards. Could cause serious injury. Stay back and wear a hard hat.

Fig. 2-56:

Injury hazard, Personal Protection Equipment (PPE) Required (3) This message is located on the upper structure of the machine at the entrance to the pump bay. Eye, ear, head, hand and foot protection are mandatory beyond this place.

Fig. 2-57:

WARNING Serious injury can result from failure to use personal protective equipment. Wear appropriate personal protective equipment required for tasks being performed.

Hazardous noise level (5) This message is located on the upper structure of the machine at the entrance to the pump bay. Ear protection is mandatory beyond this place. CAUTION Hazardous noise level when engine running. May cause loss or degration of hearing over a period of time. Wear proper personal protective equipment / ear protection beyond this point. Fig. 2-58:

Always Use Seat Belt (22) This message is located in the cab on the right side of the operator’s seat. CAUTION A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury.

Fig. 2-59:

2-35

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Additional messages (ANSI) – Description

Lashing point (6) This message is located in two locations.  On the right-hand side of the carbody in the near of each of the lashing points,  On the left-hand side of the carbody in the near of each of the lashing points.

Fig. 2-60:

Notes on welding (4) This message is located on the upper structure of the machine at the entrance to the pump bay. Electric components may be damaged when electric welding work is performed near to them. Refer to Operation and Maintenance Manual, “Welding and flame cutting works - Safety Instructions” for further information. Fig. 2-61:

Notes on cleaning electric assemblies (12)

Fig. 2-62:

2-36

This message is located on electrical components in six locations. This message is located on the upper structure of the machine  at the entrance to the pump bay,  on the control cabinets in the cab module,  on the control cabinets near the doors to the engine compartments,  on the control cabinet behind the hydraulic fluid reservoir. Washing with high pressure water jet is prohibited. Refer to Operation and Maintenance Manual, “Electrical System” and “Inspection and Servicing Safety Instructions” for further information.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Emergency exit (19) This message is located in the cab on the left, slidable window pane. Refer to Operation and Maintenance Manual, “Emergency exit in operator’s cab and escape ladder” for further information.

Fig. 2-63:

Location of fire extinguisher (13) This message is located on the deck of the upper carriage behind the cab. It is located near the fire extinguishers. Read operation instructions given on the fire extinguishers.

Fig. 2-64:

Hydraulic fluid level (30 and 32) This message is located at the hydraulic fluid reservoir near the inspection glass. Refer to Operation and Maintenance Manual, “Hydraulic System” for further information.

Fig. 2-65:

Fan rotation (27) This message is located in two locations. This message is located inside the oil cooler module and inside the counterweight near the cooling fan wheels. The message shows the direction of rotation.

Fig. 2-66:

2-37

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

CE – Sign (25) This message is located inside the cab on the left window pane (in Europe only). This message indicates that the machine has been built in compliance with European directives.

Fig. 2-67:

Machine Operation (20,21) This message is located inside the cab on the left window pane. The message shows the function of the operator controls, one message is for machines with backhoe attachment, one is for machines with shovel attachment. Refer to Operation and Maintenance Manual, “Monitoring, Warning and Control Elements” for further information.

Fig. 2-68:

2-38

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Machine number

Engine serial number

The identification plate with the machine number (Fig. 2-70:) is attached to the front side of the Aframe (arrow, Fig. 2-69:).

The serial number plate (arrow, Fig. 2-71:) for the diesel engines are located on the diesel engines.

Fig. 2-69: Fig. 2-71:

Engine Information Plate The Information Plate is on the left side top surface of the cylinder block in front of the front cylinder head (arrow, Fig. 2-71:).

Fig. 2-70:

Fig. 2-72:

Component numbers Other larger units also have identification plates indicating, among other things, their serial number. On steel components, the CGM-HMS GmbH part number or the serial number may be stamped into the metal at a clearly visible place.

2-39

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Entering and leaving the machine - Safety instructions Clean off oil, grease, soil, mud, snow, ice and other substances from footwear, grab handles, ladders and steps. Keep ladders, steps, platforms and grab handles in a non-slippery condition. Risk of injury due to slipping. For entering and leaving use only the ladders, steps, platforms and grab handles provided (see: illustration in Fig. 2-73:). Always face the machine when entering or leaving it. Always maintain a three point contact with the steps and the grab handles.

Access ladder - Lighting The access ladder of the machine can be illuminated. From outside: The pull-switch (2, Fig. 2-74:) of the lighting system is located beneath the upper structure. The lights are switched on from the ground by means of the pull-rope. From the cab: The switch is located besides the door (arrow, Fig. 2-75:). The lighting remains on during a presettable ON time. The ON time of the lighting is factory-adjusted to three minutes.

Fig. 2-74:

Fig. 2-73:

Fig. 2-75:

2-40

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Swinging ladder - Function Raising resp. lowering the swinging ladder (Fig. 2-76:).

Lowering the swinging ladder from the upper structure (for leaving the machine)  Start an engine.  Push lever (1, Fig. 2-77:) on control valve (2) downwards to position “ II “ and hold. The swinging ladder is lowered (Fig. 2-76:). The swinging ladder can also be lowered when the engine ist stopped.

Fig. 2-76:

Raising the swinging ladder from the upper structure (after entering the machine)  Start an engine.  Pull lever (1, Fig. 2-77:) on control valve (2) upwards to position “ I “ and hold. The swinging ladder is raised (Fig. 2-78:).

Fig. 2-78:

 Leave the lever on the control valve in position “ I ” while operating the machine. This keeps the hydraulic ladder in the upper position (Fully retracted).

Lowering the swinging ladder from the ground (in case of emergency)  Pull down rope (3, Fig. 2-79:). The swinging ladder is lowered (Fig. 2-76:).

Fig. 2-77:

Fig. 2-79:

The upper structure can only be swung when the folding ladder is raised completely (Fig. 2-78:).

2-41

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Folding ladder (optional) – Function Raising resp. lowering the folding ladder (Fig. 2-80:).

Lowering the folding ladder from the upper structure (for leaving the machine)  Start an engine.  Push lever (1, Fig. 2-81:) on control valve (2) downwards to position “ II “ and hold. The folding ladder is lowered (Fig. 2-80:). The folding ladder can also be lowered when the engine is stopped.

Fig. 2-80:

Raising the folding ladder from the upper structure (after entering the machine)  Start an engine.  Pull lever (1, Fig. 2-81:) on control valve (2) upwards to position “ I “ and hold. The folding ladder is raised (Fig. 2-77:).  Leave the lever on the control valve in position “ I ” while operating the machine. This keeps the hydraulic ladder in the upper position (Fully retracted).

Fig. 2-82:

Lowering the folding ladder from the ground (in case of emergency)  Pull down rope (3, Fig. 2-83:). The folding ladder is lowered (Fig. 2-80:).

Fig. 2-83:

Fig. 2-81:

The upper structure can only be swung when the folding ladder is raised completely (Fig. 2-82:).

2-42

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Emergency exit in operator’s cab and escape ladder The sliding window (arrow, Fig. 2-84:) on the lefthand side of the operator’s cab serves as an alternative opening / emergency exit. To open the sliding window from inside the cab:  Lift latch (1).  Grasp handle (2) and slide window pane to the left. The escape ladder (arrow, Fig. 2-85:) is located beside the operator´s cab. Function of ladder locking as well as free movement of the ladder must be regularly checked according to the maintenance plans. Before unlocking the ladder: Be sure that no person is near to the position the ladder moves to.

Fig. 2-84:

 Pull out locking pin (1, Fig. 2-86:). The escape ladder is now unlocked and the release lever (2) is free to move.  Move release lever (2) away from the machine. The escape ladder is now released and moves down quickly to the ground.  Swing barrier (3, Fig. 2-86:) to the right and use the ladder to escape downwards.

Fig. 2-85:

Fig. 2-86:

2-43

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Cab interior lighting – Switch on and off The cab interior lighting can be switched on and off with the switches (arrow, Fig. 2-87:), (96, Fig. 2-88:) and (arrow, Fig. 2-89:) The cab interior light is supplied with power even when the electrical system is shut down. When leaving the machine, the interior light must therefore be switched off. The batteries could be discharged if the interior light is allowed to remain on for a prolonged period.

Fig. 2-87:

Fig. 2-88:

Fig. 2-89:

2-44

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Maintenance lights – Switch on and off The maintenance lights in the various modules can be activated from a central point with the switches (arrow, Fig. 2-90:) or (95, Fig. 2-91:). The invidual modules are also equipped with switches, for example the engine module: Switch at the switchgear cabinet behind the hydraulic oil reservoir (1, Fig. 2-92:).

Fig. 2-90:

Fig. 2-91:

Fig. 2-92:

2-45

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Emergency shut-off - Function The emergency shut-off function can be triggered from six different places on the machine:  by pressing the switch (red) on the front panel of the control column (35, Fig. 2-93:),

Emergency shut off switch in the operator’s cab

 by pressing the switch (red) on the drive regulators on the right-hand and on the lefthand side (Fig. 2-94:),  by pressing the switch (red) on the control cabinet in the engine module (Fig. 2-95:),  by pulling the pull-switch below the counterweight on the left (5, Fig. 2-96:),  by pressing the switch (red) on the control box at the Servicestation (Fig. 2-97:). Fig. 2-93:

The emergency shut-off function disconnects all power outputs of the electronic control units. In this case, all engines are shut off and all valves are deenergized so that no working movements can be performed anymore. The power supply of the electronic control units of the engines (ECM) and of the machine (BCS, PLC) is, however, not interrupted. For this reason, the monitoring functions continue to remain active. Other auxiliary functions such as:  the fire extinguishing system,  the service station (tank-lift) and,  the radio, the cab interior lighting and the access ladder lighting remain functional as well. The emergency shut-off function can also be triggered before maintenance operations are performed on the machine. For this purpose, one of the switches is depressed and secured with a padlock. Any inadvertent starting of the engine is thus prevented.

Emergency shut off switch at the engine compartments

Fig. 2-94:

Emergency shut off switch on the control cabinet engine module

(continued next page)

Fig. 2-95:

2-46

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Emergency shut off switches (continued) Emergency shut off pull switch between left fuel tank and counterweight

Putting the machine back into operation, reset of emergency shut off function The machine can only be put back into operation when all switches listed above are again in their basic position (i.e. not actuated). Additionally the Reset button (arrow, Fig. 2-98:) has to be pushed. The Reset button is located in the front door of the 24Volt-control cabinet in the cab module. Please note the message film near the Reset button (Fig. 2-98).

Fig. 2-96:

Emergency shut off switch on the Servicestation (tanklift)

Fig. 2-98:

Fig. 2-97:

Fig. 2-99:

2-47

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Battery isolator switch - Shut off supply voltage The battery isolator switch (1, Fig. 2-101:) is located inside the control cabinet on the deck of the engine module (Fig. 2-100:). The supply voltage is shut off when the battery isolator switch has been turned to position “OFF”. This function shuts off the complete electrical system of the machine by disconnecting the two poles from the batteries (battery main switch). In this case, all engines are shut off so that no working movements can be performed anymore. The power supply of the electronic control units of the engines and of the machine is shut off after a brief delay. The delay ensures that the current operating data can be saved and the systems shut down properly. Lock the battery isolator switch in position “OFF” by means of a padlock. The machine can only be put back into operation when the battery isolator switch is unlocked and switched in the “ON” position. A green LED located near the switch comes on.

Fig. 2-100:

Starter isolator switch - Shut off starter voltage The starter isolator switch (2, Fig. 2-102:) is located inside the control cabinet on the deck of the engine module (Fig. 2-100:). After turning the “Starter Isolator” switch to position “OFF” the engines could not be started. All other sections of the electrical system are supplied with voltage. This is to ensure personal safety during testing and trouble shooting purposes. Lock the starter isolator switch in position “OFF” by means of a padlock. The engines can only be put back into operation when the starter isolator switch is unlocked and switched into the “ON” position. A green LED located near the switch comes on.

Fig. 2-101:

Fig. 2-102:

2-48

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Operator’s seat The operator’s seat (Fig. 2-103: and Fig. 2-104:) can be adjusted in several positions.

Never adjust the seat while driving. Concentrate on the road to avoid accidents. Before carrying out any seat adjustments stop the machine and set the control levers to "0"

Fig. 2-103:

2-49

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-104:

2-50

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Reducing operators exposure to vibrations Vibrations, oscillations and movements of the machine cannot be avoided when the machine is in operation. They also have an effect on the operator. These effects on the operator can however be avoided, if the operator's seat is adjusted correctly. Therefore, make use of the seat's various adjustment features (see Fig. 2-103: and Fig. 2-104:):  shock absorption (Absorber),  body weight setting (Weight adjustment),  horizontal movement damping (Fore/aft isolator). Adjust the seat before beginning work to suit your personal requirements. Check whether all adjustments are functional. If this is not possible, have the seat checked and repaired as soon as possible.

Windscreen washer The fluid reservoir (1, Fig. 2-106:) of the windscreen washer is located in the cab module. The capacity of the reservoir is indicated under "Refilling quantities - Other".

Fig. 2-106:

Trainer's / instructor's seat For operator training / instructing purposes it is often required that a trainer / instructor accompanies the operator in the cab. For the safety of the trainer / instructor during hydraulic shovel operation the cab is equipped with a second seat. This seat is installed behind the operator's seat (Fig. 2-105:).  Sit down on this seat and do not forget to fasten the seat-belt, if installed (arrow, Fig. 2-105:).  Do not leave this seat during the training / instruction session and /or as long as the machine is in operation.

Operating hours meter (if equipped) Three operating hours meters (Fig. 2-107:) are located in the left front door of the “24 Volts switchgear cabinet” in the cab module. 1

LH engine hours meter

2

RH engine hours meter

3

Travel hours meter

Fig. 2-107: Fig. 2-105:

2-51

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Fire extinguisher The hydraulic shovel can be equipped with fire extinguishers. Base plates for mounting brackets are located at the rear wall of the operator’s cab and in the pump compartment (arrow, Fig. 2-108:).

Fig. 2-108:

The hydraulic shovel operator and the maintenance personnel must inform themselves about how to handle the fire-extinguisher in order to be able to act fast and efficiently in case of beginning fires. Such instruction should be given by a qualified instructor. Have the extinguishers inspected at regular intervals by an expert. This is required by local authorities and insurance companies and is in the interest of your own safety.

2-52

Automatic fire-extinguishing system Please contact your local Cat dealer for more detailed information. The automatic fire-extinguishing system prevents fire from spreading. It is, however, assumed that the machine is thoroughly cleaned of combustible and easily flammable substances. The hydraulic shovel operator and the maintenance personnel must familiarize themselves with the automatic fire-extinguishing system. Such instruction should be given by a qualified instructor. The fire-extinguishing system is activated automatically in an emergency. Have the extinguishing system inspected regularly by an expert. This is required by authorities and insurance companies and is in the interest of your own safety.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

2-53

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-109:

2-54

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-109:) BCS, Board-Control-System No. 1

2

3

4

Element BCS

Function Electronic system for measured data acquisition and processing

Board Control System, acquisition and display of important operating data of the hydraulic shovel

Monitor

BCS

The monitor displays collected operating data, warning messages and – if needed – instruction for help.

Push-button

Navigation in menus Control of cursor movements, program selection within the BCS, confirmation of inputs / displayed values (Enter), quitting of menus / sub-menus Numeric keypad Input of numeric values.

Push-button

Symbol

The surface of the monitor is sensitive to the touch (touch-screen technology). A touchscreen permits selecting menus and programs by touching graphic control symbols and to recall, for instance operating data of the hydraulic shovel. For further information please refer to section 5 of this Operation and Maintenance Manual, chapter “Board-Control-System”.

2-55

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-110

2-56

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-110) BCS, Board Control System, display screen example (For further information please refer to section 5 of this Operation and Maintenance Manual, chapter “BoardControl-System”). No. 1

2

3

4 5 6

Element

Function

Status line

Indicates activated functions and operating hours. The symbols displayed are those of the switches in the control column

Touch-screen Monitor

BCS

Indicates collected operating data graphically and / or numerically, displays warning messages, fault messages and – if needed – instructions for help.

Pushbutton

Navigation in menus

Control of cursor movements, program selection within the BCS, confirmation of inputs / displayed values (Enter), quitting of menus / sub-menus

Push-button

Numeric keypad

Input of numeric values.

Touch-screen buttons Status line

Examples Fault messages

Symbol

Displays fault messages as a code number and as plain text. The "Fault" button permits displaying further fault messages stored in the system.

2-57

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-111:

2-58

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-111:)

No.

Element

Function

Key-switch

Switches the electrical system on and off.

33

Buzzer (inside the control column)

Gives three acoustic warning signals if a fault is reported. The signals appear every 30 seconds.

34

Socket connectors

Connection of electronic devices for fault diagnosis purposes.

32

35

Switch

Emergency shut-off

Symbol

De-energizes the outputs of the electronic control units: The engines are shut off, all valves are deenergized, working movements no longer possible. (see: "Emergency shut-off function").

2-59

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-112:

2-60

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-112:)

Engine 1 (LH), control and monitoring All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated. No. 41 42 43

44 45

46 47 48

Element

Function

Push-button

Start

Starting of the engine. For starting, press the push-button face with the symbol.

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

Push-button

Idle

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol.

Warning lamp

Engine oil pressure

Lit up when the engine oil pressure is too low.

Warning lamp

Alternator

Lit up when the batteries are not being charged or in the event of an alternator defect.

Warning lamp

Engine oil temperature

Lit up when the engine oil temperature is too high.

Warning lamp

Cooling liquid temperature

Lit up when the engine cooling liquid temperature is too high.

Switch

Engine speed

Press switch face without symbol: the speed of the engine increases.

Symbol

Press the switch face with the symbol: the speed of the engine reduces. 49

50

Warning lamp

Warning lamp

Engine monitoring

STOP!

Engine monitoring

Lamp is lit up in the event of a critical fault on the left engine 1. Shut off engine immediately. Check the BCS display for further fault messages and give an information to the responsible service personnel immediately. Not used on this machine.

2-61

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-113:

2-62

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-113:)

Engine 2 (RH), control and monitoring All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated. No. Element Function Symbol Starting of the engine. For starting, press the Push-button Start 51 push-button face with the symbol. 52 53 54 55 56 57 58

59

60

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

Push-button

Idle

Warning lamp

Engine oil pressure

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol.. Lit up when the engine oil pressure is too low.

Warning lamp

Alternator

Warning lamp

Engine oil temperature

Lit up when the batteries are not being charged or in the event of an alternator defect. Lit up when the engine oil temperature is too high.

Warning lamp

Cooling liquid temperature

Lit up when the engine cooling liquid temperature is too high.

Switch

Engine speed

Press switch face without symbol: the speed of the engine increases. Press the switch face with the symbol: the speed of the engine reduces.

Warning lamp

Engine monitoring

STOP!

Engine monitoring

Lamp is lit up in the event of a critical fault on the right engine 2. Shut off engine immediately. Check the BCS display for further fault messages and give an information to the responsible service personnel immediately. Not used on this machine.

Warning lamp

2-63

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-114:

2-64

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-114:) All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated. No. 61

Element Push-button

Function Upper structure holding brake

Symbol

Blocks the upper structure. Press this button when the upper structure is stationary. Do not use this button while the upper structure is still in motion. Risk of damage to the brake and the swing gearboxes. Not connected.

62 63

Switch

Hydraulic shovel parking brake

Not actuated: The parking brake is applied automatically ca. 5 secs after the hydraulic shovel has stopped moving. The parking brake is released automatically when the "Travel" function is activated. Press the switch face with the symbol: The parking brake is applied permanently. The hydraulic shovel cannot be moved. Actuate this switch only when the hydraulic shovel is stationary. Do not use this switch while the hydraulic shovel is still in motion. Risk of damage to the brakes and the travel gearboxes.

64

Push-button

Central greasing system reset

Reset function of the central greasing system control (Press for at least 3 sec.). Press switch face without symbol: Resets the control of the upper structure. Press the switch face with the symbol: Resets the control of the undercarriage.

65

Push-button

Emergency lowering

Lowering of the attachment in an emergency situation. For instance, if the engines have failed. For more information refer to chapter “Engine-off lowering of the attachment”.

66

Switch

Automatic speed reduction

Reduces the speed of the diesel engines to about 1000 min-1, if no working movement is being executed during about 8 seconds.

2-65

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-115:

2-66

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-115:)

All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated. No. 71

72

Element

Function

Switch

Servo-control

Press the switch face with the symbol: The electro-hydraulic servo-control is enabled.

Switch

Traveling speed

Not actuated: 1st traveling stage traveling forwards / backwards is possible.

Symbol

Press the switch face with the symbol: 2nd traveling stage traveling forwards / backwards is possible. Not connected.

73 74

Monitoring lamps

Engine oil interval prolongation

Not connected.

75 76

Lamp is lit up, when the right or the left pump of the prolongation system is running.

Push-button

When the machine has to be manoeuvered out of dangerous situations

Press the switch face with the symbol: The machine can be driven and the upper structure be swung although these functions are automatically deactivated. Use this function only in dangerous situations to manouever yourself or the machine out of hazard zones. Risk of damaging parts of the machine, e.g. the hydraulic ladder or the tanklift.

81 82 83 84 85 86

Switch

Floodlamps

Switches the floodlamps on the operator´s cab on and off.

Switch

Floodlamps

Switches the floodlamps on the hydraulic oil cooler module on and off.

Switch

Floodlamps

Switches the floodlamps on the cab module on and off.

Switch

Floodlamps

Switches the floodlamps on the boomon and off.

Switch

Floodlamps rear

Switches the floodlamps on the counterweight on and off.

Switch

Not connected.

2-67

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-116:

2-68

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-116:) All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated. No.

Element

Function

91

Push-button

Dumper count

Press the switch face with the symbol: Resets the loaded dumper count.

92

Switch

Windscreen wiper

Press the switch face with the symbol: Windscreen wiper in intermittent operation mode.

Symbol

Press the switch face without symbol: Windscreen wiper in permanent operation mode. 93

Pushbutton

Windscreen washer

Press the switch face with the symbol: Windscreen wiper in wipe/wash operation.

94

Switch

Rotary beacon (option)

Press the switch face with the symbol: Rotary beacon ON.

95

Switch

Lighting

Press the switch face with the symbol: Switches on the maintenance lights in the modules.

96

Switch

Lighting

Press the switch face with the symbol: Switches on the lights in the operator's cab.

97

Outlet

For connecting electrical driven devices, e. g. for charging small accumulators. Operating voltage: 12 Volts. Maximum power output: 120 Watts.

2-69

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-117:

2-70

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-117:) No. Element 101 Push-button

102 Push-button

103 Push-button

104 Push-button 105 Push-button inside the seat

111 Pedal 112 Pedal 113 Pedal 114 Footrest 115 Control lever

116 Control lever

117 Push-button 118 Thumb wheel

119 Push-button

120 Thumb wheel

Function Symbol Can be used as a push-to-speak button on a radio, or to switch over from one camera to another one. Button is pressed: Stick floating The stick cylinders are pressurized on position (shovel retracting. equipment only) Press button (102) only in position "0" of control lever (115). Button is pressed: Boom floating The boom cylinders are pressurized on position retracting. Press button (103) only in position "0" of control lever (116). Warning signal Button is pressed: Acoustic warning signal / horn is activated. Electronic hydraulic Button in the seat. The electronic hydraulic shovel control shovel control (servo-control) is activated when the (servo-control) operators sits down on the seat. The electronic hydraulic shovel control (servo-control) is deactivated when he leaves the seat. Shovel trap (shovel Forwards – shovel trap is opened; Backwards – shovel trap is closed. equipment only) Travel, left track Forwards – forward travel; Backwards – backward travel. Travel, right track Forwards – forward travel; Backwards – backward travel.

(Free for options)

Forwards – raising the stick Backwards – lowering the stick. To the left / right – swinging and braking of the upper structure. Forwards – lowering the boom; Backwards – raising the boom. To the left – backwards tipping of shovel / bucket; To the right – dumping of shovel / bucket. Not used on this machine. Shovel trap (shovel Turn Forwards – shovel trap is opened; Turn Backwards – shovel trap is closed. equipment only) Function can be overridden by Pedal 111. (Thumb wheel is spring centered). Lower half pushed – automatically stopped By-pass for the automatically switch stick- and/or backhoe cylinders can be off for stick- and /or driven slowly to the limit stopps. backhoe cylinders Upper half pushed – Each press on the (Option) button increments the loaded dumper count for by "1". (Count reset with button (91)). Not used on this machine.

2-71

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-118:

2-72

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-118:) Engine 1 (left) monitoring No.

Element

121

Monitoring device

Engine monitoring Indicates different parameters on the display (E) (engine 1 left) Use push buttons (C and D) to scroll through parameter list. Indicator lamps (A and B) lit when an active fault occurs.

122

Thermometer

Engine temperature (engine 1 left)

123

Pressure gauge

Engine oil pressure Indicates the oil pressure in the diesel engine lubricating system. (engine 1 left)

124

Warning device

Engine monitoring (engine 1 left)

Function

Symbol

Indicates the cooling-water temperature.

Gives an acoustic warning signal if a fault is reported, e.g.  Engine oil pressure too low, 

Engine temperature too high. Lower the equipment to the ground and shut off engine immediately if the warning device (124) sounds. The warning device (124) continues to sound until the fault has been rectified.

Lits up when engine is in idle phase.

125

Indicator lamp

Idle (engine 1 left)

126

Warning lamp

Cooling water level Lits up when the cooling-water level is too low. (engine 1 left)

127

Warning lamp

Alternator (engine 1 left)

Lits up when the batteries are not recharged.

2-73

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-119:

2-74

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-119:) Engine 2 (right) monitoring No.

Element

131

Monitoring device

Engine monitoring Indicates different parameters on the display (E) (engine 2 right) Use push buttons (C and D) to scroll through parameter list. Indicator lamps (A and B) lit when an active fault occurs.

132

Thermometer

Engine temperature (engine 2 right)

133

Pressure gauge

Engine oil pressure Indicates the oil pressure in the diesel engine lubricating system. (engine 2 right)

134

Warning device

Engine monitoring (engine 2 right)

Function

Symbol

Indicates the cooling-water temperature.

Gives an acoustic warning signal if a fault is reported, e.g.  Engine oil pressure too low, 

Engine temperature too high. Lower the equipment to the ground and shut off engine immediately if the warning device (134) sounds. The warning device (134) continues to sound until the fault has been rectified.

Lits up when engine is in idle phase.

135

Indicator lamp

Idle (engine 2 right)

136

Warning lamp

Cooling water level Lits up when the cooling-water level is too low. (engine 2 right)

137

Warning lamp

Alternator (engine 2 right)

Lits up when the batteries are not recharged.

2-75

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-120:

2-76

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-120:)

Optional equipment: Auxiliary heating; Fuel Pre-heating (Depending on the options ordered with the machine, the described elements can be found on different positions on the control column). Nr. 140 141 142

143

144

Funksjon

Element Auxiliary heating (option) Auxiliary heating blower (option) Auxiliary heating (option)

Auxiliary heating for operator's cab ON / OFF. Blower levels 1,2,3.

Switch

Fuel Pre-heating (option)

Switches the fuel pre-heating function of RH engine on and off.

Switch

Fuel Pre-heating (option)

Switches the fuel pre-heating function of LH engine on and off.

Switch Switch Switch

Symbol

Auxiliary heating for operator's cab ON / OFF. Automatic regulation.

2-77

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-121:

2-78

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-121:)

Optional equipment: Air conditioning (Depending on the options ordered with the machine, the described elements can be found on different positions on the control column). No. 150 151 152

Function

Element

Blower levels 1,2,3.

Knob

Blower of air conditioner Thermostat

Rotary switch

Selector

Selects the following functions: heating, cooling, ventilation, defrosting.

Rotary switch

Symbol

Presetting of desired temperature.

2-79

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Fig. 2-122:

2-80

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION (Fig. 2-122:)

Optional equipment: Air filter monitoring (Depending on the options ordered with the machine, the described elements can be found on different positions on or near the control column). Function

No.

Element

191

Underpressure gauge

Air filters (left engine 1, outside)

192

Underpressure gauge

Air filters (left engine 1, inside)

193

Underpressure gauge

Air filters (right engine 2, outside)

194

Underpressure gauge

Air filters (right engine 2, inside)

Symbol

Indicates the underpressure in the air filters. Underpressure must be less than 25 inches (635 mm) water column. Otherwise clean / replace the filterelement. Indicates the underpressure in the air filters. Underpressure must be less than 25 inches (635 mm) water column. Otherwise clean / replace the filterelement. Indicates the underpressure in the air filters. Underpressure must be less than 25 inches (635 mm) water column. Otherwise clean / replace the filterelement. Indicates the underpressure in the air filters. Underpressure must be less than 25 inches (635 mm) water column. Otherwise clean / replace the filterelement.

2-81

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION PUTTING THE MACHINE INTO OPERATION

Reducing the operator's exposure to noise

Before daily start-up, carry out works in accordance with servicing plan T (see: Part 3 "Inspection and servicing")

All noise protection devices of the machine must be in place and fully functional when the machine is in operation. e.g.  doors, flaps and cover of the engine compartments must be closed,

Increased fire and explosion hazard will exist. Prior to your daily start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

Electrical Storm Injury Prevention When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures:  Mount the machine. 

Dismount the machine.

If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

2-82



access doors to the compartments of the radiator fans must not be left open,



the cab door must be closed,



the exhaust silencer must be checked for holes,



the screwed conections of all components fastend with bolts must be checked for tightness. Loose components tend to vibrate and to rattle, thus increasing the noise level.

Wear ear protectors when leaving the operator's cab with the engines on and running.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Refuelling Refuelling - Safety instructions Explosion hazard. Risk of fire. Fuels and fuel gases are inflammable. Avoid open flames and stop smoking.

Back-up heating (option) - Fill in fuel  The fuel reservoir for the back-up heating system is located in the module below the operator’s cab (Fig. 2-123:).  Fill in clean fuel through the filler neck.

Fuel may cause skin injury. Wear protective gloves or use a barrier cream. Stand attachment on the ground. Shut off the engines.  Fuel is to be filled in using the service station (tanklift), see the following chapter "Service station (tanklift), Fuel Tank". Do not spill fuel and do not allow fuel to penetrate into the soil. Fuel pollutes the environment. Wipe off spilt fuel immediately with cleaning rags or soak up with binding agents. Fuel and cleaning material must be disposed of without polluting the environment. Report fuel accidents immediately to the responsible person. Check the grounding straps (equipotential bonding) at the tank lift regularly for proper fastening. Grounding straps can remove voltages and prevent fire during refuelling only when properly fastened.

Fig. 2-123:

Diesel fuel – Recommendations Diesel fuel must meet the “Caterpillar Specification for Destillate Fuel” and the latest versions of “ASTM D975” (Nr. 1-D or Nr. 2-D fuel) or “EN 590” in order to ensure optimum engine performance. Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for the latest fuel information and for Cat fuel specification. This manual may be found on the Web at www.safety.cat.com or contact your Cat dealer. Failures that result from the use of improper fuels are not Caterpillar factory defects. Therefore the costs of repairs would not be covered by a Caterpillar warranty.

2-83

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Service Station (fast fill arm) The hydraulic shovel is equipped with a central service station (Fig. 2-124: resp. Fig. 2-125:) for refuelling. A service vehicle is needed for filling and/or draining of the fluids. The service station is accessible from the ground below the upper structure. Risk of injury. Always stay clear of the moving service station. The service station is moved downwards and upwards by means of a hydraulic driven cylinder. The up and down movement of the service station is initiated the switch (1, Fig. 2-125:). The switch is located in a control box at the hydraulic ladder (arrow).

To lower the service station:

Fig. 2-124:

 Push momentary switch (1, Fig. 2-125:) downwards and hold until the service station is in its lower position.

To bring the service station in the upmost position:  Push switch (1) upwards. Service station is moved upwards until it reaches its upmost position. With switch (1) in its middle position, movement of the service station is stopped.

Fig. 2-125:

2-84

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Express couplings are provided for refilling / draining the following consumables (fluids). Note: Connections used may vary depending on how the machine is equipped. Pos. Fig. 2-126: 1 2 3 4 5 6 7 8 9 10 11 12 13-15

Consumable

Express coupling for

Diesel fuel for lefthand and righthand fuel tank Cooling fluid for lefthand engine Cooling fluid for righthand engine Gearbox oil for left pump drive gearbox Gearbox oil for right pump drive gearbox Tank for engine oil interval prolongation lefthand engine. Tank for engine oil interval prolongation lefthand engine. Engine oil for lefthand engine Engine oil for righthand engine Hydraulic oil tank

Filling

Grease container Swing gear Not used

Filling and/or draining Filling and/or draining Filling and/or draining Filling and/or draining Filling and/or draining

Refilling and draining For filling in or for draining consumables / fluids, unscrew the cap of the corresponding express coupling (Fig. 2-126:). Attach express coupling of filling hose from the service vehicle to the corresponding express coupling at the service station. Fill in or drain off consumable / fluid. Take off filling hose and refit cap on the express coupling.

Emergency off switch The control box at the service station is equipped with an emergency off switch (arrow, Fig. 2-127:). In case of emergency press the button. The electrical system is switched off.

Filling and/or draining Filling and/or draining Filling and/or draining Filling and/or draining Filling Filling

Fig. 2-127:

Fig. 2-126:

2-85

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Assemblies resp. Measuring device reservoirs Fuel tank BCS fuel indicator (Fig. 2-128:)

Fig. 2-128:

2-86

Remarks Switch on the monitoring system by using toggle switch (23, Fig. 2-129:). The indicator light (22) comes on. Fill in fuel using express coupling (1). The indicator light (32) comes on when the LH fuel tank is full. Stop filling when the fuel tank is full. The indicator light (33) comes on when the RH fuel tank is full. Stop filling when the fuel tank is full. Switch off the monitoring system by using toggle switch (23), indicator light (22) is off.

Fig. 2-129:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Assemblies resp. Measuring device reservoirs Pump drive Dipstick (1, Fig. 2-130:) gearboxes

Engines

Dipstick (1, Fig. 2-132:)

Engine oil tank (option)

Monitoring lamps (1 and 2, Fig. 2-133:)

Remarks Fill in gear oil using express couplings (4 and 5, Fig. 2-131:). Stop filling when the oil reaches the "max" mark on the dipstick (see: Part 3, chapter "Pump drive gearbox gearbox - Check oil level/Fill in oil"). Fill in engine oil using express couplings (8 and 9, Fig. 2-133:). Stop filling when the oil reaches the "max" mark on the dipstick (see chapter "Engine oil – Check level/top up"). Small amounts of oil can be filled in through the filler neck (2, Fig. 2-132:) at the engine. Fill in engine oil using express couplings (6 and 7, Fig. 2-133:). Stop filling when monitoring lamps (1 and / or 2) lit up, (see chapter "Engine - Fill in oil").

Fig. 2-132: Fig. 2-130:

Fig. 2-133:

Fig.

2-131:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Assemblies resp. Measuring device reservoirs

Remarks

Hydraulic oil tank

Checking the oil level: Extend the piston rods of stick and bucket cylinders halfway. Stand attachment on the ground. Check oil level at an oil temperature of ca. 50 °C / 122 °F, with the engines stationary. Fill in oil through express coupling (10, Fig. 2-136:) when the oil level in the inspection glass has dropped below the "min" mark on sign (2). Stop filling if the acoustic warning signal “Travel Alarm” sounds and oil reaches the "max" mark on sign (2) near the inspection glass (see chapter "Hydraulic oil level Check").

Inspection glass (1, Fig. 2-134:), sign (2. Fig. 2-134: and Fig. 2-135:)

Fig. 2-134: Fig. 2-136:

Fig. 2-135:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Assemblies resp. Measuring device reservoirs

Remarks

Cooling system reservoir

Fill in cooling fluid using express couplings (2 and/or 3, Fig. 2-139:). Stop filling when the level indicator indicates maximum filling level. (see chapter "Cooling liquid level - Check"). BCS gives a warning if the grease container is nearly empty. Switch on the display system (optional) with the toggle switch (23), indicator lamp (22) comes on. Fill in grease using express coupling (11, Fig. 2-140:). Stop filling when the grease container is full, the indicator lamp (34) lights up. On completion of filling, switch the display system off again with the toggle switch (23), indicator lamp (22) is off.

Level indicator (4, Fig. 2-137:)

Grease container – BCS display (Fig. 2-138:) cental lubricating system

Fig. 2-137:

Fig. 2-138:

Fig. 2-139:

Fig. 2-140:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Electrical system – Switch on and off The electrical system is switched on with keyswitch (32, Fig. 2-141:).  Insert key into key-switch and turn to the right. If the electrical system cannot be switched on, check first whether the battery main switch is on (see chapter "Battery isolator switch - Shut off supply voltage").

Engines - Emergency shut-off In an emergency, the engines can be stopped out of full load. To do so:  Depress the emergency shut-off switch (35, Fig. 2-142:). The engines are stopped. (see chapter "Emergency shut-off function").  Switch off the electrical system with key-switch (32).

Fig. 2-142: Fig. 2-141:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Preheating system for engine and hydraulic oil (if equipped) Preheating system for engine and hydraulic oil, function The preheating system consists of heating elements for engine oil, engine coolant and hydraulic oil. At low outside temperatures, the system facilitates starting of the engine and ensures that the hydraulic system reaches its operating temperature faster. The preheating system is operated electrically with an external supply voltage. This voltage is available at a socket outlet at the service-station (fast fill arm) (Fig. 2-143:). (The system has been set at the factory for a standard supply of 400 volts, three phase AC. Other voltages are available on request as well as socket outlets meeting other standards).

When the temperatures of the engine oil, engine coolant and the hydraulic oil are below -10°C / 14°F:  Connect the system to the external power supply.  Switch on the preheating system with switch (1, Fig. 2-144:). The pilot lamp (2, Fig. 2-144:) lights up.  Switch off the preheating system with switch (1, Fig. 2-144:) when the engine and the hydraulic system have reached a temperature above 0°C / 32°F. The pilot lamp (2, Fig. 2-144:) goes out.  Switch on the fuel preheating system (see "Fuel preheating system (if equipped)").

Switching the preheating system for engine and hydraulic oil on and off Risk of an electric shock. Check first: Insulation of the socket outlet on the machine in good condition? Insulation of the connecting cable in good condition? Connect the system to the power supply only if the insulation of the components is in perfect condition. Observe the national safety regulations to be applied in the presence of electric current.

Fig. 2-143:

Switch and pilot lamp are located at the switchgear cabinet in the engine module behind the hydraulic oil reservoir (Fig. 2-144:).

Fig. 2-144:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Fuel preheating system (if equipped) Fuel preheating system, function At temperatures below 0°C / 32°F, the paraffin particles contained in the diesel fuel begin to clump together. They form flakes which clog up the fuel lines and the filters. Starting of the engine is then no longer possible. To prevent this, the diesel fuel must be preheated. Preheating is effected by means of two heating elements in the fuel line. The heating elements are attached to the engines. They are equipped with internal thermostats ensuring an automatic temperature regulation. Switch on the fuel preheating only after preheating of the engine and of the hydraulic oil is terminated (see "Preheating system for engine and hydraulic oil (if equipped)"). The preheating time is dependent on the outside temperature.

Fig. 2-145:

Switching the fuel preheating system on and off  Switch on the ignition by turning key-switch (32, Fig. 2-145:) to position 1.  At temperatures below 0°C / 32°F, switch on the fuel preheating: switch (144, Fig. 2-146:) for the left hand engine, switch (143) for the right hand engine. The pilot lamp located above the resp. switch lights up.  After a short time start up the engines (see also "Starting and stopping the engines").  Switch off the fuel preheating with switches (143 and 144), when the engines has reached their operating temperatures. The pilot lamp (Fig. 2-146:) goes out.

2-92

Fig. 2-146:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION ENGINES - STARTING AND STOPPING Engines - Start

Starting the left-hand engine

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm. Start and operate combustion engines only on well-ventilated premises. In closed rooms, exhaust gases must be evacuated to the outside. Do not work on the exhaust system an do not make any modifications to it. All control levers and pedals must be in position "0". Pull out all emergency shut-off switches. Pull out both switches for the battery main switch. Check for persons on the machine. Do not start engines until all persons have left the machine. Activate the horn before you start the engines to give a warning signal to people around. Start the engines one after another.

Fig. 2-147:

Starting the right-hand engine

 Switch on the electrical system with key-switch (32). Warning lamps (44 – 47, Fig. 2-147:) and (54 – 57, Fig. 2-148:) light up. The engine starts up only after the lubrication pressure has built up inside the engine. An acoustic warning signal sounds.  Press button (41, Fig. 2-147:) to start the lefthand engine. Release button (41) as soon as the engine has fired. Warning lamps (44 – 47) go out.  Press button (51, Fig. 2-148:) to start the righthand engine. Release button (51) as soon as the engine has fired. Warning lamps (54 – 57) go out.

Fig. 2-148:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Repeat the starting procedure if one of the engines does not fire. Repeat starting procedure not more often than three to four times. Do not operate the starter for more than 10 seconds. If warning lamps (44 – 47, Fig. 2-147:) or (54 – 57, Fig. 2-148:) do not go out or when the BCS (Fig. 2-149:) displays a fault message after starting, the engine concerned must be stopped immediately. Locate the cause of the fault and rectify before restarting the engine.

Engines – Adjust speed Adjust the speed of the left-hand engine with switch (48, Fig. 2-147:). Adjust the speed of the right-hand engine with switch (58, Fig. 2-148:).  Press the switch face without symbol the engine speed is raised up to maximum speed.  Press the switch face with the symbol the engine speed is reduced to idling speed.

Engines - Start at low temperatures

Fig. 2-149:

2-94

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device. The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment. The vessel is screwed into an electro-mechanical metering valve. When the engine is started at temperatures below 0 °C (32 °F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of coldstarting fluid into the air intake duct of the engine. Ether is toxic and highly inflammable. Safety instructions and information concerning the handling of pressure vessels for cold-starting fluids (ether) can be found in the following chapters: "Fundamental safety instructions", "Inspection and servicing - Safety instructions", "Cold-starting fluid (ether) - Replacing the pressure vessel".

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Engines - Shut off

Shutting off the left-hand engine

During interruptions of the work and after the work, stand attachment on the ground. Do not shut off the engines before the attachment rests on the ground.

Do not shut off the engine out of full load. The engine should be run at no more than one-half of the rated rpm for another 5 minutes to allow the lubricating oil and the cooling liquid to dissipate the combustion heat from the combustion chamber and from bearings and shafts.  Reduce the speed of the engines to idling by pressing the left side of the speed adjusting switches (48, Fig. 2-150:) and (58, Fig. 2-151:).  Press button (42, Fig. 2-150:) for the left-hand engine. The left-hand engine is stopped. Warning lamps (44 – 47) light up.  Press button (52, Fig. 2-151:) for the righthand engine. The right-hand engine is stopped. Warning lamps (54 – 57) light up.

Fig. 2-150:

Shutting off the right-hand engine

 Switch off the electrical system with key-switch (32). Warning lamps (44 – 47, Fig. 2-150:) and (54 – 57, Fig. 2-151:) go out. The engines will be shut off with a delay of a few seconds. During this time, the current operating data are saved and the electronic units shut down.

Fig. 2-151:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION AIR CONDITIONER (OPTIONAL) Control unit (SIGMA dual) The air conditioning system (single or dual) is installed under the cab roof (Fig. 2-152:). The illustration (Fig. 2-153:) shows a control unit for a dual air conditioner. The control unit of a single air conditioning system contains the control elements only once. Do not switch on the air conditioner when the backup heating is set to ”heating”.

Unit 1 Pos. Element 1 Rotary switch 2 3

Thermostat Rotary switch

Unit 2 Pos. Element 4 Rotary switch 5

Thermostat

6

Rotary switch

Function selects the intensity level of the blower (3 levels) sets the desired temperature inside the cab selects the desired control function (heating, cooling, ventilation, defrosting)

Fig. 2-152:

Function selects the intensity level of the blower (3 levels) sets the desired temperature inside the cab selects the desired control function (heating, cooling, ventilation, defrosting) Fig. 2-153:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Back-up heating operator’s cab (optional) The back-up heating for the operator’s cab is located in the module below the operator’ cab (Fig. 2-154:). The heating consists of one or two heating units (1) and the fuel reservoir (2).  Switch on the back-up heating using switch (142, Fig. 2-155:). The pilot lamp above switch (142) lights up. The heating system has an automatic regulation. Do not switch on the back-up heating when the air conditioner is set to ”cooling”.

Fig. 2-154:

Fig. 2-155:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Back-up heating (optional) The back-up heating is located in the module below the operator’ cab (Fig. 2-156:). The heating system uses the engine cooling fluid. Therefore full heating power is available after the engines reach their operating temperature. Before switching on the blower, turn the valves (arrow, Fig. 2-156:) into direction of flow. The back-up heating control elements are located at the control column unit (Fig. 2-158:).

Control unit (Fig. 2-158:):

Do not switch on the back-up heating when the air conditioner is set to ”cooling”.

Fig. 2-158:

Pos. Element

Fig. 2-156:

Fig. 2-157:

2-98

Function

1

Indicator lamp heating ON

2

Indicator lamp blower ON

3

Indicator lamp heating

4

Indicator lamp cooling

5

Switch

heating ON

6

Switch

blower ON

7

Indicator lamp blower level 3

8

Indicator lamp blower level 2

9

Indicator lamp blower level 1

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION OPERATIONAL PRACTICES Working operation - Safety instructions

Personnel Any work with the machine must be executed only by reliable, skilled and well trained personnel in good healthy condition. Statutory minimum age limits must be observed. Never operate the machine while impared with drugs or alcohol. Read the sections "Fundamental safety instructions" and "Operation, safety instructions" in this Operation and Maintenance Manual carefully and observe the instructions given in this sections. Observe all job site safety requirements. State of the site Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life! Clear all obstacles from the path of the machine. Sound the horn to warn persons in the immediate vicinity before starting work. Stop work if anyone is in the hazard range of the machine. Make sure all persons have left the hazard range before resuming work.

State of operator’s workplace Inspect and fasten your seat belts. Adjust the operator’s seat for comfortable reach all controls and pedals. Adjust for operator height and weight. Keep your workplace clean. Remove all unsecured items like tools and other supplies from the cab. Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements. Clean and secure all windows and doors. Clean and adjust all mirrors for optimum vision. Start the engines only from the operator’s compartment. Operate the machine only while sitting on the operator’s seat. State of the machine Operate the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional. Do not operate the machine,  when several track rollers or upper rollers have been removed; 

when one or several swing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Machine stability Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk. When working or traveling on a slope is required, do not exceed the maximum machine inclination for working operation and for traveling (refer to Operation and Maintenance Manual section “Maximum machine inclinations”). Ensure that the attachment has adequate clearance below overhead power lines and structures. Trenches and working faces may give way. Keep well clear of them. As travel brakes are deactivated, the machine could slightly move in direction of excavating during operation. Whenever loading operation is interrupted, stand attachment on the ground. This avoids slight movement of the machine and possible consequential damage of lowered ladder, in case ignition remains engaged.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs. Such circumstances are considered by CGM HMS as "abusive utilization". CGM HMS refuses to assume the guarantee for damage and consequential damage caused by an abusive utilization of the machine.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Before starting work

Warming up the hydraulic system

Perform a machine walk around inspection. Report any obvious damage and defects – including changes in the machine’s working behaviour- to your supervisor. In the event of malfunctions, stop the machine immediately and lock it.

At low outside temperatures from 0 °C to -20 °C (32 °F to -4 °F) it is necessary to run the hydraulic system nearly up to operating temperature. The outside temperatures at which warming up is necessary depend on the type of hydraulic fluid used; refer to section "LUBRICANTS / CONSUMABLES".  Switch the SERVO switch in the control tower to the OFF position.  Switch the SWING BRAKE switch in the control tower to the ON position.  Bring the engines to moderate speed (i.e. ca. 2/3 full speed), then use the boom-up-function or the stick-out-function to engage the hydraulic pumps until the hydraulic fluid temperature reaches 10 °C (50 °F) and the PTO temperature reaches 4 °C (39 °F). Watch the BCS screen.  Switch the SERVO switch to ON.  Move the attachment components in a slow function one at a time. Do not extend the cylinders fully to the stop.  Bring the attachment to the ground.  Switch the SWING BRAKE switch in the control tower to the OFF position.  Switch the SERVO switch in the control tower to the ON position.  Use swing-left or swing-right-function slowly. This will heat the swing hydraulic system quickly.  Once the swing temperature is warm you can lift the attachment and swing the upper structure in a slow 360 degree left turn then a right turn.  Use the travel function forward or reverse slowly to warm up the travel circuits. If the BCS indicates problems with the cooling liquid temperature, engine oil pressure, coolant level, alternator or hydraulic fluid filter control (with hydraulic fluid at service temperature):  Lower the attachment to the ground and shut off the engines.  Call your supervisor and report the problem. When working constantly at low outside temperatures activate the “Cold area warm-up mode” of the BCS (At machines with CAMP / SIL electric system). Refer to Operation and Maintenance Manual, section “Cold area warm-up mode – activate”.

Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded equipment for abt. 5 minutes. This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts. Prior to each shift perform a complete 360° swing movement of the upper structure. Doing this ensures proper distribution of grease and brings all the bearing rollers inside the swing ring to new positions.

Machine Operating Temperature Range The machine must function satisfactorily in the anticipated ambient temperature limits that are encountered during operation. The standard machine configuration is intended for use within an ambient temperature range of −20 °C (-4 °F) to 55 °C (131 °F). Special configurations for different ambient temperatures may be available. For use at temperatures below -10 ° C (14 ° F), the machine can be equipped with a cold weather package. Consult your Caterpillar dealer for additional information on special configurations of your machine.

2-100

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Electronic hydraulic shovel control (pilot control) – activate The hydraulic shovel can execute working movements only after the electronic hydraulic shovel control (pilot control) has been activated. The pilot control block is enabled by switch (71, Fig. 2-159:). At the beginning of the work, the electronic hydraulic shovel control (pilot control) is activated by a contact in the operator's seat (105):  Electronic hydraulic shovel control ON The operator is sitting on his seat.  Elektronic hydraulic shovel control is OFF The operator's seat is empty. Note: During operation it is absolutely necessary that the operator keeps sitting on his seat. Otherwise working movements may be interrupted suddenly. Risk of damaging the holding brakes and the gearboxes.

Fig. 2-159:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Working operation – basics This section gives you basic information about the functions of the joystick controls. For further detailed information refer to section “Operation Techniques” in this Operation and Maintenance Manual:  “Machine operation with backhoe attachment Best Practices”,  “Machine operation with backhoe attachment – Restricted Operation”,  “Machine operation with face shovel attachment - Best Practices”,  “Machine operation with face shovel attachment – Restricted Operation”.

Working on level ground CGM HMS recommends operating the machine on level and stable ground. Doing so ensures maximum productivity and prevents machine components from premature wear.

Working on slopes or on rough terrain Clean and level rough terrain before moving into the bank. A clean, level pit floor is necessary for safe and stable machine operation and prevents the tracks and other components of the undercarriage from being damaged. When working or traveling on a slope is required, do not exceed the maximum machine inclination for working operation and for traveling (refer to Operation and Maintenance Manual section “Maximum machine inclinations”). If the machine begins to sideslip on a slope, immediately lower the attachment and the load to the ground and turn the machine facing downhill. Operate the machine slowly, accelerate and decelerate attachment movements gently. Sudden movements with full speed and filled bucket are a huge strain for the structure which could tip the machine over. When working on a slope, always operate the hydraulic shovel with the attachment positioned uphill or downhill, never sideways. When traveling up and down a slope or when traveling over rough terrain reduce travel speed mode to slow (refer to Operation and Maintenance Manual section “Traveling”).

Operate joystick controls gently Accelerate and decelerate attachment movements gently. Sudden acceleration and abrupt braking with full speed and filled bucket are a huge strain for the structure. Avoid aggressive operating practices. Do not overload the machine.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Upper structure – swing Swinging of the upper structure is possible only when:  the upper structure holding brake is released and  the hydraulic shovel operator is sitting on his seat and  the hydraulic ladder is raised and  the servicestation (tanklift) is raised and  the BCS swing circuit test was successful.  To swing the upper structure to the right move the left joystick to the right (115, Fig. 2-160: and Fig. 2-161:).  To swing the upper structure to the left move the left joystick to the left (115). After releasing, the joystick returns automatically to position "0". Note: Releasing the joystick (115) is not sufficient to brake the swinging upper structure automatically. In order to brake the upper structure, the joystick must be moved in the direction opposite the swinging movement (reversing).

Fig. 2-160:

Upper structure – brake The upper structure can only be braked by moving the joystick (115) in the direction opposite the swinging movement (reversing).

The swinging upper structure does not stop automatically by simply releasing the left joystick (115). To brake the upper structure, the left joystick (115) must be moved in opposite direction. In an emergency, push the Emergency-Stop button (35, Fig. 2-161:) or activate the holding brake by pressing switch (61, Fig. 2-161:).

Fig. 2-161:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Stick in / Stick out control When released, all joysticks for working operation return automatically to position "0".  To extend the stick (Stick out): push joystick (115, Fig. 2-162:) forwards.  To retract the stick (Stick in): pull joystick (115) backwards.  To retract the stick with pressure: depress button (102, Fig. 2-163:) and push joystick (115) backwards. Note: This function works on face shovel attachment only, here the stick-in-function is normally done by gravity.

Fig. 2-162:

Fig. 2-163:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Raising and lowering the boom When released, all joysticks for working operation return automatically to position "0".  To raise the boom: pull joystick (116, Fig. 2-164:) backwards.  To lower the boom: push joystick (116) forwards.  To lower the boom with pressure: depress button (103; Fig. 2-165:) and push joystick (116) forwards. Note: This function works on face shovel attachment as well as on backhoe attachment. The boom-down-function is normally done by gravity.

Fig. 2-164:

Fig. 2-165:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Filling and emptying the backhoe bucket When released, all joysticks for working operation return automatically to position "0".  To fill / tip back the backhoe bucket: shift joystick (116, Fig. 2-166:) to the left.  To empty the backhoe bucket by dumping / tipping: shift joystick (116) to the right.

Fig. 2-166:

Filling the face shovel, curl close / curl open When released, all joysticks for working operation return automatically to position "0".  To fill / curl close the face shovel: shift joystick (116, Fig. 2-167:) to the left.  To curl open the face shovel: shift joystick (116) to the right.

Fig. 2-167:

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OPERATION Opening and closing the face shovel clam When released, all joysticks for working operation return automatically to position "0".  To open the face shovel clam: press pedal (111, Fig. 2-168: and Fig. 2-169:) forwards or turn thumb wheel (118) forwards.  To close the face shovel clam: press pedal (111) backwards or turn thumb wheel (118) backwards. Note: Pressing pedal (111) overrides turning the thumb wheel (118).

Fig. 2-168:

Fig. 2-169:

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OPERATION OPERATION TECHNIQUES Machine operation with backhoe attachment, Best Practices Machine Stability

When working with the attachment in a cross direction to the tracks, be sure that the track is not raised off the ground. This can cause the track to set-off from the rollers when it is lowered down on the ground. Also the flanges of the track rollers and the track shoes can be bent by the excessive load. Refer to Operation and Maintenance Manual, “Restricted Operation” for further detailed information. Do not overfill / overload the bucket, the machine may tip over.

Fig. 2-170:

When working or traveling on a slope is required (Fig. 2-171:), do not exceed the maximum machine inclination for working operation and for traveling (refer to Operation and Maintenance Manual section “Maximum machine inclinations”). Do not operate the shovel on rain-slicked, slippery slopes. The shovel may slip. Clean and level the pit floor before moving into the bank. A clean, level pit floor is necessary for safe and stable machine operation and prevents the tracks and other components of the undercarriage from being damaged. Position the hydraulic shovel on level, consistent, firm and stable ground. The hydraulic shovel may gradually sink on soft and yielding ground. Always re-enforce soft and yielding ground with firm material.

Fig. 2-171:

The hydraulic shovel must always be operated in a way, that its stability is always ensured and the danger of tipping over is avoided. Machine stability is greater when the bucket is parallel with the tracks (Fig. 2-170:). When working with the bucket parallel to the tracks, the final drives should be in the rear position, for the following reasons:  The travel motors and final drives are protected from falling rocks etc. 

When the hydraulic shovel is operated on muddy ground and the tracks are covered with mud, the sprocket runs on a clean track when backing up.

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If it is unavoidable to work on soft and yielding ground, operate the machine at reduced bucket loads to avoid tipping of the machine. When working on high-density and coarse material, operate the machine at reduced bucket loads to avoid overloading and damaging components of the machine. Stand attachment down to the ground during breaks in working operation. Do not operate the hydraulic shovel in water or in mud deeper than the breather valves of the final drives. Refer to section “Restricted Operation”.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Know the situation on site To maximize productivity of the machine, it is important that the operator understand characteristics of the material they are digging and how to adjust their operating style accordingly. Material penetrability:  Easily penetrable material: All loose, free flowing material and all materials which can be excavated without blasting. 

Difficult to penetrate material: Blasted or unblasted material containing large chunks, wet clayey soil and overburden.

Material flow:  Free flowing / loose. 

Sticky / in situ.

Conditions favorable to hydraulic backhoes: (Preferred option for overburden and softer material)  Low to moderate bench heights (Refer to section “Bench Heights – Recommendations for BH-machines”) 

Truck spotted either on top of bench or on the floor below the backhoe



Tight load area



Short swing – 60°



Well-shot material

Conditions unfavorable to hydraulic backhoes:  High benches 

Excessive tramming



Multiple benches



Unstable benches



Low angle of repose



No cleanup support

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OPERATION Bench - Climbing and Leaving Climbing Onto a Bench Do not exceed the maximum machine inclination or working. Refer to Operation and Maintenance Manual section “Maximum machine inclinations”. Build the ramp.  Travel up the ramp onto a bench with idlers first, keep the bucket close to the ground. If necessary, engage the bucket into the ground and move working equipment towards the machine. This procedure supports the machine while climbing the steep ramp (Fig. 2-172:).

Fig. 2-172:

Leaving a Bench

 Build the ramp. If the bench is steep, bring the hydraulic shovel down the bench with the final drive first.  Keep the bucket close to the ground (Fig. 2-173:).

Fig. 2-173:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Bench Heights – Recommendations for BH-machines Insufficient bench height

A too low bench does not allow good bucket fills and involves the risk to pull material against the tracks (Fig. 2-174:). Insufficient height increases the danger of collision between excavator and truck under certain circumstances (Fig. 2-174: and Fig. 2-175:).

Fig. 2-174:

Fig. 2-175:

Sufficient bench height

A sufficient bench height is essential for efficient and safe operation. The ideal bench height is equal to the stick length or equal to the truck body rail height (Fig. 2-176:). Note: This is a rule of thumb and is valid only if the material allows this bench height and only for standard truck match. For more information please refer to section “Bench Heights – Recommendations for BHmachines, table”.

Fig. 2-176:

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OPERATION Loading setups The following setups are used for digging and loading with the hydraulic shovel:  Hydraulic shovel on top of the bench, and truck below (This is the typical application). 

Hydraulic shovel and truck on the same level.

Working with the hydraulic shovel on a proper bench height and the truck below (Fig. 2-177: and Fig. 2-178: and Fig. 2-179:) offers the following improvements:  15-20% more production.

Fig. 2-177:



Clear separation of loading and hauling equipment.



Less risk of collision.



Excellent operator view into the truck body.



Potential for short swing angles.



Shortest attachment lifting distance possible.



Various options for truck positioning with loading through the body gate or over the side wall.

Productivity increases:  10 – 15% higher productivity when bench is correct height vs. too high or to low.

Fig. 2-178:

Fig. 2-179:

2-112



15 – 20% higher productivity when trucks are spotted on the floor below the excavator vs. on top of bench.



5% higher productivity when excavator swings 60º vs. 90º.



Higher productivity when positioned as close to edge as safely possible.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Truck on lower level — drive-by loading (Fig. 2-180:): Advantage:  Truck spotting time is eliminated, for the highest productivity, because the next truck does not need to reverse for positioning. Disadvantages:  More than 90° swing angle. 

Fig. 2-180:

Loading through the gate could be more difficult due to limited space for dumping.

Truck on upper level — top loading (Fig. 2-181:): Working with the hydraulic shovel and the truck on the same level offers the following improvements:  Loading over side walls offers reduced swing angle. 

Loading over tail offers reduced lifting effort for faster cycles.

This working technique is best applied for drop cuts and in difficult to access or wet areas at the pit bottom. Disadvantages:  Increased lifting effort and larger swing angle requires longer cycle time.

Fig. 2-181:



Productivity is approximately 15 to 20% lower.

Bench Heights – Recommendations for BH-machines, table Rule of thumb Model

Stick length

Truck body loading edge @ 4 to 5 pass match

Recommended bench height

6015B

3.6 m / 4.1 m

3.7 m (775G)

~ 3-4 m

6020B

3.9 m

4.4 m (777G)

~ 3.5-4.5 m

6030

4.0 m

4.4 m (777G)

~ 3.5-4.5 m

6040

4.6 m

5.0 m (785C)

~ 4.0-5.0 m

6050

5.5 m

5.6 m (789D)

~ 5.0-6.0 m

6060

5.0 m

5.9 m (793D)

~ 5.0-6.0 m

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Digging and Loading Loading Trucks, do:  Start at "key cut" and work toward the truck. 

Always work over the idler and swing no more than 60° to the truck.



Prepare the next cuts in advance.



General digging advance is backwards.



Maintain a proper bench height.



Position the truck close enough to the machine for effective loading, but not too close so that the machine cannot hit and damage the truck.



Most productive work is performed with the truck on a lower level.



Swing the attachment at a sufficient height over the loading platform.



Distribute material evenly on the truck bed.



Remove sticky material from the bucket.



Always keep the shovel as close as possible to the work area. This minimizes short stick and boom movements - high efficiency.



Correct bucket size and properly adjusted equipment prevents overloading and ensures maximum operating efficiency of the hydraulic shovel.

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Loading Trucks, do not:  Do not swing the attachment over unprotected driver cabs. 

Do not overload the truck.



When turning into a pit, the swing motion must not be stopped by the walls of the pit. Doing so can cause structural damage to the attachment. Use the machine hydraulic system to stop the swing motion.



Only a bucket with a complete set of teeth and cutting edges in good condition ensures efficient performance.



Loosen hard material and rocks with the bucket, not with the stick crowding thrust.



Avoid digging with corner tooth to avoid torsional forces into attachments.



Avoid contacting mechanical stops and cylinders end of stroke.

Refer to Operation and Maintenance Manual chapter “Backhoe Operation - Restricted Operation” for further details.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Digging and loading a truck

Fig. 2-182:

Fig. 2-183:

Use the following guidelines when digging and loading a truck (Fig. 2-182: and Fig. 2-183:):  Position the stick at an angle to the ground as shown in (Fig. 2-183:).  Position the bucket cutting edge at an angle to the ground as shown in (Fig. 2-183:). This allows maximum breakout force to be exerted throughout the dig cycle.  Move the stick towards the cab and keep the bucket parallel to the ground.  If the stick stops due to the load, raise the boom and / or perform a curl in order to adjust the depth of the cut.  To apply the greatest force at the cutting edge, decrease the down pressure as you move the stick toward the cab.  Maintain a bucket attitude that ensures a continuous flow of material into the bucket.  Continue the pass in a horizontal direction so that material peels into the bucket.  Curl in the bucket and raise the boom when the pass has been completed.  Swing the load from the rear of the truck or from the side of the truck. Never swing a load over a truck cab or personnel.  To dump a load, move the stick outward and open the bucket in a smooth motion.  Load trucks evenly. This will help to avoid overloading the rear axle.  When bucket is empty, swing the upper structure back and begin the next loading cycle.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Double Benching

Rules for “Double Benching”

Double Benching is an operation method which could be productive but also be very harmful to component life. This method should be used only by well trained and experienced operators in accordance with the following rules.

Material: Loose, well blasted and easy to dig material is absolutely essential for Double Benching. Boom down function should be used in float position only to pull down material from the wall. Note: Digging poorly blasted material with great boulders or too tough material is a great stress for the steel structure and could result in serious damages. Do not use the “Power boom down” - function. Always maintain a proper distance to the highwall to avoid operating at the limits of the cylinders.

Fig. 2-184:

Bench height: A high bench is split up into two segments, 1/3 of the bench is below the excavator and 2/3 is above the excavator (Fig. 2-184:). The ideal upper bench height is when the bucket could lay flat on the top of the bench (1, Fig. 2-184:). The ideal lower bench height is equal to the length of the stick or equal to the truck body side wall edge. Note: Too low lower benches can cause collisions of the counterweight and the truck body. Working direction: While digging the upper bench, the cab must be on the opposite side of the high wall, swing direction is to the truck / cabin side (Fig. 2-184:). Dig forward (arrow, Fig. 2-184:). While digging the lower bench, the cab must be on the opposite side of the high wall, swing direction is to the truck / cabin side (Fig. 2-185:). Dig backwards (arrow, Fig. 2-185:).

Fig. 2-185:

Working method: Dig the upper bench first, progressing from right to left, by digging down material from the face (Fig. 2-184:). Dig the lower bench on the way back in standard setup from left to right (Fig. 2-185:). Dig a trench in front of the machine and along the high wall (2, Fig. 2-184:). Leave this trench along the dig face (approx. 1.5 meters / 5 ft. deep) while digging forward. If any spillage falls out it is collected in the trench and won’t damage the excavator. The hole in front of the machine also eases bucket fill.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Grading the pit floor The described grading function can be performed precisely by simultaneously use of the boom, stick and bucket function.  Position the stick slightly forward of the vertical position with the bucket in the dumped position (Fig. 2-186:).  Operate the stick-retract function while slowly raising the boom. When the stick moves past the vertical position, slowly lower the boom to allow the bucket to maintain a smooth surface.

Fig. 2-186:

Park the Machine

Park the machine in a location that is smooth, stable, level and hard. The location should also be dry and free of debris and not endangered by falling rock. Bring the attachment in a position like shown in (Fig. 2-187:): - Half extend the boom cylinders. - Bring the stick in a vertical position. - Lower the boom until the bucket is on the ground. Note: Other positions of the attachment are not allowed when parking the machine. Refer to section “Backhoe Operation - Restricted Operation”. Fig. 2-187:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Backhoe Operation – Restricted Operation

Avoid extreme positions of the attachment. Parts of the attachment may damage the machine if they are moved to close to the machine, e. g. - the tracks (Fig. 2-188:), - the boom (Fig. 2-189:), - the railings or the cab roof (Fig. 2-190:).

Fig. 2-188:

Fig. 2-189:

Fig. 2-190:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not operate the machine when - one or several teeth, - parts of the hardfacing, - lip shrouds or side shrouds, - or other parts of the bucket are worn or missing (Fig. 2-191:). Working under these conditions reduces digging performance, results in heavy wear, potential damage and high repair costs.

Fig. 2-191:

Do not operate cylinders to the end of stroke during operation, excessive force will occur on the inside of the cylinder (Fig. 2-192:). This will reduce the life of the cylinder and structures. To avoid this issue, always leave around 10% of the cylinder stroke unused when the cylinder is operated.

Fig. 2-192:

If cylinders must be operated to the end of stroke, extend or retract speed must be reduced to 10% (Fig. 2-193:).

Fig. 2-193:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not use the dropping force of the bucket as a hammer, breaker or pile driver (Fig. 2-194:). This will bring excessive force on the machine and possible damage to the machine could result.

Fig. 2-194:

If the stick IN function is operated at high speed to the end of the cylinder stroke, excessive force will be applied to the stick cylinder, stick and boom (Fig. 2-195:). To avoid this problem, always operate a stick In function with moderate speed and stop motion prior to reaching the end of cylinder stroke.

Fig. 2-195:

Do not use the bucket to lever rocks out (Fig. 2-196:). If the back of the bucket contacts the rock behind, the lever action will cause excessive force on the attachment. Use only the force of the stick and bucket to carry out digging operations. When the force of the stick and the bucket are used for digging, hydraulic relief valves protect the attachment from excessive force.

Fig. 2-196:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not operate the machine in unsuitable material for digging (Fig. 2-197:). Ensure material is blasted or has appropriate penetrability and material fragmentation. Operating the machine in inappropriate conditions will reduce durability, productivity and increase cost of ownership. If material conditions cannot improve, the bucket or working tool may need to be exchanged. Please consult your dealer for machine bucket and/or work tool options and recommended operational/maintenance techniques in severe applications.

Fig. 2-197:

Avoid working in materials having higher density than appropriate for bucket or work tool (Fig. 2-198:). If unavoidable, operate the machine at reduced bucket loads to avoid overloading, tipping and reducing machine durability.

Fig. 2-198:

Do not suspend a loaded bucket for more than 5 minutes (Fig. 2-199:). Ground the bucket.

Fig. 2-199:

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OPERATION

Do not overload the attachment and do not allow the tracks to rise off the ground (Fig. 2-200:). If the tracks rise off the ground while digging, lower the machine back to the ground smoothly.

Fig. 2-200:

Do not use the dropping force weight of the machine to pry material in the bank or for excavation (Fig. 2-201:). Doing so may damage the machine and the attachment. If the tracks rise off the ground while digging, lower the machine back to the ground smoothly.

Fig. 2-201:

Machine stability is greater when the load is positioned parallel with the tracks and over the front idlers (Fig. 2-202:).

Fig. 2-202:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Machine stability is reduced when the load is swung to the side and when operating the attachment perpendicular to the tracks (Fig. 2-203:). Sudden stopping of the attachment movement can result in the tipping of the machine, especially when the attachment is perpendicular to the tracks. Never overload the attachment.

Fig. 2-203:

Do not drag the bucket down or swing the upper structure when digging hard rock if the bucket teeth will not penetrate the rock (Fig. 2-204:). The teeth will slip on the rock surface and cause excessive vibration of the machine that will damage the attachment or frame.

Fig. 2-204:

Do not propel the machine while the bucket is engaged in the material (Fig. 2-205:). This operation will potentially damage components of the attachment.

Fig. 2-205:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not allow the boom to hit the ground when excavating below grade (Fig. 2-206:).

Fig. 2-206:

Do not swing the machine while the bucket is engaged in the material. Do not stop swinging by contacting an object such as a bank or ditch. Do not sweep the pit floor (Fig. 2-207:). Do not start swinging until the bucket is completely removed from the bank. Do not begin digging before the swing motion is stopped.

Fig. 2-207:

Do not allow rocks or other material build up between the H-link and the gooseneck or between stick and bucket (Fig. 2-208:). Serious damage of attachment components will occur while:  retracting or extending the curl cylinders with rocks in the H-link / gooseneck region, 

Fig. 2-208:

2-124

curling the bucket with rocks between stick and bucket.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not swing a load over a truck cab or over personnel (Fig. 2-209:).

Fig. 2-209:

Fig. 2-210:

Do not attempt to travel on slopes with the bucket loaded or any load suspended from the bucket. Never attempt to ascend or descend steep slopes, refer to the Operation and Maintenance Manual for maximum slope. Keep the bucket pointed in the direction of travel, approximately 0.5 to 1.0 m above the ground (Fig. 2-210:). If the machine starts to skid or becomes unstable, lower the bucket immediately to the ground. Avoid swinging the upper carriage on slopes. Never attempt to swing the upper structure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upper structure and boom at slow speed. If the engine stalls on a slope, immediately lower the bucket to the ground. Return joysticks to neutral. Then, restart engine. Be sure to thoroughly warm-up the machine before ascending steep slopes. If the hydraulic oil has not warmed-up sufficiently, performance may be effected.

Always ascend the slope at a 90 degree angle (Fig. 2-211:). Driving across the face of a slope or steering on a slope may cause the machine to slide or tip over.

Fig. 2-211:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Driving across the face of a slope or steering on a slope (Fig. 2-212:) may cause the machine to slide or tip over. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

Fig. 2-212:

Do not exceed the maximum machine inclination for working operation (Fig. 2-213:). Refer to section “Maximum Machine Inclinations” for more information.

Fig. 2-213:

Do not use the force of the bucket, the stick or the boom to assist in turning the machine while the machine is traveling (Fig. 2-214:). This technique is referred to as “jump steering.” The force applied to the swing motors and swing drives by this method may cause damage to the swing motors and swing drives. For proper turning procedures refer to section “Traveling”.

Fig. 2-214:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not contact the ground with the heal of the bucket (Fig. 2-215:). Doing so could apply excessive force to the bucket linkage and bucket cylinder as well as potentially damaging the bucket.

Fig. 2-215:

Do not operate the machine with the final drives facing the attachment (Fig. 2-216:). Risk of damaging components of the gearboxes and sprockets and hydraulics.

Fig. 2-216:

Do not operate the machine on uneven, rough ground (Fig. 2-217:). Doing so is extremely detrimental to undercarriage component life.

Fig. 2-217:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

When initiating material penetration with the bucket, do not contact material at high speeds (Fig. 2-218:). High speed contacts will reduce machine life.

Fig. 2-218:

Do not park the machine with the stick cylinder and the bucket curl cylinder fully retracted (Fig. 2-344:).

Fig. 2-219:

Do not park the machine with the stick cylinder and the bucket curl cylinder fully extended, so that gooseneck and H-link contact the ground (Fig. 2-220:).

Fig. 2-220:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Machine operation with face shovel attachment - Best Practices Machine stability When working with the attachment in a cross direction to the tracks, be sure that the track is not raised off the ground. This can cause the track to set-off from the rollers when it is lowered down on the ground. Also the flanges of the track rollers and the track shoes can be bent by the excessive load. Refer to Operation and Maintenance Manual, “Restricted Operation” for further detailed information. Do not overfill / overload the face shovel, the machine may tip over.

Fig. 2-221:

When working or traveling on a slope is required (Fig. 2-222:), do not exceed the maximum machine inclination for working operation and for traveling (refer to Operation and Maintenance Manual section “Maximum machine inclinations”). Do not operate the shovel on rain-slicked, slippery slopes. The shovel may slip. Clean and level the pit floor before moving into the bank. A clean, level pit floor is necessary for safe and stable machine operation and prevents the tracks and other components of the undercarriage from being damaged. Position the hydraulic shovel on level and firm ground. The hydraulic shovel may gradually sink on soft ground. Always re-enforce soft ground with firm material.

Fig. 2-222:

The hydraulic shovel must always be operated in a way, that its stability is always ensured and the danger of tipping over is avoided. Machine stability is greater when the bucket is parallel with the tracks (Fig. 2-221:). When working with the bucket parallel to the tracks, the final drives should be in the rear position, for the following reasons:  The travel motors and final drives are protected from falling rocks etc. 

When working on soft ground or on high density material, operate the machine at reduced bucket loads. Stand attachment down to the ground during breaks in working operation. Do not operate the hydraulic shovel in water or in mud deeper than the breather valves of the final drives. Refer to section “Restricted Operation”.

When the hydraulic shovel is operated on muddy ground and the tracks are covered with mud, the sprocket runs on a clean track when backing up.

2-129

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Know the situation on site To maximize productivity of the machine, it is important that the operator understand characteristics of the material they are digging and how to adjust their operating style accordingly. On the site different bench height characteristics can exist:  A steep slope with an angle > approx. 60° and sticky, in-situ material (Fig. 2-223:). 

Fig. 2-223:

A flat slope with an angle ≤ approx. 60° and free flowing, loose, blasted material (Fig. 2-224:).

Material penetrability:  Easily penetrable material: All loose, free flowing material and all materials which can be excavated without blasting. 

Difficult to penetrate material: Blasted or unblasted material containing large chunks, wet clayey soil and overburden.

Material flow:  Free flowing / loose. 

Fig. 2-224:

2-130

Sticky / in situ.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Bench Heights on Steep Slopes

Minimum Bench Height Hydraulic face shovels can work on low faces due to their kinematics. The working face should be at least as high as the bucket itself for sufficient bucket fill. With the 6030, for example, it is about three meters (Fig. 2-225:). Continuous high lifting effort and frequent relocation results in unproductive loading cycles.

Fig. 2-225:

Bench Height on Steep Slopes Example situation: The material to dig is e.g. free - dig overburden. - Material characteristics is – sticky / in situ, - It is a steep slope - angle is approx. 60°. The optimal bench height is for tough digging (Fig. 2-226:): - Cabin roof height (e.g. for 6030 FS): ~7m

Fig. 2-226:

The maximum bench height is (Fig. 2-227:): - 75% of the maximum vertical reach (e.g. for the 6030 FS): 13.9 m x 0.75 ≈ 10 m (These are rules of thumb, they are a guide only, values depend on the material conditions).

Fig. 2-227:

2-131

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Bench Height on Flat Slopes

Bench Height on Flat Slopes Example situation: The material to load is e.g. well blasted pile. - Material characteristics is – free flowing / loose, material has the tendency to roll down. - It is a flat slope – angle is approx. ≤ 60°. The maximum bench height is (Fig. 2-228: and Fig. 2-229:): - Maximum vertical reach (e.g. for 6030 FS): ~14 m (This is a rule of thumb, a guide only, value depends on the material conditions).

Fig. 2-228:

Fig. 2-229:

Bench Heights – Recommendations for FS - Machines, table Minimum

Steep Slope > ~approx. 60° Sticky / in situ material Tough digging

Rule of thumb

Bucket Height

Cab Roof Height

~2m

~5m

~8m

~ 11 m

6018 FS

~2m

~7m

~9m

~ 13 m

6030 FS

~3m

~7m

~ 10 m

~ 14 m

6040 FS

~3m

~8m

~ 10 m

~ 14 m

6050 FS

~3m

~9m

~ 12 m

~ 15 m

6060 FS

~3m

~9m

~ 12 m

~ 15 m

6090 FS

~4m

~ 10 m

~ 15 m

~ 20 m

Model 6015 FS

2-132

Easy digging 75% of max. vertical reach

Flat Slope ≤ ~ 60° Free flowing / loose material Max. vertical reach

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Basic setup at a bench



The undercarriage should be positioned at 45° to the face (Fig. 2-230: and Fig. 2-231:).



Sprocket / final drives shall always point away from the face.



Truck position on the left hand (cab) side of the shovel.



Shovel operator and truck driver have eye contact.



The 45° position towards the digging face allows quick escape in case of a face collapse (Fig. 2-231:).



All rollers are not exposed to damage.



Less dirt on RH from material falling from the face track.



The digging forces are transmitted lengthwise through the track pad grousers into the ground (Fig. 2-232:).



Traction is optimal in this position.



A crosswise position would apply side load to the rollers.

Fig. 2-230:

Fig. 2-231:

Fig. 2-232:

2-133

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Recommended working direction Best practice is: Working from right to left (Fig. 2-233:). Cleaning of the floor behind and beside the shovel is done by a dozer. Trucks will drive on levelled and clean ground, this results in less tire / suspension damage. Doing so is a clear separation of loading action and clean-up support. The hydraulic shovel shall always return to the right end of the face (end of the cut) and start again.

Fig. 2-233:

Not recommended – Digging advance left to right Loading the truck to the left side means increased swing angle and longer cycle times (Fig. 2-234:) = unproductive.  The operator might try to reduce the swing angle, tails are left behind / no straight face. 

Truck position on rough ground / spillage, results in cleanup delays, dozer standby required, risk of tire damage.

Fig. 2-234:

Not recommended – Digging advance left to right Loading the truck to the right side (Fig. 2-235:) results in loading on the blind side.  Poor visibility of shovel operator to the truck means swing over the blind side. 

Fig. 2-235:

2-134

Poor visibility of truck driver to the shovel means difficult positioning.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Loading setups Single side loading The hydraulic shovel loads the trucks only on the left hand side (Fig. 2-236:). Truck driver and shovel operator have direct eye contact. Single side loading with standard truck spotting is the best solution for most applications. Advantages:  The hydraulic shovel can follow a straight working face without major repositioning effort.

Fig. 2-236:



Good floor conditions that are easy to maintain.



Support equipment can clean the excavated area behind the shovel without interfering with the loading action.

The face should always be mined from right to left, then travel back and continue. The tracks should be positioned 45º toward the face; travel motors to rear.

Double side loading The hydraulic shovel loads the trucks alternately on left and right hand side (Fig. 2-237:). Double side loading with self spotting increases productivity only short term and only if perfectly executed. A long-term productivity advantage will not be achieved because of the many disadvantages and requirements. Disadvantages:  Higher risk of collisions. Fig. 2-237:



Well-trained operators are required.



While loading to the right side, both shovel operator and truck driver are on the blind side.



Shovel cannot follow straight working face and has higher repositioning effort.



Permanent clean-up support required.

The tracks should be positioned 90º toward the face; travel motors to rear.

2-135

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Digging and Loading

Digging  Maintain a digging face which avoids any major slides which could cause an accident.  Always check the digging face for large boulders, large rocks, or frozen material which could slide and cause damage to the machine.  Always inspect the bank, it could collapse. Rocks can damage track pads, idler and the track tensioning system.  Building a safety trough in front of the tracks will protect the machine (Fig. 2-238:).  Avoid overhanging material.

Fig. 2-238:

 Always strive to work from top to bottom (Top / Center / Bottom in Fig. 2-239: to Fig. 2-241:).  Penetrate as high as possible to reduce lifting effort and shorten cycle times.  Always use the full cutting surface of the shovel lip to contact the bank on each pass. A full face cut combined with a deep bank penetration will result in a well filled shovel.  Use the float function of the boom while penetrating the material.  Always keep the shovel as close as possible to the work area. Short boom trips - high efficiency. Fig. 2-239:

Digging, do not  When swinging towards the bank, the swing motion must not be stopped by the walls of the pit or by the material. Doing so can cause structural damage to the attachment. Use the machines hydraulic system to stop the swing motion.  Do not work with a bucket with missing teeth, missing shrouds or missing components of the hardfacing.  Loosen hard material and rocks with the bucket, not with the stick crowding thrust. Fig. 2-240:

 Do not swing the bucket into the material; penetrate only after swing is complete  Never penetrate the material with an open bucket.

2-136

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Loading Trucks  Position the truck as closely as possible to the hydraulic shovel (Fig. 2-243:).  Swing the attachment at a sufficient height over the loading platform. Do not swing the attachment over unprotected driver cabs.  Distribute material evenly on loading platform.  Do not overload the truck.  Remove sticky material from the bucket.

Fig. 2-241:

 Utilize the time between trucks (during truck spotting) to prepare the 1st pass for the next truck load (Fig. 2-242:).  Use low penetration height to clean up the ground and fill the shovel. There is enough time for a large swing angle until the next truck arrives.  Take the opportunity to check the face for potential rock fall and large and oversize material.

Fig. 2-242:

 For the 2nd and the subsequent passes (the truck is in position) dig again from top to bottom maintain smaller swing angles. This minimizes truck loading time.

Fig. 2-243:

2-137

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Dumping the load Correct bucket position during dumping will reduce bucket wear. To center the load, the bucket should be tipped forward as the clam is opened (Fig. 2-244:).

Fig. 2-246:

Closing the bucket clam

Fig. 2-244:

If the bucket is tipped too far forward, the load will fall to the near side of the truck bed (Fig. 2-245:).

 Close the clam using gravity to resist motion as shown in Fig. 2-247:. Doing this  will improve control when clam and backwall near contact. 

reduces impact forces on clam cylinders, clam and backwall.

 Do not close the clam with gravity assisting motion. This motion can be difficult to control. The clam can bang against the backwall and applying impact forces to the clam, backwall and cylinders. These impact forces will reduce the durability of the clam, backwall and cylinders.

Fig. 2-245:

If the bucket is fully crowded back, the load will fall to the far side of the truck bed (Fig. 2-246:). Fig. 2-247:

2-138

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Digging on Ground Level

 When digging at ground level, keep the heel of the bucket off the ground (Fig. 2-248:).  Operate with the ground engaging tools (GET) doing all the work.

Fig. 2-248:

Forcing the heel into the ground causes premature wear on the rear of the bucket (Fig. 2-249:).

Fig. 2-249:

2-139

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Cleaning up the Pit Floor using the Attachment

As loading continues it will be necessary to remove material from the lower down the face (Fig. 2-250:). Leave some material between the bucket and the tracks.

Fig. 2-250:

Once all the material has been removed from the shovels reach move back 1 to 2 meters to enable the material in front of the tracks to be cleaned up (Fig. 2-251:).  Move back to cleanup material.  Maintain clearance between the bucket and the tracks. If possible this should be completed between trucks and loaded directly into a truck to avoid lost production.

Fig. 2-251:

Drop cuts

Fig. 2-252:

2-140

Drop cuts are difficult but possible (Fig. 2-252:).  Drop cuts are uncomfortable for the operator due to working on an inclination.  Slewing uphill puts stress on components.  The operator has to be careful while slewing downhill because of additional acceleration and operate the machine slowly.  The maximum working inclination for CGM HMS Shovels is 8.7%, this is less than the recommended haul road grade of 10%. Procede as follows: Maintain 8.7% with the CGM HMS Shovel and put to final 10% grade with a track type tractor.  For building of ramps, the values specified may be exceeded. In this case, however, a reduced service life of the components can be expected. Drop cut = Digging down from current level to the next level down, creating a ramp in the process. 

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Handling Oversized Boulders / Overhangs Note: Make sure that no truck or other machine is close proximity or in the projected slope line of the rock.  Ensure the tracks are 90° to the working face.  Position the hydraulic shovel to one side of the boulder/overhang before attempting to undercut. This ensures, that the hydraulic shovel will not be in its path when the rock falls (Fig. 2-253:).  Position the hydraulic shovel little to the right below the boulder/overhang. This ensures best visibility to the boulder/overhang.  Swing to the right hand side and work with the very left tooth.  Watch the size of the boulder; if it is too big to pass through the clam, it should be returned to the face. Fig. 2-253:

 Place some material into the truck body first (1, Fig. 2-254:).  Warn the truck driver using the horn.  Tip the rock off the front of the bucket onto the material as shown (2, 3 and 4, Fig. 2-254:). Do not try to get oversized boulders through the clam.

Fig. 2-254:

2-141

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Park the Machine

Fig. 2-255:

2-142

Park the machine in a location that is smooth, stable, level and hard. The location should also be dry and free of debris and not endangered by falling rock. Lower the bucket to the ground and ensure that the stick is vertical to the ground (Fig. 2-255:).

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Face Shovel Operation – Restricted Operation

Avoid extreme positions of the attachment. Parts of the attachment may damage the machine e.g. the tracks if they are moved to close to the machine (Fig. 2-256:).

Fig. 2-256:

Do not operate the machine when - one or several teeth - parts of the hardfacing - lip shrouds or side shrouds - or other parts of the bucket are worn or missing (Fig. 2-257:). Working under these conditions reduces digging performance, results in heavy wear, potentional damage and high repair costs.

Fig. 2-257:

Do not operate the machine on uneven, rough ground (Fig. 2-258:). Doing so is extremely detrimental to undercarriage component life.

Fig. 2-258:

2-143

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not use the dropping force of the bucket as a hammer, breaker or pile driver (Fig. 2-259:). This will bring excessive force on the machine and possible damage to the machine could result.

Fig. 2-259:

Do not operate the machine with the final drives facing the attachment (Fig. 2-260:). There is a risk of damaging components of the gearboxes and sprockets and hydraulics.

Fig. 2-260:

Do not operate the cylinders to the end of stroke during operation (Fig. 2-261:), excessive force will occur on the inside of the cylinder. This will reduce the life of the cylinder and the structures. To avoid this issue, always leave a small margin of play when the cylinder is operated (Fig. 2-262:). If cylinders must be operated to the end of stroke, extend or retract speed must be reduced to 10%.

Fig. 2-261:

2-144

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not operate cylinders to the end of stroke during operation, excessive force will occur on the inside of the cylinder. This will reduce the life of the cylinder and structures. To avoid this issue, always leave a small margin of play when the cylinder is operated (Fig. 2-262:). If cylinders must be operated to the end of stroke, extend or retract speed must be reduced to 10%.

Fig. 2-262:

Do not operate the machine in unsuitable material for digging (Fig. 2-263:). Ensure material is blasted or has appropriate penetrability and material fragmentation. Operating the machine in inappropriate conditions will reduce durability, productivity and increase cost of ownership. If material conditions cannot improve, the bucket or working tool may need to be exchanged. Please consult your dealer for machine bucket and/or work tool options and recommended operational/maintenance techniques in severe applications.

Fig. 2-263:

Avoid working in materials having higher density than appropriate for bucket or work tool (Fig. 2-264:). If unavoidable, operate the machine at reduced bucket loads to avoid overloading, tipping and reducing machine durability.

Fig. 2-264:

2-145

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not operate the clam cylinders to the end of stroke when opening the shovel clam (Fig. 2-265:), excessive force will occur on the inside of the cylinder. This will reduce the life of the cylinder and the structures. To avoid this issue, always leave a small margin of play when the clam is opened. If the clam must be operated to the end of stroke, cylinder speed must be reduced to 10%.

Fig. 2-265:

Do not extend the bucket cylinder to cause contact between bucket and stick stops (located on the top of the stick) (Fig. 2-266:). Curl out the bucket to avoid contact with the stick. The bucket may contact the stick when the stick is retracted or the boom is lowered. Curl out the bucket when lowering the boom or retracting the stick to avoid contact.

Fig. 2-266:

The bucket may contact the end of the travel stops located on the top of the stick when the stick is retracted (Fig. 2-267:). Curl out the bucket when retracting the stick to avoid contact.

Fig. 2-267:

2-146

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

The bucket may contact the end of travel stops located on the top of the stick when the boom is lowered (Fig. 2-268:). Curl out the bucket when lowering the boom to avoid contact.

Fig. 2-268:

Do not retract the bucket cylinder to cause contact between the travel stops between the stick and bucket (located on bottom of the stick) (Fig. 2-269:). Curl in the bucket to avoid contact.

Fig. 2-269:

The bucket may contact the end of the travel stops located on the bottom of the stick when the stick is extended (Fig. 2-270:). Curl in the bucket when extending the stick to avoid contact.

Fig. 2-270:

2-147

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

The bucket may contact the end of the travel stops located on the bottom of the stick when the boom is raised (Fig. 2-271:). Curl in the bucket when raising the boom to avoid contact.

Fig. 2-271:

Be aware that no rocks or other material are between the bucket and the stick (Fig. 2-272:). Crushing rocks or other material between bucket and stick will damage stick and bucket.

Fig. 2-272:

Do not engage the bank or any other material when the clam is not fully closed (Fig. 2-273:). This will damage the clam and the clam cylinders.

Fig. 2-273:

2-148

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not push down on the attachment with the clam in contact with the ground (Fig. 2-274:). Do not use the fully curled bucket for tamping the ground. Doing so will damage the clam, the bucket, the bucket cylinder or other parts of the attachment.

Fig. 2-274:

Do not dig with the bucket cylinder fully retracted and the bucket teeth stuck in the ground (Fig. 2-275:). The attachment will be subjected to excessive force.

Fig. 2-275:

Do not open the clam and use the bucket backwall or rear of clam for grading operations, as this will damage the bucket backwall and the clam (Fig. 2-276:).

Fig. 2-276:

2-149

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not use the bucket clam for loosening or removing anchored rocks or other solid objects, since such operations may result in severe damage to the clam pivot bearings (Fig. 2-277:).

Fig. 2-277:

Do not suspend a loaded bucket for more than 5 minutes (Fig. 2-344:). Ground the bucket.

Fig. 2-278:

Do not swing a load over an unprotected truck cab or over personnel (Fig. 2-279:).

Fig. 2-279:

2-150

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not overload the attachment and do not allow the rear of tracks to rise off the ground. Do not undercut a bank (Fig. 2-280:), undercutting a bank could result in bank collapsing and material falling onto the attachment.

Fig. 2-280:

Do not use the dropping force weight of the machine to pry material in the bank or for excavation (Fig. 2-281:). Doing so may damage the machine and the attachment.

Fig. 2-281:

If the tracks rise off the ground while digging, lower the machine back to the ground smoothly (Fig. 2-282:).

Fig. 2-282:

2-151

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not try to move or load oversized material pieces (Fig. 2-283:). Doing so could damage the attachment.

Fig. 2-283:

Machine stability is reduced when the load is swung to the side and when operating the attachment perpendicular to the tracks (Fig. 2-284:). Sudden stopping of the attachment movement can result in the tipping of the machine, especially when the attachment is perpendicular to the tracks. Never overload the attachment.

Fig. 2-284:

Machine stability is greater when the load is positioned parallel with the tracks and over the front idlers (Fig. 2-285:).

Fig. 2-285:

2-152

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Never try to catch falling / rolling material using the attachment (Fig. 2-286:). Doing so can extremely overload the structures and can result in severe damage of mechanical and hydraulic components.

Fig. 2-286:

Do not use the clam to grip rocks or other objects (Fig. 2-287:).

Fig. 2-287:

Do not use the clam, the bucket backwall, or the bucket to scrap down rocks or material (Fig. 2-288:).

Fig. 2-288:

2-153

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not raise the bucket to scrape the wall to loosen or remove material (Fig. 2-289:). This is an extremely damaging practice and will reduce the lifetime of the shovel.

Fig. 2-289:

Do not sweep the pit floor. Do not swing the machine while the bucket is engaged in the material (Fig. 2-290:). Do not stop swinging by contacting an object such as a bank or ditch. Do not start swinging until the bucket is completely removed from the bank. Do not begin digging before the swing motion is stopped.

Fig. 2-290:

Do not propel the machine while the bucket is engaged in the material (Fig. 2-291:). This operation will potentially damage components of the attachment.

Fig. 2-291:

2-154

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Do not propel the machine longer than 5 minutes with the propel motors to the front (Fig. 2-292:).

Fig. 2-292:

Fig. 2-293:

Do not attempt to travel on slopes with the bucket loaded or any load suspended from the bucket. Never attempt to ascend or descend steep slopes, refer to the Operation and Maintenance Manual for maximum slope. Keep the bucket pointed in the direction of travel, approximately 0.5 to 1.0 m above the ground (Fig. 2-293:). If the machine starts to skid or becomes unstable, lower the bucket to the ground immediately. Avoid swinging the upper carriage on slopes. Never attempt to swing the upper carriage downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upper carriage and boom at slow speed. If the engine stalls on a slope, immediately lower the bucket to the ground. Return joysticks to neutral. Then, restart engine. Be sure to thoroughly warm-up the machine before ascending steep slopes. If the hydraulic oil has not warmed-up sufficiently, performance may be effected.

Always ascend the slope at a 90 degree angle (Fig. 2-294:).

Fig. 2-294:

2-155

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

Driving across the face of a slope or steering on a slope may cause the machine to slide or tip over (Fig. 2-343:). If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

Fig. 2-295:

Do not exceed the maximum machine inclination for working operation (Fig. 2-344:). Refer to section “Maximum Machine Inclinations” for further information.

Fig. 2-296:

Do not use the force of the bucket, the stick or the boom to assist in turning the machine while the machine is propelling (Fig. 2-297:). This technique is referred to as “jump steering.” The force applied to the swing motor and swing drive by this method may cause damage to the swing motor and swing drive. For proper turning procedures refer to section “Traveling”.

Fig. 2-297:

2-156

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

When working in any body of water or mud be careful that the level of water or mud is not higher than the breather valves on top of the final drives (Dimension A, Fig. 2-298:). Water or mud could enter the gearboxes and cause serious damages. While you cross any body of water or mud, carefully confirm the depth of the water or mud with the bucket. Do not move the machine into an area that has a water or mud depth that is higher than the breather valves of the final drives (Dimension A, Fig. 2-298:).

Fig. 2-298:

2-157

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION TRAVELING Traveling - Safety Instructions Personnel Any work with the machine must be executed only by reliable, skilled and well trained personnel in good healthy condition. Statutory minimum age limits must be observed. Avoid aggressive operating practices and never operate the machine while impared with drugs or alcohol. Do not overload the machine. State of operator’s workplace Inspect and fasten your seat belts. Adjust the operator’s seat for comfortable reach all controls and pedals. Adjust for operator height and weight. Keep your workplace clean. Remove all unsecured items like tools and other supplies from the cab. Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements. Clean and secure all windows and doors. Clean and adjust all mirrors and cameras (if equipped) for optimum vision. Travel the machine only while sitting on the operator’s seat. State of the machine The engines must be at operating temperature before being subjected to full load. If the machine is to be driven a longer distance, the upper structure must be secured against turning by means of the upper structure holding brake. Sound the horn to warn persons in the immediate vicinity before starting traveling. Sound the horn and allow adequate time for bystanders to clear the area before moving the machine into a restricted visibility area. Follow local practices for your machine application. For more information refer to Operation and Maintenance Manual, section "Restricted Visibility".

2-158

Clear the hazard range of the machine Check the surrounding area around the machine (the hazard range of the machine):  No personnel around the machine. 

No personnel on the machine outside the cab.

State of the site and machine stability Before starting traveling, inspect the condition of the ground you want to travel on. The machine may sink on soft ground. Do not travel into a water surface without knowing how deep the water is and how stable the underground is. The underground may be sludgy and with insufficient bearing capacity. The machine may sink. Do not travel through water or mud that is deeper than the breather valves of the final drives, refer to section “Restricted Operation”. Ground that has been newly filled with earth / gravel may collapse from the weight of the machine. Rocks and moisture of the surface material may drastically affect the machine's traction and machine's stability. Rocky surfaces may promote side slipping of the machine. The machine may be less stable when traveling on uneven ground. Have the attachment raised only so far as to permit the machine to be driven under overhead power lines without any risk. Do not exceed the maximum machine inclination (refer to Operation and Maintenance Manual, section “Maximum machine inclinations”). Do not travel across slopes. Always travel 90° to the slope face (upwards and downwards). Place the heaviest end of the machine uphill when you are traveling on an incline. Do not drive the machine close to an overhang, to the edge of a cliff, or to the edge of an excavation. Take the utmost care on slippery, greasy ground. If the upper structure is turned by more than 90° from the basic position (refer to section “Upper structure - basic position”), the hydraulic shovel travels in the opposite direction to that selected. If the position of the upper structure in relation to the undercarriage is not exactly known, touch the travel pedals lightly to see which direction the machine takes, before initiating the full traveling movement. Safe operation on steep slopes may require special machine configuration. Excellent skill of the operator and proper attachment for specific applications are also required. Consult the Operation and Maintenance Manual sections for the proper fluid level requirements and intended machine use.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Before starting traveling  Read and observe all notes given in section “Traveling – Safety Instructions”.  Lift up the hydraulic access ladder.  Lift attachment up to the traveling position.  Activate the signal horn.  Release the travel brake switch (if applied).  Watch the mirrors and the camera monitor (if equipped).  Start traveling.

Fig. 2-299:

Upper structure - basic position Travel only with the upper structure in its basic position. The drive sprockets should be at the rear of the machine. Before moving the machine, check the position of the undercarriage. Travel direction and sense of actuation of travel pedals (112 and 113, Fig. 2-299:) are identical only when the upper structure is in its BASIC POSITION (Fig. 2-300:). In this BASIC POSITION (Fig. 2-300:) the counterweight (3) is positioned above the final drives (4). The operator’s cab (1) is above the left idler (2).

Fig. 2-300:

Forwards means: Machine movement in direction of the idlers. Backwards means: Machine movement in direction of the final drives. Note: If the upper structure is swung out of its basic position by more than 90° (Fig. 2-301:), the hydraulic shovel moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-299:) are depressed. If the operator is not completely sure of the position of the upper structure with regard to the undercarriage, pedals (112 and 113) should be depressed slightly in order to find out which way the hydraulic shovel moves before initiating the full traveling movement. Fig. 2-301:

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OPERATION Travel Speed – Recommendations Traveling Situation

Travel Speed

Adjusting machine position while loading trucks

Slow

Travelling rearwards

Slow

Traveling long distances on flat or slight ramps and slopes

Slow or fast

Turning

Slow

Traveling uphill / downhill on ramps and steep slopes

Slow

Traveling on soft or inconsistent material

Slow

Traveling on rough terrain

Slow

Loading machine onto a trailer

Slow

For detailed information on Traveling Speed refer to section “Travel Speed – adjust”.

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OPERATION Traveling – Basic Movements

Fig. 2-302:

Travel straight forward/backward

Traveling movement is controlled by means of the travel pedals (112 and 113, Fig. 2-302:). The travel pedals return automatically to their neutral positions when released. During traveling, an acoustic warning signal sounds (Travel Alarm). All instructions with regard to travel direction control are applicable only as long as the crawler tracks have sufficient grip and do not slip. For information regarding traveling speed refer to section “Traveling speed – adjust”. The information given in this section are applicable when traveling on level ground and also when traveling the machine on moderate inclinations, e. g. on haulroads. For additional information about traveling on steep ramps and steep slopes refer to section “Traveling uphill and downhill on ramps and steep slopes”. Operate travel pedals gently Accelerate and decelerate travel movements gently. Sudden acceleration and abrupt braking from full speed are a huge strain for the machine. Avoid aggressive traveling practices.

Traveling straight forward  Move both travel pedals in the direction of the front window. The machine moves in direction of the idlers (Fig. 2-303:). To stop travel movement, release the pedals, they return in neutral position. Fig. 2-303:

Note: Reverse the hydraulic shovel only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

Fig. 2-304:

Traveling straight backward  Move both travel pedals in the direction of the operator’s seat. The machine moves in direction of the final drives (Fig. 2-304:). To stop travel movement, release the pedals, they return in neutral position.

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OPERATION Turning

Note: Traveling through curves in a single sharp turn should be avoided whenever possible. When traveling through curves it is necessary to divide the curve movement into small gradual turns followed by a short distance of straight travel. Doing so prevents from material build up between rollers and tracks which could lead in excessive wear and damage of undercarriage components. Turning, make a gradual right turn forward  Move the left travel pedal in the direction of the front window. Leave the right travel pedal in neutral. The machine moves in a gradual right turn forward (Fig. 2-305:). To stop the turn, release the pedal, it returns in neutral position.

Fig. 2-305:

Turning, make a gradual left turn forward  Move the right travel pedal in the direction of the front window. Leave the left travel pedal in neutral. The machine moves in a gradual left turn forward (Fig. 2-306:). To stop the turn, release the pedal, it returns in neutral position.

Fig. 2-306:

Turning, make a gradual right turn backward  Move the left travel pedal in the direction of the operator’s seat. Leave the right travel pedal in neutral. The machine moves in a gradual right turn backward (Fig. 2-307:). To stop the turn, release the pedal, it returns in neutral position.

Fig. 2-307:

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OPERATION

Turning, make a gradual left turn backward  Move the right travel pedal in the direction of the operator’s seat. Leave the left travel pedal in neutral. The machine moves in a gradual left turn backward (Fig. 2-308:). To stop the turn, release the pedal, it returns in neutral position.

Fig. 2-308:

Note: Select slow speed level. To do so, switch speed level switch (72, Fig. 2-314:) to the left.  Change the position of the undercarriage only by turning forwards/backwards (Fig. 2-309:).

Turning to the left:  forwards from pos. 1 to pos. 2 Fig. 2-309:



backwards from pos. 2 to pos. 3



forwards from pos. 3 to pos. 4

The same procedure should be adopted if the hydraulic shovel is to be driven out of depressions (Fig. 2-310:):  Turning to the left from pos. 1 to pos. 2 

Turning to the right from pos. 2 to pos. 3

Fig. 2-310:

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OPERATION Counter-rotation turns / Turning on the spot

Fig. 2-311:

Note: Counter rotational turns/turning on the spot in a single sharp turn should be avoided whenever possible. When turning in single sharp turns, the machine can bury itself - especially in soft material. When turning on the spot it is necessary to divide the turn movement into small gradual turns followed by a short distance of straight travel. Doing so prevents from material build up between rollers and tracks which could lead in excessive wear and damage of undercarriage components. Select slow speed level. To do so, switch speed level switch (72, Fig. 2-314:) to the left. Change speed level only when the hydraulic shovel is stationary. Counter-rotation turn to the right / Turning on the spot  Move the right travel pedal in the direction of the operator’s seat. Move the left travel pedal in the direction of the front window. The machine moves in a gradual turn to the right (Fig. 2-311:). To stop the turn, release the pedals, they return in neutral position.

Counter-rotation turn to the left / Turning on the spot  Move the left travel pedal in the direction of the operator’s seat. Move the right travel pedal in the direction of the front window. The machine moves in a gradual turn to the left (Fig. 2-312:). To stop the turn, release the pedals, they return in neutral position. Fig. 2-312:

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OPERATION Track Parking Brake – set/release

Traveling speed – adjust

The hydraulic shovel is equipped with four traveling gear brakes which are integrated in the travel drives. The traveling gear brakes are parking brakes. They protect the hydraulic shovel from rolling forwards or backwards. When the machine is parked, travel brakes are activated automatically. The brakes are deactivated when the travel pedals are activated allowing the machine to travel. Note: As travel brakes are deactivated, machine could slightly move in direction of excavating during operation. Whenever loading operation is interrupted, rest the attachment on the ground. This avoids slight movement of the machine and possible consequential damage of lowered ladder, in case ignition remains engaged.

All instructions with regard to traveling speed regulation are applicable only as long as the crawler tracks have sufficient grip and do not slip.

Select travel speed level Note: Change speed level only when the hydraulic shovel is stationary.  Switch (72, Fig. 2-314:) to the left = slow gear. All forward/reverse travel movements are possible with this gear.  Switch (72) to the right = fast gear. All forward/reverse travel movements are possible with this gear. Press engine speed regulator switches (48 and 58) to the left (full-throttled position).

Adjust the traveling speed  Depress travel pedals (112 and 113, Fig. 2-314:) fully or partially depending on the travel speed wanted. Releasing the travel pedals brings the shovel to a standstill.

Fig. 2-313:

For Service and Maintenance purposes the traveling gear brakes can also be applied with switch (63, Fig. 2-313:). Actuate this switch only when the hydraulic shovel is stationary. Do not use this switch while the hydraulic shovel is still in motion. Risk of damage to the brakes and the travel gearboxes.  Press the switch face with the symbol (63): The parking brake is applied permanently. The hydraulic shovel cannot be moved. For more detailed information refer to the Service Manual, chapters eight and nine.

Fig. 2-314:

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OPERATION Traveling uphill and downhill on ramps and steep slopes Note: When traveling uphill or downhill on ramps and steep slopes, the travel drives must always face downhill (1, Fig. 2-342: to Fig. 2-318:). Otherwise track tension loss may occur. Do not exceed the maximum machine inclination when traveling uphill or downhill (refer to section “Maximum machine inclinations”). Read and observe section "Traveling – Safety instructions".

Traveling uphill:

Fig. 2-316:

 Select slow speed level. To do so, switch speed level switch (72, Fig. 2-319:) to the left. Note: Change speed level only when the hydraulic shovel is stationary.  Bring shovel in a position shown in Fig. 2-315: and Fig. 2-316:. The final drives (1) and the counterweight are facing downhill.  Depress travel pedals (112 and 113, Fig. 2-319:).

Traveling downhill:  Select slow speed level. To do so, switch speed level switch (72, Fig. 2-319:) to the left. Note: Change speed level only when the hydraulic shovel is stationary.  Bring shovel in a position shown in Fig. 2-317: and Fig. 2-318:. The final drives (1) are facing downhill. The counterweight is facing uphill.  Depress travel pedals (112 and 113, Fig. 2-319:).

Fig. 2-317:

Fig. 2-318:

Fig. 2-315:

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OPERATION Note: Avoid changing the direction of travel on a slope. Changing the direction of travel on a slope could result in tipping or side slipping of the machine. Be extremely careful on slippery and greasy ground. The machine may slip. Do not travel across slopes. Keep the working attachment close to the ground. Be careful to avoid any ground condition which could cause the machine to tip. Tipping can occur when you travel on hills, on banks or on slopes. If the machine begins to sideslip on a grade, immediately dump the load and turn the machine uphill.

Traveling speed on ramps and slopeschange  Select slow speed level. To do so, switch speed level switch (72, Fig. 2-319:) to the left. Note: Change speed level only when the hydraulic shovel is stationary.  Depress travel pedals (112 and 113, Fig. 2-319:) fully to the limit stop.  Regulate the travel speed only with the engines speed control switches (48 and 58, Fig. 2-319:).

When traveling downhill, the travel retarder valve acts as a speed limiter. If the traveling speed nevertheless becomes too high when traveling downhill, release travel pedals (112 and 113) to stop the shovel.

Fig. 2-319:

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OPERATION Traveling over long distances Note: Travel only forwards with the hydraulic shovel in its basic position. Traveling backwards over longer distances could wear out or damage parts of the undercarriage. Read and observe section "Traveling – Safety instructions". Do not exceed the maximum machine inclination (refer to section “Maximum machine inclinations”). When traveling, pay attention to sufficient headroom, e. g. under cable bridges or high-tension cables. Lower the attachment when traveling underneath obstacles. Keep the face shovel or the backhoe bucket close to the ground. For a more uniform loading of the tracks, the attachment must, however, be kept at a steep angle (Fig. 2-320: and Fig. 2-321:). NOTICE If non-OEM buckets are installed, be careful to avoid contact between bucket and machine (i.e. boom). Set the upper structure holding brake. Recommended position of the face shovel attachment (Fig. 2-320:):  Fully extend boom cylinder (1).  Retract bucket cylinder (2).  Retract stick cylinder (3).  Retract bucket cylinder (2) and stick cylinder (3) to such an extent as to reach the position of the attachment shown in (Fig. 2-320:). Recommended position of the backhoe bucket attachment (Fig. 2-321:):  Fully extend boom cylinder (1).  Extend backhoe cylinder (2).  Extend stick cylinder (3).  Extend backhoe cylinder (2) and stick cylinder (3) to such an extent as to reach the position of the attachment shown in (Fig. 2-321:). If the attachment position must be changed:  Stop the hydraulic shovel,  Change the position,  Continue to travel.

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Fig. 2-320:

Fig. 2-321:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION Upper structure holding brake – set/release The hydraulic shovel is equipped with four upper structure holding brakes which are integrated in the swing gearboxes. The upper structure holding brakes lock the upper structure with respect to the undercarriage. The gearbox brakes are holding brakes only. Note: Do not press the button unless the upper structure is stationary. Do not use this button while the upper structure is still in motion. Risk of damage to the brakes and the slewing gears. Apply the holding brake:  When the hydraulic shovel is parked.  When traveling longer distances.  To apply the holding brakes, press switch (61, Fig. 2-322:).

Track roller temperature – check After traveling for 15 minutes without interruption, stop the hydraulic shovel and check the temperature of the track rollers. If you use an infrared thermometer, you can measure the temperature from some distance (Fig. 2-323:). If the temperature is below 70 °C (158 °F):  Continue traveling. If the temperature is between 70 °C and 90 °C (158 °F and 194 °F):  Monitor the temperature of the track rollers.  Continue traveling but check temperature in short intervals. In case of higher temperatures above 90 °C (194 °F):  Stop traveling.  Resume traveling only after the track rollers have cooled down to approx. 40° C (104°F). Note: Do not walk beside the machine and try to cool down track rollers by hand with a bucket of water or with a water hose. In principle it is possible to use a water truck to spray water on the track rollers from a safe distance. This will rapidly cool down the track rollers.

Fig. 2-322:

Fig. 2-323:

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OPERATION Traveling – Best Practices

When traveling down from a steep bench (Fig. 2-324:), lower the bucket so that the distance to ground is about 0.5 m to 1 m (about 2 ft. to 3 ft.). Travel slowly and in the lower gear mode. In case the machine tends to tip to the front, lower the attachment to ground and protect the machine from tipping over.

Fig. 2-324:

When crossing the sharp edge of a steep bench upwards or downwards, travel very slowly and let the machine tip over the edge very carefully. Doing so prevents the machine from being damaged when impact on the ground (Fig. 2-325:).

Fig. 2-325:

Traveling in mud and water When traveling through any body of water or mud be careful that the level of water or mud is not higher than the breather valves on top of the final drives (Dimension A, Fig. 2-326:). Water or mud could enter the gearboxes and cause serious damages. While you cross any body of water or mud, carefully confirm the depth of the water or mud with the bucket. Do not move the machine into an area that has a water or mud depth that is higher than the breather valves of the final drives (Dimension A, Fig. 2-326:). Fig. 2-326:

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OPERATION Traveling – Restricted Operation

Do not travel the machine longer than 5 minutes with the final drives to the front (Fig. 2-327:). This will reduce the durability of the undercarriage and the travel system components.

Fig. 2-327:

Do not travel with a filled bucket (Fig. 2-328:).

Fig. 2-328:

If traveling down from a steep bench, do not place the bucket on the ground in order to prevent the machine from slipping or tipping (Fig. 2-329:). The weight of the machine will force the stick cylinders and the bucket curl cylinders over the relief valves causing them to extend into their end stops. The weight and inertia of the machine pressing on the cylinder – this could lead to overstressing cylinder clevis bolts.

Fig. 2-329:

Do not travel too steep ramps. Doing so can exceed the hydraulic capability of the machine. This can cause an uncontrolled state and damage to the machine. Refer to Operation and Maintenance Manual, section “Maximum Machine Inclinations” for information about maximum inclinations.

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OPERATION

Always ascend the slope at a 90 degree angle (Fig. 2-330:). Driving across the face of a slope or steering on a slope may cause the machine to slide or tip over.

Fig. 2-330:

Driving across the face of a slope or steering on a slope (Fig. 2-331:) may cause the machine to slide or tip over. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

Fig. 2-331:

Do not travel through loose gravel material which could penetrate between rollers and track (Fig. 2-332:). This could result in damaging components of the under carriage. Tracks may point load on rocks making the machine less stable.

Fig. 2-332:

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OPERATION

Do not operate the machine in FAST travel speed unless in appropriate situations (Fig. 2-333:). Refer to the “Travel Speed – Recommendations – Table“ for further details.

Fig. 2-333:

Do not travel over large rocks or unblasted material. Large rocks can damage components of the under carriage (Fig. 2-334:).

Fig. 2-334:

Do not use the force of the bucket, the stick or the boom to lift and assist in turning the machine while the machine is traveling (Fig. 2-335:). This technique is referred to as “jump steering”. Doing so creates the risk of high stress and damage to:  Swing ring and mounting bolts. 

Bucket or shovel front clam and back wall.



Undercarriage components.

For more information about correct turning the machine refer to section “Turning”.

Fig. 2-335:

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OPERATION Maximum Machine Inclinations The machine must not exceed the inclinations indicated for working, traveling and servicing operations and during downtimes. The values specified in the tables below (next page) are valid for all types of attachment. If the maximum inclinations are exceeded, there is a risk of severe damage to the engines due to insufficient lubrication. In the event of extreme inclinations the machine can topple over. The working performance of the machine is especially economical when the machine stands on firm and level ground.

A loss of performance and higher wear must be accepted when the machine works in an inclined position, e.g. when building a ramp or when slewing uphill. For the building of ramps, the values specified in the table "Maximum inclinations during working operations" may be exceeded. In this case, however, a reduced service life of the components can be expected. During downtimes, the machine must be parked in such a way that its inclination does not exceed 3° / 5.2 %.

Maximum machine inclinations during working operations:

forward inclination

rearward inclination

side inclination

5° / 8.7%

5° / 8.7%

5° / 8.7%

Maximum machine inclinations during traveling: The (theoretically) possible inclination is limited by the max. possible engine oil pan angle. Exceeding these limitations will cause severe damage to the engine. Forward deg / %

Rearward deg / %

Side deg / %

6030, 6030 FS C27 (TWM engine)

20° / 36.4%

20° / 36.4%

20° / 36.4%

C27 (TZD engine)

30° / 57.7%

30° / 57.7%

30° / 57.7%

6040, 6040 FS

C32

30° / 57.7%

30° / 57.7%

30° / 57.7%

6050, 6050 FS

K1500E

30° / 57.7%

30° / 57.7%

30° / 57.7%

6060, 6060 FS

C3512C

24° / 44.5%

24° / 44.5%

24° / 44.5%

6090 FS

QSK60

20° / 36.4%

20° / 36.4%

20° / 36.4%

Type

Engine

Maximum machine inclinations during maintenance operations:

2-174

forward inclination

rearward inclination

side inclination

0° - 2° / 3.4%

0° - 2° / 3.4%

0° - 2° / 3.4%

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION TRANSPORTING THE MACHINE Transport - Safety instructions The machine must be loaded and transported only after all safety regulations have been observed and complied with. Entrust loading and transporting of the machine to a company experienced in the transport of heavy equipment. The responsability for loading and transporting lies with the transport company or their representative. Remove oil, grease, soil, mud, snow, ice and other materials from the hydraulic shovel's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping. Secure the transport vehicle against rolling away. Use only tying equipment of sufficient strength (the weights and dimensions of the hydraulic shovel are set out in the "Product Specification Sheet”, which can be found in the annex).

Transport The dimensions and the service weight of the fully assembled hydraulic shovel do not allow the hydraulic shovel to be transported in an undismantled state on a low-bed trailer over public roads. Therefore, the components and modules must be dismantled beforehand. Suspensions points as well as the center of gravity are marked on the modules (see example, Fig. 2-336:). Dimensions and weights of the machines modules can be found in the annex, chapter “Product Specification Sheet” as well as in the “„Service Manual“”. Detailed instructions for disassembling and assembling the machine can be found in the Service Manual.

Fig. 2-336:

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OPERATION Engine-off lowering of the attachment In case of a failing out of the electronic hydraulic shovel control and / or the engines, lower the equipment as follows:  Sit down on the operator’s seat. Switch inside seat (105, Fig. 2-337:) is activated then.  Switch on the electric system with key-switch (32).  Operate switch (71), hydraulic servo system is activated then.  Operate switch (65, Fig. 2-338:) and hold.  Push control lever (116) forwards to lower the attachment to ground.  Contact the responsible service personnel as soon as possible.

Fig. 2-337:

Fig. 2-338:

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OPERATION After daily operation Parking the machine  Park the machine on level and stable ground. This is particularly important in winter to avoid freezing of the tracks.  Stand the attachment on the ground.  Shut off the engines.  Shift both control levers into all directions todepressurize the hydraulic cylinders.  Withdraw the key from the electrical system key-switch.  Close the cab window.  Lock the cab door and all lockable hatches and covers on the machine.  Clean the machine of coarse dirt as well as of combustible and easily flammable substances, if possible with a stream jet (rubber parts and electric components with compressed air refer to information label). Otherwise, the fire and explosion hazard will exist.

Escaping oil pollutes the environment.

 Repair leaks immediately (or have them repaired).  Report oil accidents to the responsible person.  Check the upper structure, undercarriage and the attachment for damage and all steel components for cracks or fractures.  Report detected damage immediately to the responsible person.  Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler.

 Fill up the fuel tanks.  Inspect the engines, the hydraulic system, the track rollers, upper rollers, idlers and gearboxes visually for leaks.

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OPERATION ASSEMBLING ATTACHMENT SAFETY INSTRUCTIONS Personel Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal. If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM-HMS GmbH. The Operation and Maintenance Manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood. Only such persons may start up the machine during assembly work in order to adjust the attachments. Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Personal protective gear and working clothes Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury. Wear your personal protective equipment: a safety helmet, safety goggles, safety footwear and gloves.

Safety line on boom When carrying out work on the attachment, f.ex. on the monobloc boom (Fig. 2-339:), use a fall arrester. Falling down from great hight may cause severe injuries. Connect the fall arrester to the safety line on the boom (arrow, Fig. 2-339:).

Tools and auxiliaries Tools, hoists, slings, trestles and other devices must be in a reliable, safe state. Metal splinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn. Use only the steps, platforms and handrails when climbing onto or off the machine. Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing the attachment Stand attachment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached. Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out work on the attachment only if the machine is secured as described in the "Securing the machine" section.

Selecting the attachments

Fig. 2-339:

The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application. Operate the machine only with the equipment and component combinations expressly approved by CGM-HMS GmbH for this type of machine. Never install and commission other equipment and component combinations without CGM-HMS GmbH first having inspected and approved the project in writing.

Protective roof against falling objects The machine is equipped with an integrated cabprotection roof (FOPS).

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OPERATION Main control valves – attach/remove the handrail

Securing the machine

The handrail as well as the safety line fitted to the attachment ensure your safety when working on the main control valve block of the hydraulic system. If you do not use the safety equipment provided you may fall down and seriously hurt yourself. Before starting work at the main control valves:  Bring the surface of the walkway (1, Fig. 2190) to a horizontal position by moving the attachment. The GET must hit the ground.

The machine must not be started by unauthorized persons. Therefore, secure the machine. Observe the accident prevention regulations. Depressurize pipeline systems, on which work is to be carried out, by appropriate measures. Protective shrouds of moving machine parts may only be opened or removed when the drive unit is stationary and protected against inadvertent starting. Before carrying out fitting works, the machine and the equipment must be protected against inadvertent starting by placing chocks under the tracks and by standing the attachment on the ground. Hydraulic and lubricating systems: Close all open bores, pipe and hose connections with pressureresistant plugs. Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of non re-usable oils without polluting the environment. All components of CGM-HMS GmbH machines have been carefully purpose-coordinated. Troublefree operation and a long service life can only be achieved with original CGM-HMS GmbH spare parts. Respect the sequence of working operations when fitting or replacing the attachments. The sequence has been determined and tested by qualified experts.

 Put on your harness (part of PPE).  Lift the handrail (2) from its storage position (3) and fit it to the walkway (1).  Connect the safety line of your harness to the safety line on the attachment.  Carry out your work.  After completing your work detach the handrail (2) from the walkway (1), put the handrail into its storage position (3) and secure it with the wingscrews. Parts of the machine may be damaged when moving the attachment with the handrail attached. After completing work at the main control valves put handrail (2) into its storage position (3) and secure it using the wingscrews.

Risk of injury

Secure the machine as described below:  before carrying out any fitting and modification work on the attachment, 

before carrying out any servicing and repair work on the machine.

 Park the machine on level and stable ground.  Stand the attachment on the ground.  Shut off the engines.  Depressurize the hydraulic system.  Withdraw the key from the key-switch.

Fig. 2-340:

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OPERATION CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) Use "GLEITMO 815" anti-corrosive agent only. Other agents are not approved by CGM-HMS GmbH. All pins and bearings (bushings and hubs) of the attachment or in equipment componenents must be treated with "GLEITMO 815" anti-corrosive agent before fitting. Doing so  permits easy fitting and dismantling 

protects against rust, oxidation and similar wear



prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminium and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden. SAP Part no. for "GLEITMO 815" is 1519702, available from CGM-HMS GmbH Spare-Parts Service.

2-180

Application of GLEITMO 815  Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel. Rust patches must be thoroughly removed, if any. All parts must present a dry, bright metal surface.  Apply a thin layer of GLEITMO 815 on pins and all bearings using a brush or a spray can. Pin shafts and bearings must be completely co-vered by the protective layer. If the protective layer of a pin already treated with GLEITMO 815 is damaged, these areas must be touched up before fitting the part.  Fitting and securing of pins If the pin is too heavy to be fitted manually, apply GLEITMO 815 at first only on abt. a quarter of the pin's length Then position pin by means of a lifting gearready for fitting. Apply GLEITMO 815 on the remaining length of pin shaft, fit pin and secure.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION ON-BOARD CRANE (OPTIONAL) The on-board crane is designed for lifting heavy parts only. Do not lift persons. Observe all national directives as well as specific regulations relevant to crane operation.

On-board crane - Monitoring, warning and control elements (Fig. 2-341:)

Personel Crane work may be carried out only by operators who have the necessary know-how and the permission to operate cranes. If such know-how or such permission is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM-HMS. Incorrect operation of the crane may give rise to life-threatening situations.

Fig. 2-341:

Pos. Element 1 Monitoring lamp 2 Warning lamp 3 Warning lamp 4 Monitoring lamp 5 Key-switch

10 11 12

Button Monitoring lamp Knob Monitoring lamp Warning lamp Button Button

21

Control lever

22 23 24

Control lever Control lever Control lever

6 7 8 9

Function Alternator Engine oil pressure Engine temperature Air filter Electrical system ON/OFF Start engine of drive unit Preheating system (option) Engine speed variation Crane in operation Malfunction EMERGENCY STOP Emergency lowering of winch Extending and retracting of boom extension Folding the boom Swinging the boom Winch up / down

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION On-board crane- Putting into operation Risk of serious injuries due to movements of the crane. Put the crane into operation only after all persons have left the danger area. Do not exceed the maximum lifting capacity (observe the lift capacity chart attached to the boom).

On-board crane - Drive unit The drive unit (Fig. 2-342:) supplies the crane with hydraulic power. So the on-board crane is functional without the shovel’s engines running. The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system. The drive unit is equipped with an Emergency OFF push switch (arrow, Fig. 2-342:). In case of emergency push the switch, the engine of the drive unit comes to standstill.

Prior to each deployment: Carry out all maintenance work as listed in the “Inspection and Servicing Plans “T” and “W”. To start the drive unit:  Turn key-switch (5, Fig. 2-341:) to position ON.  Press button (6), engine will start. The crane control unit is equipped with an Emergency OFF push switch (11). In case of emergency push the switch, the engine of the drive unit comes to standstill. After finishing work block the boom, then stop the engine (see chapter “On-board crane, - blocking the boom in position of rest”). Fig. 2-342:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION On-Board crane – Blocking the boom in position of rest Movements and accelerations produced by working operations of the machine can cause damage to the swing drive of the on-board crane, if the crane is not blocked. The hydraulic on-board crane must therefore be blocked in its position of rest. Risk of serious injuries due to movements of the crane. Put the crane into operation only after all persons have left the danger area. To block the boom:  Retract the boom completely.  Swing the boom in the direction of the blocking device (Fig. 2-343:) and lower it.  Withdraw the cotter pin at the tip of the boom.  Extend the boom carefully until the tip engages the blocking device (arrow, Fig. 2-343:).  Reinsert and lock the the cotter pin.

On-board crane - Check Extract from the inspection and testing regulations The on-board crane is approved in accordance with the Accident Prevention Regulations for Cranes (BGV D6, applicable only in Germany). The on-board crane must be inspected regularly in accordance with the regulations in force in the country of use. The inspections must be requested by the user of the crane. The expert or specialist entrusted with the inspection can be appointed at the user's discretion. The user must ensure, however, that the appointed person meets the requirements. The user is obliged to make available all documents required for the inspection and to ensure the smooth running of the inspection. He is furthermore obliged to provide, if required, crane operators and auxiliary personnel and the required test loads. The result of the inspection is to be documented in an inspection record signed by the inspector. The inspection record serves as proof on the part of the user that the inspections have been carried out. The inspection record must contain all data required for crane identification and for the performance of further regular inspections.

Fig. 2-343:

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OPERATION Monitoring cameras – Function This hydraulic shovel is equipped with two monitoring cameras:  one mounted on the counterweight, looking backwards;  one mounted on the hydraulic oil cooler module, looking to the right. The two cameras and the belonging LCD-diplay are operational after the electrical system of the machine has been activated with the key operated switch. The LCD-display is mounted near the control column (arrow, Fig. 2-194). To switch the LCD-display on, press key “PWR” on the display housing. Both cameras transmit their images to the same LCD-display. The display is mounted near the control column. For toggling between the camera images beeing displayed, press the key in the left joystick (arrow, Fig. 2-345:). Additional information can be found in the manuals of the camera manufacturer (see Volume 5 of the Technical Documentation "Components").

Fig. 2-345:

Operator Assist System (if equipped) There is several literature available covering the Operator Assist System. Please contact your Cat dealer for assistance.

Reference Literature Media-IdNumber

Fig. 2-344:

2-184

Title

M0083817

“Operator Assist System Operation and Maintenance Manual, Supplemental Information”

AEXQ2311-01

“Operator Assist Retrofit Kit – Flyer”

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

OPERATION

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING 3 INSPECTION AND SERVICING

Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

3-1

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING

3-2

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING INSPECTION AND SERVICING SAFETY INSTRUCTIONS Operation and Maintenance Manual No inspection and servicing work must be carried out until the Operation and Maintenance Manual has been read and understood. Pay special attention to: „Fundamental safety instructions" and all warnings and safety instructions attached to the machine. The Operation and Maintenance Manual lists all jobs to be done. The descriptions of job sequences, however, provide only experienced personnel with the necessary instructions. The Operation and Maintenance Manual must be kept with the machine at all times.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines. The necessary know-how can be acquired in a several day's instruction, e.g. by an CGM-HMS GmbH mechanic or by attending an CGM-HMS GmbH training course.

Securing the machine Carry out servicing work only if the machine is secured as described in the section "Securing the machine".

Climbing onto and off the machine Use only the ladders, steps, platforms and handrails provided when climbing onto or off the machine. Always keep ladders, steps, platforms and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately. Always maintain a three point contact with the steps and grab handles. Always face the machine when climbing on and off.

Checking the state of tools Use only fully functional, reliable tools. Select the right tool for the job. Wrenches of the wrong size, for example, may slip and cause injury.

Cleaning jobs Personal protective equipment and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury. Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

Securing the attachment Stand attachment on the ground in such a way that no movements can be made if mechanical or hydraulical connections become detached. Secure any attachment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging / supporting devices to prevent them from moving, slipping or falling inadvertently.

Prior to commencing work, clean your working area, if necessary and possible, with a steam-jet (rubber parts and electric components with compressed air - refer to information label). Exhaust pipes and turbo chargers in the engine compartments are covered with special heat insulating material. This material must not be spraywashed with steam-jet cleaners or high pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments. Use only lint-free cleaning rags when working on the hydraulic system or the engines. Cleaning agents and solvents may give off harmful, readily flammable vapors. Never work with such agents except on well ventilated premises; never inhale the vapors and never smoke. Prevent solvents and cleaning agents from coming into contact with your skin. Wear gloves. Observe the instructions on the packaging.

3-3

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Handling flammable liquids

Visible oil losses

When handling flammable liquids:  never smoke,

Have any visible leakage repaired immediately. Escaping oil is an environmental hazard. Soak up any oil that has escaped with a binding agent. Sweep up binding agent and dispose of it separately from other waste.



keep away from unshielded light sources and naked flames,

Fuel and other consumables often have low flash points and are readily ignited. Never attempt to extinguish burning liquids with water. Use:  dry powder, 

carbon dioxide or



foam extinguishers.

Water used for extinguishing purposes would vaporize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing hazards. Notify the fire brigade.

Fastening and securing elements Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again. Replace any damaged parts.

Spare parts Use only the original spare parts of CGM-HMS GmbH. They are the only ones to fulfill the technical specifications of the machine.

Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns. Never set foot within reach of the emerging oil jet. Avoid contact with the skin. Wear gloves and firm protective clothing. Used oil may be harmful to the skin. Clean soiled skin thoroughly with warm soapy water and apply a barrier cream. Never use fuels or solvents for cleaning the skin. If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

3-4

Relieving residual pressure in the hydraulic system Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with its attachments supported on the ground and its driving motors switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine. Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, the system must be depressurized: (do not leave the operator's seat)  Stand attachment on the ground,  Shut off the engines,  Move all control levers and pedals repeatedly into all directions.

Bolted connections, piping, hydraulic hoses Repair any leakage in the piping and hose system immediately. A fine, highly pressurized jet of hydraulic oil can penetrate the skin. Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles. If oil has penetrated into the skin, consult a doctor immediately. Never repair damaged piping; always replace them. Replace hydraulic hoses immediately on detecting any damage or moist areas. Tighten leaking Screw plug s only when the system is depressurized. Escaping oil is an environmental hazard.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Non-polluting disposal

Engine exhaust gases

Dispose of oils, greases, cooling liquids, detergents, solvents and oil-containing components, such as filters, cleaning rags, replaced wearing parts and unusable machine parts, without polluting the environment and separately from other waste. Do not dispose of these substances together with household wastes. Fill these substances into the containers provided for such purposes. Like any other oil, also bio-degradable, "environmental-friendly" hydraulic oil must be disposed of separately. Do not allow oils and oily wastes to penetrate into the soil or into water. They are an environmental hazard. Used pressure vessels for cold-starting fluid (ether) must be disposed of properly. Contact the supplier with regard to disposal / return of the vessels. Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine.

Start and operate combustion engines only on well-ventilated premises. In closed rooms, exhaust gases must be evacuated to the outside. Do not work on the exhaust system and do not make any modifications to it. Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.



Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

Sealing elements After replacing parts or after opening housings replace seals. Always use new seals and gaskets. Clean sealing faces prior to assembly. Check sealing elements prior to installation and replace any that are even slightly damaged. When assembling, ensure a perfect fit.

Handling batteries Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling. Batteries give off explosive gases. Never handle batteries close to naked flames and unshielded light sources, never smoke. Battery acid is toxic and corrosive. Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapors. Wear gloves, firm protective clothing and goggles / face protection shield when handling batteries. If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor. If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately. Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons. Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short-circuit resulting in burns. Dispose of used batteries separately from other waste in the interests of environmental protection.

Before working on the electrical system Before performing work on the electrical system where tools, spare parts, etc. can come into contact with electrical conductors or contacts, the battery must be disconnected. Disconnect first the negative and then the positive terminal. After the work: Reconnect first the positive and then the negative terminal.

3-5

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Handling of cold-starting fluid (ether)

Filters

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment. Read and observe the instructions on the pressure vessels. For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether). Provide for sufficient ventilation. Do not eat, drink or smoke when replacing an empty vessel. Do not inhale the vapors of escaping cold-starting fluid. In contact with the skin, ether can cause frostbites and irritations. Avoid skin contact. Wear suitable protective gloves and goggles. Even apparently empty pressure vessels can still contain rests of ether and therefore explode if they are damaged or heated up above 49°C. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine.

Replace / clean all filter elements or filter cartridges within the specified periods. All filters are coordinated carefully with the equipment. Original CGM-HMS GmbH parts must be used to ensure smooth running and a long service life of the engine and the hydraulic units.



Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

Selecting oils and greases Use the recommended qualities only, matching viscosities with the temperature level.

3-6

Oil-level check and oil change Position the machine horizontally. Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

After servicing To prevent corrosion, coat all bright metal parts with a grease film. On completing work, re-install all protective devices. Never start up the drive motors while work is being done on the machine. Carry out performance tests with the machine.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain information the national and corporate rules for the prevention of accidents and avoiding fires. Pay particular attention to hazards caused by combustible and easily flammable substances. Obtain information on the safe handling of the fire extinguishers to be used. Avoid smoking and open fire on, next to and below the hydraulic shovel. Even battery gases can ignite in open flames or fire. Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight. These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger. Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work. Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work. If necessary, also cover the ground with fireprotective blankets. Apply special protection to cables, cable ducts as well as to hose and pipe lines. Have all your welding, flame cutting and grinding work approved before starting work. The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment. Ensure sufficient ventilation. Do not keep any fire extinguishers that are not suitable or have not been tested. Do not extinguish flammable liquids with water. Use:  dry-powder, carbon-dioxide or foam extinguishing compounds. When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards. Call the fire brigade. Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground. Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING

3-8

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING INSPECTION AND SERVICING PLANS - INSTRUCTIONS Intervals The inspection and Servicing plan lists all jobs which have to be done on the machine at regular intervals. The individual inspection and Servicing plans are marked with letters providing a link between the operating hours (OH) recorded by the hours-run meter of the machine and the inspection and Servicing plans. Plan V N

Do all jobs .... ...once prior to initial commissioning. ...after initial commissioning and during the running-in period (after 100 OH). ...every 10 OH or every working shift 2) T ...every 60 OH or weekly .2 ) W ...after every 250 OH. A ...after every 500 OH. B ...after every 1000 OH. C ...after every 5000 OH. D ...after every 10000 OH. E OH = Bh = Operating hours

Change of engine oil Refer to chapter “Engine oil service interval table” for more information. Also refer to SEBU6250 Caterpillar Machine Fluid Recommendations.

2

Air-intake system The air filter must be serviced only if the BCS so indicates. Replace the filter elements after one year at the latest.

Oils / Greases For the specification of oils and greases to be used refer to the „LUBRICANTS/CONSUMABLES“ section. The numerals mentioned in the "Oil / Grease" column in the inspection and Servicing plans have the following meaning: Oils for combustion engines and comI pressors Oils for hydraulic systems II Oils for gearboxes IIIa, b Greases for bearings and swing rings V

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

Components The maintenance intervals for components, e.g. engine and gearbox, are listed in the following CGM-HMS GmbH maintenance schedules. It is possible that the manufacturer's documentation for these components states intervals deviating from the above-mentioned intervals. In such case, only the maintenance intervals specified by CGM-HMS GmbH shall apply.

Whichever comes first.

3-9

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING 3500 Engine Maintenance Interval Schedule – Notes Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

3-10

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan V Plan V - Once prior to initial commissioning Page 1 of 2 Location

Servicing work

Engine Engine oil tank (if equipped) Cooling system Cooling liquid Fuel system Electrical system Battery

Check oil level Check oil level

Lighting Monitoring, warning and control elements

Board Control System (BCS) Slewing system Hydraulic system Pressure accumulators - track tensioning system - hydraulic ladder - pilot system - engine-off attachment lowering - service station (fast fill arm) Hydraulic oil reservoir Hydraulic system Hydraulic cylinders

Pump drive gearbox and cooling system - Pre-chambers, expansion reservoir Swing gearbox Travel gearbox (PN N3683483 only) - Spur gear section - Brake-chambers Travel gearbox (PNs N3683496 and N3749598 only) - Hydraulic motor chambers Swing ring Internal gearing Undercarriage Track roller Upper roller Track tensioning system Idler

3

Quantity/ No. 2 2

Check level Fill in fuel

2

Check liquid level (not applicable when maintenance-free batteries build in) Check state of charge Check operation Check function of monitoring, warning and control elements Check emergency OFF function Check function Perform „Slew brake test“ (see chapter „Service – Slew brake test screen“)

6

Check, fill in the correct nitrogen pressure (see Service Manual, chapter 8)

Check oil level Check pressure (see „Service Manual“) Vent (see chapter “Venting hydraulic system“) Check function of working attachment and traveling movement Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level

2 2 4 2 2x1 2x2 2

Check oil level

2x2

Check grease filling Check for leaks and free movement Check grease filling, fill with grease 3 Check for leaks and free movement Check grease filling, fill with grease 3 Check pressure (see „Service Manual“) Check for leaks and free movement

1 2x7 2x2 2 2

Only machines with undercarriage greasing system

3-11

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan V – Once prior to initial commissioning Page 2 of 2 Location

Servicing work

Quantity/ No.

Central lubricating system Grease container

Check filling level

Greasing and pause cycles

Check setting

Level control

Check function

Service – Station (fast fill arm)

Check operation

- Arm bearing grease nipple

Lubricate

1

- Hydr. Cylinder bearing grease nipple

Lubricate

2

Air conditioner (optional) - Compressor

Check oil level

- Refrigerant

Check correct filling (Contact your Cat dealer)

Hydraulic ladder - Lubricating points

Lubricate

On-board crane (optional) - Fastening bolts

Check for tightness

16

- Bearings

Lubricate

4

- Joint (column / boom)

Lubricate

2

- Cylinder bearing

Lubricate

5

- Swing ring

Lubricate

1

Hydraulic oil reservoir

Check oil level

1

(See chapter “On-Board Crane, drive unit“) Crane drive engine

Check oil level

1

(See chapter “On-Board Crane, drive unit“) - Battery

Check liquid level For more detailed information see “On-board crane” documentation in Volume “Components”.

Escape ladder - Locking device - Ladder

Check function Check function Check free movement

Emergency escape device / seat (if equipped) - Harness holding device on cab roof

Check completeness and condition Check for tightness

Fall arrest static line on working attachment (optional)

Check condition Check function Check proper fastening

All lines, fittings and connections

Inspect visually for leaks, wearing marks

All articutated joints and hinges

Grease

3-12

2

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan N Plan N – After initial commissioning and during the running-in period (after 100 OH) (For the 3512C engines up to the initial 250 service hours) Page 1 of 2 Location

Servicing work

Engine Belts Engine mounts

Check tension, check condition Inspect

when required: Air filter primary element Air filter secondary element Air filter pre cleaner

Clean / replace Replace Clean

Initial 250 service hours: Engine valve lash

Check / adjust

Quantity/ No.

For more information on engine maintenance work contact your Cat dealer. Cooling system Cooling fluid

Radiator bearing fastening bolts Hydraulic system Hydraulic oil cooler - bearing fastening bolts Return-flow filter Magnetic rod Pressure accumulators - engine-off attachment lowering - hydraulic ladder - track tensioning system - pilot system - service station (fast fill arm) Pump drive gearbox and cooling system - Pre-chambers, expansion reservoir - Gearbox oil filter (cooling circuit) - Fastening bolts

4

Check level Carry out cooling liquid analysis after 250 OH For more information contact your Cat dealer. Check for tightness (see „Service Manual“)

Check for tightness (see „Service Manual“) Replace Clean Check function (see „Service Manual“)

Change oil Change oil Replace Check for tightness (see „Service Manual“)

2x7 1

24 2x13 2x1

see “Refilling quantities – Oil“ table

3-13

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan N – After initial commissioning and during the running-in period (after 100 OH) (For the 3512C engines up to the initial 250 service hours) Page 2 of 2 Location

Servicing work

Swing gearbox Fastening bolts Travel gearbox (PN N3683483 only) - Spur gear section - Brake-chambers - Magnetic plugs Fastening bolts Travel gearbox (PNs N3683496 and N3749598 only) - Hydraulic motor chambers - Magnetic plugs Fastening bolts

Change oil Check for tightness (see „Service Manual“) Change oil Change oil Change oil Clean Check for tightness (see „Service Manual“) Change oil Change oil Clean Check for tightness (see „Service Manual“)

Swing ring Fastening bolts (swing ring, undercarriage and upper structure)

Check for tightness (see „Service Manual“)

Upper structure Fastening bolts, especially at upper structure / Check for tightness (see „Service Manual“) pedestal / operator´s cab All lines, fittings and connections

3-14

Inspect visually for leaks, wearing marks

Quantity/ No. 44 24 2x14 2x24

24 2x24

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan T and Plan W Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Location

Servicing work

Hydraulic shovel

Visual check / overall cleaning

Page 1 of 3 Quantity/ No.

Plan T

Plan W 

2





Undercarriage - Tracks

Inspect track tension visually

- Track roller

Check for leaks and free movement

2x7



- Upper roller

Check for leaks and free movement

2x2



- Idler

Check for leaks and free movement

2



Service station (fast fill arm)

Inspect visually for leaks and damages

Travel gearbox

Check for leaks





2





2x1













Face shovel - Clam cylinder chambers

Inspect, remove all accumulated debris, rocks, soil and so on.

- Mechanical stops on face shovels rearwall and stick

Check for wear

All lines, fittings and connections Inspect visually for leaks, wearing marks Engine

Check oil level

2





Walk-around inspection

2

















- Belts

Inspect / replace

- Engine oil tank (if equipped)

Check oil level

- Engine monitoring (Board Control System)

Check monitoring lamps and BCS display for fault messages

When required: - Ether starting aid cylinder - Fuel system

Replace Prime

2

Cooling system - Cooling fluid

Check level

2





- Radiator

Check / clean

2





- Fuel filter

Drain off water

2x2





- Water trap (optional)

Drain off water

2x1





- Fuel tanks

Drain off water and sediment if necessary

2





Air-intake system

Check BCS – indication

1





Intake and clean-air lines

Check for tightness and leaks

Fuel system



-

Dust trap

Remove dust

4x1





-

Cyclon prefilter

Check, remove dust

4x1





3-15

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan T – Every 10 OH or every working shift (whichever comes first) Plan W – Every 60 OH or every working week (whichever comes first) Location

Servicing work

Hydraulic system

Check function of working and traveling movement

Page 2 of 3 Quantity/ No.

Plan T

Plan W



 

Inspect visually for leaks 



- Hydraulic oil reservoir

Check oil level

1

- Oil cooler

Check / clean

2

- Fan wheel

Check condition

2





Pump drive gearbox and cooling system

Check oil level

2





- pre-chambers expansion reservoir

Check oil level

2





- Oil filter (tell-tale)

Check

Swing gearbox

Check oil level





2x1 



Check filling level





Check visually





4

Central lubricating system - Grease container - Lubricating points On-board crane (optional)

5

- Fastening bolts

Check for tightness

16

- Crane drive engine

Check oil level

1



(see: “Crane drive Engine“ operating instructions) Hydraulic oil reservoir

Check oil level

1

- Reflow filter (contamination indicator)

Check

1

Reservoirs for used grease at the A-frame

Check, depollute used grease

2

Fire extinguisher (if equipped)

Inspect





Escape ladder - Locking device - Ladder

Check function Check function Check free movement

  

  

5

Before each deployment of the crane

3-16



EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan T – Every 10 OH or every working shift (whichever comes first) Plan W – Every 60 OH or every working week (whichever comes first) Location

Servicing work

Emergency escape device / seat (if equipped) - Harness holding device on cab roof Fall arrest static line on the attachment

Page 3 of 3 Quantity/ No.

Plan T

Plan W

Check completeness and condition





Check for tightness





Check condition





Check proper fastening





Check function





Operator’s cab - Window panes - Mirrors - Cameras (if equipped) - ROPS structure - Operator’s seat belt - Trainer’s seat belt

Clean Check/Clean/Adjust Check/Clean/Adjust Inspect for damage Check condition Check condition

     

     

Monitoring, warning and control elements

Check function of monitoring, warning and control elements





Board Control System (BCS)

Check function





- Lighting

Check operation





- Horn

Test





- Travel Alarm

Test





- EMERGENCY OFF button

Check function





Electrical system

6

- CAN-BUS wiring connections

Inspect



- Switchgear cabinet breather filter dust trap

Remove dust



Air conditioner (optional)

Carry out all servicing work, see “Air Conditioning manual“



Automatic fire-extinguishing system (if equipped)

Inspect





3-17

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING

3-18

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan A – E Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 1 of 7 Location

Servicing work

Quantity Plan Plan Plan Plan Plan / No. A B C D E 

Servicing in acc. with W or T









Monitoring, warning and control elements - Joystick, plate, cardan joint Clean, then grease lightly

26







- Control spool (machine with loading shovel)

Clean, then grease lightly

3x26







- Control spool (machine with backhoe bucket)

Clean, then grease lightly

2x26







Operator’s cab - Fastening bolts to cab module

Check for tightness (see “Service Manual” for tightening torque)







Operator’s seat belt

Replace within 3 years of the date of installation

Trainer’s seat belt

Replace within 3 years of the date of installation

- and control spool - Pedal

6

apply a thin layer of low temperature grease

3-19

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Location Servicing in acc. with plans W or T Engine Every 250 Service Hours: Engine oil Engine oil and filter

Page 2 of 7 Servicing work

Carry out oil analysis (see: Engine oil service interval table) Change – severe duty (see: Engine oil service interval table)

Every 500 Service Hours or 3 months: Belts Inspect / replace Engine crankcase breather Clean Engine oil and filter Change (see: Engine oil service interval table) Fuel system primary filter (water Replace separator) Fuel system secondary filter Replace Engine Clean Engine mounts Inspect - Fastening bolts Check tightness - Rubber bearing Check condition Every 4000 Service Hours: Engine valve lash

Quant. / No.

Plan A 

Plan B 

Plan C 

Plan D 

Plan E 

2x1











27











  

  

  

  









  

    

    

    















27

Check / adjust

Every 6000 Service Hours or 3 years: Cooling system water temperaReplace ture regulator Cooling system coolant extender Add (ELC) Engine water pump Inspect Every 1,420,000l (375,000 US gal) of fuel: Engine components Rebuild / install / reman Every 2,840,000l (750,000 US gal) of fuel: Engine components Clean / inspect, rebuild / install / reman, install new Overhaul: Overhaul considerations Engine oil tank (Reserve Oil System) - Filter - Breather filter

7

For more information on engine maintenance contact your Cat dealer.

Replace (see: Engine oil service interval table) Replace

see: “Refilling quantities – Oil“ table

3-20

2x2 2x1



EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan A – after every 250 OH (at 250, 750, 1250 … OH)

Plan B – after every 500 OH (at 500, 1500, 2500 … OH)

Plan C – after every 1000 OH (at 1000, 2000, 3000, 4000 … OH)

Plan D – after every 5000 OH (at 5000, 15000, 25000 … OH)

Plan E – after every 10000 OH (at 10000, 20000, 30000, … OH) Page 3 of 7 Location

Servicing work

Cooling system Radiator - Fastening bolts - Rubber bearing Cooling system coolant sample (Level 1) Lines and hoses

Inspect visually for leaks

Hose clamps Fuel system Fuel filter Fuel system primary filter Water trap (optional) - Filter element Breather filter fuel tank Fuel tank water and sediment Fuel tank Air-intake system Main filter element Secondary filter element Air-intake lines and clean-air lines Intercooler Hoses Electrical system Battery cable connections Battery

Switchgear cabinet breather filter Horn

Quantity Plan Plan Plan Plan Plan / No. A B C D E     

Check tightness Check condition Obtain



Check for leaks Inspect / Replace Check tightness Replace Clean Clean Replace Replace Drain Clean Check / replace Replace Check for tightness and leaks

2x3 2x1 2x1 2x1 2x1 2x1 2

  

  

  





  











  

     

     

      

  

  

  





2x48 2x49

Check / Clean Replace







 

 

Check for tightness

 6

 

 

 

 

1











 

 

Check fluid level (not applicable when maintenance-free batteries build in) Clean Replace Inspect / Replace

1

8

Replacement of main filter element after one year resp. after 3 cleaning cycles at the latest Replacement of secondary filter element after one year resp. after 3 cleaning cycles of the main filter element at the latest

9

3-21

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Page 4 of 7

Location

Servicing work

Hydraulic system

Check pressure settings (see „Service Manual“)

Quantity Plan Plan Plan Plan Plan / No. A B C D E   

Oil cooler bearing - Fastening bolts

Check for tightness







- Rubber bearing

Check condition













 

 

 









 

 

















 

 





Return-flow filter

Replace

Magnetic rod Bypass valve (hydraulic oil reservoir) High-pressure filter for working hydraulics

Check / clean Check / clean filter sieve

Filter for pilot control circuit

Filter for swing pump charge circuit Filter for swing circuit

Filter for bearing flushing of main pumps Hydraulic oil reservoir

Check for contamination and damage Replace Check for contamination and damage

2x7 1 6 2x4 2x4 4x1

Replace

4x1

Check for contamination and damage

2x2

Replace

2x2

Check for contamination and damage

2x1

Replace Replace

2x1 2x1

Carry out oil analysis including particle count



1









(For more information regarding particle count results, refer to section: “Hydraulic Oil Analysis – Understand Particle Count Results”)

Change oil

1 10 11

- Breather filter

Replace

2

Pressure accumulators

Check pressure (see „Service Manual“) Replace

1

Cylinder (seals and guide rings)

10

 



  

see “Refilling quantities – Oil“ table Unless it is regularly analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

11

3-22

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Page 5 of 7

Location

Servicing work

Pump drive gearbox and cooling circuit

Carry out oil analysis

- Breather filter Pre-chambers and expansion reservoirs - Breather filter Oil filter

Fastening bolts Swing gearbox Breather filter Travel gearbox (PN N3683483 only)

- Magnetic rod Spur gear section - Magnetic rod Brake-chambers Breather filter Travel gearbox (PNs N3683496 and N3749598 only)

- Magnetic rod Hydraulic motor-chambers Breather filter

Quantity Plan Plan Plan Plan Plan / No. A B C D E     2 2 12 2x1 2x1 2 x 5 12

 

 





   

2x1 2x1

 

 

 





 

 

4 4 12 4x1 2



 





   

   

Check oil level Change oil ** Clean Check oil level Change oil ** Clean Check oil level Change oil ** Clean / replace Carry out oil analysis

2 2 12 2x6 2x1 2 x 1 12 2x1 2x2 2 x 2 12 2x3 2











 

 

 



 



 

    

    

Check oil level Change oil ** Clean Check oil level Change oil ** Clean / replace

2 2 12 2x6 2x2 2 x 2 12 2x3











 

 

 







Change oil * Clean Replace Change oil * Clean Check for contamination and damage Replace Check tightness (see „Service Manual“) Carry out oil analysis Change oil * Clean / replace Carry out oil analysis

2x1 

Oil change interval with routine oil analysis every 500OH: (*) with mineral gear oil after 1000 OH, with synthetic gear oil after 3000 OH. (**) with mineral gear oil after 2000 OH, with synthetic gear oil after 6000 OH or max. 1 year whatever occurs first.

12

see “Refilling quantities – Oil“ table

3-23

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 6 of 7 Location

Servicing work

Swing ring Gearing / pinion Fastening bolts (swing ring, undercarriage and upper structure)

Check grease filling Check condition Check for tightness (see „Service Manual“)

Undercarriage Diaphragm accumulator - Diaphragm Piston accumulator Track roller (if not connected to the central lubricating system) Central lubricating system Oil filter (hydraulic circuit grease pump) Grease filter (filling grease container) Grease filter (grease lines) Breather filter grease reservoir Air conditioner resp. heating (optional)

Replace (see „Service Manual“) 13 Check wear (see „Service Manual“) Check pressure (see „Service Manual”, chapter 8) Replace Check pressure (see „Service Manual“, chapter 8) Check grease filling, lubricate

Quantity Plan Plan Plan Plan Plan / No. A B C D E     1      

2x1















2x1 2x1







2x7













1







1 1



 

 

1 2



 

 

1 1



 

 



















Check function Check for contamination and damage Replace Check for contamination and damage Replace Check for contamination and damage Replace Check / replace



- Air suction filter mat

Carry out all maintenance work acc. to the manufacturers manual. Clean, replace if necessary

- Fan motors brushes

Inspect / Replace

Hydraulic ladder - greasing points

Lubricate







Service-Station (Fast fill arm) - Arm bearing grease nipple - Hydr. cylinder grease nipple

Lubricate Lubricate

 

 

 

13

3

Replace fastening bolts first time after 30 000 OH, then after every 15 000 OH

3-24

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 7 of 7 Location On-board crane (Option) 14 - Bearing - Joint (column / boom) – Cylinder bearing – Swing ring Hydraulic system – Return-flow filter – Breather filter

Crane drive engine - Oil filter – Fastening bolts – Fuel filter – Air filter – Battery cable connection

Steel components

Modules - Fastening bolts All articulated joints and hinges

Servicing work

Lubricate Lubricate Lubricate Grease Change oil Replace Replace (see “On-Board Crane Operation and Maintenance Manual”) Clean Change oil Replace Check for tightness Replace Replace Check for tightness (see “Crane Drive Engine Operation and Maintenance Manual”) Visual inspection acc. to “Structural Inspection Report every 500 OH” 16 If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonic test. Check for tightness (see “Service Manual”) Lubricate

Quantity Plan Plan Plan Plan Plan / No. A B C D E 4 2 5 1 1 15 1 1 















































1 1 15 1 1 1 1 2

14

Do all servicing jobs at least once a year and when necessary see “Refilling quantities – Oil“ table 16 „Structural Inspection Reports“ for inspections every 500 OH can be downloaded from SIS-Web, Media-IDNo. BI644777. 15

3-25

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING LUBRICATING CHART – GREASE

Fig. 3-1:

3-26

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Lubricating chart – Grease (legend) No. Greasing point

Number

1 3

Central lubricating system – grease container

1

Track roller (if not connected to the central lubricating system)

2x7

4 5

Hydraulic ladder On-board crane

6

- Bearing - Joint (column / boom)

4 2

- Cylinder bearing

5

- Swing ring

1

Lubricant properties

V

Grease every .... operating hours 10 1000

17

Tribol 18 (*)

V

17

1000 250

V

17

250 250 250 250

Graphite spray

Monitoring, warning and control elements - Joystick: plate, cardan joint, control spool - Pedal (machine with shovel attachment)

2 19 3 x 2 19

- Pedal (machine with backhoe attachment)

2 x 2 19

V

1000 1000

17

1000

All other greasing points are supplied with grease by the central lubricating system.

Refill Capacities – Grease Greasing point Central lubricating system – grease container

Lubricant properties

kg

Filling quant. lb

V 17

approx.1000

approx. 2204.6

approx. 300

approx. 661

(different containers available) Internal gearing – Roller-bearing swing ring Idler (permanent grease filling *)

Tribol 18

2 x approx. 25

2 x approx. 55

Track rollers (permanent grease filling *)

Tribol 18

14 x approx. 21

14 x approx. 46.3

4 x approx. 14

4 x approx. 30.9

Upper rollers (permanent grease filling *)

(*) Components are pre-lubricated at the factory with a lifetime lubricant TRIBOL®, SAP P/N 4027185 (52kg / 115lb barrel). For inquiries on recommended fluid in the event of a component rebuild, please contact CGMHMS product support or your local DPSC.

17

see " LUBRICANTS / CONSUMABLES " section. Not in use when machine is equipped with undercarriage greasing system 19 apply a thin layer of low temperature grease 18

3-27

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING INSPECTION PLAN - OIL

Fig. 3-2:

3-28

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Inspection plan – Oil (legend) Number

Lubricant properties 20

Engine (Standard)

2

I

Check oil level every ... OH 10

Engine (With Reserve Oil System, if equipped)

2

I

10

3

Hydraulic system

1

10

4

2

5

Pump drive gearbox and cooling system - Pre-chambers expansion reservoirs Swing gearbox

II III.a

6

Travel gearbox

No. Location 1

- Spur gear section

2x1 4

- Hydraulic motor chambers 7

10

III.b

2 2x1

(Travel gearbox P/N N3683483 only)

10

10

500

III.a

2x2

500 500

Change oil every ... OH See: Engine Oil Service Interval Table See: Engine Oil Service Interval Table 10000 21 1000 (mineral gearoil) 3000 (synthetic gearoil) 1000 (mineral gearoil) 3000 (synthetic gearoil) 2000 (mineral gearoil) 6000 (synthetic gearoil)

On-board crane (optional) - Crane drive engine

1

- Hydraulic oil reservoir

1

I II

10

250 22

10

1000 23

20

see "LUBRICANTS / CONSUMABLES" section Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years. 22 Change oil at least once a year. 23 Change hydraulic oil at least once a year. 21

3-29

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine oil service interval table Cat 3512C engine with 152 L (40.15 USgal) oil pan Quantity of oil filters

Reserve Oil System with extra oil tank used approx. 500 L (132 USgal)

Oil change interval without SOS

Max. oil change interval with SOS

Oil filter change interval *

#

yes / no

OH

OH

OH

3

No

250

500

250

6

No

250

500

500

3

Yes

500

1000

500

6

Yes

500

1000

1000

A 500 hour / 1000 hour engine oil change interval is achievable provided that  

normal operating conditions are met, recommended multigrade oil types are used (refer to the “LUBRICANT VISCOSITIES AND REFILL CAPACITIES” section in this Operation and Maintenance Manual), and  an S·O·S oil sampling analysis program is utilized. Normal operating conditions include  altitude below 6000 ft and  fuel sulfur levels below 0.3%. When these requirements are not met, shorten the oil change interval and use an S·O·S Services oil sampling and analysis program to determine an acceptable change interval. For assistance with optimizing oil change intervals, contact your local CAT dealer. For sulfur content above 0.1% refer to SEBU6250 Caterpillar Machine Fluid Recommendations.

*Reserve Oil System Filters should be changed at the corresponding engine oil filter change interval.

3-30

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Refill Capacities - Oil Location

Filling quantity

Oil

liter

gal

Engine

2 x approx. 152

2 x approx. 40.2

Engine oil tank (if equipped)

2 x approx. 500

2 x approx. 132

Hydraulic system

approx. 9400

approx. 2483

Hydraulic oil reservoir

approx. 7100

approx. 1876

Pump drive gearbox - Pre-chambers (working pumps)

2 x approx. 85 8 x approx. 1,5

2 x approx. 22.5 8 x approx. 0.4

- Pre-chambers (hydraulic pumps) - Pre-chambers (cooling oil pumps) Swing gearbox

4 x approx. 0.4 2 x approx. 0.2 4 x approx. 38

4 x approx. 0.1 2 x approx. 0.05 4 x approx. 10

Travel gearbox (PN N3683483) - Spur gear section

2 x approx. 145 2 x approx. 10

2 x approx. 38.3 2 x approx. 2.6

- Brake chambers Travel gearbox (PNs N3683496 and N3749598) - Hydraulic motor chambers On-board crane (optional) - Crane drive engine

4 x approx. 0,5 2 x approx. 165

4 x approx. 0.13 2 x approx. 43.5

4 x approx. 3,5

4 x approx. 0.93

approx. 5.5

approx. 1.45

approx. 50

approx. 13.2

- Hydraulic oil reservoir

I I II II III.a III.b III.a III.a I II

Refill Capacities – Other Location

Filling quantity liter

gal

Cooling system - engine

2 x approx. 300

2 x approx. 79.3

Fuel tank (enlarged)

2 x approx. 6494

2 x approx. 1715.5

Fuel tank, crane drive engine (optional)

approx. 20

approx. 5.3

Screen washer

approx. 13

approx. 3.4

3-31

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING LUBRICANTS / CONSUMABLES Notes on the selection of oils and greases Original CGM-HMS GmbH oils and greases Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies. The lubricants tables in the CGM-HMS GmbH Operation and Maintenance Manual contain specifications for the oils and greases that are approved for use in CGM-HMS GmbH machines. These oils and greases are especially adapted to CGM-HMS GmbH machines and their units and assemblies. Other oils and greases which do not fulfil the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies. For this reason, CGM-HMS GmbH only approves the use of the specified oils and greases. All other qualities are not approved.

CGM-HMS Hydraulic Fluid Caterpillar is not in a position to evaluate the many types of fluids promoted by other manufactures and their effect on Caterpillar products. The use of these products is at the discretion of the customer who assumes all risks for the effects that result from this usage. The CGM-HMS Hydraulic fluid that is provided as a factory fill for the HMS has been evaluated for fluid compatibility when adding or topping off with the Caterpillar HYDO Advanced product. The 2 fluids are compatible and can be used. Follow the maintenance interval schedule and for fluid sampling that is stated in the Operation and Maintenance Manual for your machine. To have the full benefit of the properties of either fluid the cross contamination should be kept to 10% or less. With a greater cross contamination the full benefit of either of the fluids may not be realized so it is important to monitor the fluid properties regularly. For additional details about Cat HYDO Advanced and Caterpillar’s fluids recommendations, please refer to Special Publication SEBU6250, “Caterpillar Machine Fluids Recommendations” and publication EM027744, “Fluid Specifications HMS” which may be found on the Web at SIS.Cat.com. Although the lab testing has shown compatibility between the BM Hydraulic fluid and the Cat Hydo Advance, we are not able to test every situation and condition with the fluid mixtures and would

3-32

recommend that the fluid be changed out to eliminate any fluid incompatibility issues.

Alternative oils and greases The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the CGM-HMS GmbH Operation and Maintenance Manual. In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with CGM-HMS GmbH specifications, CGM-HMS GmbH does not assume any responsibility and does not accept any warranty claims.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING I.

Oils for combustion engines

Fig. 3-3:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING

II.

Fig. 3-4:

3-34

Fluids for hydraulic system

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING III.a Oils for pump distribution gearboxes and travel gearboxes

Fig. 3-5:

3-35

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING III.b Oils for swing gearboxes

Fig. 3-6:

3-36

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING V. Grease for bearings, slew rings and track system (Central lubrication system)

Fig. 3-7:

3-37

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Grease for idlers, track rollers and upper rollers (Lifetime lubrication)

Fig. 3-8:

3-38

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Coolant for use on all combustion engines

Fig. 3-9:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING SERVICING WORK Hose line for oil and cooling liquid changes Collect escaping oil and cooling liquid and discard without polluting the environment.

The engines, the hydraulic oil reservoir, the pump drive gearboxes, the swing gearboxes and the radiators (engine cooling liquid) are moreover equipped with automatic drain valves (1, Fig. 3-11:) These automatic drain valves permit oil- and cooling-liquid changes without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more easily. Filling and draining can be done by means of a hose through the service station (fast fill arm) (Fig. 3-10:). For filling and draining, a flexible hose is connected to the express coupling on the service station and to the service vehicle at the other end. The filling operations require an overpressure, whereas the draining operations require low pressure.

Fig. 3-11:

Change oil or cooling liquid as follows:  Place a collecting recipient for used oil or cooling liquid under the corresponding automatic drain valve. For the recipient capacity refer to the "Re-filling quantities - Oil" table or to the "Refilling quantities - Other" table.  Unscrew protective cap from automatic drain valve.  Screw on hose line (2) to open the valve, so that the oil or the cooling liquid can flow out.  When the oil or the cooling liquid has drained away, unscrew hose line to allow the valve to close automatically.  Screw protective cap back in place.

Fig. 3-10:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING ENGINE Engine - Safety instructions Start and operate combustion engines only on well-ventilated premises. In closed rooms, exhaust gases must be evacuated to the outside. Do not work on the exhaust system and do not make any modifications to it. Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm. Read and observe: "Inspection and Servicing – Safety Instructions" and the engine Operation and Maintenance Manual. Risk of injury from hot or rotating parts of the engine. Shut off engines and allow to cool down. Secure the machine as described in the "Securing the machine" section. Skin contact with cooling liquid is a potential health hazard. Protect the skin from potentially harmful contact with engine oil. Wear protective gloves and firm working clothing.

Attention, Ether! The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment. Secure the machine as described in section “Securing the machine” before starting Inspection and Servicing.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material. This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments. Do not clean the pumps of the Oil Reserve System with high pressure cleaning systems. High pressure cleaning will damage the pumps.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING crankshaft seal, oil pan, oil filters, valve cover, turbocharger, external oil lines and connections.

Walk-Around Inspection Inspect the Engine for Leaks and for Loose Connections A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided. For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks, coolant leaks, exhaust leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:  The guards must be in the proper place. Repair damaged guards or replace missing guards. 

Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination.

Note: For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted. Note: Accumulated grease and/or oil on an engine or deck is a fire hazard. Remove this debris with steam cleaning or high pressure water. Note: Use care when you use steam cleaning. Use care when you use high pressure water. Direct spray to rotating electrics or electronic components can cause nonfixable damage. Note: Water and/or condensation can cause damage to electrical components. Protect all electrical components from exposure to water.  Ensure that the coolant lines are properly clamped. Ensure that the fittings are tight. Check for leaks. Check the condition of all pipes. 

Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract. Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of water pump and the installation of water pump and/or seals, refer to the Service Manual for the engine or consult your Caterpillar dealer.  Inspect the lubrication system for leaks at the following locations: front crankshaft seal, rear 3-42



Inspect the fuel system for leaks. Look for loose fuel line clamps or connections.



Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps or connections.



Ensure that the exhaust system is properly clamped. Ensure that the connections are tight. Check for leaks. Check the condition of all connections and components of the exhaust system.



Inspect the alternator belt and the accessory drive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break.  Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system. 

Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires.



Inspect the ground strap for a good connection and for good condition.



Inspect the engine-to-frame ground strap for a good connection and for good condition.



Disconnect any battery chargers that are not protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery.



Check the condition of the gauges. Replace any gauges which are cracked. Replace any gauges that cannot be calibrated.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Belts - Inspect/Replace

Fuel Injector - Inspect/Adjust

Belt tension should be checked initially during the first 100 hours of engine operation (refer to the Inspection and Servicing Plan N in this Operation and Maintenance Manual). To maximize the engine performance, inspect the belts for wear and for cracking. Replace belts that are worn or damaged. For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break. If the belts are too loose, vibration causes unnecessary wear on the belts and pulleys. Loose belts may slip enough to cause overheating. If the belts are too tight, unnecessary stresses are placed on the pulley bearings and on the belts. This may shorten the service life of the components. Remove the belt guard. Inspect the condition and adjustment of the alternator belts and accessory drive belts (if equipped). To check the belt tension, apply 110 N (25 lb ft) of force midway between the pulleys. A correctly adjusted belt will deflect 9 mm (0.35 inch) to 15 mm (0.59 inch). If the belt does not require replacement or adjustment, install the belt guard. If the belt requires adjustment or replacement, contact your local Cat dealer. The engine has an automatic belt tensioner. You cannot retighten the belt by hand. If new belts are installed, check the belt tension again after 30 minutes of engine operation at the rated rpm.

Note: Perform this procedure when the engine valve lash is inspected. The Electronic Control Module produces high voltage. To prevent personal injury make sure the Electronic Control Module is not powered and the injector solenoids are disconnected. NOTICE The camshafts must be correctly timed with the crankshaft before an adjustment of the lash for the fuel injector is made. The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result. Inspect the adjustment of the lash for the fuel injector according to the Systems Operation/Testing and Adjusting, “Fuel System” topic. Adjust the lash for the fuel injector, if necessary. Contact your Cat dealer for more information.

Engine Mounts – Inspect Inspect the engine mounts for deterioration and for proper bolt torque. Engine vibration can be caused by the following conditions:  Improper mounting of the engine 

Deterioration of the engine mounts

Any engine mount that shows deterioration should be replaced. Refer to the Specifications Manual, SENR3130, “Torque Specifications”. Refer to your Caterpillar dealer for more information.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine Oil Sample – Obtain In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals. S·O·S oil analysis provides infrared analysis, which is required for determining nitration and oxidation levels. Consult your Cat dealer for complete information and assistance in establishing an S·O·S program for your engine.

Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Before you take the oil sample, complete the Label, PEEP5031 for identification of the sample. In order to help obtain the most accurate analysis, provide the following information:  Engine model 

Service hours on the engine



The number of hours that have accumulated since the last oil change



The amount of oil that has been added since the last oil change

To ensure that the sample is representative of the oil in the crankcase, obtain a warm, mixed oil sample. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean. Caterpillar recommends using the sampling valve in order to obtain oil samples. The sampling valve is covered with a dust cap (Fig. 3-12:). The quality and the consistency of the samples are better when the sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation.

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Fig. 3-12:

The 169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The fluid sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also provided. NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion into the sump. For instructions, see Special Publication, PEGJ0047, “How To Take A Good S·O·S Oil Sample”. Consult your Cat dealer for complete information and assistance in establishing an S·O·S program for your engine.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine Valve Lash – Check/Adjust Note: For procedures on adjusting the valve lash and adjusting the valve bridge, see Systems Operation/Testing and Adjusting, “Valve Lash and Valve Bridge Adjustment”. Consult your Caterpillar dealer for assistance. The initial valve lash adjustment on new engines, rebuilt engines, or remanufactured engines is recommended at the first scheduled oil change. The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components. Ensure that the engine cannot be started while this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn the flywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance.

Water Pump - Inspect A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head, a piston seizure or other potential damage to the engine. Visually inspect the water pump for leaks. If leaking of the water pump seals is observed, replace all of the water pump seals. Refer to two articles in the Disassembly and Assembly Manual, “Water Pump - Disassemble and Water Pump - Assemble” for the disassembly and assembly procedure. If it is necessary to remove the water pump, refer to two articles in the Disassembly and Assembly Manual, “Water Pump - Remove and Water Pump - Install”. Inspect the water pump for wear, cracks, pin holes and proper operation. Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed.

Valve Bridge Check the valve bridge and adjust the valve bridge, if necessary. Perform the procedure for both valve bridges for each cylinder. After the valve bridge is checked for each cylinder, proceed with the valve lash adjustment, if necessary.

Engine Valve Lash NOTICE Only qualified service personnel should perform this maintenance. Refer to the Systems Operation/Testing and Adjusting Manual, “Valve Lash and Valve Bridge Adjustment” article or consult your Caterpillar dealer for the complete valve lash adjustment procedure. Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life. The valve bridge adjustment must be performed before making a valve lash adjustment. If the valve lash is within the tolerance, an adjustment of the valve lash is NOT necessary. For the valve lash setting, see the engine’s Specifications manual. For the procedure to set the valve lash, see the engine’s Systems Operation/Testing and Adjusting manual.

3-45

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine oil level – Check level / top up The engine oil temperature and oil temperature are constantly monitored by the BCS (Fig. 3-13:) when the machine is in operation. The actual engine oil pressure is constantly displayed by the screen (Fig. 3-13:). BCS gives acoustic warnings to the operator if the engine oil temperature too high or the oil pressure is too low.

 Draw out dipstick a second time. The oil level should now lie between the marks (arrows, Fig. 3-14:). If the oil level is at the "min" mark or below, top up with engine oil through filler tube (2, Fig. 3-15:).

Fig. 3-15:

Engine oil can also be filled in from the service station (Fig. 3-16:) through:  express coupling (8) for the left hand engine, Fig. 3-13:

 Park the machine on a horizontal surface and secure against inadvertent movements.



express coupling (9) for the right hand engine,

(see chapter "Changing the engine oil").

 Shut off engines.  Draw out oil dipstick (1, Fig. 3-15:).  Wipe oil off the dipstick with a clean, lint free cleaning rag and re-insert.

Fig. 3-16:

Fig. 3-14:

3-46

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine oil reservoir (if equipped) – Check oil level / top up The hydraulic shovel is equipped with an engine oil change interval prolonging mechanism (optional). The engine oil reservoirs are located in the counterweight. If required the oil pans of the engines are automatically filled up with engine oil from the engine oil reservoirs. That means the engine oil pans of the engines are sufficient filled up with engine oil as long as engine oil is in the engine oil reservoirs. Check oil level in the engine oil reservoirs regularly and fill up if necessary.  Park the machine on a horizontal surface and secure against inadvertent movements.  Shut off engines.

Fig. 3-17:

 Check oil level at the inspection glass (arrow, Fig. 3-17:). The level should be between the “min” and “max” signs near the inspection glass.  If the oil level is below, the engine oil is filled in from the service station (Fig. 3-18:) through 

express coupling (6) for the left hand engine oil reservoir,



express coupling (7) for the right hand engine oil reservoir.

(Refer to chapter "Engine oil reservoir - Changing the oil").

Fig. 3-18:

3-47

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine oil - Change Risk of scalding from hot engine oil. The engines may also be hot. Wear protective gloves and firm working clothing. Read and observe: "Inspection and servicing – Safety instructions". Collect escaping oil and discard without polluting the environment. A description of the service station (fast fill arm) can be found in Part 2 of this manual, chapter “Service station (fast fill arm)”.

Drawing off engine oil with the service station  Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure.  Shut off the engines.

Draw off the engine oil through  express coupling (8, Fig. 3-19:) for the left hand engine 

express coupling (9) for the right hand engine.

 Unscrew cap of express coupling and connect hose line of the service vehicle.  Draw off engine oil. After the engine oil has been drawn off:  Remove the hose line. The express coupling closes automatically.  Screw on protective cap.

Fig. 3-19:

3-48

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Filling in engine oil  Fill in engine oil through filler tube (2, Fig. 3-20:) until the oil level has reached the "max" mark (Fig. 3-21:) on dipstick (1).

Filling in engine oil through the service station Fill in engine oil through  express coupling (8, Fig. 3-22:) for the left hand engine, 

express coupling (9) for the right hand engine,

until the oil level has reached the "max." mark (Fig. 3-21:) on dipstick (1, Fig. 3-20:).  Unscrew cap of express coupling and connect filling hose of the service vehicle.  Start the engines and allow to run at idling for abt. 2 minutes.

Fig. 3-20:

 Check oil level at dipstick (1, Fig. 3-20:) and top up with oil to the "max" mark (Fig. 3-21:) if required.  Remove the filling hose. The express coupling closes automatically.  Screw on protective cap.

Fig. 3-21:

Fig. 3-22:

3-49

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine oil reservoir (if equipped) - Drain / Fill oil Risk of scalding from hot engine oil. The engines oil reservoirs may also be hot. Wear protective gloves and firm working clothing. Read and observe: "Inspection and servicing – Safety instructions". Collect escaping oil and discard without polluting the environment. A description of the service station (fast fill arm) can be found in Part 2 of this manual, chapter “Service station (fast fill arm)”.

Draining off the oil  Park the machine on a horizontal surface and secure the machine.  Shut off the engines.  Draw off engine oil with the service station through 

express coupling (6, Fig. 3-23:) for the left hand engine oil reservoir,



express coupling (7) for the right hand engine oil reservoir.

To do so  Unscrew cap of express coupling and connect hose line of the service vehicle.  Drain off engine oil.  Remove the hose line. The express coupling closes automatically.  Screw on protective cap.  After the engine oil has been drawn off: Replace the oil filters for the “Oil change interval prolongation system”.

Fig. 3-23:

3-50

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine oil reservoir, filling in engine oil Oil grade see “LUBRICANTS / CONSUMABLES” section. The engine oil is filled in with the service station (Fig. 3-24:) through  express coupling (6) for the left hand engine oil reservoir, 

express coupling (7) for the right hand engine oil reservoir.

To do so  Switch on the display system with toggle switch (23, Fig. 3-24:), indicator lamp (22) lights up.  Unscrew cap of express coupling and connect hose line of the service vehicle.

Fig. 3-24:

 Fill in engine oil until the oil reservoirs are filled. Monitoring lamp (1) for the left hand oil reservoir, or monitoring lamp (2) for the right hand reservoir lit up when the reservoirs are filled.  The oil level in the reservoir can also be checked at the inspection glass (arrow, Fig. 3-25:).  Remove the hose line. The express coupling closes automatically.  Screw on protective cap.  Switch off the display system with toggle switch (23, Fig. 3-24:), indicator lamp (22) is off.

Fig. 3-25:

3-51

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine oil reservoir (if equipped) – Replace oil filters Risk of scalding from hot engine oil. The filter housing may also be hot. Wear protective gloves and firm working clothing. Do not clean the pumps with high pressure cleaning systems. High pressure cleaning will damage the pumps. Read and observe: "Inspection and servicing – Safety instructions".

Engine oil reservoir (if equipped) – Replace breather filters The engine oil tanks are located at the right and left sides of the counterweight. The tanks are vented with breather filters (arrow, Fig. 3-26). Replace breather filters regularly according to the maintenance plans. To do so:  Unscrew breather filter and replace by a new one.

Collect escaping oil and discard with-out polluting the environment Oil filters Carry out servicing of the full-flow oil filters (engine oil change interval prolongation) in accordance with the engine operating instructions. The filter elements (two for each engine) are placed in the engine compartment, at the rear wall of the hydraulic tank. Replacement:  Shut off the engines.  Unscrew the filters (arrow, Fig. 3-26:).  Install new filter together with slightly oiled sealing ring and tighten by hand. Thereafter:  Allow engines to run at idling for a short while and check filters for tightness and leaks before shutting off the engines.  Check oil level after abt. 10 minutes and top up, if required.

Fig. 3-26:

3-52

Fig. 3-27:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine oil filter – Replace Risk of scalding from hot engine oil. The filter housing may also be hot. Wear protective gloves and firm working clothing. Read and observe: "Inspection and servicing – Safety instructions".

Engine crankcase breather – Clean If the crankcase breather is not maintained on a regular basis, the crankcase breather will become plugged. A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage.

Collect escaping oil and discard without polluting the environment.

Oil filters Carry out servicing of the oil filters (arrow, Fig. 3-28:) in accordance with the engine operating and maintenance instructions. Replacement:  Shut off the engines.  Unscrew the filters.  Install new filter together with slightly oiled sealing ring and tighten by hand. Thereafter:  Allow engines to run at idling for a short while and check filters for tightness and leaks before shutting off the engines.  Check oil level after abt. 10 minutes and top up, if required.

Fig. 3-28:

Fig. 3-29:

 Loosen clamp (1, Fig. 3-29:). Slide the clamp down on tube (2).  Loosen clamps (3). Remove both breathers as a unit.

Fig. 3-30:

 Remove O-ring seals (4, Fig. 3-30:) from the valve covers. Inspect the O-ring seals for good condition. Obtain new O-ring seals, if necessary.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Cold-starting fluid (ether) - Replace the pressure vessel Read and observe: "Inspection and servicing Safety instructions" Risk of injury Cold-starting fluid is composed mainly of ether. Ether is toxic when the mists and vapors are inhaled. Ether is harmful to the eyes, the skin, the respiratory system and the central nervous system. Prolonged inhalation of ether can be fatal. In contact with the skin, ether can cause frostbites and irritations. Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Before replacing an empty pressure vessel: Read and observe the instructions on the pressure vessels. For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether). Provide for sufficient ventilation of the surroundings. Do not eat, drink or smoke when replacing an empty vessel. Do not inhale the vapors of escaping cold-starting fluid (ether). Avoid skin contact. Wear suitable protective gloves and goggles.

3-54

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device. The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment. The vessel is screwed onto an electro-mechanical metering valve. At temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine. Replacing the pressure vessel:  Remove the clamp around the pressure vessel.  Unscrew the pressure vessel carefully from the metering valve.  Remove the used seal from the metering valve.  Insert a new seal into the valve (supplied with the new pressure vessel).  Screw the new pressure vessel onto the metering valve and tighten by hand.  Fasten the clamp round the pressure vessel. Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine. 

Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose off in fire.



Keep the vessels in a place unaccessible to unauthorized persons.



Dispose off the vessels properly.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING COOLING SYSTEM Risk of scalding from hot cooling liquid. Shut off the engines and allow to cool down. Read and observe: "Inspection and servicing - Safety instructions".

Temperature The cooling liquid circuit is controlled by a thermostat. The max. admissible temperature is ca. 100° C (212°F). In case of higher temperatures, the BCS displays a warning on the screen (Fig. 3-31:).

Secure the machine as described in the "Securing the machine" section. Collect escaping cooling liquid and discard without polluting the environment. Protect the skin from contact with cooling liquid. Skin contact with cooling liquid is a potential health hazard. Wear protective gloves and firm working clothing.

Fig. 3-31:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Cooling liquid radiators - Check / clean The radiators are located on the upper structure in the counterweight module. Weekly checks:  Check radiator fins for dirt and clean, if required.

Cooling liquid level - Check An insufficient cooling-liquid level is displayed on the BCS screen (Fig. 3-32:). The level indicator (4, Fig. 3-33:) at the expansion reservoirs shows the liquid level as well. The cooling-liquid level should be between the “FULL” and the “LOW” marking. Top up with cooling liquid, if required (see “Cooling liquid – Top up”).

Fig. 3-32:

Fig. 3-33:

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INSPECTION AND SERVICING Cooling liquid – Top up Fill cooling liquid through filler tube (1, Fig. 3-34:) or through express couplings of the ServiceStation (2 and 3, Fig. 3-35:) into the cooling system (see “Topping up cooling liquid using the ServiceStation”). The caps of the expansion reservoirs (1, Fig. 3-34:) are accessible from above. Risk of scalding from hot cooling liquid under pressure. Before opening the cap: Release pressure by lifting the red lever on top of the cap. Open cap cautiously after releasing pressure.  First release pressure from the expansion reservoir by lifting up the red lever integrated in cap (1).  When the pressure has been released turn cap into the "open" position and remove. Do not fill in cold cooling liquid when the engine is at operating temperature. Before refilling, allow engine to cool down to below 50° C (122°F).

Fig. 3-35:

For topping up of the cooling system use specially prepared cooling liquid CAT ELC, CGM-HMS GmbH SAP Part No. 4275599 only. This gives an anti-freeze protection down to -37 °C / -34.6°F. For use at lower temperatures, ask the CGM-HMS GmbH Service or your CAT-dealer. After filling in cooling liquid allow the engines to run for short period to eliminate air voids before topping up with cooling liquid to the lower edge of the filler tube.  Remove hose from express coupling. The express coupling closes automatically.  Screw on protective cap.

In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks. Check regularly:  all lines for leaks and all hose clamps for tightness.

Fig. 3-34:

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INSPECTION AND SERVICING Topping up cooling liquid using the Service-Station A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (fast fill arm)”. The cooling liquid can also be filled in with the service station (Fig. 3-36:) through  express coupling (2) for the left hand engine, 

express coupling (3) for the right hand engine.

 Prior to topping up cooling liquid release pressure from the cooling system. To do so move lever of the ball valves in the direction of the arrow (Fig. 3-36:). The pressure is released then and the express couplings are then accessible.  Remove cap of express coupling. Connect the filling hose of the service vehicle. The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator at the expansion reservoirs.  Remove hose. The express coupling closes automatically.  Push on protective cap.  Close ball valves (Fig. 3-36:).

3-58

Fig. 3-36:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Cooling liquid - Change Risk of scalding from hot cooling liquid under pressure. Open cap of expansion reservoir cautiously after releasing pressure. Wait until cooling liquid has cooled down. Do not fill in cold cooling liquid when the engine is at operating temperature. Before refilling, allow engine to cool down to below 50° C (122°F). The expansion reservoirs may also be hot. Wear protective gloves and firm working clothing. Collect escaping cooling liquid and discard without polluting the environment. Only use “ELC” cooling liquid, see: “Topping up cooling liquid”. Do not use pure water. The cooling liquid must be analized regularly and changed after 6000 operating hours or after six years at the latest (Refer to the Maintenance Plan).

Drawing off cooling liquid Cooling liquid can be drained from the cooling system by means of the express couplings located at the service station (Fig. 3-37:) through  express coupling (2) for the left hand cooling circuit, 

express coupling (3) for the right hand cooling circuit.

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (fast fill arm)”.  Prior to drawing off cooling liquid release pressure from the cooling system. To do so move lever of the ball valves in the direction of the arrow (Fig. 3-37:). The pressure is released then and the express couplings are then accessible.  Remove cap of express coupling. Connect hose line of the service vehicle. The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Draw off cooling liquid.  Fill in fresh cooling liquid, see “Filling in cooling liquid”.

Fig. 3-37:

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INSPECTION AND SERVICING Filling in cooling liquid A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (fast fill arm)”.  Shut off the engines.  Fill in cooling liquid with the service station (Fig. 3-38:) through:  express coupling (2) for the left hand cooling circuit,  express coupling (3) for the right hand cooling circuit.  Check ball valves (Fig. 3-38:). They must be open. The express couplings are then accessible.  Remove cap of express coupling. Connect hose of the service vehicle. The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator at the expansion reservoirs (4, Fig. 3-39:).  Remove hose from express coupling. The coupling closes automatically.  Push on protective cap.  Close ball valves (Fig. 3-38:). The cooling liquid can also be filled in through filler neck (1, Fig. 3-39:).

Fig. 3-38:

Fig. 3-39:

Cooling liquid composition – Test The “Engine Operating and Maintenance Manual” contain a detailed description of how to prepare and test the cooling liquid composition. In case of imminent frost check that the factory-adjusted antifreeze concentration is sufficient for the expected temperatures. Check the cooling liquid in the cooling system regularly to ensure that the ELC is sufficiently concentrated to prevent corrosion under the corresponding operating conditions. Coolant samples can be taken at the couplings located at the service station. Release pressure from the cooling system before taking a cooling liquid sample. To do so use the levers at the caps of the expansion reservoirs or the ball valves at the service station. See chapter “Cooling liquid, change / Drawing off cooling liquid”.

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INSPECTION AND SERVICING Cooling System Supplemental Coolant Additive (SCA) – Add

Test the concentration of the SCA with the 8T5296 Coolant Conditioner Test Kit. Add the SCA, If Necessary

Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and eyes. Do not drink cooling system coolant additive. NOTICE Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine’s heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water pump seal. Do not exceed the recommended amount of supplemental coolant additive concentration. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” and to Special Publication, GECJ0003, “Cat Shop Supplies and Tools” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to applicable regulations and mandates. Note: Caterpillar recommends an S·O·S coolant analysis (Level 1). SEBU8226 61 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add.

Cooling Systems that Use Conventional Coolant This maintenance procedure is required for conventional coolants such as DEAC. This maintenance is NOT required for cooling systems that are filled with Extended Life Coolant.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Remove the cooling system filler cap slowly. 2. If necessary, drain some coolant in order to allow space for the addition of the SCA. 3. Add the proper amount of SCA. For the proper amount of SCA, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic. The proper concentration of SCA depends on the type of coolant that is used. For the proper concentration of SCA, refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations”. 4. Clean the cooling system filler cap. Install the cooling system filler cap.

Cooling Systems that Use Water and SCA Test the Concentration of the SCA Test the concentration of the SCA with a 298-5311 Coolant Nitrite Test Kit for SCA or perform an S·O·S Coolant Analysis. The test kit includes the following items: a tool for the testing, 30 ampoules for testing nitrite, instructions, and a case. 2947420 Test Kit contains the refill ampoules for the 298-5311 Coolant Nitrite Test Kit. Use the instructions that are included with the test kit in order to properly conduct the testing. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for the times at which the procedures should be conducted. Test the concentration of the SCA more frequently if more frequent testing is indicated by the results of the S·O·S Coolant Analysis. NOTICE Do not exceed the recommended eight percent supplemental coolant additive concentration.

Test the Concentration of the SCA NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration.

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INSPECTION AND SERVICING Add the SCA, If Necessary Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Remove the cooling system filler cap slowly. 2. If necessary, drain some coolant in order to allow space for the addition of the SCA. 3. Add the proper amount of SCA. For the proper amount of SCA, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic. For the proper concentration of SCA, refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations”. 4. Clean the cooling system filler cap. Install the cooling system filler cap.

Cooling System Water Temperature Regulator –Replace Replace the water temperature regulator before the water temperature regulator fails. This is a recommended preventive maintenance practice. Replacing the water temperature regulator reduces the chances for unscheduled downtime. A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine. A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive overheating could result in cracking of the cylinder head or piston seizure problems. A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner. NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage. Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed. If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that the water temperature regulator vent hole is open. Do not use liquid gasket material on the gasket or cylinder head surface. Refer to two articles in the Disassembly and Assembly Manual, “Water Temperature Regulators Remove and Water Temperature Regulators Install” for the replacement procedure of the water temperature regulator, or consult your Caterpillar dealer. Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing.

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INSPECTION AND SERVICING Cooling System Coolant Sample (Level 1) – Obtain Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling system is filled with Cat ELC (Extended Life Coolant). Cooling systems that are filled with Cat ELC should have a Coolant Sample (Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule. Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant instead of Cat ELC. This includes the following types of coolants:  Commercial long life coolants that meet the Caterpillar Engine Coolant Specification -1 (Caterpillar EC-1) 

Cat DEAC (Diesel Engine Antifreeze/Coolant)



Commercial heavy-duty coolant/antifreeze Recommended Interval Level 1 Level 2 Type of coolant Yearly(1)(2) Cat DEAC Every 250 (1) Hours Cat ELC Optional(2) Yearly(2)

(1)

This is the recommended interval for coolant samples for all conventional heavy-duty coolant/antifreeze. This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC-1 specification for engine coolant. (2) The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified.

NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Note: Level 1 results may indicate a need for Level 2 Analysis. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced.

Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:  Complete the information on the label for the sampling bottle before you begin to take the samples. 

Keep the unused sampling bottles stored in plastic bags.



Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location.



Keep the lids on empty sampling bottles until you are ready to collect the sample.



Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination.



Never collect samples from expansion bottles.



Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis. For additional information about coolant analysis, see this Operation and Maintenance Manual, “Refill Capacities and Rec Recommendations” or consult your Caterpillar dealer.

Cooling System Coolant Sample (Level 2) – Obtain NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” for the guidelines for proper sampling of the coolant. Submit the sample for Level 2 analysis. For additional information about coolant analysis, see Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engines Fluids Recommendations” or consult your Caterpillar dealer.

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INSPECTION AND SERVICING AIR-INTAKE SYSTEM Risk of injury when falling down due to removed handrails. Make sure that all handrails are in place before working on the upper structure. Otherwise put on your fall protection equipment before entering the upper structure. Risk of injury caused by hot parts of the engine exhaust system. Let exhaust cool down. Read and observe the "Engine - Safety instructions" chapter.

Fig. 3-40:

Do not remove and install an air filter from its housing simply to inspect it. Dirt can reach the clean side and damage the engine. Do not start the engine when parts of the air-intake system have been detached. Engine damage may occur if the engine is allowed to draw in unfiltered air. Secure the machine as described in the "Securing the machine" section. Fig. 3-41:

Each engine is equipped with two dry-air filters (arrows, Fig. 3-40:) consisting of pre cleaner, primary air filter elements and secondary air filter elements. Insufficient air-intake performance, caused by a contaminated air filter, is displayed on the BCSscreen with the engines running at high speed. In case that an air filter is contaminated, the contamination indicator near the air filter housing (arrow, Fig. 3-41:) will give an electrical signal to the BCS. The Board Control System (BCS) notifies the operator that the air filters need service (arrow, Fig. 3-42:). New air filter elements should always be at hand to shorten shovels downtimes. Service the air filters only with the engines stopped. Engine damage can occur.

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Fig. 3-42:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Engine air pre cleaner - Inspect / clean The pre cleaner collects dust and dirt that infiltrates the air filter housing. Frequency of pre cleaner service work varies with dust severity.  Shut off the engines.  Loosen the clamps on the pre cleaner (2, Fig. 3-43:).  Remove lower pre cleaner bowl (3) and dust valves (1). Do not operate the machine with the dust valves removed. Engine damage can occur.  Clean lower pre cleaner bowl (3) and dust valves (1).  Inspect dust valves (1). Replace inverted or damaged dust valves.  Make sure that all of the tubes within the pre cleaner are free of dirt (Fig. 3-44:). Clean the tubes, if necessary with a stiff brush.

Fig. 3-43:

(1) Dust valve (2) Clamp (3) Lower precleaner bowl

Note: Never clean the tubes with compressed air unless both the primary and safety filters are properly fitted in place. Do not steam-clean the tubes.  Check pre cleaner bowls gasket for damage. Replace if damaged.  Install the clean lower pre cleaner bowl (3, Fig. 4) and the clean dust valves (1). Make shure the pre cleaner bowl seals properly 360° around the air cleaner body. Note: Do not paint the rubber dust valves (1). Paint will cause the rubber to harden and the rubber may not seal properly.

Fig. 3-44:

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INSPECTION AND SERVICING Primary air filter element - Inspect / replace The Board Control System (BCS) notifies the operator that the air filters need service. In this case:  Loosen clamps (1, Fig. 3-45:) at the air filter housing and remove cover (4).  Grasp the filter service handle and pull the primary filter element (3) out. Note: Because the filter is tightly over the outlet tube there will be some initial resistance, similar to breaking the seal on a jar. Gently move the filter from side to side to break the seal, but avoid knocking the filter against the housing during removal.  Do not remove secondary filter element (2).  Visually check secondary filter element for damage and replace if damaged. Note: Do not remove secondary filter element unless a change-out is necessary. Replace the secondary filter element every three primary filter changes. Verify that the secondary filter element is properly seated in the housing. If the secondary filter element is removed and the new filter is not to be installed immediately, be sure to cover the seal tube with a cloth or the housing cover.  Wipe the interior of the air filter housing with a clean damp cloth.  Before installing the filter element, clean contact faces at cover (4) and at filter housing.  Inspect the new primary filter element. Pay special attention to the inside and the sealing end. Do not install a damaged filter.  Install new primary filter element (3). Note: Insert the new filter carefully by hand, making certain it is completely seated into the air filter housing before securing the cover in place. The critical sealing area will compress slightly, adjust itself and distribute the sealing pressure evenly. To complete a tight seal, apply pressure by hand at the outer rim of the filter, not at the center. (Avoid pushing on the center of the end cap.) No cover pressure is required to hold the seal.  Put on cover (4) using clamps (1). If the service cover contacts the filter before it is fully in place, remove the cover and push the filter (by hand) further into the air cleaner and try again. The cover should go on with no extra force.

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Fig. 3-45:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Secondary air filter element - Replace Removal and installation  Replace the secondary filter elements (2, Fig. 3-46:) every three primary filter changes. After one year of operation at the latest. Never clean the secondary filter element, but always renew.

 Remove cover (4, Fig. 7) and primary filter element (3) as described in section “Primary air filter element, inspect / replace“.

Air-intake lines - Inspect At regular intervals:  Inspect air-intake lines for leaks and hose clamps for tightness. If there are leaks, or holes, or damage, replace immediately.  Replace hoses between filter housing and engine (clean-air lines) according to the maintenance plan. During all work on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engines.

 Withdraw secondary filter element (2).  Inspect the new secondary filter element. Pay special attention to the inside and the sealing end. Do not install a damaged filter.  Install the new secondary filter element (2).  Clean the air filter housing.  Install a new primary filter element (3) as described in section “Primary air filter element Inspect / replace“.

Fig. 3-46:

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INSPECTION AND SERVICING FUEL SYSTEM Fuel system - Safety instructions

Fuel System – Prime Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.

Read and observe the "Inspection and servicing – Safety instructions" chapter. Before and when working on the fuel system:  shut off the engines,  secure the machine as described in the "Securing the machine" section,  keep away naked flames,  do not smoke. Collect escaping fuel and discard without polluting the environment. Diesel fuel may cause skin injury. Avoid skin contact with diesel fuel. Wear firm working clothing. Wear protective gloves or use a barrier cream.

Prime the fuel system in order to purge trapped air and in order to fill the fuel filter.

Fuel tank supply valve – Function The fuel tank supply valve (arrow, Fig. 3-47:) is mounted in the fuel line from the fuel tank to the engine. It is located on top of each fuel tank. This ball valve cuts the fuel flow to the engine when closed.  To close the ball valve, shift the lever in position “0”.  To open the ball valve, shift lever in position “I”. Read and observe the "Fuel system – Safety instructions” chapter.

Fig. 3-47:

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Fig. 3-48:

 Open the fuel supply valve.  Turn the keyswitch to the ON position, but do not start the engine. Note: The engine start switch must be in the OFF position in order to prime the fuel system.  Hold priming pump switch (arrow, Fig. X) upward in order to activate the electric fuel priming pump. The priming pump will fill the engine fuel lines and the fuel filters with fuel.  Operate the fuel priming pump until the air in the fuel system has been pumped through the fuel return line back to the fuel tank.  Release the priming pump switch.  Start the engine at low idle.  If the engine starts but the engine runs rough, continue to run the engine at low idle until the engine runs smoothly.  If the engine does not start after several attempts, consult your Cat dealer.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Fuel filter – Replace Read and observe the "Inspection and servicing – Safety instructions" chapter. Collect escaping fuel and discard without polluting the environment.

Fuel system – Vent Venting the fuel filters:  Switch on primary fuel pump with switch (arrow, Fig. 3-50:). The fuel filters get filled with fuel, air is bled through the return lines into the fuel reservoir.

Fig. 3-50: Fig. 3-49:

 Shut off the fuel supply valves between fuel tanks and engines.  Unscrew filters (Fig. 3-49:).  Do not fill new filter with fuel. This prevents the injection system from being contaminated by unfiltered fuel after fuel filter change.  Apply clean diesel fuel to the new filter gasket and screw it onto the filter head by hand. Continue to tighten filter by a further ½ to ¾ turn. Tightening the filter element with a tool may damage or deform the filter head.

Venting the fuel tanks: The fuel tanks are vented with breather valves (arrow, Fig. 3-51:).

Breather filter fuel tanks - Replace  Replace breather filters regularly according to the maintenance plan. To do so unscrew cap (1, Fig. 3-51:) of breather valve and replace with a new one. The filter element is integrated in the cap.

 Open the fuel supply valves between fuel tanks and engines.  Bleed fuel system, see “Fuel system - Vent”.  Start engines and check fuel system for leaks. For more information see: “Engine Operation and Maintenance Manual”.

Fig. 3-51:

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INSPECTION AND SERVICING Fuel tanks – Clean Explosion hazard due to fuel vapors. Read and observe the "Inspection and servicing, Safety instructions" chapter. Do not use white spirit, paraffin oil or other solvents. For flushing and cleaning use diesel fuel. Avoid skin contact. Skin contact with diesel fuel may cause skin injury. Wear firm working clothing. Wear protective gloves or use a barrier cream.

 Use up as much fuel as possible.  Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plugs of the tanks.  Shut off the fuel supply valves (arrow, Fig. 3-52:). To do so, shift lever of the ball valve from position “I” to position “0”.  Loosen drain plug (5, Fig. 3-53:) at the bottom of the fuel tank and drain off fuel.  Flush tank with diesel fuel.  Inspect fuel tank inside for damages.  Screw drain plug back (5) in place.

Fuel must be prevented from penetrating into the soil. Keep fuel for filtering and re-use or discard without polluting the environment.

Fig. 3-52:

Fig. 3-53:

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INSPECTION AND SERVICING

 After cleaning the fuel tanks fill in fresh fuel.  Open cover of filler tube on top of the fuel tanks and screw off lid of filler tube (2, Fig. 3-54:).  Fill in fuel through the strainer in filler tube.  Fuel can also be filled into both fuel tanks through the service station (1, Fig. 3-55:). For more information see chapter “Refuelling” in Part 2 of this manual.  Start filling in fuel. The filling level is displayed on the BCS screen (Fig. 3-56:).  Stop filling when the fuel tanks are filled.  Remove filling hose. The express coupling closes automatically.

Fig. 3-54:

 Screw on protective cap.  Open fuel supply valves (arrow, Fig. 3-52:). To do so, shift lever of the ball valve from position “0” to position “I”.

Fig. 3-55:

Fig. 3-56:

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INSPECTION AND SERVICING Water trap (option) - Clean / replace Water contained in the fuel is removed by the water trap (Fig. 3-57:).

Servicing Draining off water Carry out the following works in accordance with the servicing schedule and at regular intervals: Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.  Loosen venting plug (9, Fig. 3-58:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve. The liquid flowing out of the valve flushes and cleans the filter element (6) von from top to bottom.  Close drain valve (3) and tighten venting plug (9).

Fig. 3-57:

Fig. 3-58:

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INSPECTION AND SERVICING Checking / cleaning the filter element Replace filter element (6, Fig. 3-59:) only when the suction resistance is too high. Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.  Loosen venting plug (9) and leave drain valve (3) open until the reservoir is completely empty.  Remove cover (5).  Remove spring holder (7) and filter element (6) from filter housing (4).  Check / replace filter element (6)

Fig. 3-59:

 Clean filter housing (4) using diesel fuel.

 Clean recipient (1) and filter housing (4).

 Check cover sealing and replace,if necessary.

 Loosen flange (2).

 Insert filter element (6) and spring housing (7) into filter housing (4).

 Take off recipient (1) and clean with diesel fuel

 Fasten cover (5) on filter housing (4).

 Attach recipient (1) with flange (2) at filter housing (4).

Check for proper sealing.

 Check cover sealing and replace, if necessary.

Check for proper sealing.

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INSPECTION AND SERVICING Hoses and Clamps - Inspect/Replace Hoses and clamps must be inspected periodically and replaced at the recommended interval to ensure safe and continuous operation of the engine. Failure to replace a fuel hose at the recommended change interval may result in a hazardous situation. Take proper safety precautions before inspecting or replacing hoses and clamps. Note: Always use a board or cardboard when the engine components are checked for leaks. Leaking fluid that is under pressure can cause serious injury or possible death. Leaks that are the size of a pin hole are included. Refer to Operation and Maintenance Manual, “General Hazard Information” for more information. Note: Ensure that the hose is compatible with the application.

Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions. Replace any hose which exhibits any of the following conditions. Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation.  Hoses which are cracked 

Hoses which are soft



Outer covering that is chafed or cut



Exposed wire that is used for reinforcement



Outer covering that is ballooning locally



Flexible part of the hose that is kinked or crushed



Armoring that is embedded in the outer covering



Hoses which exhibit signs of leakage which arenot the result of loose couplings or clamps

Inspect all clamps for the following conditions. Replace any clamp which exhibits signs of any of the following conditions.  Cracking 

Looseness



Damage

Inspect all couplings for leaks. Replace any coupling which exhibits signs of leaks. Each installation application can be different. The differences depend on the following factors:  Type of hose 

Type of fitting material



Anticipated expansion and contraction of the hose



Anticipated expansion and contraction of the fittings

Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen which can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps. Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses that show signs of damage. Replace hose clamps that are cracked or damaged. Tighten or replace hose clamps which are loose.

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INSPECTION AND SERVICING Replace the Hoses and the Clamps Note: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Cat Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Inspect the vacuum valve and seat for debris or damage. Replace the filler cap if the gaskets are damaged. Install the filler cap.  Start the engine. Inspect the cooling system for leaks.

Fuel System Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.

Cooling System Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.  Stop the engines.  Allow the engines to cool.  Before servicing a coolant hose, slowly loosen the filler cap for the cooling system in order to relieve any pressure.  Remove the filler cap for the cooling system.  Drain the coolant from the cooling system to a level that is below the hose that is being replaced. Drain the coolant into a suitable clean container. The coolant can be reused.  Remove the hose clamps.  Disconnect the old hose.  Replace the old hose with a new hose.  Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and installing the proper hose clamps.  Refill the cooling system.  Clean the coolant filler cap. Inspect the gaskets on the filler cap. Inspect the gasket seat.

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. Note: Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque. Note: Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components. Note: High-pressure fuel lines may be installed between the high-pressure fuel pump and the fuel injectors. High-pressure fuel lines are constantly charged with high pressure. Do not check the high pressure fuel lines with the engine or the starting motor in operation. Wait for 10 minutes after the engine stops before you perform any service or repair on high-pressure fuel lines. Waiting for 10 minutes will to allow the pressure to be purged.  Drain the fuel from the fuel system to a level that is below the hose that is being replaced.  Remove the hose clamps.  Disconnect the old hose.

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INSPECTION AND SERVICING

Note: When servicing fuel system, use cap/s or cover/s as required to protect the system and maintain fuel system cleanliness.  Replace the old hose with a new hose.  Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and installing the proper hose clamps.  Carefully inspect the engine for any spilled fuel. Make sure that no fuel remains on or close to the engine. Note: Fuel must be added to the fuel system ahead of the fuel filter.  Refill the fuel system. Refer to this Operation and Maintenance Manual, “Fuel System Prime” for information about priming the engine with fuel.  Start the engine. Inspect the fuel system for leaks.

Lubrication System Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.  Drain the oil from the lubrication system to a level that is below the hose that is being replaced.  Remove the hose clamps.  Disconnect the old hose.  Replace the old hose with a new hose.  Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and installing the proper hose clamps.  Refill the lubrication system. Refer to this Operation and Maintenance Manual, “Engine Oil Level - Check” in order to ensure that the lubrication system is filled with the proper amount of engine oil.  Start the engine. Inspect the lubrication system for leaks.

Air System Remove the hose clamps. Disconnect the old hose. Replace the old hose with a new hose. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and installing the proper hose clamps. Note: The bellows and the V-clamps that are used on the exhaust bellows should never be reused.  Start the engine. Inspect the air lines for leaks.    

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INSPECTION AND SERVICING ELECTRICAL SYSTEM Electrical system - Safety instructions Risk of injury caused by battery acid and gases. Read and observe the "Inspection and servicing – Safety instructions" chapter. Carry out every work on the electrical / electronical systems only if you are a qualified electrician and after having received special trainings. Wear goggles, working gloves and firm working clothing. Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument. Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the electronic modules of the PMS and the CMS.

Alternator - Instructions Never disconnect cables from the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator. Do not interchange the cables when connecting the battery (observe polarity). Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument. Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the regulator. Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

Electrical circuit diagrams The electrical circuit diagrams and wiring diagrams are annexed to the spare-parts list. Further information can be found in the CGM-HMS Service Manual "Working with circuit diagrams".

Electrical system switch-cabinets The electrical system switch-cabinets are located in the cab module, in the pump compartment and behind the hydraulic reservoir. The cabinets are described in the spare-parts list (electrical circuit diagram) together with the designation of the electrical components. Fuses and their function are listed on a sheet inside the switch-cabinets in the cab module. Use only original fuses with the specified current rating.

Lamps and bulbs – Replace If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked. Xenon-working floodlights are operated with high voltage. Read and observe the chapter: “Floodlight projector, replacing the lamp”. Floodlights working with LED-technology do not have replaceable lamps / bulbs. The floodlight must be replaced if defective.

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INSPECTION AND SERVICING Xenon floodlight projector (optional) - Replace the lamp Safety instructions The floodlight projectors use xenon technology. The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector. When the projector is turned on, the ballast unit generates a high-voltage pulse of more than 25000 volts to start the xenon lamp. Warning! This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance,  if the lamp is operated improperly, 

if the projector housing is opened in an inappropriate way or



by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp. Allow the xenon lamp to cool off before removing it from the projector. Wear googles and safety gloves when replacing the lamp. Never stick your hand into the lamp holder. The contacts may still be live with residual voltage. Never switch on the projector when the xenon lamp has been removed. There is a risk of voltage discharge and damage to the lamp holder. The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters). If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector. If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol. The replaced Xenon lamp must be disposed of as special waste. Never switch on projectors when housing or electrical wiring is damaged. Have damaged projectors be replaced by a qualified electrician as soon as possible.

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INSPECTION AND SERVICING Replacing a defective Xenon-lamp Read and observe the: „Xenon floodlight projector, replacing the lamp, Safety instructions“.  Switch off the projector, shut off the engine and cut out the battery main switch.  Wait until the housing of the floodlight projector has cooled down.  Withdraw the power supply connector from the projector.

Fig. 3-60

 Remove four screws (1, Fig. 3-60) and withdraw the reflector (2) from the projector housing.  Withdraw connector (Fig. 3-61) from Xenon lamp socket.  Unscrew Xenon lamp holding clamp (Fig. 3-62).  Remove the defective Xenon lamp and replace by a new one. Do not touch the glass bulb of the lamp.  Reinstall the new lamp. Screw lamp holding clamp back in place.  Plug the power supply connector onto the lamp.  Re-assemble the housing.

Fig. 3-61

Fig. 3-62

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INSPECTION AND SERVICING Lighting systems in LED technology - Instructions The lights of the maintenance lighting system (Fig. 3-63) as well as the working floodlights (Fig. 3-64) are equipped with lamps in LED technology (lightemitting diodes). High-performance LEDs ensure the emission of light with high luminance. If the light is allowed to shine directly into the eyes from a short distance and over prolonged periods, there is a risk of injury to the retina. Do not look for a prolonged period into the light cones of the LEDs. Adjust the lights in such way that they do not shine directly into the eyes and that you are not blinded by the glare. The lights become hot in operation. The heat is dispersed via the ribbed metal housing. For this reason, the housings must not be covered up and cleaning rags or similar things placed over them.

Fig. 3-63

The high-performance LEDs in these lights have a very long service life and can therefore not be replaced. If one or more of these LEDs fail, the light can remain in service if the remaining luminance is still sufficient.

Fig. 3-64

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INSPECTION AND SERVICING Battery- Check the state of charge Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Risk of injury caused by battery acid and gases. Wear goggles, working gloves and firm working clothing. Do not eat, drink or smoke when handling batteries. Wash hands after handling. Read and observe the "Inspection and servicing – Safety instructions" chapter.

Checking the battery fluid level (Not applicable in case of maintenance-free batteries)  Unscrew caps (Fig. 3-65:).

Checking charge of batteries The acid temperature must be 20 ° C / 68°F.  Unscrew caps of the battery (Fig. 3-65:).  Measure the acid density of the battery using a commercial acid tester (Fig. 3-65:). The acid density measured is in direct correlation with the battery charge.

Acid density kg / dm3 Charge Normal Tropical condicondition tions 1,28 1,23 fully charged 1,20 1,12 half charged, recharge 1,12 1,08 discharged, recharge immediately On closed / sealed (so called „maintenance-free“) batteries, the charging status can be checked using a charge meter. Ask your Caterpillar dealer for assistance.

 If checking inserts are provided, the battery acid must reach up to their bottom.  If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm / 0.4".  If the fluid level is too low, top up with distilled water only.

Fig. 3-65:

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INSPECTION AND SERVICING Battery - Remove and install Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Risk of injury caused by battery acid and gases. Wear goggles, working gloves and firm working clothing. Do not eat, drink or smoke when handling batteries. Wash hands after handling. Read and observe the "Inspection and servicing – Safety instructions" chapter. Disconnect and reconnect the terminal clamping lugs in the prescribed order. Disconnecting and connecting in the wrong order may cause short-circuits.

The batteries (Fig. 3-66:) are located in a cabinet behind the hydraulic oil reservoir. The six 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

 Shut off the engines before removing the batteries to avoid damaging the alternator and the regulator.  Turn key in key-switch to position "0" and withdraw.  Switch battery-isolator-switch to position "0" (if equipped with).  Switch battery-main-switch to position "0" (if equipped with).  Open battery cabinet.  Unscrew wing nuts (4, Fig. 3-66:)  Detach battery holder (3).  Disconnect the cable lug from the negative terminal of the battery.  Disconnect the cable lug from the positive terminal of the battery.  Insulate the cable lugs.  Lift battery out of battery cabinet. Before installing new batteries, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.  Install the new batteries.  Connect the cable lug to the positive terminal of the battery. Tighten the clamping screws of the cable lugs. Do not use too much force to avoid deformation.  Connect the cable lug to the negative terminal of the battery.  Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs. Loose or corroded clamping lugs will lead to alternator or regulator overloading.  Attach battery holder (3). Fasten with wing nuts (4).  Close battery cabinet.

Fig. 3-66:

After putting the machine back to operation:  Check battery cabling for tightness, retighten if necessary.  Check battery holders and wing nuts for tightness, retighten if necessary.  Repeat these checks regularly.

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INSPECTION AND SERVICING Battery charge inside the machine - Safety instructions Explosion hazard. Battery gases are highly flammable. Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries. Risk of injury from acid splashes and battery gases. Wear safety goggles or a face protection shield and acid proof protective gloves. Do not lean over the batteries while charging. The batteries of the machine can also be charged while installed in the machine. For this purpose, the arm of the service station (Fig. 3-67:) is equipped with a socket outlet for a charging cable. Risk of fire. Do not use the socket outlet (Fig. 3-67:) for jump-starting of the engines. The connectors and the cables are not designed for the high currents flowing during the starting phase. Check before charging why the batteries are discharged and replace the batteries if they are defective. Check the connecting cables of the battery set for damage, corrosion and tight fit. Never charge the batteries while they are frozen. Warm them up beforehand and check for proper functioning. Do not charge the batteries when they are warmer than "warm to the touch" (45 °C / 113 °F). Use only approved chargers for 24 volts DC. Read and observe the instructions for the charger. The charging cable must have a conductor crosssection of at least 70 mm2.

Charging the batteries  Cut out the battery main switch.  For battery ventilation unscrew the cover of the battery cabinet.  Connect the charging cable to the socket outlet (Fig. 3-67:).  Switch on the charger and watch the charging process. Stop the charging process:  if the batteries are getting hot,  if acid escapes from the batteries,  if the charge current is still insignificantly low even after 15 minutes of charging. Before starting a new charging cycle, check the batteries and the connecting cable thoroughly and replace any damaged components. It may be necessary to remove the batteries and to charge them one by one. When the batteries are full:  Shut off the charger first before withdrawing the charging cable from the socket outlet. Read the instructions of the charger in order to know when the charging cycle has ended. The batteries are fully charged, if  the charging current and voltage remain constant (for voltage-controlled chargers);  the charging current does not any rise longer for two hours (current-controlled chargers);  the charger shuts off or switches over to trickle charge (automatic chargers).

Fig. 3-67:

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INSPECTION AND SERVICING Switchgear cabinet filter – Clean Breather filter In the switchgear cabinet, the air is drawn in by a ventilator via the filter (Fig. 3-68:).

Emptying dust trap  Press dust trap (14, Fig. 3-68:) and hold until the dust trap is empty.

Emptying the dust collector  Loosen clamps (11, Fig. 3-68:).  Remove dust collector (12) and empty. Fig. 3-68:

Filter element  Remove the dust collector (12, Fig. 3-68:).  Withdraw filter element (13, Fig. 3-69:).  Replace or clean filter element (13).  Refit dust collector (12, Fig. 3-68:).

Fig. 3-69:

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INSPECTION AND SERVICING Checking and cleaning the filter element Check the filter paper of the element by inserting a lamp into the element (Fig. 3-70:). Any damage can then be seen. Replace damaged or distorted element immediately.

 Check element seal. If damaged, replace filter element too. Cleaning with compressed air allows the filter element to be re-used immediately.  Blow filter element (Fig. 3-71:) dry with compressed air by moving the compressed-air piston up and down inside it.

Fig. 3-70:

The pressure at the nozzle must not exceed 30 kPa / 43psi. Cleaning is completed when no more dust is seen to leave the filter element. Never clean filter element by beating it against hard objects. Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Fig. 3-71:

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INSPECTION AND SERVICING CAN-Bus wiring connections – Inspect The CAN bus wiring connects the manual control levers (joysticks), the travel pedals and the pedal for the bucket lid to the switch cabinet in the cab module.

Before inspecting    

Stand the attachment on the ground. Shut off the engines. Switch off the electrical system. Switch off the battery main switch.

Inspect

Fig. 3-72:

 Check CAN Bus wiring inside the cab module (Fehler! Verweisquelle konnte nicht gefunden werden. and Fehler! Verweisquelle konnte nicht gefunden werden.) for damage. Note: Damaged wiring needs to be replaced immediately. Contact your Cat dealer. Bring the machine back to operation only after the repair is completed.  Inspect wiring connections (arrows, Fehler! Verweisquelle konnte nicht gefunden werden. and Fehler! Verweisquelle konnte nicht gefunden werden.). All connections must be interconnected to the stop and secured.

Fig. 3-73:

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INSPECTION AND SERVICING HYDRAULIC SYSTEM Hydraulic system - Safety instructions Risk of injury caused by hydraulic fluid under high pressure. Never open hydraulic connections while the system is pressurized. Depressurize the hydraulic system section before starting any work on the section. Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves). Allow hydraulic components to cool down before starting any work. Contact with hydraulic oil can cause skin injury. Avoid skin contact with hydraulic oil. Wear protective gloves and firm working clothing. Secure the machine as described in the "Securing the machine“ section. Read and observe the "Inspection and servicing – Safety instructions" chapter.

Hydraulic system - Depressurize Hydraulic systems may only be opened if they are completely depressurized. Even when an hydraulic shovel is parked on a horizontal surface with the attachment resting on the ground (Fig. 3-74: und Fig. 3-75:) and with its drive engines stationary, there may still be a considerable amount of residual pressure in parts of the hydraulic system, as e.g. the primary pressure resulting from the last hydraulic movements before the immobilization. Residual pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be freed from pressure, i.e. depressurized:  Locate the system section to be opened.  Depressurize the section to be opened. If required, the necessary measures described must be combined.  Open the depressurized system section with caution.

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated.

Fig. 3-74:

Fig. 3-75:

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INSPECTION AND SERVICING Examples of system sections: 1) attachment circuits 2) track tension circuit 3) swing circuit 4) travel circuit 5) hydraulic ladder circuit 6) engine off lowering accumulator circuit 7) service station (fast fill arm) circuit

The following screen appears on the BCS display:

Attachment circuits – Depressurize  Ensure that the accumulator in the engine off lowering circuit has 10L capacity and is charged to 1700 kPa / 247 PSI.  Ensure that the updated BCS software is installed.  If the E stop was hit, reset it.  Park the hydraulic shovel on level ground.

Fig. 3-77:

To continue depressurization mode:  move a joystick (115 or 116, Fig. 3-74) or 

a pedal (111) or

 Shut off the engines.



a thumbwheel (118)

 Sit in the operator’s seat to activate the seat switch (105, Fig. 3-72).

within the next 15 seconds. Otherwise depressurization mode will be deactivated.

 Set the attachment on the ground.

 Switch on the electric system with the key switch (32).  Activate the hydraulic system with the switch (71).  Activate switch (65) and hold for at least five seconds, then release it. Depressurization mode is now activated.

Fig. 3-78:

 Activate and hold the float valves for “boom lower” and “stick in” functions.  Actuate “bucket curl” function.  In one second actuate “clam close” function. Fig. 3-76:

 In one second release “bucket curl” function.  In one second actuate “bucket dump” function.

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INSPECTION AND SERVICING  In one second release “clam close” function.  In one second actuate “clam open” function.

Hydraulic oil level – Check

 In one second release “bucket dump” function.

 Bring hydraulic oil to operating temperature (abt. 50 °C / 122°F).

 In one second actuate “bucket curl” function.

 Park the machine on a horizontal surface.

 In one second release all the functions.

 Stand attachment on the ground as shown on the sign (2, Fig. 3-79:).

The attachment circuits are depressurized. Before starting any maintenance work on the hydraulic system sections it is necessary to verify the pressure is released. To check pressure, use the information of chapter 8.2 “Depressurizing, bleeding and flushing the hydraulic system” as well as of chapter 8.6 “Pressure checking and setting” in the Service Manual of this machine.

The oil level must be between the “min” and “max” marks of the sign (2, Fig. 3-79:) near the inspection glass (1).

Hydraulic system sections – Depressurize To depressurize the track tension circuit use the pressure relief valves in the undercarriage, refer to chapter “ Swing and travel circuits are depressurized when the machine is off. Depressurizing procedures for the other hydraulic system sections are described in chapter 8.2 “Depressurizing, bleeding and flushing the hydraulic system” in the Service Manual of this machine.

Fig. 3-79:

The hydraulic oil level is also monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-80:) if the hydraulic oil level is too low or too high. In this case: Shut off the engines, locate cause and rectify.

Fig. 3-80:

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INSPECTION AND SERVICING  Stand attachment on the ground as shown on the sign (Fig. 3-81:).  Sign (2, Fig. 3-82:) is attached beside the hydraulic oil tank inspection glass (1).

Fig. 3-83:

Hydraulic oil can also be filled in by means of the service station (Fig. 3-84:). A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (fast fill arm)”.

Fig. 3-81:

 Unscrew cap of express coupling (10). Connect filling hose of the service vehicle to the express coupling.  Fill in hydraulic oil until the oil level is between the “min” and “max” marks of the sign (2, Fig. 3-82:) near the inspection glass (1). (Oil grade see “LUBRICANTS / CONSUMABLES”). The acoustic warning signal “Travel Alarm” sounds.  Disconnect the filling hose; the express coupling closes automatically.  Screw protective cap back in place

Fig. 3-82:

If necessary, fill in hydraulic oil through the returnflow filters.  Remove cover (19, Fig. 3-83:).  Fill in hydraulic oil through the opening until the oil level is between the “min” and “max” marks of the sign (2, Fig. 3-82:) near the inspection glass (1). (Oil grade see “LUBRICANTS / CONSUMABLES”).  Before fitting the cover (19), check the sealing ring and replace, if damaged.  Fit cover together with sealing ring.

3-90

Fig. 3-84:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic Oil Analysis – Understand Particle Count Results CGM-HMS recommends to carry out particle counting in any regularly performed oil analysis. In case the result of the particle count shows values of above than “ 19 / 16 / 13 ”, an off-board filtration of the hydraulic fluid is recommended. The string “ 19 / 16 / 13 “ is a three factor code which shows levels of Particle Count Range according to ISO 4406. This code represents fluid cleanliness. The three factor codes “ X / Y / Z “ represent three different particle sizes:  X = particle size equal or larger than 4 microns,

Tooling and Equipment Refer to Special Publication M0080900 “Contamination Control Guidelines, Filtration Procedure for Hydraulic Mining Shovel Hydraulic Oil” for the selection of the required tools suitable for your machine:  Hydraulic Oil Filtration Skid,  Analyzer Group,  Suction and Return Adapters,  Hoses.

Reference Literature

 Y = particle size equal or larger than 6 microns,

Media-IdNumber

Title

 Z = particle size equal or larger than 14 microns.

M0080900

The numbers in the code sample above represent a particle number range, listed in ISO 4406:  X : “19“ = 2500 – 5000 particles in 1 ml of fluid,

“Filtration Procedure for Hydraulic Mining Shovel Hydraulic Oil”

M0073390

“Tool Operating Manual 514-4590 to 514-4596 Hydraulic Oil Filtration Skid for Hydraulic Mining Shovels”

NEHS0799

“Tool Operating Manual for 1708500 Analyzer Group”

PEGJ0045

“Reporting Particle Count by ISO Code”

PEGJ0047

“How to take a good S.O.S. Oil Sample”

SEBF8482

“Obtaining an Oil Sample for Analysis”

 Y : “16” = 320 – 640 particles in 1 ml of fluid,  Z : “13” = 40 – 80 particles in 1 ml of fluid. This is the cleanliness level of new oil. Note: This data shows only particle size, not the specific particle composition (metal or not metal). For more detailed information about the particle composition a spectrographic analysis may help. Please contact your Cat dealer for assistance. If the contamination values are above the recommended values (“ 19 / 16 / 13 “), please perform off-board filtration during the next and the after next planned maintenance to confirm oil cleanliness. For more information about the filtration procedure please refer to section “Reference Literature” and ask your Cat dealer for assistance.

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INSPECTION AND SERVICING Remove return flow filter elements

Hydraulic oil return-flow filters, Replace Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Wait until the hydraulic oil has cooled down before starting work on the filters. Read and observe the "Inspection and servicing – Safety instructions" chapter.

 Remove covers (3, Fig. 3-86:) together with sealing rings (5).  Unscrew ring nuts (6) and remove retaining disk (7).  Remove press parts (8) with o-rings (10).  Withdraw filter elements (9) with o-rings (11) from filter-baskets (12).  Inspect filter elements for damage. If no damages are visible, insert new filter elements (9) with new o-rings (11) into filterbasket (12), (see: “Install return flow filter elements”). If a filter element (9) is damaged, remove filterbasket (12) and inspect / clean, (see: “Remove filter-basket, inspect / clean”).

Shut off the engines. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Wear protective gloves and firm working clothing. Collect escaping hydraulic oil and discard without polluting the environment. Dispose off used filter elements according to the environmental regulations.

The return-flow filters must be replaced:  when servicing works in accordance with the servicing plan are carried out; 

when the BCS displays a warning on the screen (Fig. 3-85:). In this case, the filter elements (9, Fig. 3-86:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-85:

Fig. 3-86:

3-92

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Install return flow filter elements  Insert new filter elements (9, Fig. 3-87:) into filter-basket with marking “TOP” upwards.  Attach new o-rings (10 and 11) to press parts (8).  Put press parts (8) onto filter elements (9).  Fasten retaining disk (7) with ring nuts (6).  Clean magnetic rod (17, Fig. 3-88:). The magnetic rod is located under cap (16). If metal filings are detected, locate cause and rectify. Contact your Caterpillar dealer service, if required. It is essential to find the source of the metal filings and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.  Reattach cap (16) together with magnetic rod and sealing ring to cover (3).  Install covers (3) together with sealing rings (5). Tighten bolts (18) crosswise using a torque wrench (torque = 79 Nm / 58.3 lbf ft).

Fig. 3-87:

Remove filter-basket, inspect / clean If you found one of the return flow filter elements (9, Fig. 3-87:) damaged, remove the filter-basket (12) and inspect / clean the filter-basket as well as the filter chamber of the hydraulic tank. To do so:  Unscrew bolts (13) and remove washers (15) and brackets (14).  Remove filter-basket (12) and clean in paraffin oil.  Inspect the filter chamber inside the hydraulic oil tank for contamination. If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately. It is essential to find the source of contamination and foreign objects and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.

Fig. 3-88:

 Reinsert the filter-baskets (12).  Place brackets (14) in the correct position and screw in bolts (13) together with washers (15).  Tighten bolts (13) using a torque wrench (torque = 46 Nm / 34 lbf ft).  Install new return flow filter elements (9), see “Install return flow filter elements”.

3-93

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic oil return-flow filters Replace (from machine no. 340173 / DHN60173) Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Wait until the hydraulic oil has cooled down before starting work on the filters. Read and observe the "Inspection and servicing – Safety instructions" chapter.

Remove return flow filter elements  Remove covers (3, Fig. 3-90:) together with sealing rings (5).  Unscrew ring nuts (6) and remove retaining disk (7).  Remove press parts (8) with o-rings (10).  Withdraw filter elements (9) with o-rings (11) from filter-baskets (12).  Inspect filter elements for damage. If no damages are visible, insert new filter elements (9) with new o-rings (11) into filterbasket (12), (see: “Install return flow filter elements”). If a filter element (9) is damaged, remove filterbasket (12) and inspect / clean, (see: “Remove filter-basket, inspect / clean”).

Shut off the engines. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Wear protective gloves and firm working clothing. Collect escaping hydraulic oil and discard without polluting the environment. Dispose off used filter elements according to the environmental regulations.

The return-flow filters must be replaced:  when servicing works in accordance with the servicing plan are carried out; 

when the BCS displays a warning on the screen (Fig. 3-89:). In this case, the filter elements (9, Fig. 3-90:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-89:

Fig. 3-90:

3-94

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Install return flow filter elements  Insert new filter elements (9, Fig. 3-91:) into filter-basket with marking “TOP” upwards.  Attach new o-rings (10 and 11) to press parts (8).  Put press parts (8) onto filter elements (9).  Fasten retaining disk (7) with ring nuts (6).  Clean magnetic rod (17, Fig. 3-92:). The magnetic rod is located under cap (16). If metal filings are detected, locate cause and rectify. Contact your Caterpillar dealer service, if required. It is essential to find the source of the metal filings and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.  Reattach cap (16) together with magnetic rod and sealing ring to cover (3).  Install covers (3) together with sealing rings (5). Tighten bolts (18) crosswise using a torque wrench (torque = 79 Nm / 58.3 lbf ft).

Fig. 3-91:

Remove filter-basket, inspect / clean If you found one of the return flow filter elements (9, Fig. 3-91:) damaged, remove the filter-basket (12) and inspect / clean the filter-basket as well as the filter chamber of the hydraulic tank. To do so:  Unscrew bolts (13) and brackets (14).  Remove filter-basket (12) and clean in paraffin oil.  Inspect the filter chamber inside the hydraulic oil tank for contamination. If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately. It is essential to find the source of contamination and foreign objects and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.

Fig. 3-92:

 Replace o-ring (15) located in the filter brackets top plate.  Reinsert the filter-baskets (12).  Place brackets (14) in the correct position and screw in bolts (13).  Tighten bolts (13) using a torque wrench (torque = 46 Nm / 34 lbf ft).  Install new return flow filter elements (9), see “Install return flow filter elements”.

3-95

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Bypass valves - Clean / replace Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Wait until the hydraulic oil has cooled down before starting work on the filters. Read and observe the "Inspection and servicing – Safety instructions" chapter. Shut off the engines. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Wear protective gloves and firm working clothing. Collect escaping hydraulic oil and discard without polluting the environment. Dispose off used filter elements according to the environmental regulations.

Fig. 3-93:

Cleaning the filter screens  Remove covers (3, Fig. 3-93:) together with sealing rings.  Unscrew bolts (1, Fig. 3-94:). Withdraw bypass valves (2).  Take off screen (3) together with o-ring (5) and clean in white spirit or paraffin oil. Replace, if damaged.  Check o-ring (4) inside the valves for damage and replace, if required.  Re-assemble the bypass valves.  Check o-ring (5) for damage and replace, if required.  Insert bypass valves and fasten with bolts (1).

Replacing the bypass valves and sealing rings  Remove bypass valves as described under "Cleaning the filter screens".  Re-assemble the bypass valves with a new oring (4) and a new filter screen (3, Fig. 3-94:).  Insert bypass valves with new o-rings (5) and fasten with bolts (1).

3-96

Fig. 3-94:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic oil tank breather filters - Replace Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Wait until the hydraulic oil has cooled down before starting work on the filters. Read and observe the "Inspection and servicing – Safety instructions" chapter. Shut off the engines. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Wear protective gloves and firm working clothing. Collect escaping hydraulic oil and discard without polluting the environment. Dispose of used filter elements according to the environmental regulations.

Replacing the filter elements Two breather filters (Fig. 3-95:) on top of the hydraulic tank ensure venting of the hydraulic oil tank at varying hydraulic oil levels. Inspect and replace the filter elements according to the maintenance plans. In case the machine is working in very dusty conditions or in an environment with high air humidity, the filter elements must be inspected and replaced in shorter intervals. This protects the hydraulic tank from being contaminated. To replace the filter elements:  Unscrew bolts (2, Fig. 3-95:) and remove holding brackets (1).  Withdraw filter elements (4).  Check foam rings (3), replace if damaged.  Attach new filter elements (4) with foam rings (3) to their cylindrical connections  Install holding brackets (1) using bolts (2).

Fig. 3-95:

3-97

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Filters (pilot control circuit) Check / replace Risk of scalding caused by hot hydraulic oil. The filter housings themselves may also be hot. Wear protective gloves and firm working clothing. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Read and observe the "Inspection and servicing – Safety instructions" chapter.  Shut off the engines.  Depressurize the hydraulic system.  Clean the filter housings as well as the immediate vicinity carefully.

Replacing the filter element There are four filters in the pilot control circuits (Fig. 3-96:). Replace filter elements regularly and when the BCS indicates a contamination.  Unscrew filter housing (4, Fig. 3-96:) by counterclockwise rotation. Pour out the oil.  Withdraw filter element (3) with a slight turn from the centering spigot in the filter head (1).  Check filter housing (4) as well as used filter surface for debris.  Clean filter housing (4) and the sealing face at the filter head (1) with white spirit or paraffin oil.  Install the new filter element (3) with a new, lightly oiled sealing ring (2) on the filter heads spigot by slightly turning it.  Screw in the filter housing (4) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check for leaks after putting the hydraulic system into operation.

Check for contamination and damage  Unscrew filter housing (4, Fig. 3-96:) by counterclockwise rotation. Pour out the oil.  Withdraw filter element (3) with a slight turn from the centering spigot in the filter head (1).  Clean filter element (3) in white spirit or paraffin oil and check for contamination and damage.  If significant contamination or foreign objects are detected, contact your Cat dealer service immediately.  Replace filter element (3) if it is damaged.  Check seal (2) and replace, if damaged.  Re-assemble the filter element in reverse order.  Screw in the filter housing (4) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check for leaks after putting the hydraulic system into operation.

3-98

Fig. 3-96:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic oil filters for working hydraulics – Check / replace To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with eight high-pressure filters (arrows, Fig. 3-97:). The filters are attached to the valve block in front of the hydraulic oil tank, they are accessible from the pump compartment. Risk of scalding caused by hot hydraulic oil. The filter housings themselves may also be hot. Wear protective gloves and firm working clothing. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Read and observe the "Inspection and servicing – Safety instructions" chapter.  Shut off the engines.  Depressurize the hydraulic system.  Clean the filter block and the filter housings carefully.

Check for contamination and damage  Unscrew filter housing (5, Fig. 3-97:) by counterclockwise rotation. Pour out the oil.

Replacing the filter elements  Place a suitable collecting recipient under the filter housings (Fig. 3-97:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Unscrew filter housing (5) by counterclockwise rotation. Pour out the oil.  Disengage filter element (2) with a slight turn from the centering spigot in the filter head.  Check filter housing (5) as well as used filter surface for debris.  Clean filter housing (5) and the sealing faces at the filter head with white spirit or paraffin oil.  Check sealing ring (3) and support ring (4) on the filter housing for position and damage. Replace, if necessary.  Install the new filter element (2) with a new seal (1) on the spigot again by slightly turning it.  Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check high-pressure filters for leaks after putting the hydraulic system back into operation.

 Disengage filter element (2) with a slight turn from its retaining catch and withdraw from filter housing (5).  Clean filter element (2) in white spirit or paraffin oil and check for contamination and damage.  If significant contamination or foreign objects are detected, contact your Cat dealer service immediately.  Replace filter element (2) if it is damaged.  Check seals (1, 3 and 4) and replace, if damaged.  Re-assemble the filter element in reverse order.  Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Fig. 3-97:

 Check for leaks after putting the hydraulic system into operation.

3-99

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Filters for swing pump charge circuit – Check / replace

Replacing the filter elements

The hydraulic shovel has four high-pressure filters (Fig. 3-98:) for the charging circuits of the swing pumps. Two high-pressure filters each are installed beside the pump drive gearbox. Replace filter elements regularly according to the maintenance plans and when the contamination indicator (1) indicates a contamination, a red sector is visible then through transparent cap (2).

 Remove filter housings (5) and pour out used oil.

Risk of scalding caused by hot hydraulic oil. The filter housings themselves may also be hot. Wear protective gloves and firm working clothing. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Read and observe the "Inspection and servicing – Safety instructions" chapter.

 Detach flanges (4, Fig. 3-98: and Fig. 3-99:).

 Disengage filter element (6) with a slight turn from the centering spigot in the filter head.  Clean filter housing (5) and the sealing faces at the filter head with white spirit or paraffin oil.  Install the new filter element (6) with a new, lightly oiled o-ring (7) on the filter heads spigot by slightly turning it.  Attach the filter housing (5) with a new, lightly oiled sealing ring (8) to filter head.  Remount flanges (4).  Check for leaks after putting the hydraulic system into operation.

 Shut off the engines.  Depressurize the hydraulic system.  Clean the filter housings as well as the immediate vicinity carefully.

Check for contamination and damage  Detach flanges (4, Fig. 3-98: and Fig. 3-99:).

Fig. 3-98:

 Remove filter housings (5) and pour out the oil.  Disengage filter element (6) with a slight turn from the centering spigot in the filter head.  Clean filter element (6) in white spirit or paraffin oil and check for contamination and damage.  If significant contamination or foreign objects are detected, contact your Cat dealer service immediately.  Replace filter element (6) if it is damaged.  Check seals (7 and 8) and replace, if damaged.  Re-assemble the filter element in reverse order.  Attach the filter housing (5) ) to filter head.  Remount flanges (4).  Check for leaks after putting the hydraulic system into operation.

3-100

Fig. 3-99:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Filters for swing circuits - Replace The shovel has two high-pressure filters for the swing circuits (Fig. 3-100:). Replace filter elements regularly according to the maintenance plans. Risk of scalding caused by hot hydraulic oil. The filter housings themselves may also be hot. Wear protective gloves and firm working clothing. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Read and observe the "Inspection and servicing – Safety instructions" chapter.  Shut off the engines.

Replacing the filter elements  Unscrew filter housings (5, Fig. 3-100:) and pour out used oil.  Disengage filter elements (3) with a slight turn from the centering spigot in the filter head (1).  Check filter housing (5) as well as used filter surface for debris.  Clean filter housings (5) and the sealing faces at the filter head with white spirit or paraffin oil.  Install the new filter elements (3) with a new, lightly oiled O-ring (2) on the filter heads spigot by slightly turning it.  Screw on the filter housings (5) with a new, lightly oiled sealing ring (4). Screw in the filter housings to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check for leaks after putting the hydraulic system into operation.

 Depressurize the hydraulic system.  Clean the filter housings as well as the immediate vicinity carefully.

Check for contamination and damage  Unscrew filter housings (5, Fig. 3-100:) and pour out used oil.  Disengage filter elements (3) with a slight turn from the centering spigot in the filter head (1).  Clean filter element (3) in white spirit or paraffin oil and check for contamination and damage.  If significant contamination or foreign objects are detected, contact your Cat dealer service immediately.  Replace filter element (3) if it is damaged.

Fig. 3-100:

 Check seals (2 and 4) and replace, if damaged.  Re-assemble the filter element in reverse order.  Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check for leaks after putting the hydraulic system into operation.

3-101

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Bearing flushing for main pumps - Replace filter Bearing flushing, function The hydraulic shovel has two bearing flushing circuits for the main hydraulic pumps. The bearing flushing circuit removes air pockets in the housing of the main pumps and reduces internal temperature. This also increases life expectancy of the main pumps. Two filters are integrated into the circuit. They are built-on the right hand side and on the left hand side of the pump compartment, each near the main pumps (1, Fig. 3-101:).

Replacing the filter element Risk of scalding from hot hydraulic oil. The filter housings may also be hot. Let the area cool down before starting maintenance work. Read and observe: "Inspection and servicing - Safety instructions".

 Relieve pressure from filter housing. To do so, loosen screw plug (7, Fig. 3-102:).  Unscrew filter housing (5) without spilling hydraulic oil. Pour out hydraulic oil into a waste oil tank.  Withdraw filter element (6) from filter head (9) by twisting it. Check filter housing (5) as well as used filter surface for debris.  Clean filter housing (5) and sealing faces at filter head (9).  Attach new filter element onto cone in filter head with a turn.  Refit filter housing with a new, lightly oiled sealing ring (8) to the filter head (9). Screw in the filter housings to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  After putting the machine into operation, bleed filter housing. To do so, loosen screw plug (7) until clear hydraulic fluid pours out.  Check filter housing for leaks after putting the machine into operation.

Shut off the engines. Relieve the hydraulic system totally from pressure. Avoid potentially harmful skin contact with hydraulic oil. Wear protective gloves and firm protective clothing. Collect escaping hydraulic oil, used filter elements and oil impregnated cleaning rags and discard without polluting the environment.

Fig. 3-101:

Fig. 3-102:

3-102

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic oil – Change Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Read and observe the "Inspection and servicing – Safety instructions" chapter. Shut off the engines. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Wear protective gloves and firm working clothing. Collect escaping oil and discard without polluting the environment. Do not start up the drive engines when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry. Avoid mixing of different hydraulic fluids (see chapter “Avoid mixing of different hydraulic fluids” for more information). Oil grade see “LUBRICANTS / CONSUMABLES” section. Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

CGM-HMS Hydraulic Fluid Caterpillar is not in a position to evaluate the many types of fluids promoted by other manufactures and their effect on Caterpillar products. The use of these products is at the discretion of the customer who assumes all risks for the effects that result from this usage. The CGM-HMS Hydraulic fluid that is provided as a factory fill for the HMS has been evaluated for fluid compatibility when adding or topping off with the Caterpillar HYDO Advanced product. The 2 fluids are compatible and can be used. Follow the maintenance interval schedule and for fluid sampling that is stated in the Operation and Maintenance Manual for your machine. To have the full benefit of the properties of either fluid the cross contamination should be kept to 10% or less. With a greater cross contamination the full benefit of either of the fluids may not be realized so it is important to monitor the fluid properties regularly. For additional details about Cat HYDO Advanced and Caterpillar’s fluids recommendations, please refer to Special Publication SEBU6250, “Caterpillar Machine Fluids Recommendations” and publication EM027744, “Fluid Specifications HMS” which may be found on the Web at SIS.Cat.com. Although the lab testing has shown compatibility between the BM Hydraulic fluid and the Cat Hydo Advance, we are not able to test every situation and condition with the fluid mixtures and would recommend that the fluid be changed out to eliminate any fluid incompatibility issues.

3-103

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Drawing off hydraulic oil  Bring the hydraulic oil to operating temperature (abt. 50 ° C / 122°F).  Retract the hydraulic cylinders as far as possible and stand the attachment on the ground.  Shut off the engines.  Drain the hydraulic oil at express coupling (1, Fig. 3-103:). The use of the hose line is described under "Hose line for oil and cooling-lequid changes".  Place suitable recipients under the drain valve (1) of the hydraulic oil reservoir. For the required capacity refer to the "Refilling quantities - Oil" table.  Unscrew the hose line; the oil drain valve closes automatically.  Screw protective cap back in place.

Drawing off hydraulic oil using the Service Station (fast fill arm) The hydraulic oil can also be drawn off through the service station (Fig. 3-104:). A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (fast fill arm)”.  Bring hydraulic oil to operating temperature (ca. 50° C / 122°F).  Retract hydraulic cylinders as far as possible and stand attachment on the ground.  Shut off the engines.  Unscrew cap of express coupling (10).  Connect hose line of the service vehicle.  Remove hose line. The coupling closes automatically.  Screw on protective cap.

Fig. 3-103: Fig. 3-104:

3-104

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic oil tank- Clean Explosion hazard. Do not use white spirit, paraffin oil or other solvents for cleaning. Read and observe the "Inspection and servicing - Safety instructions" chapter. Use only diesel fuel or a special flushing oil for cleaning the hydraulic tank. Skin contact with hydraulic oil, diesel fuel or special flushing and cleaning fluids may cause skin injury. Avoid skin contact. Wear protective gloves and firm working clothing. Dispose off contaminated hydraulic oil, diesel fuel or special flushing and cleaning fluids without polluting the environment and separately from other waste.

Fig. 3-105:

 Close the shut-off valves in the suction pipes at the hydraulic tank (arrows, Fig. 3-105:).  Detach the return-flow filters, see chapter “Hydraulic oil return-flow filters, replace”.  Detach the bypass valves, see chapter “Bypass valves, clean / replace”.  Detach the hydraulic tank lid which carries the breather filters, see chapter “Hydraulic oil tank breather filters, replace”.  Detach the manhole-lid (2, Fig. 3-106:).  Detach the sieves inside the hydraulic tank (1).  Place a collecting recipient for the flushing oil under the hydraulic oil tank.  Clean the inside of the hydraulic oil tank with diesel fuel or special flushing and cleaning fluid. Remove all sediments and also the residues of the cleaning agent thoroughly.

Fig. 3-106:

 Install the sieves inside.  Install the manhole-lid.  Install the bypass valves.  Install the return-flow filter elements.  Open shut-off valves in the suction pipes (arrows, Fig. 3-105:).

3-105

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Filling in hydraulic oil Fill in hydraulic oil through the return-flow filters.  Remove cap (1, Fig. 3-107:).  Fill in hydraulic oil through the opening until the oil level is between the “min” and “max” marks of the sign (2, Fig. 3-108:) near the inspection glass (1). (Oil grade see “LUBRICANTS / CONSUMABLES”).  Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir. Top up with oil, if required.  Refit cap (1, Fig. 3-107:).

Hydraulic oil can also be filled by means of the service station (Fig. 3-109:).  Unscrew cap of express coupling (10).  Connect filling hose express coupling of the service vehicle.  Fill in hydraulic oil until the oil level is between the “min” and “max” marks of the sign (2, Fig. 3-108:) near the inspection glass (1). (Oil grade see “LUBRICANTS / CONSUMABLES”). The acoustic warning signal “Travel Alarm” sounds.  The oil level is also displayed on the BCSscreen (Fig. 3-110:).  After filling in vent the hydraulic system.  Check the oil level in the hydraulic oil tank. Top up with oil, if required.  Unscrew the hose line. The express coupling closes automatically.  Screw protective cap back in place.

Fig. 3-107:

Fig. 3-109:

Fig. 3-108:

Fig. 3-110:

3-106

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic system – Vent Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented  after assembly on site and prior to initial commissioning, 

before each recommissioning of the hydraulic shovel, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes,



after each hydraulic oil change,



after replacement of hoses or lines. Fig. 3-112:

Venting / filling the hydraulic components 

Hydraulic pumps and hydraulic motors (with engines shut off): Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening. Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the attachment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions.



Hydraulic cylinders: Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-111: and Fig. 3-112:) must be either completely retracted or completely extended.

Always admit oil first to that side of the cylinder where the piston (2) is. This is  the piston-side port (3) when the piston rod is retracted (1, Fig. 3-111:),  the rod-side port (4) when the piston rod is extended (1, Fig. 3-112:). If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the pistonside port (4). When oil is admitted for the first time to the cylinder, the oil flow must be reduced. Therefore extend or retract the piston rod as slowly as possible. The screws/nozzles of the following components must be opened until oil emerges bubble-free from the opening: Always vent only the system section that has been opened.



the travel brake valve at the venting screw,



the oil cooler manifold at the mini-measuring ports,



the servo system at the venting screws of the control blocks (under the servo caps),



the intake line at the venting screw (with drive motors stationary).

Fig. 3-111:

3-107

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic oil cooler – Clean Risk of injury from rotating cooler fan blades. Shut off the engines. Never start cleaning work until the cooler fan blades have stopped turning. The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning. Allow the hydraulic oil cooler to cool down. Wear protective gloves and firm protective clothing.

Cleaning The hydraulic oil coolers are located in the oil cooler module. Clean the hydraulic oil coolers at regular intervals.  Shut off the engines.  Remove any accumulated dirt.  Clean the fan blades (2).  Clean the radiators with a jet of water or compressed air from outside to inside.  Leave hydraulic oil coolers to dry.  Check the hydraulic motors (1) for free movement. In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan. The speeds of the fan motors (1, Fig. 3-113:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C / 140°F.

Fig. 3-113:

3-108

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Electronic hydraulic shovel controls - Clean / lubricate Joystick At regular intervals acc. to the maintenance plans:  Loosen gaiter and move upwards.  Apply a thin layer of low temperature grease on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-114:) to prevent jamming of the joysticks.

Pedal At regular intervals acc. to the maintenance plans:  Remove old grease and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-115:).  Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

 Refit gaiter using a cable strap.

Fig. 3-115:

Fig. 3-114:

3-109

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Pressure accumulator - Emergency lowering To permit the attachment to be lowered in an emergency, the machine is equipped with a pressure accumulator (arrow, Fig. 3-116:). The pressure accumulator is located in the module beneath the operator’s cab.

Fig. 3-116:

Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Group II p  l bar and p·x l  200

3-110

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work. Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been released.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations]. Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory: Checking the gas charging pressure in the pressure accumulator. After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Inspections prior to commissioning at the factory at the place of use Pressure testing Inspection certificate Prototype and pressure test (Check of correctness and certified by the manufacturer correct installation) issued by an expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and fluid.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING PUMP DRIVE GEARBOX Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too. Shut off the engines. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing. Park and secure the machine as described in the "Securing the machine" section. Read and observe: "Inspection and servicing Safety instructions”.

Pump drive gearbox – Check oil level / Top up with oil

Fig. 3-117:

The pump drives must be in operation for at least 30 minutes prior to checking the oil level, because oil is accumulated in the pump mounting flanges for lubrication of the profile hollow shaft. Checking the oil level when the pump drives are cold give wrong results. Observe the information decals attached to the gearbox housings near the dipsticks.  Unscrew dipstick (1, Fig. 3-117: and Fig. 3-118:) and wipe clean.  Insert dipstick (1) again until the thread lies on top of the dipsticks tube (2, Fig. 3-118:). Do not screw in.

Fig. 3-118:

 Pull out dipstick (1) a second time. Oil level should be between the two dipstick markers “min” and “max” Top up with fresh gearbox oil if required through opening of breather filter (2, Fig. 3-117:). (Oil grade see: “LUBRICANTS / CONSUMABLES”).  Inspect dipstick’s sealing ring and replace if damaged.  Screw in dipstick (1) back in place. In case of significant oil losses check for leaks at the gearbox and on all components of the gearbox oil cooling system. Too much oil in the gearbox may be a signal of defective seals at hydraulic components. Contact your Caterpillar dealer service.

3-111

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Pre-chambers – Check oil level / top up with oil The oil level in the pre-chambers is visually at the inspection glass (3, Fig. 3-119) in expansion reservoir (1). The oil level should reach up at least to the middle of the inspection glass (3). Top up with gearbox oil, if required. Oil grade see: “LUBRICANTS / CONSUMABLES”.  Unscrew breather filter (2).  Fill in oil up at least to the middle of the inspection glass (3).  Screw breather filter back in place.

Pump drive gearbox oil sample Obtain Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing. Obtain an oil sample of the pump transfer gearbox oil through the opening for the oil level dipstick (1, Fig. 3-117: and Fig. 3-118:). Refer to CGMHMS publication “Service Manual for Oil Samples and Oil Analysis”. For additional information about taking an oil sample, refer to:  Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”,  Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

Fig. 3-119

3-112

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Pump drive gearbox – Change gearbox oil Change the oil when the machine is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better. Recommendation: If the gearbox oil is heavily soiled, the gearbox should be flushed with fresh gearbox oil. In this case contact your Caterpillar dealer

The oil level is to be checked after about 30, 60 and 240 minutes running time as oil collects in the mounting flanges or is dammed there to lubricate the splined hollow shafts. The gearbox oil cooling system is also to be filled with oil. Therefore it is absolutely necessary to check the oil level and top up with oil up to the correct level.

Draining off oil The gearbox oil is drained with the service station (Fig. 3-120:) through  express coupling (4) for the left hand pump drive gearbox, 

express coupling (5) for the right hand pump drive gearbox.

 Unscrew cap of express coupling and connect hose line of the service vehicle.  Remove hose after the oil has been drawn off. The coupling closes automatically.

Fig. 3-120:

 Screw on protective cap.

Filling in oil (Oil grade see “LUBRICANTS / CONSUMABLES”). The gearbox oil is filled in with the service station (Fig. 3-120:) through  express coupling (4) for the left-hand pump drive gearbox 

express coupling (5) for the right-hand pump drive gearbox.

 Unscrew protective cap of express coupling and connect hose line of the service vehicle.  Fill in gearbox oil until the oil level reaches the ”max” mark on dipstick (1, Fig. 3-121:).

Fig. 3-121:

 Remove hose after the oil has been filled in. The coupling closes automatically.  Screw on protective cap.  Start engine and run for a maximum of two minutes at idle speed, then stop. The pump drive oil cooling circuit has now been filled with oil.  Check gearbox oil level and top up to the correct filling level.  Check for leaks and for correct filling level after putting the machine back into operation. Top up with gearbox oil if required. Note: 3-113

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Pre-chambers - Change gearbox oil Draining off oil  Prepare a collecting recipient for used oil. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew plugs (7, Fig. 3-122) and drain off oil.  Screw plugs (7) back in place.

Filling in oil

Pump drive gearbox breather valve - Replace The pump drive gearbox is vented through a breather valve, mounted on top of the gearbox housing (arrow, Fig. 3-123:).  Replace breather valve in accordance with the servicing plan.  Clean area around the breather to prevent contamination of the gearbox.  Unscrew breather filter and replace by a new one.

Filling in oil see “Pre-chambers, checking oil level, topping up with oil”.

Fig. 3-123:

Fig. 3-122

3-114

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Pre-chamber breather valve - Replace The pre-chambers of the pump drive gearbox are vented through a breather valve, mounted on top of the expansion reservoir (2, Fig. 3-124:).  Replace breather valve in accordance with the servicing plan.  Clean area around the breather to prevent contamination of the gearbox.  Unscrew breather filter and replace by a new one.

Fig. 3-124:

3-115

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Pump drive gearbox lube oil filters - Replace In the oil cooling circuit of each pump drive gearbox there is a filter element (Fig. 3-125:). Check filter tell-tale (1, Fig. 3-126:) regularly - at operating temperature - for indication of contamination. If the red sector is visible through transparent cap (2), the filter element must be replaced. Filter element (5, Fig. 3-127:) must be replaced after 1000 operating hours at the latest. To do so:  Remove flange (3, Fig. 3-126:).  Pour oil out of filter pot (4, Fig. 3-127:) and remove filter element (5).

Fig. 3-125:

 Clean filter head (6, Fig. 3-126:) and filter pot (4).  Place new filter element into filter pot. Oil the new O-ring (7, Fig. 3-126:) lightly and attach.  Re-assemble filter pot (4) with flanges (3).  Check filter for leakage after recommencing operation.

Fig. 3-126:

Fig. 3-127:

3-116

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING SWING GEARBOX Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too. Shut off the engines. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing. Park and secure the machine as described in the "Securing the machine" section. Read and observe: "Inspection and servicing Safety instructions”.

Swing gearbox - Check oil level / Top up with oil  Park the machine as described under "Securing the machine".  Screw out dipstick (1, Fig. 3-128:) and wipe clean.  Insert dipstick (1) fully again (do not screw in) and withdraw a second time. The oil level must reach up at least to the lower mark on dipstick (1).  Top up with gearbox oil through the opening of plug (4), if required. (oil grade see: „LUBRICANTS / CONSUMABLES“). To reach plug (4) remove cover plate above swing gearbox.  Screw dipstick (1) back in place.

Swing gearbox oil sample - Obtain Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing. Obtain an oil sample of the swing drive oil through the opening for the oil level dipstick (1, Fig. 3-128:). Refer to CGMHMS publication “Service Manual for Oil Samples and Oil Analysis” for more information. For additional information about taking an oil sample, refer to:  Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”,  Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

Fig. 3-128:

Swing gearbox - Vent The gearbox is vented through breather filter (2, Fig. 3-128:). Clean breather filter in accordance with the servicing plan.  Unscrew breather filter (2), clean in white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter (2) back in place.

3-117

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Swing gearbox oil – Change Carry out oil change when gear oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil. Swing gearboxes are drained by means of the drain valves (2, Fig. 3-129: / arrow, Fig. 3-130:). Swing gearboxes are filled with gearbox oil by means of the express couplings (1, Fig. 3-129:).  Prepare a collecting recipient for used oil. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Draining off oil  Remove cover plates from the gearboxes.

Fig. 3-130:

 Unscrew plug (4, Fig. 3-131:) to ventilate the gearbox.  Attach draining hose to the drain valve and drain off oil completely. The drain valves (arrow, Fig. 3-130:) are accessible from below the undercarriage. The use of the oil draining hose is described in the "Hose line for oil and cooling liquid changes" chapter.  Drain off gearbox oil.  Remove hose. The oil drain valve closes automatically.  Fill in fresh gearbox oil, see: “Filling in new oil / Topping up”.

Fig. 3-129:

3-118

Fig. 3-131:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Fill in new oil / Top up (oil grade see: „LUBRICANTS / CONSUMABLES“). A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (fast fill arm)”.  Remove cap of express coupling (12, Fig. 3-132:) and connect hose line for filling swing gearbox oil from the service vehicle.  Connect the gearbox filling hose (Fig. 3-133:) to express coupling near to the hydraulic reservoir (arrow, Fig. 3-134:).  Connect other end of the filling hose to express coupling at the swing gearbox (1, Fig. 3-135:).  Open ball valve at filling hose (Fig. 3-133:) and fill swing gearbox with gearbox oil.

Fig. 3-133:

 Check filling level at dipstick.  After filling in oil, disconnect filling hose.  Screw in plug (4) again.  Attach cover plates to the gearboxes.

Fig. 3-134:

Fig. 3-132:

Fig. 3-135:

3-119

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING TRAVEL GEARBOX (GEARBOX P/N 3683483) Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too. Shut off the engines. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Spur gear section – Check oil level / Top up with oil  Check oil level at the inspection glass (2, Fig. 3-137:). The oil level should reach the center of the inspection glass. Top up with oil if required through the bore of plug (4). Oil grade see: “LUBRICANTS / CONSUMABLES”.

Park and secure the machine as described in the "Securing the machine" section. Read and observe: "Inspection and servicing Safety instructions”. Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”. To identify the gearbox part number (P/N) check the name plate attached to the gearbox.

Travel gearbox - Check oil level / Top up with oil  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-136:) are in the displayed position.  Unscrew checking screw (1). The oil level should reach up to the lower edge of the opening. Top up with oil, if required. Oil grade see: “LUBRICANTS / CONSUMABLES”.  Screw checking plug (1) back in place.

Fig. 3-137:

Brake housing - Check oil level / Top up with oil  Unscrew checking screw (6, Fig. 3-138:). The oil level should reach up to the lower edge of the opening. Top up with oil, if required.  Screw checking plug (6) back in place. Oil grade see: „“LUBRICANTS / CONSUMABLES”.

Fig. 3-136: Fig. 3-138:

3-120

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Travel gearbox - Change oil Carry out oil change when oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

Draining off oil  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-139:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2) and drain off the oil completely. Slackening plug (3) allows the oil to run out more readily.  Clean screw plugs (2 and 3)  Screw screw plug (2) back in place.

Filling in oil

Spur gear section - Change oil / Drain off oil  Place a collecting recipient for used oil under the pre-chamber. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (3, Fig. 3-140:) and drain off the oil completely. Slackening plug (4) allows the oil to run out more readily.  Clean screw plugs (3 and 4)  Screw screw plug (3) back in place.

Filling in oil  Unscrew screw plug (4).  Fill in oil through opening of plug (4) until it reaches the center of the inspection glass (2). Oil grade see: “LUBRICANTS / CONSUMABLES”.  Screw plug (4) back in place.

 Unscrew screw plug (1 and 3).  Fill in oil through opening in plug (3) until it flows out of opening in plug (1). Oil grade see: “LUBRICANTS / CONSUMABLES”.  Screw plugs (1 and 3) back in place.

Fig. 3-140:

Fig. 3-139:

3-121

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Brake housing - Change oil Drain off oil

Travel gearbox breather filter – Replace

 Place a collecting recipient for used oil under the brake housing. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Unscrew breather filters (1 and 5, Fig. 3-142:) and clean in white spirit or paraffin.

 Unscrew drain plug (7, Fig. 3-141:) and drain off the oil completely. Slackening breather filter (5) allows the oil to run out more readily.  Clean screw plug (7).  Screw screw plug (7) back in place.

Filling in oil  Unscrew screw plug (6).  Fill in oil through opening of breather filter (5) until it flows out of the bore of plug (6). Oil grade see: “LUBRICANTS / CONSUMABLES”.  Screw plug (6) and breather filter (5) back in place.

Fig. 3-142:

Travel gearbox oil sample – Obtain Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Fig. 3-141:

Obtain an oil sample from the following travel gearbox housings:  Planetary Housing (3, Fig. 3-139:). 

Spur gear housing (2, Fig. 3-140:).



Hydraulic motor chambers (6, Fig. 3-141:).

Refer to CGM-HMS publication “Service Manual for Oil Samples and Oil Analysis”. For additional information about taking an oil sample, refer to:  Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”, 

3-122

Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING TRAVEL GEARBOX (GEARBOX P/N 3683496) Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too. Shut off the engines. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing. Park and secure the machine as described in the "Securing the machine" section. Read and observe: "Inspection and servicing Safety instructions”. Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”. To identify the gearbox part number (P/N) check the name plate attached to the gearbox.

Travel gearbox - Check oil level / Top up with oil  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-143:) are in the displayed position.  Unscrew plug (3). The oil level should reach up to the lower edge of the bore. Top up with oil, if required.  Screw plug (3) back in place.

Alternatively:  Open cover of travel motors.  Check oil level at the inspection glass (arrow, Fig. 3-144:). The oil level should reach the center of the inspection glass. Top up with oil if required through the bore of plug (3, Fig. 3-143:). Oil grade see: „“LUBRICANTS / CONSUMABLES”.

Fig. 3-143:

Fig. 3-144:

3-123

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic motor chamber - Brake housing – Check oil level / Top up with oil

Travel gearbox oil sample – Obtain

 Unscrew checking screw (6, Fig. 3-145:). The oil level should reach up to the lower edge of the opening. Top up with oil, if required.  Screw checking plug (6) back in place. Oil grade see: “LUBRICANTS / CONSUMABLES”.

Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing. Obtain an oil sample from the following travel gearbox housings:  Planetary Housing (3, Fig. 3-143:). 

Hydraulic motor chambers (6, Fig. 3-145:).

Refer to CGM-HMS publication “Service Manual for Oil Samples and Oil Analysis”. For additional information about taking an oil sample, refer to:  Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”, 

Fig. 3-145:

3-124

Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Travel gearbox oil - Change Carry out oil change when oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

Draining off oil  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-146:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2) as well as the drain plug at the bottom side of the hollow wheel (arrow) and drain off the oil completely. Slackening plug (3) allows the oil to run out more readily.

Fig. 3-146:

 Clean screw plugs.  Screw plugs (2 and arrow) back in place.

Filling in oil  Move the shovel slowly until plug (3) reaches the “3-o’clock” position shown in (Fig. 3-147:). Drive only this short way to bring plugs in the shown position. Driving longer distances may damage the gearbox. Remember, the gearbox is without oil.

Fig. 3-147:

 Unscrew screw plug (3).  Fill in oil through bore of plug (3) until it flows out of the bore. Oil grade see: “LUBRICANTS / CONSUMABLES”.  Screw plug (3) back in place.  Open cover of travel motors.  Check oil level at the inspection glas (Fig. 3-148:). Fill in oil if necessary.

Fig. 3-148:

3-125

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic motor chamber - Brake housing - Change oil Draining off oil  Place a collecting recipient for used oil under the hydraulic motor chamber. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Travel gearbox breather filter – Replace  Unscrew breather filters (1 and 5, Fig. 3-150:) and clean in white spirit or paraffin.

 Unscrew drain plug (7, Fig. 3-149:) and drain off the oil completely. Slackening breather filter (5) allows the oil to run out more readily.  Clean screw plug (7).  Screw plug (7) back in place.

Filling in oil  Unscrew screw plug (6).  Fill in oil through opening of breather filter (5) until it flows out of the bore of plug (6). Oil grade see: “LUBRICANTS / CONSUMABLES”.  Screw plug (6) and breather filter (5) back in place.

Fig. 3-149:

3-126

Fig. 3-150:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING TRAVEL GEARBOX (GEARBOX P/N 3749598) Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too. Shut off the engines. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing. Park and secure the machine as described in the "Securing the machine" section. Read and observe: "Inspection and servicing Safety instructions”. Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”. To identify the gearbox part number (P/N) check the name plate attached to the gearbox.

Travel gearbox - Check oil level / Top up with oil  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-151:) are in the displayed position.  Unscrew plugs (1 and 3). The oil level should reach up to the lower edge of the bore of plug (3). Top up with oil, if required through bore of plug (1).  Screw plugs (1 and 3) back in place.

Alternatively:  Open cover of travel motors.  Check oil level at the inspection glass (arrow, Fig. 3-152:). The oil level should reach the center of the inspection glass. Top up with oil if required through the bore of plug (1, Fig. 3-151:). Oil grade see: „“LUBRICANTS / CONSUMABLES”.

Fig. 3-151:

Fig. 3-152:

3-127

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic motor chamber - Brake housing – Check oil level / Top up with oil

Travel gearbox oil sample – Obtain

 Unscrew checking screw (6, Fig. 3-153:). The oil level should reach up to the lower edge of the opening. Top up with oil, if required.  Screw checking plug (6) back in place. Oil grade see: “LUBRICANTS / CONSUMABLES”.

Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too. Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing. Obtain an oil sample from the following travel gearbox housings:  Planetary Housing (3, Fig. 3-151:). 

Hydraulic motor chambers (6, Fig. 3-153:).

Refer to CGM-HMS publication “Service Manual for Oil Samples and Oil Analysis”. For additional information about taking an oil sample, refer to:  Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”, 

Fig. 3-153:

3-128

Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Travel gearbox oil – Change Carry out oil change when oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

Draining off oil  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-154:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2) as well as the drain plug at the bottom side of the hollow wheel (arrow) and drain off the oil completely. Slackening plug (1) allows the oil to run out more readily.

Fig. 3-154:

 Clean screw plugs.  Screw plugs (2 and arrow) back in place.

Filling in oil  Unscrew plugs (1 and 3, Fig. 3-155:).  Fill in oil through bore of plug (1) until it flows out of the bore of plug (3). Oil grade see: “LUBRICANTS / CONSUMABLES”.

Fig. 3-155:

 Screw plugs (1 and 3) back in place.  Open cover of travel motors.  Check oil level at the inspection glass (Fig. 3-156:). Top up with oil if necessary.

Fig. 3-156:

3-129

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Hydraulic motor chamber - Brake housing – Change oil Draining off oil  Place a collecting recipient for used oil under the hydraulic motor chamber. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Travel gearbox breather filter – Replace  Unscrew breather filters (1 and 5, Fig. 3-154) and clean in white spirit or paraffin.

 Unscrew drain plug (7, Fig. 3-153) and drain off the oil completely. Slackening breather filter (5) allows the oil to run out more readily.  Clean screw plug (7).  Screw plug (7) back in place.

Filling in oil  Unscrew screw plug (6).  Fill in oil through opening of breather filter (5) until it flows out of the bore of plug (6). Oil grade see: “LUBRICANTS / CONSUMABLES”.  Screw plug (6) and breather filter (5) back in place.

Fig. 3-157:

3-130

Fig. 3-158:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING CRAWLER TRACKS

Upper roller fastening - Check

Cleaning

 Check fastening bolts (3, Fig. 3-156) regularly for tightness.

Clean tracks, track and upper rollers, sprockets and idlers regularly and whenever required. Cleaning is especially important in winter to prevent:  the tracks from being thrown off, 

oil from leaking out of track and upper rollers, sprockets and idlers,



excessive wear,



the track from breaking.

 Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual“).

To clean the tracks:  Raise one side of the hydraulic shovel with the attachment and allow track to turn.  Clean the side member supporting the track.  Clean support and track rollers (1 and 2, Fig. 3-159:) thoroughly.  Clean the sliding planes on the idler guides.

Fig. 3-160:

Undercarriage – Check for leaks and free movement Fig. 3-159:

Track roller fastening - Check Check fastening bolts (4, Fig. 3-156) regularly for tightness:  Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual“).

Check the upper rollers, the track rollers, and the idler wheels for possible leakage. Check the upper rollers, the track rollers, and the idler wheels for free movement. Check the surface of the track, the upper rollers, the track rollers, the idler wheels, and the drive sprockets. Look for signs of wear and loose mounting bolts. Listen for any abnormal noises while you are moving slowly in an open area. If abnormal wear exists or abnormal noises or leaks are found, consult your Caterpillar dealer.

3-131

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INSPECTION AND SERVICING Track roller - Lubricate (Not applicable at machines equipped with undercarriage lubricating system). The track rollers (Fig. 3-158) have a lifetime grease filling with Tribol® (see chapter “LUBRICANTS / CONSUMABLES”). To check the correct filling level, unscrew hex head screw on the visible front side of the roller. Grease must reach the lower edge of the bore. Lubricating the track rollers is necessary only after repair work. To do so:  Remove plate below the skid plate (arrow, Fig. 3-157). The lubrication lines are accessible then.  Unscrew plug (6, Fig. 3-158) from breather line.

Fig. 3-161:

 Remove dust cap (1) from coupling (2).  Remove dust cap (4) from plug (5).  Connect grease hose (3) to coupling (2).  Press in grease as long as used grease emerges from breather line.  Screw on plug (6) to breather line.  Disconnect the grease hose (3).  Fix dust caps (1 and 4) back in place.

Fig. 3-162:

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INSPECTION AND SERVICING Track tensioning system Design Each crawler track is kept automatically and constantly tensioned by a hydraulic track tensioning system. After starting one or both engines the track tensioning system is pressurized. Prior to start of operation and after repair work on the track tensioning system make sure that the stop cocks (5, Fig. 3-156:) are opened to make the system functional. Fig. 3-163: and Fig. 3-164: show parts of the tracks and the tensioner:

Technical data Track tensioning pressure Pressure limiting valve Gas pressure in diaphragm accumulator (nitrogen filling pressure)

appr. 7000 kPa / 1015 psi appr. 33000 kPa / 4786 psi appr. 5000 kPa / 725 psi

Releasing the track tension For cleaning and servicing work, the tracks can be slackened. To do so:  Stop the engines.  Open both pressure limiting valves (3, Fig. 3-164:) to slacken the tracks.  After the work, screw down the pressure limiting valves (3) to the limit stop.

Fig. 3-163:

1 2 3 4 5

Pressure accumulator Pressure cylinder Pressure limiting valve Mini- measuring port Stop cock valve

The tensioning system is under permanent pressure of ca. 7000 kPa / 1015 psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engines have been started. Retensioning is not required. The pressure-limiting valves (3) are preset to a pressure of 33000 kPa / 4786 psi and sealed in this position. The lead seal must not be removed and the pressure setting of 33000 kPa / 4786 psi must not be changed.

Fig. 3-164:

The pressure accumulators have to be checked for correct nitrogen pressure every 1000OH. Diaphragm has to be replaced every 5000OH (see “Service Manual, chapter 8”).

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INSPECTION AND SERVICING Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work. Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations]. Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year. The above-mentioned pressure tests are required to ensure the functioning of the track tensioner. They are no substitute for the inspections as required by the "Pressure Vessel Regulations". Before checking the gas charging pressure (nitrogen filling pressure) in the pressure accumulator, the track must first be slackened, i.e. the hydraulic part of the tensioning system must be depressurized. See under "Function".

Tab. 3-1

Group IV p  l bar p·x l  1000

3-134

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Internal inspection: every 10 years for noncorrosive fluids; otherwise pressure testing every 5 years: every 10 years by an expert

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing (1, Fig. 3-166:) and the pinion (2) are enclosed in a housing (3, Fig. 3-167:). The housing forms a grease-filled trough in which the pinion of the swing mechanism moves.

Shut off the engines. Wear protective gloves and firm protective clothing.

Swing ring – Instructions The grease filling must be replaced:  when repairs have been carried out on the swing ring, the swing ring seals or the swing ring housing. Remove old grease completely before filling in new grease. If greater losses are detected, locate cause immediately to prevent damage to the swing ring. Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

Bearing races The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing . The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-165:).

Fig. 3-166:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-165:). The amount of grease used up during operation is replenished by the central lubricating system. The housings have a check opening which is closed with a cover (2, Fig. 3-167:). For checking, the cover must be removed.

Fig. 3-167:

Fig. 3-165:

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INSPECTION AND SERVICING Swing ring grease filling – Check Read and observe: "Inspection and servicing - Safety instructions.

Swing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease. Add grease when:  the housing has been replaced, 

Shut off the engines Wear protective gloves and firm protective clothing. At regular intervals  check internal gearing and teeth of swing mechanism pinion for condition 

old grease has been removed in the course of other work.

Always fill in fresh grease by hand. Risk of accidents. Never swing the upper structure when refilling grease.

check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm / 0.79" of grease over its whole circumference (Fig. 3-168:). In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued swing movements.

Fig. 3-168:

3-136

Swing ring bolts – Check for tightness The fastening bolts of the swing ring in the upper structure and the undercarriage are tightened with their respective torque.  Check torque (see: "Service Manual"). When these values are reached, the fastening bolts are perfectly tight. Loosen slack bolts before tightening them with a torque wrench to the prescribed torque (see: "Service Manual").

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING CENTRAL LUBRICATING SYSTEM Central lubrication system - Design The hydraulic shovel is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those mentioned in the "Lubricating chart - Grease". The central lubricating system is activated when the electrical system is switched on with the keyswitch and at least one engine is running. All greasing points connected to the system are greased at regular intervals. The automatic greasing is interrupted when the engines are stopped with the idle timers. The central lubricating system is controlled electrohydraulically by one of the controllers of the CAMP system.

If a fault occurs, BCS gives a warning on the screen (Fig. 3-169:). This happens, for example, if the filter element in the hydraulic line is contaminated. If one of the following faults occurs, BCS gives a warning and at the same time the grease pump is switched off:  Grease container is empty, 

Greasing pressure in the grease lines is below 25000 kPa (3626 psi).

In this cases, BCS switches off the hydraulic function of the shovel/backhoe cylinders after 15 minutes. This prevents damages from lack of greasing. Inform the responsible maintenance personnel immediately. Keep on working after the fault has been fixed.

After the fault has been fixed, actuate the "Reset" button in the control column (64, Fig. 3-170:) or the “Reset” button in the control box located at the grease container. The buttons must be actuated for at least one second. For further information on the function and setting refer to the Technical Handbook, chapters 9 and 11.

Fig. 3-169:

Fig. 3-170:

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INSPECTION AND SERVICING Central lubrication system - Function The grease is pumped by hydraulically driven pumps (2 and 3, Fig. 3-171:) via greasing lines from the grease container to the main distributors on the upper structure and on the undercarriage. Pump (2) supports greasing points on upper structure and attachment, pump (3) supports the undercarriage (optional). The control elements of the lubricating system are installed on a control panel (1) attached to the grease container. As soon as the grease container is empty, the BCS (Fig. 3-172:) gives a warning signal (fault). In the event of a fault, the "dumping” function (shovel or backhoe cylinder) is switched off automatically after 15 min. Work can be continued when the grease container is filled with grease. Fig. 3-171:

Fig. 3-172:

3-138

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INSPECTION AND SERVICING Grease container – Fill up Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions. Fill up the grease container through the service station (Fig. 3-173:). A description of the Service Station (Fast fill arm) can be found in Part 2 of this manual, chapter “Service Station (fast fill arm)”.  Switch on the indicator system with toggle switch (23, Fig. 3-173:). Monitoring lamp (22) lights up.  Unscrew the cap of the express coupling (11).

Grease container breather filter Check / replace Check / replace the breather filter of the grease container at regular intervals.  Unscrew wing nut on top of the breather filter.  Withdraw cover (1, Fig. 3-174:) and filter element (2).  Check the filter element (2) and replace if it is soiled or damaged.  Replace sealing rings of the filter element.  Re-install breather filter.

 Connect the filling hose of the service vehicle.  When the grease container is full, the indicator lamp (34) lights up.  Switch off the indicator system with toggle switch (23). Monitoring lamp (22) is off.  Remove the flexible hose. The express coupling closes automatically.  Refit the protective cap.

Fig. 3-174:

Fig. 3-173:

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INSPECTION AND SERVICING Greasing pressure - Check

Grease line - Unblock

Check regularly (accord. to the maintenance plan), whether the oil pressure indicated by pressure gauge (3, Fig. 3-175:) at the hydraulic oil filter is 55 – 6000 kPa / 798 - 870 psi. The pressure is depending on temperature and viscosity of the oil and may vary. This oil pressure is reduced so that the pressure indicated by pressure gauge (2) is 3500 – 4000 kPa / 507 – 580 psi and by pressure gauge (1) is 4900 – 5100 kPa / 711 – 740 psi. The necessary greasing pressure of 32000 kPa / 4641 psi for the upper structure and 18000 kPa / 2611 psi for the lower carriage is generated by means of a pressure translator. The greasing pressure for upper structure and attachment is indicated by pressure gauge (4). The greasing pressure for the undercarriage (optional) is indicated by pressure gauge (5). In the event of deviating pressure values, shut off the engines and inform the responsible maintenance personnel. The central greasing system has to be checked.

In the event of faults at the central greasing system inform the responsible maintenance personnel immediately. Detailed information about the central greasing system can be found in the “Technical Handbook” chapter 11. Even when the grease pump isn’t active, there can be residual pressures in the grease lines up to 3000 kPa (435 psi). Relieve this residual pressure before opening a grease line. Put the hydraulic shovel back into operation only after the greasing system works properly and after having actuated the unloaded attachment for abt. 5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

Lower oil / grease pressure means that not all of the greasing points are supplied with grease. Higher oil / grease pressure may cause bursting of a greasing line.

Fig. 3-175:

3-140

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INSPECTION AND SERVICING Oil filter (hydraulic circuit grease pump) - Replace Risk of scalding caused by hot hydraulic oil. Risk of injury by hydraulic pressure. Shut off the engines. Switch off the electrical system. The filter housings may also be hot. Wear protective gloves and firm working clothing. Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Read and observe the "Inspection and servicing - Safety instructions" chapter.

Replacing the filter element For filtering of the hydraulic oil, a high pressure filter is installed in the pumping line (Fig. 3-176:). At the filter head there is a contamination indicator. Replace filter element if a red colored pin is visible at the contamination indicator.  Relieve hydraulic pressure.  Unscrew filter housing (3).  Withdraw filter element (2) from filter housing (3).  Clean filter housing and the sealing face at the filter head with white spirit or paraffin oil.  Insert the new filter element into filter housing and refit to the filter head with new, lightly oiled sealing ring (1).  Check for leaks after putting the filter into operation.

Fig. 3-176:

3-141

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INSPECTION AND SERVICING Grease filter (filling the grease container) - Check / replace Shut off the engines. Switch off the electrical system. Skin contact with grease may cause skin injury. Avoid skin contact. Read and observe the "Inspection and servicing - Safety instructions" chapter.

Checking for contamination and damage  Unscrew the filter housing (4, Fig. 3-177:).

Replacing the filter element A grease filter (arrow, Fig. 3-177:) is installed in the grease filling line to the grease container. Replace filter element regularly according to the maintenance plans.  Unscrew filter housing (4).  Withdraw filter element (2) from housing.  Remove the grease.  Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert the new filter element into filter housing and refit to the filter head with new, lightly oiled sealing rings (1 and 3).  Check for leaks after putting the filter into operation.

 Withdraw the filter element (2) from the filter housing (4).  Remove the grease.  Clean the filter element (2) in white spirit or paraffin oil and check it for contamination and damage.  If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.  Replace the filter element (2) if it is damaged.  Insert the filter element (2) and a new sealing ring (1) into the filter housing (4) and reassemble it with a new, lightly oiled sealing ring (3) to the filter head.  Check for leaks after putting the lubricating system back into operation.

Fig. 3-177:

3-142

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INSPECTION AND SERVICING Grease filter (grease lines) Check / replace Risk of injury by grease under pressure. Shut off the engines. Switch off the electrical system. Skin contact with grease may cause skin injury. Avoid skin contact. Read and observe the "Inspection and servicing - Safety instructions" chapter.

Replacing the filter element Two grease filters (Fig. 3-178:) are installed in the greasing lines to the grease distributors. Replace filter element regularly according to the maintenance plans.  Unscrew filter housing (4).  Withdraw filter element (2) from housing.  Remove the grease.  Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert the new filter element into filter housing and refit to the filter head with new, lightly oiled sealing rings (1 and 3).

Checking for contamination and damage

 Check for leaks after putting the filter into operation.

 Unscrew the filter housing (4, Fig. 3-178:).  Withdraw the filter element (2) from the filter housing (4).  Remove the grease.  Clean the filter element (2) in white spirit or paraffin oil and check it for contamination and damage.  If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.  Replace filter element (2) if it is damaged.  Insert the filter element (2) and a new sealing ring (1) into the filter housing (4) and reassemble it with a new, lightly oiled sealing ring (3) to the filter head.  Check for leaks after putting the lubricating system back into operation. Fig. 3-178:

3-143

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INSPECTION AND SERVICING OTHER MAINTENANCE WORK Engine – Clean Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “DO NOT OPERATE”. Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on the engine. Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material. This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Periodic cleaning of the engines is recommended. Steam cleaning the engines will remove accumulated oil and grease. A clean engine provides the following benefits:  Easy detection of fluid leaks 

Maximum heat transfer characteristics



Ease of maintenance

If the engine is cleaned with a steam-jet cleaner, make sure that the jet is not directed towards electrical components. If no steam-jet cleaner is available, the engines must be cleaned with suitable cleaning agents (cold cleaners). Note: Caution must be used in order to prevent electrical components from being damaged by excessive water when you clean the engine. Avoid electrical components such as the alternator, the starter, and the ECM. Further servicing works not described are carried out by your Caterpillar dealer.

Travel Alarm – Test Move the machine in order to test the travel alarm. Start the engines. Raise the work tool in order to avoid any obstacles. Make sure that there is adequate overhead clearance. Use the travel pedals to move the machine forward. The travel alarm should sound. Release the travel pedals in order to stop the machine. Use the travel pedals to move the machine backward. The travel alarm should sound. Stop the machine. Lower the work tool to the ground. Stop the engines.

3-144

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INSPECTION AND SERVICING Radiator – Clean Radiators are located in the counterweight (Fig. 3-179:) and in the oil cooler module (Fig. 3-180:). Note: Adjust the frequency of cleaning according to the effects of the operating environment. Inspect the radiators for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the radiator, if necessary. Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded. Do not clean radiators with a wire brush or similar hard objects. Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the air flow. Hold the nozzle approximately 6 mm (0.25 inch) away from the fins. Slowly move the air nozzle in a direction that is parallel with the tubes. This movement will remove debris that is between the tubes. Pressurized water may also be used for cleaning. The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides. Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water. In case of firmly adhering dirt, remove radiator and clean. After cleaning, start the engines and accelerate the engines to high idle rpm. This procedure will help in the removal of debris and drying of the core. Stop the engines. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary. Inspect the fins for damage. Bent fins may be opened with a “comb”. Inspect these items for good condition:  welds, mounting brackets, air lines, connections, clamps and seals.

Fig. 3-179:

Radiators located in the counterweight: 1 – Engine intake air aftercooler 2 – Engine cooling liquid

Fig. 3-180:

Radiators located in the oil cooler module: 3 – Hydraulic oil coolers 4 – Pump drive gearbox oil coolers

Make repairs, if necessary.

3-145

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INSPECTION AND SERVICING Aftercooler Core - Clean/Test Note: Adjust the frequency of cleaning according to the effects of the operating environment. Inspect the aftercooler for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the aftercooler, if necessary. For air-to-air aftercoolers, use the same methods that are used for cleaning radiators. Note: If parts of the aftercooler system are repaired or replaced, a leak test is highly recommended. Inspect these items for good condition:  welds, mounting brackets, air lines, connections, clamps and seals.

Reservoirs for used grease at the A-frame - Empty Remove used grease from the reservoirs (Fig. 3-182:) regularly according to the maintenance plans. Do not re-use the grease because it is polluted. Dispose off used grease as well as cleaning rags without polluting the environment and separately from other waste.

Make repairs, if necessary. Contact your Caterpillar dealer for more information.

Fig. 3-182:

Fig. 3-181:

Radiators located in the counterweight: 1 – Engine intake air aftercooler 2 – Engine cooling liquid

3-146

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INSPECTION AND SERVICING Air conditioning filter – Clean

Attachment - Check for cracks

Clean or replace the filter mats in the air suction regularly. The filter mats are located in the air conditioner housing (Fig. 3-183:) below the roof of the cab.  Open housing of air conditioner.

Check the welded joins of the attachment regularly. Inspections must be carried out acc. to the "Structural Inspection Reports" every 500 OH. "Structural Inspection Report" forms for those inspections can be downloaded from the CGM-HMS website, section "Support, Warranty". If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonic test. The inside located joins are accessible through the man-holes in stick (arrow, Fig. 3-184:) and boom (arrow, Fig. 3-185:).

 Clean or replace filter mats.  Close housing.

Fig. 3-183:

Fig. 3-184:

Fig. 3-185:

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INSPECTION AND SERVICING Clam cylinder chamber - Check for soiling In unfavourable circumstances during working operation loose material can reach the clam cylinders chambers in the shovel rear wall. To avoid damage to the clam cylinders and their hydraulic lines and hoses, inspect the clam cylinder chambers before starting each working shift.

Window panes - Clean  Clean the outside of the cab windows from the walkways (see Fig. 3-187:).  Use a clean sponge or a soft cloth.  Wash the windows with a mild soap or with a mild detergent. Also use plenty of lukewarm water.  Rinse the windows thoroughly.  Dry the windows with a moist chamois or with a moist cellulose sponge.

Fig. 3-186:

 Lift up the rubber cover plate of the clam cylinder chambers (arrows, Fig. 3-186:).  Remove all accumulated material from the chamber.  Check cylinders and all hydraulic lines, hoses and connections for damage and leaks.

3-148

Fig. 3-187:

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING Mirror – Clean / adjust position Adjust all mirrors as specified in this Operation and Maintenance Manual. Failure to heed this warning can lead to personal injury or death. Slips and falls can result in personal injury. Use the machine's access systems when adjusting the mirrors. Mirrors provide additional visibility around your machine. Make sure that the mirrors are in proper working condition and that the mirrors are clean. Adjust the rearview mirrors (if equipped) for the best visibility close to the machine. Adjust all mirrors at the beginning of each work period and adjust the mirrors when you change operators.  Park the machine on a level surface.  Lower the work tool to the ground.  Stop the engine.  Adjust rear view mirrors in order to provide maximum visibility besides and behind the machine (arrow, Fig. 3-188:). Hand tools may be needed in order to adjust the mirrors.

Fig. 3-188:

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INSPECTION AND SERVICING Seat belt – Inspect

Seat belt – Replace

Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. Replace any parts that are damaged or worn before you operate the machine. Inspect buckle (1, Fig. 3-183) for wear or for damage. If the buckle is worn or damaged, replace the seat belt. Inspect seat belt (2) for webbing that is worn or frayed. Replace the seat belt if the webbing is worn or frayed. Inspect all seat belt mounting hardware for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight. If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension. Contact your Cat dealer for the replacement of the seat belt and the mounting hardware. Note: The seat belt should be replaced within 3 years of the date of installation. A date of installation label is attached to the seat belt retractor and buckle. If the date of installation label is missing, replace belt within 3 years from the year of manufacture as indicated on belt webbing label, buckle housing, or installation tags (non-retractable belts).

The seat belt should be replaced within 3 years of the date of installation. A date of installation label is attached to the seat belt retractor and buckle (See Fig. 3-184 for example). If the date of installation label is missing, replace belt within 3 years from the year of manufacture as indicated on belt webbing label, buckle housing, or installation tags (non-retractable belts). Consult your Cat dealer for the replacement of the seat belt and the mounting hardware. Determine age of new seat belt before installing on seat. A manufacture label is on belt webbing and imprinted on belt buckle. Do not exceed install by date on label. Complete seat belt system should be installed with new mounting hardware. Date of installation labels should be marked and affixed to the seat belt retractor and buckle. Note: Date of installation labels should be permanently marked by punch (retractable belt) or stamp (non retractable belt). If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.

Fig. 3-190:

Fig. 3-189:

3-150

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INSPECTION AND SERVICING Cameras – Check/Clean/Adjust (If equipped) There are two remotely mounted cameras (1 and 2, Fig. 3-191:) on the machine that allow the operator greater visibility while machine operation. The cameras can be positioned for best view but as a minimum should optimize the operator's visibility to the rear and far right side of the machine. Check/Clean/Adjust all cameras as specified in this Operation and Maintenance Manual. Failure to heed this warning can lead to personal injury or death. Slips and falls can result in personal injury. Use the machine's access systems when adjusting the cameras. Note: In order to access the cameras it may be necessary to use a portable access system (ladder, stair assembly, man lift, or other portable access system) that is suitable and compliant to local regulations.

Fig. 3-191:

Make sure that the cameras are in proper working condition and that the cameras are clean. Adjust the cameras for the best visibility close to the machine. Check/Clean/Adjust all cameras at the beginning of each work period and check/clean/adjust the cameras when you change operators.  Park the machine on a level surface.

For more information on the camera system refer to: - Operation and Maintenance Manual, “Monitoring Cameras - Function”, - Camera manufacturer documentation which can be found in volume 5 “Components” of the shovels Technical Documentation.

Note: The cameras are equipped with an internal heater to help counteract the effects of condensation, snow, or ice. The cameras are sealed units. The cameras are not affected by high-pressure spray.

 Lower the work tool to the ground.  Stop the engines.  Verify that there is no damage to: -

the camera housing, the camera lens window, the cameras mounting brackets and to the camera wiring.

 Use a soft, damp cloth or water spray in order to clean the camera lens windows. Avoid dry rubbing to protect the lens windows against scratches.  Adjust cameras in order to provide maximum visibility besides and behind the machine. Hand tools may be needed in order to adjust the cameras.

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INSPECTION AND SERVICING Horn – Inspect / Replace

Inspect

The horn is an important signal instrument to warn people around the hydraulic shovel. Therefore, the signal horn has to be inspected and replaced at regular intervals according to the maintenance plans. Fig. 3-192: shows a typical mounting location of the horn. The horn can be mounted elsewhere. There can also be mounted several horns.

 Park the machine.

Note: Use a working platform or a man lift machine for work carried out in great height. Wear your personal protective equipment and approved fall protection equipment.

 Check the tight fit of the mounting screws of horn and bracket (Tightening torque = 79Nm / 58 lbf ft).  Check the condition of the bracket. Repair or replace if damaged.  Check the electrical connection. Repair or replace if the connection cable or plug connection is damaged or in case the plugs contacts are corroded.  Check the condition of the horn. If it is dirty, clean the horn. Replace the horn immediately if it is damaged.  Check the function. Note: Wear hearing protection in the immediate vicinity of the horn. If the horn does not sound or sounds inadequately / too quiet, it must be replaced immediately.

Replace  Disconnect the electrical connector in the power cable.  Unscrew the screws (1, Fig. 3-193:).  Remove the old horn from the bracket.  Mount the new horn with the screws (1) (Tightening torque = 79Nm / 58 lbf ft).  Connect the electrical connector to the power cable. Fig. 3-192:

 Check the function. Note: Wear hearing protection in the immediate vicinity of the horn.

Fig. 3-193:

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INSPECTION AND SERVICING Hydraulic ladder – pressure accumulator To allow the hydraulic ladder (Fig. 3-194: and Fig. 3-195:) to be lowered in an emergency, the ladder mechanism is equipped with a pressure accumulator (arrow, Fig. 3-196:). The pressure accumulator is located in the module beneath the operator’s cab.

Fig. 3-194:

Fig. 3-195:

Fig. 3-196:

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INSPECTION AND SERVICING Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work. Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Pressure accumulator - Checking the gas charging pressure After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations]. Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory: Group III p  l bar and p·x l  200 bars p·x l  1000 bars

3-154

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and operating fluids.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING ON-BOARD CRANE, DRIVE UNIT (OPTIONAL) The drive unit supplies the crane with hydraulic power. The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

Crane engine More and detailed information about the diesel engine can be found in the Operating and Maintenance Manual for the crane engine.  Before each shift check engine oil level. If necessary top up with engine oil through opening of dipstick (3, Fig. 3-197:).  After each shift fill up fuel tank (1).  Regularly check batteries (4) and cable connections.  Regularly, at least once a year: - change engine oil, - replace engine oil filter, - check / replace air filter (2), - replace fuel filter. Do not start engine with air filter (2) removed.

Fig. 3-197:

Hydraulic system For more and detailed information, see crane operating instructions.  Prior to each deployment, check the hydraulic oil level at the inspection glass (1, Fig. 3-198:); top up with hydraulic oil if necessary.

Fig. 3-198:

 Check contamination of hydraulic oil filter regularly at contamination indicator (4).  Regularly, but at least once a year replace the hydraulic oil filter (3) and the breather filter (2).

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INSPECTION AND SERVICING On-board crane - Lubricate Servicing work  Lubricate all bearings regularly and as required, and spray swing ring with a graphite spray (Fig. 3-199:). 1 2 3 4

bearing joint (column/boom) cylinder bearing swing ring

4 lube points 2 lube points 5 lube points Graphite spray

On-Board crane fastening bolts Check tightness The hydraulic driven on-board crane (Optional) is fixed on the upper structure of the machine by means of 16 fastening bolts. The upper and lower fastening bolts (Fig. 3-200:) are important and safety relevant components, they carry all loads and forces of the crane. Check tightness of all fastening bolts:  in regular intervals according to the maintenance plans and 

before every start of the on-board crane.

Check tightness of the fastening bolts by means of a torque wrench. The tightening torque for fastening bolts M20, quality 10.9, lightly oiled is: 557 Nm.

Fig. 3-199:

Fig. 3-200:

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INSPECTION AND SERVICING PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING Putting the hydraulic shovel out of operation  Park the hydraulic shovel on firm and level ground.  Set the attachment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.  Set all control element to "0".

Battery storage During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C / 68°F. Observe the following points with regard to maintenance:  Clean the batteries.  Check the acid density and the electrolyte level of the battery every two weeks.  Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.  Keep the batteries clean and dry on the outside.

 Clean the machine.  Carry out a visual inspection of the hydraulic shovel.

Recommissioning

 Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.

 Remove the covers.

 Carry out engines preservation. Ask your Cat dealer for assistance

 Remove engines preservation. Ask your Cat dealer for assistance.

 Protect all bright metal parts (e.g. piston rods) from rust and dirt.

 Check the fuel level in tanks.

 Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.  Fill up the fuel tanks.  Remove the batteries; see: "Battery storage".  Secure the machine against unauthorized starting by: withdrawing the key from the key-switch, locking the cab door, securing all lockable hatches.  Cover up all openings.

 Degrease / clean all protected components.

 Check track tension (visual inspection).  Check level and condition of the cooling liquid in the cooling system.  Check grease filling in grease container.  Oil level

- drive engines, - swing gearboxes, - pump drive gearboxes, - travel gearboxes.

 Check oil level in hydraulic oil reservoir.  Check battery acid density and level.  Install batteries and reconnect.  Function checks:

- upper structure holding brake, - track brake, - lighting system, - signaling equipment.

 Vent the hydraulic system.

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INSPECTION AND SERVICING

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INSPECTION AND SERVICING NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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INSPECTION AND SERVICING

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK 4 REPAIR WORK Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

4-1

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK

4-2

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK REPAIR WORK - SAFETY INSTRUCTIONS Operating instructions Never carry out repair work without having read and understood the operating instructions. Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine. The descriptions of job sequences provide only experienced personnel with the necessary instructions. The Operation and Maintenance Manual must be kept with the machine at all times.

Repair personnel Repair personnel must have know-how and experience relevant to repairing this or comparable machines. In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from CGM HMS.

Working in greater heights Always wear safety harnesses when working at greater heights. Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Prestressed units Never open defective prestressed units but replace them as an entirety. In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available. The Operation and Maintenance Manual contains no information on this point.

Dismantling components Never do dismantling while the machine is at operating temperature. Oils, greases, or coolants may have a high temperature and result in burning or scalding. Leave time for the machine to cool down. Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units. Replace defective components in good time to prevent major damage. Clean the defective component carefully before dismantling it. Mark the dismantled parts in the correct sequence to faciliate re-assembly. When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of CGM HMS. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film. On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material. Never start up the drive engines while work is being done on the machine. Check the repaired components and all machine functions in a trial run. Never release the machine for recommissioning until it is fully functioning.

4-3

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK CONFINED SPACES - SAFETY INSTRUCTIONS Work in confined spaces can lead to unexpected dangerous situations, such as  the formation of flammable vapors exploding during welding operations or 

the lack of oxygen and harmful gases causing loss of consciousness.

What are "confined spaces"? Confined spaces on this machine are, for instance, components of the attachment such as the monoblock boom, the lower part of the boom, the stick or the hydraulic reservoir (Fig. 4-1: - Fig. 4-3:). These components are provided with manholes. Manholes offer access to the inside of these components in order to carry out inspections or repairs such as welding work. Dangerous situations can also exist in other spaces which are not very often visited or which are badly ventilated. In these spaces, harmful or flammable gases can accumulate unnoticed.

Fig. 4-1:

Work in such spaces may only be carried out by specially qualified persons who have been instructed as to the situational risks. Before visiting these spaces, the following safety precautions must be taken:  The narrow space must be ventilated for a prolonged time, e.g. with a blower. Do not blow oxygen into the space. Oxygen increases the risk of fire.

Fig. 4-2:

 Use your personal protective equipment, e.g. respiratory mask.  Use a safety harness and have a second person stand by with a rescue rope attached to the harness.  Evacuate the gases produced during welding.

Fig. 4-3:

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK REPAIR WORK, FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents and avoiding fires. Pay particular attention to hazards caused by combustible and easily flammable substances. Obtain information on the safe handling of the fire extinguishers to be used. Avoid smoking and open fire on, next to and below the hydraulic shovel. Even battery gases can ignite in open flames or fire. Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight. These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger. Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work. Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work. If necessary, also cover the ground with fireprotective blankets. Apply special protection to cables, cable ducts as well as to hose and pipe lines. Have all your welding, flame cutting and grinding work approved before starting work. The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment. Ensure sufficient ventilation. Do not keep any fire extinguishers that are not suitable or have not been tested. Do not extinguish flammable liquids with water. Use:  dry-powder, carbon-dioxide or foam extinguishing compounds. When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards. Call the fire brigade. Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground. Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK REPAIR WORK, ENGINE Read and observe the "Repair - Safety instructions" chapter and the engine operating instructions before working on the engine. The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49 °C / 120 °F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment. Risk of injury caused by rotating or hot parts of the engine. Shut off the engine and allow to cool down.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material. This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments. Carry out repair work only if the machine has been secured as described in the "Securing the machine" section of these operating instructions. Check and replace V-belts only when the engine is stationary.

Overhaul Considerations Reduced hours of operation at full load will result in a lower average power demand. A decreased average power demand should increase both the engine service life and the overhaul interval. The need for an overhaul is generally indicated by increased fuel/oil consumption and/or by reduced power. The following factors are important when a decision is being made on the proper time for an engine overhaul:  The need for preventive maintenance 

The quality of the fuel that is being used



The operating conditions



The results of the S·O·S analysis

Note: The aftertreatment system can be expected to function properly for emissions durability period, as defined by regulation. All prescribed maintenance requirements must be followed.

Oil Consumption as an Overhaul Indicator Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals. Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases. The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake specific oil consumption (BSOC) depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine. When the oil consumption of engine has increased to three times the nominal oil consumption due to normal wear, the engine should be considered for overhaul. There may be a corresponding increase in blowby and a slight increase in fuel consumption. Using Fuel Consumption for Calculating the Overhaul Intervals Experience has shown that overhaul life is most accurately based on fuel consumption. Use the actual records of fuel consumption, when possible. These fuel consumption targets are a guide and may vary based upon actual customer applications, load factors, site conditions and maintenance practices.

4-6

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons:  Costly unplanned downtime can be avoided. 

Parts can be reused according to Guidelines for Reusable Parts and Salvage Operations.



The engine service life can be extended without the risk of a major catastrophe due to engine failure.



The best cost/value relationship per hour of extended life can be attained.

After Failure Overhaul If a major engine failure occurs and the engine must be removed, many options are available. An overhaul should be performed if the engine block or the crankshaft needs to be repaired. A lower rebuild cost can be achieved by utilizing:  Specially designed Caterpillar engine features. 

Caterpillar dealer exchange components.



Caterpillar Inc. remanufactured exchange components.

Overhaul Recommendation To minimize downtime, Caterpillar Inc. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. This will provide you with the best cost/value relationship. Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life.

Rebuild or Exchange Cylinder Head Assembly, Connecting Rods, Pistons, Cylinder Liners, Turbocharger, Cylinder Packs, Oil Pump, and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications. The Special Publication, SEBF8029 lists the reusability publications that are needed for inspecting the engine parts. If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline, the parts should be reused. Parts that are not within the established inspection specifications should be dealt with in one of the following manners:  Salvaging 

Repairing



Replacing

Using out-of-spec parts can result in the following problems:  Unscheduled downtime 

Costly repairs



Damage to other engine parts



Reduced engine efficiency



Increased fuel consumption

Reduced engine efficiency and increased fuel consumption translates into higher operating costs. Therefore, Caterpillar Inc. recommends repairing out-of-spec parts or replacing out-of-spec parts.

4-7

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK Inspection and/or Replacement Piston Rings, Crankshaft Bearings, Valve Rotators, and Crankshaft Seals The following components may not last until the second overhaul.  Thrust bearings 

Main bearings



Rod bearings



Valve rotators



Crankshaft seals



Nonmetallic fuel lines (if equipped)

Caterpillar Inc. recommends the installation of new parts at each overhaul period. Inspect these parts while the engine is disassembled for an overhaul. Inspect the crankshaft for any of the following conditions:  Deflection

Every 1,420,000 L (375,000 US gal) of Fuel or 6750 hours 1. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”. 2. Refer to Disassembly and Assembly manual for removal and installation instructions Caterpillar recommends this maintenance for the following engine components. Consult your Caterpillar dealer for further information. The quantity of consumed fuel is a better indicator for this service interval than service hours. If the load factor is higher, the number of service hours for service interval will be lower. If the load factor is lower, the number of service hours for service interval will be higher. The following list contains components that should be rebuilt or replaced with a remanufactured product. Engine Components – Rebuild/Install Reman  Fuel Transfer Pump



Damage to the journals



Injectors



Bearing material that has seized to the journals



Turbochargers

Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:  Rod bearing 

Main bearings

Note: If the crankshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the crankshaft. Inspect the camshaft for damage to the journals and to the lobes. Note: If the camshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the camshaft. Inspect the following components for signs of wear or for signs of scuffing:  Camshaft bearings 

Camshaft followers

Caterpillar Inc. recommends replacing the crankshaft vibration damper.

4-8

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK Every 2,840,000 L (750,000 US gal) of Fuel or 13,500 hours

Install New Components  All seals, Gaskets and O-rings

Refer to this Operation and Maintenance Manual in order to determine the maintenance interval for a major overhaul. The need for a major overhaul is determined by several factors.  An increase of oil consumption



Camshaft Bearings



Engine Mounts



Updated Engine Software



Fuel Pressure Regulating Valve



Fuel Priming Pump



Gear train bushings, Bearings and thrust plates



An increase of crankcase blowby



The total amount of fuel consumption



The wear metal analysis of the lube oil



Heat Shields



An increase in the levels of noise and vibration



Main Bearings, Rod Bearings and Crankshaft thrust plates



Piston Rings,



Wiring Harness

An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced. An increase in the levels of noise and vibration indicates that rotating parts require service. Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute the wear metals. Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about scheduling a major overhaul. Note: The driven equipment may also require service when the engine is overhauled. Refer to the literature that is provided by the OEM of the driven equipment. For the major overhaul, all of the bearings, seals, gaskets, and components that wear are disassembled. The parts are cleaned and inspected. If necessary, the parts are replaced. The crankshaft is measured for wear. The crankshaft may require regrinding. Alternatively, the crankshaft may be replaced with a Caterpillar replacement part. Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications. If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the following recommendations.

Reuse (Clean and Inspect for Reusability) Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”.  Aftercooler Core 

Camshaft



Camshaft Lifters



Connecting Rods



Crankshaft



Cylinder Block



Cylinder Liners



Damper



Fan Drive (if equipped)



Gear Train



Pistons



Piston Pins



Spacer Plates (Head)

Rebuild or Remanufactured  Cylinder Heads 

Oil Coolers – If applicable



Oil Pump



Scavenge Oil Pump – If applicable



Turbochargers

4-9

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK Cleaning of Components Clean the oil cooler core and the aftercooler core. Then, pressure test both of these cores. For instructions on cleaning the cores, see this Operation and Maintenance Manual, "Aftercooler Core Clean/Test" topic. Clean the oil suction screen. Also, remove side covers in order to clean the oil sump. For instructions on removal and installation of components, see the Service Manual, "Disassembly and Assembly" module.

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REPAIR WORK HYDRAULIC SYSTEM Repair instructions Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes. Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair Safety instructions". Replace damaged and leaking hydraulic hoses and pipes as soon as possible by new ones. Use original spare parts from CGM HMS GmbH. They are adapted to the respective function. Do not re-use old hoses. Never repair damaged hoses. Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

Hydraulic hoses – Instructions Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited. Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years). Check the date of manufacture on the hose or on the hose fitting regularly. The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading. The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multi-shift operation and round-the-clock work). Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection:  Damage to the outer fibre reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks). 

Embrittlement of the outer fibre reinforcement layer (cracks in the hose material).



Changes in the usual shape of the hose under pressure or in pressureless condition in bends or curves such as detachment of fibre layers, formation of bubbles or bulges.



Leaks.



Non-observance of fitting requirements.



Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.



Detachment of the hose from the fitting.



Corrosion in fittings reducing the strength of the function of the fitting.

4-11

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure. The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion. So:  Never handle accumulators mechanically, never weld or solder.  Testing and servicing work must be carried out by experts only.  Prior to any testing and servicing work, depressurize the hydraulic part of the system.  To dismantle the accumulator, always wear goggles and working gloves.  Fill accumulator with nitrogen only, never with compressed air or oxygen.  Report any defects or damage to the machine owner without delay.  Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.  Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately.

4-12

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work". Read these safety instructions before starting any welding or flame-cutting operations.

Welding work by qualified personnel only Carry out welding work only if you have received special training and if you have been ordered to perform such work. Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons. Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country. Observe all warning and instruction signs attached to the machine. Wear the prescribed personal protective equipment such as:  protective clothing,

Increased risk of fire during welding work Always bear in mind that the heat, the sparks or dripping red-hot metal or slag produced in the process constitute a considerable risk of fire. The present safety instructions provide information on how to minimize the risk of fire. Remove all combustible materials close to the welding location or cover them up with noncombustible materials. If works in the vicinity of combustible materials cannot be avoided, further persons with firefighting equipment must be present on site as fireguards. Observe the instructions of the machine owner and of the mine.

Health hazards Welding operations produce harmful gases. Do not inhale the fumes and gases and make sure the surroundings of the welding location are well ventilated or equipped with an exhaust system. Remove all kinds of paint and all coatings as well as all residues of oils and greases from the weld area. Do not wind the welding cables round your body or parts of your body. The electromagnetic fields produced may damage your health.

 protective gloves,  protective mask and,  a fall-arrest system for persons working at height.

4-13

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK Tanks, pressure vessels and pressure accumulators Any work on vessels containing or having contained  combustible or combustion-accelerating substances,  potentially explosive substances or  substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work. This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease. Welding work on pressure vessels and pressure accumulators is forbidden. Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment. Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the vessels against damage and high temperatures. Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured. Inform yourself about the locations in the machine where the pressure accumulators of the hydraulic system are installed. Do not perform welding work in the vicinity of these pressure accumulators before they have been covered up safely against accidental contact or flying sparks. Have the pressure accumulators removed from the machine, if safe protection cannot be ensured.

Slewing rings and articulated joints The welding current must not flow through ballbearing or roller-bearing slewing rings, through bolted connections or articulated joints or through hydraulic cylinders. An electric current flowing through an air gap (e.g. in the bearing or in the articulation) produces a spark which damages the metallic surface. The welding clamps must therefore always be connected very close to the weld area (max. 2 - 3 m away (6.6-9.8 ft)).

Information relating to the electrical system and to electronic modules Electric arc welding produces electromagnetic fields, electrostatic charges and voltage spikes which can cause damage to electronic modules. Although the electronic modules of the machine are carefully protected against these influences, it is nevertheless necessary to take additional precautions in order to prevent such damage to the greatest possible extent.  Switch off the electrical system ("ignition OFF").  Open the battery main switch (or disconnect the starter batteries from the machine).  Lay the welding cables as far away from electric lines as possible. If it is not possible to implement all of the abovementioned precautions, all connectors must be removed from the electronic modules before beginning any welding work.  Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.  Never touch the enclosures of electrical and electronic modules with the welding electrode.  Protect electric lines against the heat emanating from the weld area.  Restore all electrical connections when the welding operations are terminated. Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK Welding on the counterweight Counterweights may contain a build-up of flammable gases. In case these flammable gases were ignited, deflagrations may occur. Please note the safety films on the counterweight (A, Fig. 4-4:). Before starting to work on the counterweight, like  Welding,

Welding on components of the attachment and on other fully or partly closed steel structures



Flame cutting,



Grinding,

Components may be equipped with pipelines routed inside. These lines can contain combustible substances such as hydraulic oil or lubricating grease which may be set on fire by welding operations.  Check whether pipes or hosepipes are connected to the steel component.



Drilling, milling and

 Depressurize these lines.



All other mechanical work that generates heat

 Open the screwed connections and empty the lines routed inside the component.

the counterweight must be ventilated in order to remove these build-ups of gas. To do so, remove the plugs (B, Fig. 4-4:) and flush the chambers of the counterweight with compressed air until the flammable gases are fully displaced. For more information on the correct flushing procedure please refer to Special Instruction M0078482 and contact your local Caterpillar dealer.

 Start welding only after these operations have been carried out. Electric lines may also be laid inside partly open steel structures in order to protect them against damage. They are not always visible from each viewing direction. Electric lines may catch fire as a result of the heat produced during welding.  Therefore check carefully whether electric lines are laid in the vicinity of the weld area.  Protect electric lines against the heat produced at the weld area or have them removed before starting the welding operations.

Welding on the cab The operator's cab is designed in such a way that it meets the FOPS (Falling Objects Protective Structure) requirements in accordance with DIN EN ISO 3449. Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

Further information

Fig. 4-4:

More detailed information concerning the state-ofthe-art execution of welding operations can be found in the Service Manual "Welding for maintenance and repair". For problems or queries please contact the competent service personnel. If parts of the machine have to be removed or dismantled, please read and observe the chapters: "Assembly of attachment, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

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EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK DISPOSAL AT THE END OF THE SERVICE LIFE Dismantling and removal instructions Before beginning work, think about the risks involved, e.g.:  Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity. 

Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

Read the following text attentively and observe the instructions given. Respecting the instructions will help you to protect yourself against health hazards and injuries and to prevent avoidable environment pollution.

4-16

Risk of deflagrations In the course of time, flammable gases may have formed or accumulated in the hollow spaces of welded constructions, e.g. the counterweight. To remove these flammable gases, the hollow spaces must be purged carefully with compressed air before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Risk of fire Remainders of fuel or oils may lead to the formation of flammable gases in tanks or other hollow spaces. When these tanks or hollow bodies are cut into pieces, the gases may ignite or even explode. For this reason, remove all fuel or oil remainders from these components and purge them carefully with compressed air in order to eliminate flammable gases (other efficient methods of removing flammable gases can also be applied) before work with hand grinders, flame cutters or other sparking tools is being undertaken.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK Disposing of the machine without polluting the environment

Further hazardous substances 

Batteries contain lead and acid.

Before stripping down the machine at the end of its service life observe the following instructions: The assemblies of the machine contain various operating fluids or lubricants. These substances may pollute the environment (so-called hazardous substances) and must therefore be disposed of properly. Observe the national laws and regulations governing the non-polluting disposal of these substances. Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly.  Fuel system: fuel tanks, fuel filters, fuel lines, filling station. Auxiliary attachment and units, such as an onboard crane or an auxiliary heater have their own fuel tanks with the correpsonding line systems.



Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.



Pressure accumulators contain nitrogen under high pressure and possibly remainders of hydraulic oil.



Lamps of Xenon working lights contain mercury. The required electronic control circuits are integrated in the housings of the working lights.



The fluorescent lamps of the maintenance lighting (discharge types) contain mercury.



Insulating material of cables can contain PVC.



The fire extinguishing system (if installed) contains trigger charges (ATTENTION, explosion risk) on the extinguishing agent containers. Pressure accumulators, extinguishing gas and extinguishing powder. For more detailed information please refer to the manufacturer's safety datasheets.



Hydraulic oil: hydraulic oil reservoir, hydraulic cylinders, hydraulic motors, hosepipes, piping, hydraulic pumps, hydraulic valves, hydraulic oil filter, filling station.



Engine coolant: engine, radiator, expansion reservoir, piping and hosepipes, filling station.



Gearbox oil in swing, traveling and transfer gearbox systems, expansion tanks, piping and hosepipes, filling station; idlers, support and track rollers.



Have the refrigerant (R134A) sucked out of the air conditioner system.



Grease from the central lubricating system, grease drum, piping and hosepipes, distributors, filling station; grease accumulations in bearings of the attachment, grease filling in the swing ring, grease filling in track and upper rollers as well as in idlers.

4-17

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK Appropriate disposal of batteries The machine is equipped with batteries containing lead and other harmful and polluting substances. Damaged or used batteries must therefore not be disposed of in the environment. They must be disposed of properly and separately from other waste. The batteries are marked with the corresponding symbols (Fig. 4-5:). Since batteries contain also reusable materials, they are taken back free of charge by the manufacturer, dealer or by other specialized companies. In the European Community, the final consumer is obliged by law to dispose off used batteries in designated waste collections centers. Observe the current regulations and laws of your country with regard to the handling of damaged or used batteries.

4-18

Fig. 4-5:

The symbols in Fig. 4-5: have the following meaning:  Crossed-out waste bin= Do not dispose of batteries with normal household waste. 

Pb……= Chemical symbol for lead.



Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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4-1

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

REPAIR WORK

4-2

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX 5 ANNEX Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

5-1

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX

5-2

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX BOARD-CONTROL-SYSTEM BCS III, what’s that? What it is The BCSIII is the third generation of the Board Control System. This generation represents the current stage of development of this reliable monitoring and control system for hydraulic mining hydraulic shovels from CGM HMS GmbH. The BCSIII communicates with other electronic units in the hydraulic shovel and makes up the CAMP system, the Control And Monitoring Platform. Controllers actuate and monitor functions such as the motor management, drive and control of the hydraulic pumps, the servo control and others. The controllers are basically computers that have been configured for their special application. Other electronic units of the CAMP system that communicate with the BCSIII are located in cabinets in the module below the operator’s cab, the pump compartment and the engine compartment. The exchange of data between sensors, controllers, the BCSIII and other involved components takes place via the CAN bus.

What it does The Board Control System, abbreviated to BCS, monitors all the essential functions of the hydraulic shovel and its components. It releases an appropriate signal if any maximum value is exceeded and also sends a report to be archived in the memory bank. If a normal operating status can be reached by temporarily reducing the hydraulic shovel's output, then this is monitored by BCS and done by the CAMP system. If it is necessary for the operator to take certain action, e.g. to stop one of the engines a relevant command is sent to the BCS display screen. BCS also gives information on servicing and trouble-shooting. Sensors installed at various points on the hydraulic shovel constantly transmit their readings to the controllers of the CAMP system. All essential pieces of operating data are displayed on the BCSIII screen in the form of simulated instruments as well as they are archived and can be called up as and when required.

Fig. 5-1:

Benefits for the operator Because BCS automatically warns of any abnormal conditions that require a corrective action, the operator can concentrate fully on the work in hand, and is not distracted by constantly having to keep an eye on many instruments or by having to decide upon appropriate actions to be taken in case of limit values being exceeded. The operator and the servicing crew also have the means of calling up particular background information from the BCS archive. The housing – installed in the control column inside the operator’s cab (Fig. 5-1:) – integrates the computer, the monitor, the control elements and the interfaces.

SIL2 functionality Safety related functions on the machine have been checked to minimize the risk of faults in their own function. Tests were performed according to the standards of functional safety (ISO 61508). To fulfill the requirements for reaching the Safety Integrated Level 2 (SIL2) new components and electronic units had to be used on the machine. These components and units are servo-controllers, sensors, switches, hand levers (joysticks), foot pedals and valves.

Want more information? More detailed and more technical information for service personnel could be found in the “„Service Manual“”, chapter 9. There are more extensive information given about the communicating units and about troubleshooting.

5-3

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX The keys on the front side

Other elements on the front side

A membrane keypad is located on the front side of the housing (Fig. 5-2:). The keys can be used to navigate through the screen pages. The keys in the row below the screen (1 – 0) will perform the same task as the active area on the screen above. Example: In (Fig. 5-2:) the key (1) lies directly below the active area "Service". Touching the "Service" area or pressing key "1", will take you to the same screen page. They can also be used for numerical inputs. The keys provided with arrows on the right side of the screen are used to navigate in a screen page. Pressing the key with the "door symbol" gives access to the previous screen page. Pressing the bottom key in the row confirms an input (like “Enter”).

(located on top of the column of keys on the right side) The green LED lights up when the electrical system of the machine is switched on, operating voltage is available. The green LED flashes with each keypress and when the background lighting of the screen is turned off. The yellow LED flashes if the temperature inside the device lies outside the permissible range. The automatic heating system is then active. The brightness sensor measures the ambient brightness. The BCS automatically controls the background illumination of the screen and the illumination of the keypad.

Fig. 5-2:

5-4

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX BCSIII, the start screen The screen displays the graphical user interface of the Board Control System. The basic screen (Fig. 5-3:) appears when all electronic units of the CAMP system have started and when their selftests have been completed. Note: At low outside temperatures it is possible that the basic screen appears a few minutes after switching on the electrical system (warming up phase). Starting from this basic screen, the user can access a number of other screens. This does not require an input device such as a keyboard, mouse or similar. The BCS screen is designed as a touch-screen. By slightly touching the active areas, the user can perform activities such as changing to another screen page.

Active areas are shown on the screen as threedimensional graphics. In the basic configuration – not activated - they seem to project out of the user interface. When touched, they appear to be lowered. Never use pointed objects such as a ball pen, screwdriver, nail or similar. This could damage the active surface of the touch-screen. Do not press on the sensitive areas, just slightly touch them with your fingertips! Note: Do not remove the film visible on the screen surface. This is a polarization film which makes the displayed graphics much better visible.

Fig. 5-3:

5-5

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Information given on the start screen, top section The symbols shown in the top row of the start screen (Fig. 5-4:) appear in grey color if function is not activated, in green color if everything is OK or in red if a warning is given. In this case more information is displayed in the red “failure row” below.

6

Operating hours meter.

7

Right engine monitoring.

8

Service station, turns to red color if lowered. Swinging upper structure or traveling the machine not possible then.

1

Left engine monitoring.

2

Central lubrication system monitoring.

9

3

The number of dumpers you loaded is displayed here (if counted with the key in the right joystick).

Hydraulic ladder, turns to red color if lowered. Swinging upper structure or traveling the machine not possible then.

10

Track parking brakes monitoring.

11

Upper structure holding brakes monitoring.

12

Servo-switch inside seat monitoring.

4

Connection to Remote Service System (optional).

5

Hydraulic system monitoring.

Fig. 5-4:

5-6

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Information given on the start screen, central section 1

Left engine data during operation: bar = engine oil pressure, Rpm = revolutions per minute, Ltr = fuel in fuel reservoir, red means: top up with fuel soon. Water = temperature of cooling fluid in degrees Celcius, left arrowhead-shaped symbol slides up and down displaying the current temperature. The symbol showing a halfed arrowhead is a trailing pointer displaying the maximum temperature. Slide to “0” with your fingertip.

2

Hydr. Oil = Hydraulic oil temperature in degrees Celcius, displayed graphically and numerically. V = on-board voltage, displayed graphically and numerically. Spanner symbol = operating time until next service is to be due, symbols are red then.

3

Right engine data during operation: bar = engine oil pressure, Rpm = revolutions per minute, Ltr = fuel in fuel reservoir, red means: top up with fuel soon. Water = temperature of cooling fluid in degrees Celcius, left arrowhead-shaped symbol slides up and down displaying the current temperature. The symbol showing a halfed arrowhead is a trailing pointer displaying the maximum temperature. Slide to “0” with your fingertip.

Fig. 5-5:

5-7

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Information given on the start screen, lower section 1

2

Button “Service”. Tapping with your fingertip opens a gate to much more information about the hydraulic shovels current behavior. A menu will appear where you can select the section you want information about (see chapter “Service screen”). Button “Setup”. Tapping with your fingertip opens a login window that permits access to the BCS section that is exclusively for service personnel. A password is needed to get access.

Note: Modifying parameters in BCS must be carried out by skilled, trained personnel only. Misuse could lead to serious damage on the hydraulic shovel. A passcode for BCSIII Service Level I and Level II is requested. Refer to Service Magazine Media-IDNo. BI644793-01 “BCS Passcodes” for more information.

Fig. 5-6:

5-8

3

Button “Fault”. Tapping this button opens a list of failures stored in the failure memory. A detailed description can be found in the “„Service Manual“”, chapter 9.

4

The red “failure row”. Here the system displays detailed information about the failure occurred and gives instructions about what to do.

5

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

6

Clock. Can be adjusted in the “Setup” section by service personnel.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Emergency Stop, reset function In case the Emergency Stop function has been activated by one or more of the Emergency Stop switches or by operating the battery circuit breaker, the main screen changes and displays the reset button (1, Fig. 5-7:). The machine is inactivated then, engines cannot be started. Call the responsible service personnel immediately. The fault has to be located and eliminated. Before being able to restart the engines the reset button, located in the front door of the 24Voltswitch cabinet (X1) must be pressed. The switch cabinet is located in the cab module. After pushing the reset button, the green LED inside the push switch lights up. This signalizes that the Emergency Stop function is back in function again.

1

This symbol appears on the main screen when the Emergency Stop function has been activated.

Fig. 5-7:

5-9

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Swing circuit lock-out function If the system detects an error with the swing function the swing circuit lock-out screen pops up on the main page displaying the faulty component(s). Call the responsible service personnel immediately. The fault has to be located and eliminated. The pop-up window disappears after touching anywhere in the window. It will stay in the background until another fault happens or the operator navigates to a different screen and goes back to the main screen. The fault can be reviewed on the “Servo Controller Menu”, available after logging in to the Setup-Level I-Menu (password required).

Fig. 5-8:

5-10

Squared symbols meanings: Green color = OK Yellow color = Minor fault detected, 48 hours to solve the problem before status changes to red and safe stop sequence is initiated. Red color = Major fault detected, safe stop sequence is initiated. The all-over status (green, yellow, red) of the swing circuit is displayed at the end of the chain and correlates with the three conditions mentioned above.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Information given on the “Service” screen 1

2

3

Tapping on the photo of the engine opens a screen displaying current engine data (see “Engine data screen”). Same result when tapping on button “Engine” or pressing key “1” on the housing. Tapping on the photo of the hydraulic pumps opens a screen displaying current hydraulic data (see “Hydraulic data screen”). Same result when tapping on button “Hydraulic” or pressing key “3” on the housing. Tapping on the photo of the lubrication control opens a screen displaying current lubrication data (see “Lubrication data screen”). Same result when tapping on button “Lubrication” or pressing key “5” on the housing.

4

Tapping on the photo of the control lever (joystick) opens a screen displaying control elements adjusting data (see “Controls adjustment data screen”). Same result when tapping on button “Servosystem” or pressing key “7” on the housing.

5

Tapping on this button opens the “View documents” screen (see: “View documents screen”).

6

Adjusting screen brightness. Sliding the green button sets screen brighter / darker. Tapping on button “Autom.” sets brightness to automatic mode.

7

Tapping on this button opens the “Signal Table” screen (see: “Signal Table screen”).

8

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-9:

5-11

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Engine data screen This screen displays data of the left engine. Same data for the right engine are available after tapping on the button “right engine”. 1

This section of the screen displays current engine data.

2

Here the oil change interval is displayed as well as the remaining operating hours (h) until the next oil change. After carrying out oil change tap on button “done”, this resets the graphical oil change bar and the (h) counter.

Fig. 5-10:

5-12

3

In this section information about faults and malfunctions are displayed. Fault description follows the SAE J1939 standard. SPN Number = Suspect Parameter Number, FMI = Failure Mode Indentifier. The “failure row” below displays a failure description.

4

All data displayed can be saved to an USBstick after tapping this button (see: “Saving data to an USB-stick”).

5

Tapping on this button opens a window displaying all the faults / malfunctions the system is able to display (see: “Code Table screen”).

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Hydraulic data screen 1

This screen displays data related to the hydraulic system.

2

All data displayed can be saved to an USBstick after tapping this button (see: “Saving data to an USB-stick”).

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-11:

5-13

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Lubrication data screen 1

2

This screen displays data related to the central lubrication system. Here are information about the status of the lubricating system of the upper structure.

3

Here you get information about the status of the lubricating system of the under carriage.

4

If the system detects faults or malfunctions in the lubrication system of the upper structure they are marked here with a red dot. Call the responsible service personnel.

If the system detects faults or malfunctions in the lubrication system of the under carriage they are marked here with a red dot. Call the responsible service personnel.

5

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-12:

5-14

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Controls adjustment data screen The characteristic curves of control levers (1, Fig. 5-13:) and control pedals (2) are adjustable by service personnel. The adjusted values are shown here graphically and numerically. Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

If adjustment is needed, call the responsible service personnel. Adjustment is to be done in the “Setup” section of BCSIII. Access to this area is for service personnel only (password required).

Fig. 5-13:

5-15

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX View documents screen Technical documentation for the machine is stored in memory. Tapping on the buttons opens the appropriate pdf file and displays it on the screen by means of the build in viewer. You can navigate inside the documents using the navigation elements known from other computer usage, like buttons, sliders, links from the contents page and so on.

Fig. 5-14:

5-16

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Signal table screen This is a listing of all the signal sources that are connected to the BCS- and CAMP-system. In the “Status” column small icons visualize the signal status: green=ok; red=malfunction. In column “Code” you can find the identifier for the sensor or unit that helps the maintenance personnel to localize the sensor in the electric schematics (in this example the identifier for the sensor is “3B22”) .

1

To identify and localize sensors and units on the machine, some photos were attached. If you tap on a “Name” and then the button “Location” became readable, a photo is available. Otherwise the button is greyed. In Fig. 5-15: ID 110 “Main Pump 1/3 Pressure” is marked and button “Location” (1) is readable. When tapping on it, a photo appears and shows where the sensor is located (see Fig. 5-16:).

2

Tapping on button “Diagram” opens a screen showing the data coming from four sensors in a diagram (see Fig. 5-17:).

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-15:

5-17

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Signal table screen, location Button “Location” has been tapped, a photo appears showing where the sensor “3B22” is located at the machine.

Fig. 5-16:

5-18

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Signal table screen, diagram This is a diagram showing the data coming from four signal sources (sensors) for a longer period of time. The signal sources (channel 1-4) can be selected from a listing after tapping the “Config” button (see: “Signal table screen, diagram configuration”). 1

2

Tapping on button “Config.” opens a window listing all the signal sources available for BCS and CAMP (Fig. 5-18:). Listing of the four signal sources selected: ID, Name, actual value and value at cursor in the diagram.

3

Rec = starts recording the data from the selected sources; Stop = stops recording data; Rev = scrolls the diagram in reverse; Fwd = scrolls the diagram forwards.

4

Diagram window, displays the data from four sources as four lines in different colors.

5

Save = save data to memory; Load = load older data from memory; Delete = delete data displayed.

6

Buttons to scroll, scale up, scale down and reset to base setting the diagram window.

7

Select signal source to be displayed (channel 1-4)

8

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-17:

5-19

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Signal table screen, diagram configuration Button “Config.” has been tapped, a window appears displaying all the signal sources available. In column “Channel” you can mark four signal sources whose data you want to display in the diagram (Fig. 5-17:). Mark the line with the signal source you want and press the appopriate numeric key on the BCS housing: “1” for channel 1; “2”, “3” and “4” for the other channels.

Fig. 5-18:

5-20

1

For example: This signal source is selected and marked to be displayed on channel 3.

2

For example: This signal source is selected and marked to be displayed on channel 2.

3

Tapping the button will confirm your selection.

4

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Code table screen Coming from the “Engine data screen” (Fig. 5-10:) after tapping the “Code Table” button. This screen displays a listing of all available trouble codes according to the SAE J1939 standard. Active faults or malfunctions are displayed on the “Engine data screen” with their “SPN Number” and their “FMI Number”. To get the description for the fault or malfunction, key in both numbers at (1) and tap on the button left aside. The appropriate description will be displayed (2).

1

SPN = Suspect Parameter Number, according to SAE J1939 standard, For example: 94

2

FMI = Failure Mode Identifier, according to SAE J1939 standard, For example: 18

3

Tapping these buttons will scroll the listing: forward, reverse, to beginning, to end.

4

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-19:

5-21

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Slew brake test screen The slew brake test screen (Fig. 5-20:) is available after logging in to the Setup-Level I-Menu (password required). A slew brake test must be performed during commissioning of the machine and after repair work or maintenance work carried out on the slewing system. The slew brake test should be performed at every maintenance scheduled by the customer. This is to ensure proper functioning of the slew brake system. Proper functioning of the slew brake system has influence to machine safety. Before performing the slew brake test, ensure the machine is placed on a firm, even and safe workplace where the machine can rotate 360° without hitting an obstacle. Lift the bucket from the ground. Check that all persons have left the area around the machine. Activate the horn. To perform the slew brake test, follow the instructions (4) given on the screen.

Fig. 5-20:

5-22

1

2 3 4 5 6

Preconditions to be fulfilled before performing the slew brake test, from left to right: - swing brake applied, - servo control switch in control column must be in position OFF, - operator sitting on his seat. Symbols change to green with precondition fulfilled. Time limit to fulfill preconditions is 60 sec. Button to start the test. Hydraulic pressures in the units of the slewing systems, left hand and right hand. Instructions to perform the slew brake test. Instruments displaying hydraulic pressure in left hand / right hand slewing system. Indicators showing the progress during testing: - “pending”, color red after starting the test, - “in progress”, color yellow when 300 bar, - “passed”, color green when test OK.

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX BCS III, interfaces The BCS system comes with different data interfaces. This feature allows the communication with external electronic devices. Three connectors are located on the right-hand side-wall of the control column (Fig. 5-21:): 1

USB 2.0, jack type A. This jack accepts, for example, a USB stick used to save operating data for evaluation on an external computer.

2

Jack D sub, 9 pins. Used to connect a computer with a diagnosis software with access to the CAN bus. This connection is reserved for service personnel.

3

Fig. 5-21:

Ethernet, jack type RJ45. For the connection of future extensions, for example, the CMDI-system (i.e. Caterpillar Mining Data Interface).

USB interface, data storage A USB stick can be connected to the USB plug-in connection of type A (1, Fig. 5-21:). Suitable are such USB sticks that would also work on computers with WINDOWS® operating systems; they may be formatted with the NTFS or the FAT32 file system. If a screen page displays the symbol of a USB stick, the operating data of this screen page can be saved. The BCS will create a text file. For a detailed description see: “Saving data to a USB stick”.

5-23

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Saving data to a USB stick All screens which have the “USB-stick-button” (1, Fig. 5-22:) offer the functionality to store data for external use. All data related to the current screen will be stored to a USB stick. In this example all data from the “Service, left engine” screen will be saved to a file. Fileformat is RTF (Rich Text Format). The file name will be automatically created following this pattern: “Shovel type+serial number+screen name.rtf”. For example: “RH120172_Engine_LH.rtf”. If this file already exists, an extension with increment numbers will be added to the file name: “RH120172_Engine_LH_(1).rtf”. “RH120172_Engine_LH_(2).rtf”. ……

Fig. 5-22:

5-24

Save data: Plug a USB stick into the USB jack (see: “BCSIII, interfaces”). To save the data, tap on button (1, Fig. 5-22:). The BCS system checks the USB interface before saving the data. If no USB stick is detected, a new window appears showing the folder structure on the CF-card as well as the message “Please plug a USB stick”.. If a USB stick is found, a new window appears, see next page (Fig. 5-23:).

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Saving data to a USB stick, continued This window shows the current data you want to save in a file and askes for confirmation. If you want to save the data tap on the “Yes” button (1, Fig. 5-23:). The file will be written on the USB stick. Otherwise tap on the “No” button and return to the screen you want. If you want to see the files stored on the USB stick, tap on the “Open” button (2). A new window appear showing the folder / file structure on the USB stick, see next page (Fig. 5-24:).

Fig. 5-23:

5-25

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Saving data to a USB stick, continued This window (Fig. 5-24:) displays the folder / file structure on the USB stick plugged into the USB jack. Mark the file you want to see by tapping on the filename (2). Tapping an button “show” (1) opens another window which shows the file. Tapping the button with the door icon (3) leaves the current screen and opens the previous screen.

Fig. 5-24:

5-26

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX BCSIII, cleaning

BCSIII, disposal

Clean dirty screens with a soft, slightly moist cloth. In order to remove persistent dirt, you can use in addition a conventional cleaning agent for LCD monitors.

This electronic device contains substances that might be harmful to the environment. The electronic components and the tubes of the background illumination contain, for example, lead (Pb) and mercury (Hg). The background illumination lamps are CCFL-typelamps (Cold Cathode Fluorescent Lamps). The battery for backing up the memory contains lithium. Therefore, this device must not be disposed of with your regular household waste. It must be disposed of properly as electronic scrap.

Never use solving or scouring cleaning agents. This could damage the surface of the screen. Do not use compressed air or water under pressure (high pressure cleaner or steam cleaner). This could damage the electronic components.

The escaping liquid from a damaged LCD screen may be harmful. Do not come in contact with escaping liquids. In case of skin contact, wash immediately with water and soap.

5-27

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX TROUBLESHOOTING Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced. For this reason, it is vital to read through the relevant section of the Operation and Maintenance Manual once again before rectifying any faults. If you are unable to detect the cause of the fault or to rectify it, apply to the CGM HMS GmbH aftersales service. Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM HMS GmbH after-sales service. Exact data allow for fast troubleshooting. Never do any jobs for which you are not qualified. The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

Fault The fault is described here as the outcome of an observation or a previous activity. Therefore make careful observations. Study the problem carefully. First think, then act. Ask yourself the following questions:  Which warning signals preceded the fault? 

What repair and servicing work was carried out previously?



Has this defect already occurred?



Is it one or several simultaneously occurring faults?

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the Operation and Maintenance Manual. If there is no entry, the CGM HMS GmbH after-sales service should be consulted

5-28

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX FAULT TABLES Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts, but runs enevenly or intermittently Engine gets too hot, temperature warning activated Engine not working at full power Engine not working on full cylinder papacity Engine without oil pressure or oil pressure too low

  

Engine oil comsumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly Cause Oil level too low  Oil level too high     

Engine inclination too big



Engine oil of wrong SAE-class













 

1) Contact the CGM HMS GmbH Service

Chapter ref. Engine oil level

A

Engine oil level

S

Engine Op. P Instr. W Lubricants



Air filter contaminated / turbo-charger defective

Engine Op. W Instr. Air intake syst. P

Fuel filter contaminated

Fuel filter



Charge-air line leaking

Fuel quality not corresponding to specification

  

Remedial action P Check E Adjust W Replace A Top up S Reduce R Clean

P/W P



Radiator / cooling fins contaminated

Cooler cleaning R



Cooling fan or water pump defective or loose

Engine Instr.



Cooling air gets too hot / heat buid-up

Op. P/W P



Battery defective or discharged



Cable connections in starter circuit loose or corroded



Starter defective or pinion not in mesh

P

Shut-off relay jamming

1)







   







   



 

Incorrect valve setting

Injection valve defective Combustion engine blocked on output side





 

 PMS malfunction  Celect coding lamp flashing/lit Celect defective (software error)

P P

Engine Instr.

Op. E

Engine Instr.

Op. P/W

P

Injection line leaking  

 

Battery

1) 1) 1) 1)

5-29

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Working hydraulics – Fault table Fault

Remedial action

Working and swing functions not operational No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS GmbH Uncontrolled working movements Service Cause Abschnitt Electronic hydraulic shovel control not activated/defective Working P  1)       Malfunction of pressure-relief valve Servo system pump defective 1)   1)       Malfunction of primary / sencondary pressure-relief valves Engine speed too low P  ECO-power switch in 80%-position P  Fuel filter contaminated Fuel filter P/W  Insufficient engine power Engine mal- 1)  function Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R  lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS fault 1)  indicator lamp flashing) 1)  Malfunction of solenoid valves 1)   Malfunction of control spool Engine coupling defective 

5-30

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Track drive – Fault table Fault

Remedial action

No forward travel and no reversing travel Maximum travel speed cannot be reached Insufficient traction power

  

        

   

Cause Malfunction of pressure-relief valves Servo system pump defective Malfunction of travel valve (pedal) Engine nominal speed too low Malfunction of control spool ECO-power switch in 80%-position Insufficient engine power

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS Service Chapter ref.

1) 1) 1) 1) 1) Traveling P Engine mal- 1) fuction Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil P/R cator lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS 1) fault indicator lamp flashing)

5-31

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Swing mechnism – Fault table Fault

Remedial action

No swing possible No righthand or lefthand swinging Swing performance insufficient Uncontrolled swinging movement

     



 

    

5-32

Cause Electronic hydraulic shovel control not activated / defective Limiting switch optional, ramp-type ladder not complete retracted Upper structure holding brake applied Pressure-relief valve adjusted too low level / defective Servo system pump defective Malfunction in feed-pressure circuit of swing pump Malfunction in high-pressure circuit of swing system Malfuction of moment-regulating valve Malfunction in swing pump displacement cylinder Excessive leakage in swing motor

Check Adjust Replace Top up Reduce Clean 1) Contact the CGM HMS Service Chapter ref. Working Operation

P E W A S R

P P P 1) 1) 1) 1) 1) 1) 1)

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX Central lubricating system – Fault table Fault

Remedial action

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

   

  



  

    

Cause Timer defective Lines between timer and hydraulic motor defective Hydraulikmotor defektive Grease pump defective Grease sieve clogged Distributor defective Grease container empty Grease pump does not suck grease Leaky lines Non-return valve defective Pressure switch defective

Check P Adjust E Replace W Top up A Reduce S Clean R Vent L 1) Contact the CGM HMS GmbH Service Chapter ref. P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

5-33

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX HYDRAULIC CIRCUIT DIAGRAM

Vibration data

Detailled information can be found in the „Service Manual“ chapter 8 or contact CGM HMS GmbH Service.

On the condition that the hydraulic shovel is used within the limits of its designated use, the installation of seats for operators in conformity with ISO 7096 ensures that the weighted vibration accelerations awz (measured in compliance with ISO 2631 Part I) fulfill the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG. The vibrations transferred are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. the "Lärm - und Vibrations-Arbeitsschutzverordnung" of 18.12.2008, Section 4. The effective value of the weighted acceleration to which the whole-body is exposed, does not exceed 0.5 m/s2. The measurement uncertainty is ±3% (tolerance of the measuring instruments).

5-34

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX ABBREVIATIONS A abt. AC acc. Ah

Ampere (SI base unit of electric current) about Alternating Current according to Ampere hours (SI base unit of quantity of electricity) ANSI American National Standards Institute, Inc. API American Petroleum Institute approx. / approximately appr. bar Bh CAMP CE CECE

CEN CGM cm cm3/rev CCW CW dB(A)

i i.e.

id est = that is

IFN

ISO service rating, blocked

IN in Incl. ISO kg kg/dm3

unit of pressure, 1 bar = 14.5 psi = OH = Operating hour Control and Monitoring Platform Communauté Européenne = European community Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee Caterpillar Global Mining centimeter (= 1/100 m) Cubic centimeters per revolution counterclockwise clockwise

km/h kPa kNm kW

Rated current Inch (unit of distance), 1 in = 25,4 mm Including, inclusive of International Standardization Organization Kilogram (unit of weight), 1 kg = 2.2 lb Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour Kilopascal (unit of pressure), 100kPa = 1bar = 14.5psi KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

l LAN lb lbf lb/in² LED l/min LpA LwA

Liter (unit of volume), 1 liter = 0.26 gal Local Area Network pound (unit of mass), 1 lb = 0.45 kg Poundforce (unit of force), 1 lbf = 4,45 N Pounds per square inch (= psi) Light-emitting diode Liters per minute Sound pressure at workplace Sound power level of the machine in stationary operation

dia. DIN

Decibel (sound intensity according measuring method A) Diameter German Industrial Standard

ECM eff. e.g. ELC etc.

Electronic Control Module on engines effective for example Extended Life Coolant etcetera

m MA mA max. MDG

Fig. FMI

min. min-1 mm

FOPS FS ft

Figure, serial number of illustration Failure Mode Identifier, description malfunctions according to SAE J1939 Falling objects protective structures Rock shovel (attachment) foot (unit of distance), 1 ft = 0.30 meter

Meter (unit of distance), 1 m = 3.28 ft Tightening torque Milliampere (=1/1000 A) maximal, maximum Mining Design Guidelines (Australian Standards in Mining Industries) minimal, minimum Revolutions per minute Millimeter (=1/1000 m)

gal GET GmbH

gallon (unit of volume), 1 gal = 3.78 liters Ground Engaging Tool German legal business form

N, kN NLGI NLGI– Klasse Nm No.

Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency – lubricant classification acc. To DIN 51 818 Newtonmeter (unit of torque) Number

HD HMS Hydr. Hp

Heavy duty Hydraulic Mining Shovels Hydraulic, Hydraulics Horse power (unit of power), 1 Hp = 0,75 kW Hertz (unit of frequency)

OH OMM oz

Operating hour Operation and Maintenance Manual ounce (unit of volume) 1 oz = 0.03 liter

Hz

to

Transmission ratio

of

5-35

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX ABBREVIATIONS PDF

PLC

Portable Document Format (trademark of ADOBE Inc.) Pump Managing System Part number Personal Protection Equipment Metric horsepower (1 PS = 0.74 kW) pund per sqare inch (unit of pressure), 1 psi = 0.069 bar Programmable logic controller

Qty.

Quantity

PMS P/No. PPE PS psi

R, r resp. RTF ROPS rpm

Radius Respectively Rich Text Format, text based file format Roll-over protective structures Revolutions per minute (= min-1)

SAE sec./s. SCA SM SN SPN

Society of Automotive Engineers (USA) Second Supplemental Coolant Additive Service Manual CGM HMS GmbH part number Suspect Parameter Number, description of malfunctions according to SAE J1939 Width across flats

SW t tm typ.

Metric ton (= 1000 kg) Tons by meters (obsolescent unit of swing torque) Typical

U/min U.S./ EPA USB

Revolutions per minute United States Environmental Protection Agency Universal Serial Bus, interface for fast data exchange

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W

Watt (unit of electric power)

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

5-36

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX PRODUCT SPECIFICATION SHEET

5-37

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX

5-38

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

5-39

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

ANNEX

5-40

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INDEX 6 INDEX Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

6-1

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INDEX

6-2

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INDEX

3 3500 Engine Maintenance Interval Schedule Notes ........................................................... 3-10

A ABBREVIATIONS ........................................... 5-35 About this Operation and Maintenance Manual 1-4 Access ladder - Lighting ................................. 2-40 Additional messages (ANSI) – Description .... 2-36 Additional messages (ISO) – Description ....... 2-21 After daily operation ...................................... 2-178 Aftercooler Core - Clean/Test ....................... 3-146 AIR CONDITIONER (OPTIONAL) .................. 2-96 Air conditioning – Clean ................................ 3-147 Air-intake lines - Inspect ................................. 3-67 AIR-INTAKE SYSTEM .................................... 3-64 ALL PRODUCTS FOREWORD ........................ 1-3 Alternator - Instructions................................... 3-77 Appropriate disposal of batteries .................... 4-18 ASSEMBLING ATTACHMENT - SAFETY INSTRUCTIONS ....................................... 2-179 Attachment - Check for cracks ..................... 3-147 Attachment circuits – Depressurize ................ 3-88 Automatic fire-extinguishing system ............... 2-52 Automatic reset to idling ................................... 2-9

B Backhoe Operation – Restricted Operation .. 2-119 Back-up heating (option) - Fill in fuel .............. 2-83 Back-up heating (optional) .............................. 2-98 Back-up heating operator’s cab (optional) ...... 2-97 Selection and qualification of personnel ......... 1-11 Basic setup at a bench ................................. 2-134 Battery - Check the state of charge ................ 3-81 Battery - Remove and install .......................... 3-82 Battery charge inside the machine - Safety instructions .................................................. 3-83 Battery isolator switch - Shut off supply voltage . 248 Battery storage ............................................. 3-157 BCS III, interfaces ........................................... 5-23 BCS III, what’s that? ......................................... 5-3 BCSIII, cleaning .............................................. 5-27 BCSIII, disposal .............................................. 5-27 BCSIII, the start screen..................................... 5-5 Bearing flushing for main pumps - Replace filter 3102 Bearing races................................................ 3-135 Before starting traveling ................................ 2-160 Before starting work ...................................... 2-100 Belts - Inspect/Replace ................................... 3-43 Bench - Climbing and Leaving...................... 2-111 Bench Height on Flat Slopes ........................ 2-133 Bench Heights – Recommendations for BHmachines ................................................... 2-112

Bench Heights – Recommendations for BHmachines, table ............................................ 114 Bench Heights – Recommendations for FS Machines, table ............................................ 133 Bench Heights on Steep Slopes ................... 2-132 BOARD-CONTROL-SYSTEM .......................... 5-3 Board-Control-System (BCS) ........................... 2-9 Breather filter fuel tanks - Replace ................. 3-69 Bypass valves - Clean / replace ..................... 3-96

C Cab interior lighting – Switch on and off ......... 2-44 Cameras – Check/Clean/Adjust (If equipped) .... 3151 CAN-Bus wiring connections – Inspect........... 3-86 CENTRAL LUBRICATING SYSTEM ............ 3-137 Central lubricating system – Fault table.......... 5-33 Central lubrication system - Design .............. 3-137 Central lubrication system - Function ........... 3-138 CGM-HMS Hydraulic Fluid ............................. 3-32 Checking the gas charging pressure in the pressure accumulator ................................ 3-134 Clam cylinder chamber - Check for soiling ... 3-148 Cleaning up the Pit Floor using the Attachment . 2141 Code table screen ........................................... 5-21 Cold-starting fluid (ether) – Replace the pressure vessel .......................................................... 3-54 Combustion engine - Fault table ..................... 5-29 CONFINED SPACES - SAFETY INSTRUCTIONS ....................................................................... 4-4 Control and Monitoring Platform (CAMP) ......... 2-8 Controls adjustment data screen .................... 5-15 Coolant for use on all combustion engines ..... 3-39 Cooling liquid - Change .................................. 3-59 Cooling liquid – Top up ................................... 3-57 Cooling liquid composition – Test ................... 3-60 Cooling liquid level - Check ............................ 3-56 Cooling liquid radiators - Check / clean .......... 3-56 COOLING SYSTEM........................................ 3-55 Cooling System Coolant Sample (Level 1) – Obtain .......................................................... 3-63 Cooling System Coolant Sample (Level 2) – Obtain .......................................................... 3-63 Cooling System Supplemental Coolant Additive (SCA) - Add ................................................. 3-61 Cooling System Water Temperature Regulator – Replace ....................................................... 3-62 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...... 2-181 Counter-rotation turns / Turning on the spot . 2-165 CRAWLER TRACKS .................................... 3-131

D Declaration of Conformity ................................. 1-6 Demand control / Zero-flow regulation.............. 2-9

6-3

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INDEX DESCRIPTION OF THE HYDRAULIC SHOVEL 26 DESIGNATED USE ................................... 1-6, 1-9 Diesel fuel – Recommendations ..................... 2-83 Digging and Loading .......................... 2-115, 2-137 Digging and loading a truck .......................... 2-116 Digging on Ground Level .............................. 2-140 Dismantling and removal instructions ............. 4-16 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................... 4-16 Disposing of the machine without polluting the environment ................................................ 4-17 Double Benching .......................................... 2-117 Drive unit ........................................................... 2-8 Dumping the load.......................................... 2-139

E Electrical circuit diagrams ............................... 3-77 Electrical Storm Injury Prevention .................. 2-82 Electrical system ............................................... 2-9 ELECTRICAL SYSTEM .................................. 3-77 Electrical system - Safety instructions ............ 3-77 Electrical system – Switch on and off ............. 2-90 Electrical system switch-cabinets ................... 3-77 Electronic hydraulic shovel control (pilot control) – activate ...................................................... 2-102 Electronic hydraulic shovel controls - Clean / lubricate ..................................................... 3-109 Emergency exit in operator’s cab and escape ladder .......................................................... 2-43 Emergency off switch...................................... 2-85 Emergency shut-off - Function ....................... 2-46 Emergency Stop, reset function ....................... 5-9 ENGINE .......................................................... 3-41 Engine – Clean ............................................. 3-144 Engine - Safety instructions ............................ 3-41 Engine 1 (LH), control and monitoring ............ 2-61 Engine 2 (RH), control and monitoring ........... 2-63 Engine air pre cleaner - Inspect / clean .......... 3-65 Engine crankcase breather – Clean ............... 3-53 Engine data screen ......................................... 5-12 Engine Mounts – Inspect .......................... 3-43 Engine oil - Change ........................................ 3-48 Engine oil filter – Replace ............................... 3-53 Engine oil level – Check level / top up ............ 3-46 Engine oil reservoir (if equipped) – Check oil level / top up ........................................................ 3-47 Engine oil reservoir (if equipped) - Drain / Fill oil 350 Engine oil reservoir (if equipped) – Replace breather filters ............................................. 3-52 Engine oil reservoir (if equipped) – Replace oil filters ............................................................ 3-52 Engine Oil Sample – Obtain ........................... 3-44 Engine oil service interval table ...................... 3-30 Engine Valve Lash – Check/Adjust ................ 3-45 Engine-off lowering of the attachment .......... 2-177 Engines – Adjust speed .................................. 2-94 Engines - Emergency shut-off ........................ 2-90 6-4

Engines - Shut off ........................................... 2-95 Engines - Start ................................................ 2-93 Engines - Start at low temperatures ............... 2-94 engines - STARTING AND STOPPING.......... 2-93 Entering and leaving the machine - Safety instructions .................................................. 2-40

F Face Shovel Operation – Restricted Operation .. 2144 FAULT TABLES .............................................. 5-29 Filters (pilot control circuit) - Check / replace . 3-98 Filters for swing circuits - Replace ................ 3-101 Filters for swing pump charge circuit – Check / replace....................................................... 3-100 FIRE AND EXPLOSION HAZARD .......... 1-15, 2-5 Fire extinguisher ............................................. 2-52 Fluids for hydraulic system ............................. 3-34 Folding ladder (optional) – Function ............... 2-42 Fuel filter – Replace ........................................ 3-69 Fuel Injector - Inspect/Adjust .......................... 3-43 Fuel preheating system (if equipped) ............. 2-92 FUEL SYSTEM ............................................... 3-68 Fuel System – Prime....................................... 3-68 Fuel system - Safety instructions .................... 3-68 Fuel system – Vent ......................................... 3-69 Fuel tank supply valve – Function .................. 3-68 Fuel tanks – Clean .......................................... 3-70 Further hazardous substances ....................... 4-17 Further machine documentation ....................... 1-4

G Gas, dust, steam and smoke .......................... 1-13 Grading the pit floor ...................................... 2-118 Grease container – Fill up ............................. 3-139 Grease container breather filter - Check / replace ................................................................... 3-139 Grease filter (filling the grease container) - Check / replace..................................................... 3-142 Grease filter (grease lines) - Check / replace 3-143 Grease for bearings, slew rings and track system (Central lubrication system) ........................ 3-37 Grease for idlers, track rollers and upper rollers (Lifetime lubrication) .................................... 3-38 Grease line - Unblock ................................... 3-140 Greasing pressure - Check ........................... 3-140

H Handling Oversized Boulders / Overhangs .. 2-142 Horn – Inspect / Replace .............................. 3-152 Hose line for oil and cooling liquid changes ... 3-40 Hoses and Clamps - Inspect/Replace ............ 3-74 HYDRAULIC CIRCUIT DIAGRAM.................. 5-34 Hydraulic data screen ..................................... 5-13 Hydraulic equipment ....................................... 1-14 Hydraulic hoses – Instructions ........................ 4-11 Hydraulic ladder – pressure accumulator ..... 3-153 Hydraulic oil – Change .................................. 3-103

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INDEX Hydraulic oil cooler – Clean .......................... 3-108 Hydraulic oil filters for working hydraulics – Check / replace ...................................................... 3-99 Hydraulic oil level – Check ............................. 3-89 Hydraulic oil return-flow filters - Replace (from machine no. 340173 / DHN60173) ............. 3-94 Hydraulic oil return-flow filters, Replace ......... 3-92 Hydraulic oil tank breather filters - Replace .... 3-97 Hydraulic oil tank- Clean ............................... 3-105 Hydraulic shovel layout ..................................... 2-7 Hydraulic system .............................................. 2-8 HYDRAULIC SYSTEM ................................... 3-87 HYDRAULIC SYSTEM ................................... 4-11 Hydraulic system - Depressurize .................... 3-87 Hydraulic system - Safety instructions............ 3-87 Hydraulic system – Vent ............................... 3-107 Hydraulic system sections – Depressurize ..... 3-89

I Information given on the Service screen ........ 5-11 Information given on the start screen, central section ........................................................... 5-7 Information given on the start screen, lower section ........................................................... 5-8 Information given on the start screen, top section ...................................................................... 5-6 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ........................................... 3-3 INSPECTION AND SERVICING PLANS INSTRUCTIONS ........................................... 3-9 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ......................... 3-7 INSPECTION PLAN - OIL .............................. 3-28 Inspection plan – Oil (legend) ......................... 3-29 Instructions on troubleshooting....................... 5-28 ISO – compliant safety messages set ............ 2-11

K Know the situation on site ............................. 2-131

L Lamps and bulbs – Replace ........................... 3-77 Layout of the fault table .................................. 5-28 Lighting systems in LED technology - Instructions .................................................................... 3-80 Loading setups .................................. 2-113, 2-136 LUBRICANTS / CONSUMABLES .................. 3-32 LUBRICATING CHART – GREASE ............... 3-26 Lubricating chart – Grease (legend) ............... 3-27 Lubrication data screen .................................. 5-14

M Machine Operating Temperature Range ...... 2-100 Machine operation with backhoe attachment, Best Practices .......................................................109 Machine operation with face shovel attachment Best Practices ........................................... 2-130

Machine stability ........................................... 2-130 Machine Stability ........................................... 2-109 Main control valves – attach/remove the handrail ................................................................... 2-180 Maintenance lights – Switch on and off .......... 2-45 Maximum Machine Inclinations..................... 2-175 Measures ........................................................ 5-28 Mirror – Clean / adjust position ..................... 3-149 Monitoring cameras – Function .................... 2-185 MONITORING, WARNING AND CONTROL ELEMENTS ................................................. 2-54

N Noise emission information ............................... 1-7 NOTES .............................................................. 4-1 NOTES ........................................ 1-2, 2-186, 3-159 NOTES ............................................................ 5-39 Notes on the selection of oils and greases ..... 3-32

O Oil filter (hydraulic circuit grease pump) - Replace ................................................................... 3-141 Oils for combustion engines ........................... 3-33 Oils for pump distribution gearboxes and tarvel gearboxes.................................................... 3-35 Oils for swing gearboxes ................................ 3-36 On-Board crane – Blocking the boom in position of rest ........................................................ 2-184 On-board crane - Check ............................... 2-184 On-board crane - Drive unit .......................... 2-183 On-board crane - Lubricate ........................... 3-156 On-board crane - Monitoring, warning and control elements .................................................... 2-182 On-board crane - Putting into operation ....... 2-183 ON-BOARD CRANE (OPTIONAL) ............... 2-182 On-Board crane fastening bolts - Check tightness ................................................................... 3-156 ON-BOARD CRANE, DRIVE UNIT (optional) .... 3155 Operating hours meter (if equipped) ............... 2-51 OPERATION - SAFETY INSTRUCTIONS ....... 2-3 Operation and Maintenance Manual, where to store it in the operator’s cab .......................... 2-4 Operation Techniques .................................. 2-109 OPeraTIONAL practices ................................. 2-99 Operator Assist System (if equipped) ........... 2-185 Operator’s seat ............................................... 2-49 ORGANIZATIONAL MEASURES ................... 1-10 Other elements on the front side ...................... 5-4 OTHER MAINTENANCE .............................. 3-144 Overhaul Considerations .................................. 4-6 Overhaul Recommendation .............................. 4-7

P Park the Machine ............................... 2-118, 2-143 Plan A - E ........................................................ 3-19 Plan N ............................................................. 3-13 Plan T and Plan W .......................................... 3-15 6-5

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INDEX Plan V ............................................................. 3-11 Possible causes .............................................. 5-28 Pre-chamber breather valve - Replace......... 3-115 Pre-chambers - Change gearbox oil............. 3-114 Pre-chambers - Check oil level / top up with oil . 3112 PREFACE ......................................................... 1-4 Preheating system for engine and hydraulic oil (if equipped) .................................................... 2-91 Pressure accumulator - Checking the gas charging pressure ..................................... 3-154 Pressure accumulator - Emergency lowering3-110 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ......................................... 4-12 Pressure-accumulator inspection regulations3-134 Pressure-accumulator inspection regulations3-154 Primary air filter element - Inspect / replace ... 3-66 PRODUCT SPECIFICATION SHEET ............ 5-37 PUMP DRIVE GEARBOX ............................ 3-111 Pump drive gearbox - Change gearbox oil ... 3-113 Pump drive gearbox - Check oil level / Top up with oil ............................................................... 3-111 Pump drive gearbox breather valve - Replace ... 3114 Pump drive gearbox lube oil filters - Replace 3-116 Pump drive gearbox oil sample - Obtain ...... 3-112 Putting the hydraulic shovel out of operation 3-157 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-157 Putting the machine back into operation, reset of emergency shut off function ........................ 2-47 PUTTING THE MACHINE INTO OPERATION .. 282

R Radiator – Clean ........................................... 3-145 Recommended working direction ................. 2-135 Recommissioning ......................................... 3-157 Reducing operators exposure to vibrations .... 2-51 Reducing the operator's exposure to noise .... 2-82 Refill Capacities - Grease ............................... 3-27 Refill Capacities - Oil ...................................... 3-31 Refill Capacities - Other .................................. 3-31 Refuelling ........................................................ 2-83 Repair instructions .......................................... 4-11 REPAIR WORK - SAFETY INSTRUCTIONS ... 4-3 REPAIR WORK, ENGINE ................................ 4-6 REPAIR WORK, FIRE AND EXPLOSION HAZARD ....................................................... 4-5 Reservoirs for used grease at the A-frame Empty ........................................................ 3-146 Restricted Visibility............................................ 1-8 Risk of deflagrations ....................................... 4-16 Risk of fire ....................................................... 4-16

S Safety films and warning messages – Overview and Description ........................................... 2-10

6-6

Safety instructions governing specific operational phases ......................................................... 1-11 Safety line on boom ...................................... 2-179 Safety messages (ANSI) – Description .......... 2-32 Safety messages (ISO) – Description............. 2-17 Saving data to a USB stick ............................. 5-24 Saving data to a USB stick, continued... 5-25, 5-26 Seat belt – Inspect ........................................ 3-150 Seat belt – Replace....................................... 3-150 Secondary air filter element - Replace............ 3-67 Section ............................................................ 5-28 Securing the machine ................................... 2-180 Service Station (fast fill arm) ........................... 2-84 SERVICING WORK ........................................ 3-40 Signal table screen ......................................... 5-17 Signal table screen, diagram .......................... 5-19 Signal table screen, diagram configuration .... 5-20 Signal table screen, location ........................... 5-18 Slew brake test screen ................................... 5-22 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work disposal of parts and consumables ........................................ 1-12 Starter isolator switch - Shut off starter voltage .. 248 Swing circuit lock-out function ........................ 5-10 SWING GEARBOX ....................................... 3-117 Swing gearbox - Check oil level / Top up with oil 3117 Swing gearbox - Vent.................................... 3-117 Swing gearbox oil – Change ........................ 3-118 Swing gearbox oil sample - Obtain ............... 3-117 Swing mechnism – Fault table ........................ 5-32 SWING RING ................................................ 3-135 Swing ring – Instructions ............................... 3-135 Swing ring bolts – Check for tightness.......... 3-136 Swing ring grease filling – Check.................. 3-136 Swinging ladder – Function ............................ 2-41 Switchgear cabinet filter – Clean .................... 3-84

T Temperature ................................................... 3-55 The keys on the front side ................................ 5-4 Track drive – Fault table ................................. 5-31 Track Parking Brake – set/release................ 2-166 Track roller - Lubricate .................................. 3-132 Track roller temperature – check .................. 2-170 Track tensioning system ............................... 3-133 Trainer's / instructor's seat .............................. 2-51 Transport - Safety instructions ...................... 2-176 TRANSPORTING THE MACHINE ............... 2-176 Travel Alarm – Test....................................... 3-144 Travel gearbox - Change oil ......................... 3-121 Travel gearbox - Check oil level / Top up with oil 3120, 3-123 Travel gearbox – Check the oil level / Top up with oil ............................................................... 3-127 TRAVEL GEARBOX (GEARBOX P/N 3683483) 3120

EM024061-1 OMM 6060, 6060FS(3 847 031.02)-EN

INDEX TRAVEL GEARBOX (GEARBOX P/N 3683496) 3123 TRAVEL GEARBOX (GEARBOX P/N 3749598) 3127 Travel gearbox breather filter - Replace ....... 3-130 Travel gearbox breather filter – Replace . 3-122, 3126 Travel gearbox oil - Change .............. 3-125, 3-129 Travel gearbox oil sample – Obtain .. 3-122, 3-124, 3-128 Travel Speed – Recommendations .............. 2-161 Travel straight forward/backward ................. 2-162 Traveling ....................................................... 2-159 Traveling – Basic Movements ...................... 2-162 Traveling – Best Practices ............................ 2-171 Traveling – Restricted Operation .................. 2-172 Traveling – Safety Instructions ..................... 2-159 Traveling over long distances ....................... 2-169 Traveling speed – adjust............................... 2-166 Traveling speed on ramps and slopes- change . 2168 Traveling uphill and downhill on ramps and steep slopes ........................................................ 2-167 TROUBLESHOOTING.................................... 5-28 Turning .......................................................... 2-163

U Undercarriage ................................................... 2-8 Undercarriage – Check for leaks and free movement ................................................. 3-131 Upper structure ................................................. 2-8 Upper structure - basic position .................... 2-160

Upper structure holding brake – set/release . 2-170 USB interface, data storage............................ 5-23

V Vibration data .................................................. 5-34 Vibration information ......................................... 1-7 View documents screen .................................. 5-16 Visibility aids ..................................................... 2-4 Visibility Information .......................................... 1-7

W Walk-Around Inspection .................................. 3-42 Warming up the hydraulic system................. 2-100 Warning of special dangers ............................ 1-13 Warnings and symbols ..................................... 1-6 WARRANTY ..................................................... 1-5 Water Pump - Inspect ..................................... 3-45 Water trap (option) - Clean / replace .............. 3-72 WELDING AND FLAME CUTTING WORKS SAFETY INSTRUCTIONS .......................... 4-13 Window panes - Clean .................................. 3-148 Windscreen washer ........................................ 2-51 Working hydraulics – Fault table..................... 5-30 Working operation – basics .......................... 2-103 Working operation - Safety instructions .......... 2-99

X Xenon floodlight projector (optional) - Replace the lamp ............................................................. 3-78

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Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and 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. Printed in Germany