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 No.
DH360148; DH360180; DH360183 - up
DHN60177 - up

Language: Original Instructions

 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 han-
dling.

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 au-
thorization 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 Target group

Part 1 INTRODUCTION Operating personnel

+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.

Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.

Part 4 REPAIR WORK 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

iii
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TABLE OF CONTENTS

TABLE OF CONTENTS
1 INTRODUCTION __________________________________________________________________ 1-1

ALL PRODUCTS FOREWORD _______________________________________________________ 1-3

Literature Information ______________________________________________________________ 1-3
Safety _________________________________________________________________________ 1-3
Operation_______________________________________________________________________ 1-3
Product Information _______________________________________________________________ 1-3
Maintenance ____________________________________________________________________ 1-3
Maintenance Intervals _____________________________________________________________ 1-3
Product Capacity _________________________________________________________________ 1-3

PREFACE _______________________________________________________________________ 1-4

About this Operation and Maintenance Manual _________________________________________ 1-4
Further machine documentation _____________________________________________________ 1-4

WARRANTY______________________________________________________________________ 1-5

FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-6

Warnings and symbols ____________________________________________________________ 1-6
Declaration of Conformity __________________________________________________________ 1-6
Noise emission information _________________________________________________________ 1-7
Vibration information ______________________________________________________________ 1-7
Visibility Information ______________________________________________________________ 1-7
Restricted Visibility _______________________________________________________________ 1-8

DESIGNATED USE ________________________________________________________________ 1-9

ORGANIZATIONAL MEASURES ____________________________________________________ 1-10

Selection and qualification of personnel; basic responsibilities _____________________________ 1-11
Safety instructions governing specific operational phases ________________________________ 1-11
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
Warning of special dangers ________________________________________________________ 1-13
Gas, dust, steam and smoke _______________________________________________________ 1-13
Hydraulic equipment _____________________________________________________________ 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 __________________________________________ 2-6

Hydraulic shovel layout ____________________________________________________________ 2-7
Undercarriage ___________________________________________________________________ 2-8
Upper structure __________________________________________________________________ 2-8
Drive unit _______________________________________________________________________ 2-8
Hydraulic system _________________________________________________________________ 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

PUTTING THE MACHINE INTO OPERATION __________________________________________ 2-82

Electrical Storm Injury Prevention ___________________________________________________ 2-82
Reducing the operator's exposure to noise ____________________________________________ 2-82
Refuelling _____________________________________________________________________ 2-83
Diesel fuel – Recommendations ____________________________________________________ 2-83
Back-up heating (option) - Fill in fuel _________________________________________________ 2-83
Service Station (fast fill arm) _______________________________________________________ 2-84
Emergency off switch ____________________________________________________________ 2-85
Electrical system – Switch on and off ________________________________________________ 2-90
Engines - Emergency shut-off ______________________________________________________ 2-90
Preheating system for engine and hydraulic oil (if equipped) ______________________________ 2-91
Fuel preheating system (if equipped) ________________________________________________ 2-92

ENGINES - STARTING AND STOPPING ______________________________________________ 2-93

Engines - Start__________________________________________________________________ 2-93
Starting the left-hand engine _______________________________________________________ 2-93
Starting the right-hand engine ______________________________________________________ 2-93
Engines – Adjust speed___________________________________________________________ 2-94

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Engines - Start at low temperatures _________________________________________________ 2-94

Engines - Shut off _______________________________________________________________ 2-95
Shutting off the left-hand engine ____________________________________________________ 2-95
Shutting off the right-hand engine ___________________________________________________ 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 ____________________________________________________________________ 2-158

Traveling - Safety Instructions _____________________________________________________ 2-158
Before starting traveling _________________________________________________________ 2-159
Traveling – Basic Movements _____________________________________________________ 2-161
Counter-rotation turns / Turning on the spot __________________________________________ 2-164
Track Parking Brake – set/release _________________________________________________ 2-165
Traveling speed – adjust _________________________________________________________ 2-165
Traveling uphill and downhill on ramps and steep slopes ________________________________ 2-166
Traveling over long distances _____________________________________________________ 2-168
Traveling – Best Practices ________________________________________________________ 2-170
Traveling – Restricted Operation ___________________________________________________ 2-171
Maximum Machine Inclinations ____________________________________________________ 2-174

TRANSPORTING THE MACHINE ___________________________________________________ 2-175

Transport - Safety instructions ____________________________________________________ 2-175
Engine-off lowering of the attachment _______________________________________________ 2-176
After daily operation ____________________________________________________________ 2-177

ASSEMBLING ATTACHMENT - SAFETY INSTRUCTIONS _______________________________ 2-178

Safety line on boom_____________________________________________________________ 2-178
Main control valves – attach/remove the handrail ______________________________________ 2-179
Securing the machine ___________________________________________________________ 2-179

CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___________ 2-180

ON-BOARD CRANE (OPTIONAL) ___________________________________________________ 2-181

On-board crane - Monitoring, warning and control elements _____________________________ 2-181
On-board crane- Putting into operation ______________________________________________ 2-182
On-board crane - Drive unit _______________________________________________________ 2-182
On-Board crane – Blocking the boom in position of rest _________________________________ 2-183
On-board crane - Check _________________________________________________________ 2-183
Monitoring cameras – Function ____________________________________________________ 2-184

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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 Cat-
erpillar 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 __________________________________________________________ 3-28

Inspection plan – Oil (legend) ______________________________________________________ 3-29
Engine oil service interval table _____________________________________________________ 3-30
Refill Capacities - Oil _____________________________________________________________ 3-31
Refill Capacities – Other __________________________________________________________ 3-31

LUBRICANTS / CONSUMABLES ____________________________________________________ 3-32

Notes on the selection of oils and greases ____________________________________________ 3-32
I. Oils for combustion engines ____________________________________________________ 3-33
II. Fluids for hydraulic system ___________________________________________________ 3-34
III.a Oils for pump distribution gearboxes and travel gearboxes __________________________ 3-35
III.b Oils for swing gearboxes _____________________________________________________ 3-36
V. 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
Coolant for use on all combustion engines ____________________________________________ 3-39

SERVICING WORK _______________________________________________________________ 3-40

Hose line for oil and cooling liquid changes ___________________________________________ 3-40

ENGINE ________________________________________________________________________ 3-41

Engine - Safety instructions ________________________________________________________ 3-41
Walk-Around Inspection __________________________________________________________ 3-42
Belts - Inspect/Replace ___________________________________________________________ 3-43
Fuel Injector - Inspect/Adjust _______________________________________________________ 3-43
Engine Oil Sample – Obtain _______________________________________________________ 3-44
Engine Valve Lash – Check/Adjust __________________________________________________ 3-45
Water Pump - Inspect ____________________________________________________________ 3-45

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TABLE OF CONTENTS

Engine oil level – Check level / top up ________________________________________________ 3-46

Engine oil reservoir (if equipped) – Check oil level / top up ________________________________ 3-47
Engine oil - Change ______________________________________________________________ 3-48
Engine oil reservoir (if equipped) - Drain / Fill oil ________________________________________ 3-50
Engine oil reservoir (if equipped) – Replace oil filters ____________________________________ 3-52
Engine oil reservoir (if equipped) – Replace breather filters _______________________________ 3-52
Engine oil filter – Replace _________________________________________________________ 3-53
Engine crankcase breather – Clean _________________________________________________ 3-53
Cold-starting fluid (ether) - Replace the pressure vessel _________________________________ 3-54

COOLING SYSTEM _______________________________________________________________ 3-55

Temperature ___________________________________________________________________ 3-55
Cooling liquid radiators - Check / clean _______________________________________________ 3-56
Cooling liquid level - Check ________________________________________________________ 3-56
Cooling liquid – Top up ___________________________________________________________ 3-57
Cooling liquid - Change ___________________________________________________________ 3-59
Cooling liquid composition – Test ___________________________________________________ 3-60
Cooling System Supplemental Coolant Additive (SCA) – Add _____________________________ 3-61
Cooling System Water Temperature Regulator –Replace ________________________________ 3-62
Cooling System Coolant Sample (Level 1) – Obtain _____________________________________ 3-63
Cooling System Coolant Sample (Level 2) – Obtain _____________________________________ 3-63

AIR-INTAKE SYSTEM _____________________________________________________________ 3-64

Engine air pre cleaner - Inspect / clean _______________________________________________ 3-65
Primary air filter element - Inspect / replace ___________________________________________ 3-66
Secondary air filter element - Replace _______________________________________________ 3-67
Air-intake lines - Inspect __________________________________________________________ 3-67

FUEL SYSTEM __________________________________________________________________ 3-68

Fuel system - Safety instructions ___________________________________________________ 3-68
Fuel tank supply valve – Function ___________________________________________________ 3-68
Fuel System – Prime _____________________________________________________________ 3-68
Fuel filter – Replace _____________________________________________________________ 3-69
Fuel system – Vent ______________________________________________________________ 3-69
Breather filter fuel tanks - Replace __________________________________________________ 3-69
Fuel tanks – Clean ______________________________________________________________ 3-70
Water trap (option) - Clean / replace _________________________________________________ 3-72
Hoses and Clamps - Inspect/Replace ________________________________________________ 3-74

ELECTRICAL SYSTEM ____________________________________________________________ 3-77

Electrical system - Safety instructions ________________________________________________ 3-77
Alternator - Instructions ___________________________________________________________ 3-77
Electrical circuit diagrams _________________________________________________________ 3-77
Electrical system switch-cabinets ___________________________________________________ 3-77
Lamps and bulbs – Replace _______________________________________________________ 3-77
Xenon floodlight projector (optional) - Replace the lamp __________________________________ 3-78
Lighting systems in LED technology - Instructions ______________________________________ 3-80
Battery- Check the state of charge __________________________________________________ 3-81
Battery - Remove and install _______________________________________________________ 3-82
Battery charge inside the machine - Safety instructions __________________________________ 3-83
Switchgear cabinet filter – Clean ____________________________________________________ 3-84
CAN-Bus wiring connections – Inspect _______________________________________________ 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 _________________________________________________________ 3-111

Pump drive gearbox – Check oil level / Top up with oil __________________________________ 3-111
Pre-chambers – Check oil level / top up with oil _______________________________________ 3-112
Pump drive gearbox oil sample - Obtain _____________________________________________ 3-112
Pump drive gearbox – Change gearbox oil ___________________________________________ 3-113
Pre-chambers - Change gearbox oil ________________________________________________ 3-114
Pump drive gearbox breather valve - Replace ________________________________________ 3-114
Pre-chamber breather valve - Replace ______________________________________________ 3-115
Pump drive gearbox lube oil filters - Replace _________________________________________ 3-116

SWING GEARBOX ______________________________________________________________ 3-117

Swing gearbox oil sample - Obtain _________________________________________________ 3-117
Swing gearbox - Check oil level / Top up with oil ______________________________________ 3-117
Swing gearbox - Vent ___________________________________________________________ 3-117
Swing gearbox oil – Change ______________________________________________________ 3-118

TRAVEL GEARBOX (GEARBOX P/N 3683483) _______________________________________ 3-120

Travel gearbox - Check oil level / Top up with oil ______________________________________ 3-120
Travel gearbox - Change oil ______________________________________________________ 3-121
Travel gearbox breather filter – Replace _____________________________________________ 3-122
Travel gearbox oil sample – Obtain _________________________________________________ 3-122

TRAVEL GEARBOX (GEARBOX P/N 3683496) ________________________________________ 3-123

Travel gearbox - Check oil level / Top up with oil ______________________________________ 3-123
Travel gearbox oil sample – Obtain _________________________________________________ 3-124
Travel gearbox oil - Change ______________________________________________________ 3-125
Travel gearbox breather filter – Replace _____________________________________________ 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

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Travel gearbox oil – Change ______________________________________________________ 3-129

Travel gearbox breather filter – Replace _____________________________________________ 3-130

CRAWLER TRACKS _____________________________________________________________ 3-131

Undercarriage – Check for leaks and free movement ___________________________________ 3-131
Track roller - Lubricate __________________________________________________________ 3-132
Track tensioning system _________________________________________________________ 3-133
Pressure-accumulator inspection regulations _________________________________________ 3-134
Checking the gas charging pressure in the pressure accumulator _________________________ 3-134

SWING RING ___________________________________________________________________ 3-135

Swing ring – Instructions _________________________________________________________ 3-135
Bearing races _________________________________________________________________ 3-135
Swing ring grease filling – Check __________________________________________________ 3-136
Swing ring bolts – Check for tightness ______________________________________________ 3-136

CENTRAL LUBRICATING SYSTEM _________________________________________________ 3-137

Central lubrication system - Design _________________________________________________ 3-137
Central lubrication system - Function _______________________________________________ 3-138
Grease container – Fill up ________________________________________________________ 3-139
Grease container breather filter - Check / replace______________________________________ 3-139
Greasing pressure - Check _______________________________________________________ 3-140
Grease line - Unblock ___________________________________________________________ 3-140
Oil filter (hydraulic circuit grease pump) - Replace _____________________________________ 3-141
Grease filter (filling the grease container) - Check / replace ______________________________ 3-142
Grease filter (grease lines) - Check / replace _________________________________________ 3-143

OTHER MAINTENANCE WORK ____________________________________________________ 3-144

Engine – Clean ________________________________________________________________ 3-144
Travel Alarm – Test _____________________________________________________________ 3-144
Radiator – Clean _______________________________________________________________ 3-145
Aftercooler Core - Clean/Test _____________________________________________________ 3-146
Reservoirs for used grease at the A-frame - Empty ____________________________________ 3-146
Air conditioning filter – Clean ______________________________________________________ 3-147
Attachment - Check for cracks ____________________________________________________ 3-147
Clam cylinder chamber - Check for soiling ___________________________________________ 3-148
Window panes - Clean __________________________________________________________ 3-148
Mirror – Clean / adjust position ____________________________________________________ 3-149
Seat belt – Inspect______________________________________________________________ 3-150
Seat belt – Replace _____________________________________________________________ 3-150
Cameras – Check/Clean/Adjust (If equipped) _________________________________________ 3-151
Horn – Inspect / Replace _________________________________________________________ 3-152
Hydraulic ladder – pressure accumulator ____________________________________________ 3-153
Pressure-accumulator inspection regulations _________________________________________ 3-154
Pressure accumulator - Checking the gas charging pressure _____________________________ 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 _______ 3-157
Putting the hydraulic shovel out of operation__________________________________________ 3-157
Battery storage ________________________________________________________________ 3-157
Recommissioning ______________________________________________________________ 3-157

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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 _______________________________________ 4-16

Dismantling and removal instructions ________________________________________________ 4-16
Risk of deflagrations _____________________________________________________________ 4-16
Risk of fire _____________________________________________________________________ 4-16
Disposing of the machine without polluting the environment_______________________________ 4-17
Further hazardous substances _____________________________________________________ 4-17
Appropriate disposal of batteries ____________________________________________________ 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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Slew brake test screen ___________________________________________________________ 5-22

BCS III, interfaces _______________________________________________________________ 5-23
USB interface, data storage _______________________________________________________ 5-23
Saving data to a USB stick ________________________________________________________ 5-24
Saving data to a USB stick, continued _______________________________________________ 5-25
Saving data to a USB stick, continued _______________________________________________ 5-26
BCSIII, cleaning_________________________________________________________________ 5-27
BCSIII, disposal _________________________________________________________________ 5-27

TROUBLESHOOTING _____________________________________________________________ 5-28

Instructions on troubleshooting _____________________________________________________ 5-28
Layout of the fault table ___________________________________________________________ 5-28
Possible causes ________________________________________________________________ 5-28
Measures______________________________________________________________________ 5-28
Section _______________________________________________________________________ 5-28

FAULT TABLES __________________________________________________________________ 5-29

Combustion engine - Fault table ____________________________________________________ 5-29
Working hydraulics – Fault table ____________________________________________________ 5-30
Track drive – Fault table __________________________________________________________ 5-31
Swing mechnism – Fault table _____________________________________________________ 5-32
Central lubricating system – Fault table ______________________________________________ 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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INTRODUCTION

1 INTRODUCTION

Operation and Maintenance Manual Target group

Part 1 INTRODUCTION Operating personnel

+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.

Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.

Part 4 REPAIR WORK 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

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INTRODUCTION

1-2

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, transporta-
tion information, lubrication information, and mainte-
nance information. Some photographs or illustrations
in this publication show details or attachments that
can be different from your product. Guards and cov-
ers might have been removed for illustrative pur-
poses. 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 pre-
cautions. In addition, this section identifies the text
and locations of safety messages used on the prod-
uct. Read and understand the basic precautions
listed in the safety section before operating or per-
forming 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 gaug-
es, switches, controls, attachment controls, transpor-
tation, and towing information (if applicable). Photo-
graphs 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 tech-
niques develop as the operator gains knowledge of
the product and its capabilities.
Product Information
The product information section, if present, may pro-
vide specification data, product intended use, product
identification plate locations, and certification infor-
mation.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION
Maintenance
The maintenance section, if present, is a guide to
equipment care. Proper maintenance and repair are
essential to keep the equipment and systems operat-
ing correctly. As the owner, you are responsible for
the performance of the required maintenance listed in
the Owner Manual, Operation and Maintenance Man-
ual, 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 in-
tervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient serv-
icing schedules and approximate the indicated serv-
ice hour meter reading. Recommended service
should always be performed at the interval that oc-
curs first. Under extremely severe, dusty, or wet oper-
ating 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, reliabil-
ity, and applicable certifications. Contact your dealer
for further information.
1-3
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION

PREFACE
The Operation and Maintenance Manual does not
About this Operation and Mainte- contain work instructions for carrying out major re-
nance Manual pairs. Such work is willingly done for you by the
These Operation and Maintenance Manual are de- CGM HMS GmbH after-sales service.
signed to familiarize the operator with the machine
and its designated use.
The Operation and Maintenance Manual contain
important information on how to operate the ma-
chine safely, properly and with maximum efficiency. Further machine documentation
Observing these instructions helps to prevent haz- The documentation relating to the machine is listed
ardous situations, to reduce repair costs and down- according to scope, quantity and language in the
times and to increase the reliability and service life shipping note of the machine or in the covering letter
of the machine. if supplied separately. The Operation and Mainte-
The Operation and Maintenance Manual must be nance Manual, the spare-parts list and the „Service
supplemented by the respective national rules and Manuals“ are marked with the serial number of the
regulations for accident prevention and environmen- machine.
tal protection. The documentation supplied with your machine is
The Operation and Maintenance Manual must al- rather comprehensive. Therefore, it has been split
ways be available in the operator’s cab of the ma- up in several volumes:
chine. Volume 1: the present Operation and Mainte-
The Operation and Maintenance Manual must be nance Manual,
read and put into practice by any person in charge Volume 2: Parts Manual of the machine,
of carrying out work with or on the machine, such as Volume 3: electrical circuit diagram and key,
 operation, including setting-up, troubleshooting Volume 4: documentation of other components,
in the course of work, care, evacuation of pro-
Volume 5: Service Manual Volume 1
duction waste and disposal of fuels and con-
Volume 6: Service Manual Volume 2
sumables,
Depending on the size of your machine, the docu-
 maintenance (inspection, servicing, repair) and
mentation can also consist of more volumes.
/ or
If you cannot find the information you are looking for
 transport.
in the present Operation and Maintenance Manual
In addition to the Operation and Maintenance Man- please check also the other volumes of the docu-
ual and the mandatory rules and regulations for mentation.
accident prevention and environmental protection in
The „Service Manual“ Volume 1 also provides infor-
the user's country and at the place where the ma-
mation on how to assemble the machine, on func-
chine is to be used, the generally recognized tech-
tions of the hydraulic system, on hydraulic circuit
nical rules for safe and proper working must be ob-
diagrams etc.
served 1
On taking receipt of the consignment, please check
The Operation and Maintenance Manual are di-
that the documentation is complete and in the lan-
rected to the mining-machine specialist. They can-
guage requested by you.
not provide basic know-how. This can be acquired,
for example, in several days' instruction by a quali-
fied CGM HMS GmbH (Caterpillar Global Mining
Hydraulic Mining Shovels GmbH) mechanic or by
attending an CGM HMS GmbH training course for
operators or maintenance personnel.
The CGM HMS GmbH after-sales service will be
pleased to deal with any queries you may have after
reading through the Operation and Maintenance
Manual.

1
Complies with VDMA recommendation "Operation and Mainte-
nance Manual"

1-4

WARRANTY
The warranty of CGM HMS GmbH presupposes
among other things that the servicing works as de-
scribed in the Operation and Maintenance Manual
have been performed:
 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION
Do not operate the machine
 when components / assemblies are defective
or missing,
 if one or several of such components of
which more than one are installed in the ma-
chine have been removed.
In cases of doubt seek advice from the CGM
HMS GmbH Service.
CGM HMS GmbH refuses to assume the guaran-
tee 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 back-
hoe 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 forc-
es 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 consequen-
tial damage to the track rollers, but also to other
components of the machine: chassis, travel gearbox
and crawler track.
1-5
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION

FUNDAMENTAL SAFETY IN- Declaration of Conformity

STRUCTIONS
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 oper-
ator and other persons from life-
threatening danger or injuries and to
prevent extensive damage.
Information and precautionary mea-
sures designed to prevent damage to
the machine or other property.
An EC or EU Declaration of Conformity document
was provided with the machine if it was manufac-
tured 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 Declara-
tion of Conformity provided with the machine.
The extract shown below from an EC or EU Decla-
ration of Conformity for machines that are declared
compliant to "2006/42/EC" applies only to those
machines originally "CE" marked by the manufac-
turer listed and which have not since been modified.
Content of the Original EC or EU Decla-
ration 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

1-6

Noise emission information
Noise emission data are specified in acc. with
ISO 6394.
Time-averaged A-weighted emission sound pres-
sure level at operator’s position with the machine
running at high idle: LAeq = XX dB.
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 Vibra-
tion 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).
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION
Visibility Information
Before you start the machine, perform a walk-
around 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 Mainte-
nance 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 follow-
ing:
 Safety instructions
 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.
1-7
 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 opera-
tor is seated. For restricted visibility areas, an ap-
propriate 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 indi-
cation of the areas at ground level inside a radius of
24 m (79 ft) from the operator of significant restrict-
ed visibility for machines with faceshovel and back-
hoe 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 indi-
cate areas of restricted visibility for distances out-
side of the shown radius.
The areas of restricted visibility shown in the illustra-
tions are with the track and work tool of the machine
in the “travel position”. Fig. 1-1:

This machine may be equipped with optional visibil- Fig. 1-1: shows the machine with faceshovel at-
ity aids that may provide visibility to some of the tachment. Top view of machine, ground level visibil-
restricted visibility areas. Refer to this Operation and ity without use of visual aids that are not standard in
Maintenance Manual, “Mirror – Clean/Adjust” for all markets.
more information on additional visibility. Note: The shaded areas indicate the approximate
If your machine is equipped with cameras, refer to location of areas with significant restricted visibility.
this Operation and Maintenance Manual, “Monitor-
ing 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 visibil-
ity. For more information regarding job site organiza-
tion refer to Operation and Maintenance Manual,
“Visibility Information”.
When equipped with optional visual aids, the ma-
chine visibility will meet the technical requirements
found in ISO5006:2006.

Fig. 1-2:

Fig. 1-2: shows the machine with backhoe attach-

ment. 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.

1-8

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 prop-
erty (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.
The machine must be used only in technically per-
fect 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,
 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 desig-
nated use also involves observing the instructions
set out in the Operation and Maintenance Manual
and complying with the inspection and maintenance
directives.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION
Using the hydraulic shovel or its at-
tachments for purposes other than or
extending beyond those stated above,
e.g.:
 for lifting or transporting persons,
 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 equip-
ment being approved for this pur-
pose,
 for moving material to the side
(sweeping),
 for breaking down rocks by beat-
ing with the shovel or the back-
hoe,
 for fitting or reparing of other ma-
chines
is contrary to its designated use and
considered as "unauthorized use".
Lifting eyes on the lower carriage
- are settled for transporting with a
crane only.
- must not be used for towing a ma-
chine.
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 designat-
ed use. The risk involved in such misuse lies with
the user.
1-9

ORGANIZATIONAL MEASURES
The Operation and Maintenance Manual must al-
ways 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 Man-
ual, observe and instruct the user in all other gener-
ally applicable legal and other mandatory regula-
tions 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 organi-
zational 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 begin-
ning work. Reading the Operation and Maintenance
Manual after work has begun is too late. This ap-
plies especially to persons working only occasionally
on the machine, e.g. during setting up or mainte-
nance.
Check - at least from time to time - whether the per-
sonnel 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.
1-10
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION
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 at-
tached to the machine.
See to it that safety instructions and warnings at-
tached 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 op-
eration, stop the machine immediately and report
the malfunction to the competent authority/person.
Never make any modifications, additions or conver-
sions 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 specifi-
cations of the machine.
Replace hydraulic hoses within stipulated and ap-
propriate 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 pro-
cedures.
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION

Selection and qualification of per- Start the machine from the operator's seat only.
During start-up and shut-down procedures always
sonnel; basic responsibilities watch the indicators in accordance with the Opera-
Any work on and with the machine must be execut- tion and Maintenance Manual.
ed by reliable personnel only. Statutory minimum Before setting the machine in motion, make sure
age limits must be observed. that nobody is at risk.
Employ only trained or instructed staff and set out Before starting work or traveling with the machine,
clearly the individual responsibilities of the person- check that braking, signalling and lighting systems
nel for operation, set-up, maintenance and repair. are fully functional.
Make sure that only authorized personnel works on Before setting the machine in motion always check
or with the machine. that the accessories have been safely stowed away.
Define the machine operator's responsibilities giving Shut the machine down until damaged or nonfunc-
the operator the authority to refuse instructions by tioning visibility aid(s) is repaired (if applicable) or
third parties that are contrary to safety. until appropriate job site organization is used to
Do not allow persons to be trained or instructed or minimize hazards that are caused by any resulting
persons taking part in a general training course to restricted visibility.
work on or with the machine without being perma- In conditions of poor visibility and after dark always
nently supervised by an experienced person. switch on the lighting system.
Work on the electrical system and equipment of the Persons accompanying the operator must be seated
machine must be carried out only by a skilled elec- on the passenger seat provided for this purpose.
trician or by instructed persons under the supervi-
When crossing underpasses and bridges or when
sion and guidance of a skilled electrician and in
passing under overhead lines always make sure
accordance with electrical engineering rules and
that there is sufficient clearance.
regulations.
Always keep a distance from the working face and
Work on chassis and brake systems must be per-
from slopes.
formed by skilled personnel only, which has been
specially trained for such work. Avoid any operation that might be a risk to machine
stability.
Work on hydraulic systems must be carried out only
by personnel with special knowledge and experi- Never travel across slopes; always keep the atach-
ence of hydraulic equipment. ment and the load close to the ground, especially
when traveling downhill.
On sloping terrain always adapt your traveling
Safety instructions governing speed to the prevailing ground conditions.
specific operational phases Before leaving the operator's seat always secure the
Standard operation machine against inadvertent movement and un-
authorized use. Shut off the engines.
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 ca-
pacity 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 safe-
ty-oriented devices, such as removable safety de-
vices, 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 chang-
es (incl. changes in the machine's working behav-
iour) to the competent organization/person immedi-
ately. If necessary, stop the machine immediately
and lock it.
In the event of malfunction, stop the machine imme-
diately and lock it. Have any defects rectified imme-
diately.

1-11

Special work in conjunction with
utilization of the machine and
maintenance and repairs as well
as troubleshooting during work;
disposal of parts and consuma-
bles
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 per-
son to supervise the activities.
In any work concerning the operation, conversion or
adjustment of the machine and its safety-oriented de-
vices 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 se-
cured.
If the machine is completely shut down for mainte-
nance 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 ma-
chine is positioned on stable and level ground and has
been secured against inadvertent movements.
1-12
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION
To avoid the risk of accidents, individual parts and
large assemblies being moved for replacement pur-
poses should be carefully attached to lifting tackle and
secured. Use only suitable and technically perfect lift-
ing 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 preserva-
tives 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 rea-
sons - must be protected against water, steam or de-
tergent penetration. Special care must be taken with
electric motors and switch-gear cabinets.
Ensure during cleaning of the machine that the tem-
perature 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 com-
partments 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 compart-
ments.
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 immedi-
ately 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
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 in-
spected and checked at regular intervals. Defects
such as loose connections or scorched cables must
be rectified immediately.
Always start and operate the engine in a well-vented
area;
If in an enclosed area, vent the exhaust to the out-
side;
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 ad-
equately 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 au-
thorized, as there may be a risk of explosion and
fire.
Before carrying out welding, flame-cutting and grind-
ing operations, clean the machine and its surround-
ings from dust and other inflammable substances
and make sure that the premises are adequately
ventilated (risk of explosion).

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 ac-
cessories contain lead and lead compounds, chemi-
cals known to cause cancer and reproductive harm.
Wash hands after handling.

Electrical Storm Injury Prevention

When lightning is striking in the vicinity of the ma-
chine, the operator should never attempt the follow-
ing procedures:
 Mount the machine.
 Dismount the machine.
If you are in the operator's station during an electri-
cal 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.

1-13

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 accord-
ance with the specific instructions for the unit con-
cerned before carrying out any repair work.
Hydraulic lines must be laid and fitted properly. En-
sure that no connections are interchanged. The
fittings, lengths and quality of the hoses must com-
ply 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 sub-
stances
When handling oil, grease or other chemical sub-
stances, observe the product-related safety regula-
tions (see safety specifications).
Be careful when handling hot consumables (risk of
burning or scalding).
1-14
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION
Ether
The machine can be equipped with pressure ves-
sels for cold-starting fluid (ether) installed in the
engine compartment. Ether is toxic and highly flam-
mable; the vessels are under pressure. These pres-
sure vessels can explode if exposed to high tem-
peratures (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 ves-
sels (ether). Have the vessels disposed of properly.
For further details please refer to the instructions
and safety data-sheets of the manufacturer / suppli-
er 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 Place suitable fire guardings (fire barriers) if open
fire or flying sparks cannot be avoided during repair
Prior to commencing work, obtain work.
informationon the national and corpo- Apply special protection to cables, cable ducts as
rate rules for the prevention of acci- well as to hose and pipe lines.
dents and avoiding fires. If necessary, also cover the ground with fire-
Pay particular attention to hazards protective blankets.
caused by combustible and easily The engine compartment can be equipped with
flammable substances. pressure vessels containing cold-starting fluid
Obtain information on the safe han- (ether). Ether is toxic and highly flammable; the
dling of the fire extinguishers to be vessels are under pressure. These pressure vessels
used. 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
Avoid smoking and open fire on, next to and below to work in or close to the engine compartment.
the hydraulic shovel.
Ensure sufficient ventilation.
Combustible and easily flammable substances or
Clean the hydraulic shovel before starting a job.
liquids increase the fire and explosion hazard.
Do not keep any fire extinguishers that are not suit-
Do not store or transport flammable substances on
able or have not been tested.
the hydraulic shovel during the work. This is also
valid for pressure vessels containing flammable Do not extinguish flammable liquids with water. Use:
substances as, for instance, spray oil or cold-  dry-powder,
starting fluid (ether). They are heat-sensitive and  carbon-dioxide or
can explode even if exposed only to intensive sun-
light.  foam extinguishing compounds.
Clean the hydraulic shovel carefully, if oil, grease,
When getting into contact with burning substances,
fuel, detergents or cold-starting fluid have been spilt
the fire-fighting water would abruptly evaporate and
over the machine. If possible, use a steam-jet
distribute the substance such as oil over a wide
cleaner for cleaning.
area. Water causes short-circuits in the electrical
These substance can also ignite themselves if they system thus possibly entailing new hazards.
come close to hot units or objects as, for instance, a
Call the fire brigade.
turbocharger.
Have all your welding, flame cutting and grinding
Even battery gases can ignite in open flames or fire.
work approved.
Avoid parking the hydraulic shovel in places where
 combustible substances such as coal dust or tar
are present.
 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.

1-15
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INTRODUCTION

NOTES

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1-2
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

2 OPERATION

Operation and Maintenance Manual Target group

Part 1 INTRODUCTION Operating personnel

+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the
application of this or comparable machines.

Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.

Part 4 REPAIR WORK 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

2-1
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

2-2

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 opera-
tion.
Wear closely fitting working clothing when
operating the machine. Loose, wide garments may
result in control levers being inadvertently
activated.
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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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.
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 imme-
diately.
2-3

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.
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.
2-4
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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 proce-
dures that are located in this Operation and
Maintenance Manual.
Shut the machine down until damaged or nonfunc-
tioning 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 nonfunc-
tioning 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:).
Fig. 2-2:

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 cold-
starting 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.
 open or smouldering fire may occur.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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 fire-
protective 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.
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
Backhoe bucket attachment
22 – Swing pump
63 - Stick
23 – Servo system pump
65 - Boom cylinder
24 – Gearbox oil circulating pump
66 - Stick cylinder
25 – Filling pump (swing circuit)
69 - Monoblock boom
26 – Fan drive pump (engine radiator)
70 - Backhoe bucket
27 – Pump for fan drive and hydraulic oil cooling
71 - Backhoe cylinder
28 – Air conditioner (inside cab)
72 - Toggle link
29 – Swing gear
73 - Toggle lever
30 – Travel block and rotor
74 - Control valves
31 – Operator's cab
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

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 per-
formed hydraulically. The movements are con-
trolled 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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 po-
sition of hand levers and pedals.
As soon as movement is detected, the corres-
ponding 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 electro-
hydraulic valves which control the execution of the
working movements.

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"
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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 sec-
tion. Become familiarized with all safety messages.
Make sure that all of the safety messages are legi-
ble.
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 messag-
es.
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 or-
dering 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 messag-
es on the hydraulic shovel. Depending on the na-
tional 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) – Descrip-

tion
In this section you can find a description of all safe-
ty 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 Mainte-
nance Manual. Failure to follow the instructions
or heed the warnings could result in injury or
death. Contact any Caterpillar dealer for re-
placement manuals. Proper care is your re-
sponsibility.

Fig. 2-10:

Hot Fluid Under Pressure (4)

This safety message is located on the cooling sys-
tem 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
Fig. 2-11:
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 con-
nections 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 struc-
ture 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 struc-
ture 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 light-
ing burners. Could cause serious injury or
death. Read Operation and Maintenance Manu-
al.
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 struc-
ture 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 struc-
ture 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 in-
formation.
Fig. 2-17:

Hot Surface (11)

This safety message is located in two locations.
This safety message is located on the upper struc-
ture 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 com-
partments can be hot while engines are run-
ning 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 equip-
Fig. 2-18: ment to protect your skin. Wait until hot com-
ponents 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 start-
ing work.
Read Operation and Maintenance Manual.

Refer to Operation and Maintenance Manual,

Fig. 2-19: “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 counter-
weight. In case these gases were ignited, def-
lagrations may occur which could cause seri-
ous injury or death.
Any work on the counterweight such like weld-
ing, flame cutting, grinding, drilling, milling is
prohibited.
Read Operation and Maintenance Manual.

Refer to Operation and Maintenance Manual,

“Welding on the counterweight” for further infor-
mation.

Fig. 2-21:

2-20
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Additional messages (ISO) – De-

scription

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 Prohibit-

ed (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.

Refer to Operation and Maintenance Manual,

Fig. 2-26:
“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 res-
ervoir near the inspection glass.
Refer to Operation and Maintenance Manual, “Hy-
draulic 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 mes-
sage 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 col-
umn,
 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 infor-
mation.

Alternate exit (33)

This message is located in the cab on the left, slid-
able window pane.

Refer to Operation and Maintenance Manual, “Al-

ternate 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 ma-
chine 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 back-
hoe 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) – De-

scription
In this section you can find a description of all safe-
ty 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.
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 Mainte-
nance Manual. Failure to follow the instructions
or heed the warnings could result in injury or
death. Contact any Caterpillar dealer for re-
placement manuals. Proper care is your re-
Fig. 2-44:
sponsibility.

Hot Fluid Under Pressure (16)

This safety message is located on the cooling sys-
tem 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
Fig. 2-45: 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)

This safety message is positioned on the battery
Fig. 2-46: cabinet.
CAUTION
Explosion hazard. Battery gases can cause
explosions. Could cause serious injury or
death. Do not smoke. No open flames.

Crushing Hazard (2)

This safety message is located on all four corners
of the machine.
DANGER
Machine swings. Crushing hazard could cause
Fig. 2-47: serious injury or death.
Stay back.

2-32
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Falling Hazard (23)

This safety message is located on the upper struc-
ture 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 struc-
ture 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 struc-
ture 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 struc-
ture 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.

Refer to Operation and Maintenance Manual,

“Fundamental Safety Instructions” for further in-
Fig. 2-51: formation.

2-33
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Hot Surface (6)

This safety message is located in two locations.
This safety message is located on the upper struc-
ture 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 com-
partments can be hot while engines are run-
ning or immediately after engine shutdown. Hot
parts or hot components can cause burns or
serious injury. Do not allow these parts to con-
Fig. 2-52:
tact your skin, when engines are running or
immediately after engine shutdown. Use pro-
tective clothing or protective equipment to pro-
tect 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.

Refer to Operation and Maintenance Manual,

Fig. 2-53: “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 inju-
ry. Stay back and wear a hard hat.

Fig. 2-56:
Injury hazard, Personal Protec-
tion 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 man-
datory beyond this place.

WARNING
Serious injury can result from failure to use
personal protective equipment. Wear appropri-
ate personal protective equipment required for
Fig. 2-57: 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 ma-
chine 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 elec-
tric welding work is performed near to them.

Refer to Operation and Maintenance Manual,

“Welding and flame cutting works - Safety Instruc-
tions” for further information.

Fig. 2-61:

Notes on cleaning electric as-

semblies (12)
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,
Fig. 2-62:
 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.

2-36
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Emergency exit (19)

This message is located in the cab on the left, slid-
able 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 extin-
guishers.

Fig. 2-64:

Hydraulic fluid level (30 and 32)

This message is located at the hydraulic fluid res-
ervoir near the inspection glass.
Refer to Operation and Maintenance Manual, “Hy-
draulic 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 back-
hoe 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 The serial number plate (arrow, Fig. 2-71:) for the
(Fig. 2-70:) is attached to the front side of the A- diesel engines are located on the diesel engines.
frame (arrow, Fig. 2-69:).

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 Access ladder - Lighting

- Safety instructions
Clean off oil, grease, soil, mud, snow,
ice and other substances from foot-
wear, 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.
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-ad-
justed 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 Lowering the swinging ladder from the upper
Raising resp. lowering the swinging ladder (Fig. structure (for leaving the machine)
2-76:).  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)
Fig. 2-78:
upwards to position “ I “ and hold.
The swinging ladder is raised (Fig. 2-78:).
 Leave the lever on the control valve in position Lowering the swinging ladder from the ground
“ I ” while operating the machine. (in case of emergency)
This keeps the hydraulic ladder in the upper  Pull down rope (3, Fig. 2-79:).
position (Fully retracted). 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) – Lowering the folding ladder from the upper
structure (for leaving the machine)
Function
 Start an engine.
Raising resp. lowering the folding ladder (Fig.
2-80:).  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.
Fig. 2-82:
 Pull lever (1, Fig. 2-81:) on control valve (2)
upwards to position “ I “ and hold. Lowering the folding ladder from the ground (in
case of emergency)
The folding ladder is raised (Fig. 2-77:).
 Pull down rope (3, Fig. 2-83:).
 Leave the lever on the control valve in position
The folding ladder is lowered (Fig. 2-80:).
“ I ” while operating the machine.
This keeps the hydraulic ladder in the upper
position (Fully retracted).

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 Emergency shut off switch in the

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

 by pressing the switch (red) on the drive

regulators on the right-hand and on the left-
hand 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 Emergency shut off switch at the
case, all engines are shut off and all valves are de- engine compartments
energized 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 Fig. 2-94:
of the switches is depressed and secured with a Emergency shut off switch on the
padlock. Any inadvertent starting of the engine is
thus prevented. control cabinet engine module

(continued next page)

Fig. 2-95:

2-46

Emergency shut off switches
(continued)
Emergency shut off pull switch
between left fuel tank and
counterweight
Fig. 2-96:
Emergency shut off switch on the
Servicestation (tanklift)
Fig. 2-97:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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. 2-98:
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 sys-
tem 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
Fig. 2-100:
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.

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. Fig. 2-101:

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. 2-102:

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OPERATION

Operator’s seat Never adjust the seat while driving.

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

Fig. 2-104:

2-50
 EM024061-1
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OPERATION

Reducing operators exposure to Windscreen washer

vibrations The fluid reservoir (1, Fig. 2-106:) of the
Vibrations, oscillations and movements of the ma- windscreen washer is located in the cab module.
chine cannot be avoided when the machine is in The capacity of the reservoir is indicated under
operation. They also have an effect on the ope- "Refilling quantities - Other".
rator.
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 ad-
justment 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 adjust-
ments are functional. If this is not possible, have the
seat checked and repaired as soon as possible.
Fig. 2-106:

Trainer's / instructor's seat

For operator training / instructing purposes it is
often required that a trainer / instructor Operating hours meter (if
accompanies the operator in the cab. equipped)
For the safety of the trainer / instructor during Three operating hours meters (Fig. 2-107:) are
hydraulic shovel operation the cab is equipped with located in the left front door of the “24 Volts
a second seat. This seat is installed behind the switchgear cabinet” in the cab module.
operator's seat (Fig. 2-105:).
 Sit down on this seat and do not forget to
1 LH engine hours meter
fasten the seat-belt, if installed (arrow, Fig.
2-105:). 2 RH engine hours meter
3 Travel hours meter
 Do not leave this seat during the training /
instruction session and /or as long as the
machine is in operation.

Fig. 2-107:

Fig. 2-105:

2-51

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 mainte-
nance 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 quali-
fied instructor.
Have the extinguishers inspected at regular inter-
vals by an expert. This is required by local authori-
ties and insurance companies and is in the interest
of your own safety.
2-52
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Automatic fire-extinguishing
system
Please contact your local Cat dealer for more de-
tailed 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 mainte-
nance 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 automat-
ically 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
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OPERATION

(Fig. 2-109:)
BCS, Board-Control-System
No. Element Function Symbol
BCS Electronic system Board Control System, acquisition and
1
for measured data display of important operating data of the
acquisition and hydraulic shovel
processing
The surface of the monitor is sensitive to the
touch (touch-screen technology). A touch-
screen 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”.
Monitor BCS The monitor displays collected operating
2
data, warning messages and – if needed –
instruction for help.
Push-button Navigation in menus Control of cursor movements, program
3
selection within the BCS, confirmation of
inputs / displayed values (Enter), quitting of
menus / sub-menus
Push-button Numeric keypad Input of numeric values.
4

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OPERATION

Fig. 2-110

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 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 “Board-
Control-System”).
No. Element Function Symbol
Status line Indicates activated functions and operating
1
hours.
The symbols displayed are those of the
switches in the control column
Touch-screen BCS Indicates collected operating data graphically
2
Monitor and / or numerically, displays warning
messages, fault messages and – if needed –
instructions for help.
Pushbutton Navigation Control of cursor movements, program
3
in menus selection within the BCS, confirmation of
inputs / displayed values (Enter), quitting of
menus / sub-menus
Push-button Numeric keypad Input of numeric values.
4
Touch-screen Examples
5
buttons
Status line Fault messages Displays fault messages as a code number
6
and as plain text. The "Fault" button permits
displaying further fault messages stored in
the system.

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OPERATION

Fig. 2-111:

2-58
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

(Fig. 2-111:)

No. Element Function Symbol

Key-switch Switches the electrical system on and off.
32
Buzzer (inside the Gives three acoustic warning signals if a
33
control column) fault is reported. The signals appear every
30 seconds.
Socket Connection of electronic devices for fault
34
connectors diagnosis purposes.
Switch Emergency De-energizes the outputs of the electronic
35
shut-off control units:
The engines are shut off, all valves are de-
energized, working movements no longer
possible.
(see: "Emergency shut-off function").

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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. Element Function Symbol
Push-button Start Starting of the engine. For starting, press the
41
push-button face with the symbol.
Push-button Stop Stopping of the engine. For stopping, press
42
the push-button face with the symbol.
Push-button Idle Stopping of the engine with an after-run
43
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
44
low.
Warning lamp Alternator Lit up when the batteries are not being
45
charged or in the event of an alternator
defect.
Warning lamp Engine oil Lit up when the engine oil temperature is too
46
temperature high.
Warning lamp Cooling liquid Lit up when the engine cooling liquid
47
temperature temperature is too high.
Switch Engine speed Press switch face without symbol:
48
the speed of the engine increases.
Press the switch face with the symbol:
the speed of the engine reduces.
Warning lamp Engine monitoring STOP!
49
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.
Warning lamp Engine monitoring Not used on this machine.
50

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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
Push-button Start Starting of the engine. For starting, press the
51
push-button face with the symbol.

Push-button Stop Stopping of the engine. For stopping, press

52
the push-button face with the symbol.

Push-button Idle Stopping of the engine with an after-run

53
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
54
low.

Warning lamp Alternator Lit up when the batteries are not being
55
charged or in the event of an alternator
defect.
Warning lamp Engine oil Lit up when the engine oil temperature is too
56
temperature high.

Warning lamp Cooling liquid Lit up when the engine cooling liquid
57
temperature temperature is too high.

Switch Engine speed Press switch face without symbol:

58
the speed of the engine increases.
Press the switch face with the symbol:
the speed of the engine reduces.
Warning lamp Engine monitoring STOP!
59
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.
Warning lamp Engine monitoring Not used on this machine.
60

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OPERATION

Fig. 2-114:

2-64
 EM024061-1
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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. Element Function Symbol

Push-button Upper structure Blocks the upper structure.

61
holding brake

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.

62 Not connected.
Switch Hydraulic shovel Not actuated:
63
parking brake 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.
Push-button Central greasing Reset function of the central greasing system
64
system reset 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.
Push-button Emergency Lowering of the attachment in an emergency
65
lowering situation. For instance, if the engines have
failed.
For more information refer to chapter
“Engine-off lowering of the attachment”.
Switch Automatic speed Reduces the speed of the diesel engines to
66
reduction about 1000 min-1, if no working movement is
being executed during about 8 seconds.

2-65
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OPERATION

Fig. 2-115:

2-66
 EM024061-1
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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. Element Function Symbol
Switch Servo-control Press the switch face with the symbol:
71
The electro-hydraulic servo-control is
enabled.
Switch Traveling speed Not actuated:
72
1st traveling stage
traveling forwards / backwards is possible.
Press the switch face with the symbol:
2nd traveling stage
traveling forwards / backwards is possible.
73 Not connected.
Monitoring lamps Engine oil interval Lamp is lit up, when the right or the left pump
74
prolongation of the prolongation system is running.

75 Not connected.
Push-button When the machine Press the switch face with the symbol:
76
has to be The machine can be driven and the upper
manoeuvered out of structure be swung although these functions
dangerous are automatically deactivated.
situations
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.
Switch Floodlamps Switches the floodlamps on the operator´s
81
cab on and off.
Switch Floodlamps Switches the floodlamps on the hydraulic oil
82
cooler module on and off.
Switch Floodlamps Switches the floodlamps on the cab module
83
on and off.
Switch Floodlamps Switches the floodlamps on the boomon and
84
off.
Switch Floodlamps rear Switches the floodlamps on the
85
counterweight on and off.
Switch Not connected.
86

2-67
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OPERATION

Fig. 2-116:

2-68
 EM024061-1
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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 Symbol

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.
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 Press the switch face with the symbol:
(option) 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
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OPERATION

Fig. 2-117:

2-70
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

(Fig. 2-117:)
No. Element Function Symbol
101 Push-button (Free for options) Can be used as a push-to-speak button on a
radio, or to switch over from one camera to
another one.
102 Push-button Stick floating Button is pressed:
position (shovel The stick cylinders are pressurized on
equipment only) retracting.
Press button (102) only in
position "0" of control lever
(115).
103 Push-button Boom floating Button is pressed:
position The boom cylinders are pressurized on
retracting.
Press button (103) only in
position "0" of control lever
(116).
104 Push-button Warning signal Button is pressed:
Acoustic warning signal / horn is activated.
105 Push-button Electronic hydraulic Button in the seat.
inside the seat shovel control The electronic hydraulic shovel control
(servo-control) (servo-control) is activated when the
operators sits down on the seat.
The electronic hydraulic shovel control
(servo-control) is deactivated when he
leaves the seat.
111 Pedal Shovel trap (shovel Forwards – shovel trap is opened;
equipment only) Backwards – shovel trap is closed.
112 Pedal Travel, left track Forwards – forward travel;
Backwards – backward travel.
113 Pedal Travel, right track Forwards – forward travel;
Backwards – backward travel.
114 Footrest
115 Control lever Forwards – raising the stick
Backwards – lowering the stick.
To the left / right –
swinging and braking of the upper structure.
116 Control lever Forwards – lowering the boom;
Backwards – raising the boom.
To the left – backwards tipping of shovel /
bucket;
To the right – dumping of shovel / bucket.
117 Push-button Not used on this machine.
118 Thumb wheel Shovel trap (shovel Turn Forwards – shovel trap is opened;
equipment only) Turn Backwards – shovel trap is closed.
Function can be overridden by Pedal 111.
(Thumb wheel is spring centered).
119 Push-button By-pass for the Lower half pushed – automatically stopped
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)).
120 Thumb wheel 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 Function Symbol

121 Monitoring device Engine monitoring Indicates different parameters on the display
(engine 1 left) (E)
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 Indicates the cooling-water temperature.

(engine 1 left)

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

124 Warning device Engine monitoring Gives an acoustic warning signal if a fault is
(engine 1 left) 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.
125 Indicator lamp Idle Lits up when engine is in idle phase.
(engine 1 left)

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

127 Warning lamp Alternator Lits up when the batteries are not recharged.
(engine 1 left)

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 Function Symbol

131 Monitoring device Engine monitoring Indicates different parameters on the display
(engine 2 right) (E)
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 Indicates the cooling-water temperature.

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

134 Warning device Engine monitoring Gives an acoustic warning signal if a fault is
(engine 2 right) 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.
135 Indicator lamp Idle Lits up when engine is in idle phase.
(engine 2 right)

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

137 Warning lamp Alternator Lits up when the batteries are not recharged.
(engine 2 right)

2-75
 EM024061-1
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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. Element Funksjon Symbol

Switch Auxiliary heating Auxiliary heating for operator's cab ON /

140
(option) OFF.
Switch Auxiliary heating Blower levels 1,2,3.
141
blower (option)
Switch Auxiliary heating Auxiliary heating for operator's cab ON /
142
(option) OFF. Automatic regulation.

Switch Fuel Pre-heating Switches the fuel pre-heating function of RH

143
(option) engine on and off.

Switch Fuel Pre-heating Switches the fuel pre-heating function of LH

144
(option) engine on and off.

2-77
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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. Element Function Symbol

Rotary switch Blower of air Blower levels 1,2,3.

150
conditioner
Knob Thermostat Presetting of desired temperature.
151
Rotary switch Selector Selects the following functions:
152
heating, cooling, ventilation, defrosting.

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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).

No. Element Function Symbol

Underpressure Air filters (left Indicates the underpressure in the air filters.
191
gauge engine 1, outside) Underpressure must be less than 25 inches
(635 mm) water column.
Otherwise clean / replace the filterelement.
Underpressure Air filters (left Indicates the underpressure in the air filters.
192
gauge engine 1, inside) Underpressure must be less than 25 inches
(635 mm) water column.
Otherwise clean / replace the filterelement.
Underpressure Air filters (right Indicates the underpressure in the air filters.
193
gauge engine 2, outside) Underpressure must be less than 25 inches
(635 mm) water column.
Otherwise clean / replace the filterelement.
Underpressure Air filters (right Indicates the underpressure in the air filters.
194
gauge engine 2, inside) Underpressure must be less than 25 inches
(635 mm) water column.
Otherwise clean / replace the filterelement.

2-81

PUTTING THE MACHINE INTO
OPERATION
Before daily start-up, carry out works in
accordance with servicing plan T (see: Part 3
"Inspection and servicing")
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 ma-
chine, the operator should never attempt the fol-
lowing procedures:
 Mount the machine.
 Dismount the machine.
If you are in the operator's station during an elec-
trical 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Reducing the operator's exposure
to noise
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,
 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 Back-up heating (option) - Fill in

Refuelling - Safety instructions
Explosion hazard. Risk of fire.
Fuels and fuel gases are inflammable.
Avoid open flames and stop smoking.
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 Fig. 2-123:
regularly for proper fastening.
Grounding straps can remove
voltages and prevent fire during
refuelling only when properly
fastened.

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, “Caterpil-
lar Commercial Diesel Engine Fluids Recommen-
dations” 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 Cater-
pillar warranty.

2-83
 EM024061-1
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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). Refilling and draining
Note: For filling in or for draining consumables / fluids,
Connections used may vary depending on how the unscrew the cap of the corresponding express
machine is equipped. coupling (Fig. 2-126:).
Attach express coupling of filling hose from the
Pos. Consumable Express service vehicle to the corresponding express
Fig. coupling for coupling at the service station. Fill in or drain off
2-126: consumable / fluid.
1 Diesel fuel for Filling Take off filling hose and refit cap on the express
lefthand and coupling.
righthand fuel tank
2 Cooling fluid for Filling and/or
lefthand engine draining
3 Cooling fluid for Filling and/or
righthand engine draining
4 Gearbox oil for left Filling and/or Emergency off switch
pump drive gearbox draining
The control box at the service station is equipped
5 Gearbox oil for right Filling and/or with an emergency off switch (arrow, Fig. 2-127:).
pump drive gearbox draining
In case of emergency press the button. The
6 Tank for engine oil Filling and/or
electrical system is switched off.
interval prolongation draining
lefthand engine.
7 Tank for engine oil Filling and/or
interval prolongation draining
lefthand engine.
8 Engine oil for Filling and/or
lefthand engine draining
9 Engine oil for Filling and/or
righthand engine draining
10 Hydraulic oil tank Filling and/or
draining
11 Grease container Filling
12 Swing gear Filling
13-15 Not used

Fig. 2-127:

Fig. 2-126:

2-85
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Assemblies resp. Measuring device Remarks

reservoirs
Fuel tank BCS fuel indicator (Fig. Switch on the monitoring system by using toggle switch
2-128:) (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:
Fig. 2-128:

2-86
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Assemblies resp. Measuring device Remarks

reservoirs
Pump drive Dipstick (1, Fig. 2-130:) Fill in gear oil using express couplings (4 and 5, Fig.
gearboxes 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").
Engines Dipstick (1, Fig. 2-132:) 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.
Engine oil tank Monitoring lamps (1 and 2, Fill in engine oil using express couplings (6 and 7, Fig.
(option) Fig. 2-133:) 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:

2-87
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Assemblies resp. Measuring device Remarks

reservoirs
Hydraulic oil tank Inspection glass (1, Fig.
2-134:), sign (2. Fig. 2-134:
and Fig. 2-135:)
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").

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

Fig. 2-135:

2-88
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Assemblies resp. Measuring device Remarks

reservoirs
Cooling system Level indicator (4, Fig. Fill in cooling fluid using express couplings (2 and/or 3,
reservoir 2-137:) Fig. 2-139:). Stop filling when the level indicator
indicates maximum filling level. (see chapter "Cooling
liquid level - Check").
Grease container – BCS display (Fig. 2-138:) BCS gives a warning if the grease container is nearly
cental lubricating empty.
system 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.

Fig. 2-137: Fig. 2-139:

Fig. 2-140:
Fig. 2-138:

2-89

Electrical system – Switch on and
off
The electrical system is switched on with key-
switch (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").
Fig. 2-141:
2-90
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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:
 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 hy-
draulic oil, function
The preheating system consists of heating ele-
ments for engine oil, engine coolant and hydraulic
oil.
At low outside temperatures, the system facilitates
starting of the engine and ensures that the hy-
draulic system reaches its operating temperature
faster.
The preheating system is operated electrically with
an external supply voltage. This voltage is avail-
able at a socket outlet at the service-station (fast
fill arm) (Fig. 2-143:).
(The system has been set at the factory for a stan-
dard 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 hy-
draulic 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 sup-
ply only if the insulation of the com-
ponents is in perfect condition.
Observe the national safety regula- Fig. 2-143:
tions to be applied in the presence of
electric current.

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 en-
suring an automatic temperature regulation.
Switch on the fuel preheating only
after preheating of the engine and of Fig. 2-145:
the hydraulic oil is terminated (see
"Preheating system for engine and hy-
draulic oil (if equipped)").
The preheating time is dependent on
the outside temperature.

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 en-
gine, Fig. 2-146:
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
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

ENGINES - STARTING AND Starting the left-hand engine

STOPPING
Engines - Start
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
Fig. 2-147:
main switch.
Check for persons on the machine. Do
not start engines until all persons Starting the right-hand engine
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.

 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 left-

hand 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 right-

Fig. 2-148:
hand engine. Release button (51) as soon as
the engine has fired.
Warning lamps (54 – 57) go out.

2-93

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.
Fig. 2-149:
2-94
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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
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 cold-
starting 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

Fig. 2-150:
engine. The left-hand engine is stopped.
Warning lamps (44 – 47) light up.

 Press button (52, Fig. 2-151:) for the right-

Shutting off the right-hand engine
hand engine. The right-hand engine is
stopped.
Warning lamps (54 – 57) light up.

 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:

2-95
 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 Function
1 Rotary switch selects the intensity level
of the blower (3 levels)
2 Thermostat sets the desired
temperature inside the cab Fig. 2-152:
3 Rotary switch selects the desired control
function (heating, cooling,
ventilation, defrosting)

Unit 2
Pos. Element Function
4 Rotary switch selects the intensity level
of the blower (3 levels)
5 Thermostat sets the desired
temperature inside the cab
6 Rotary switch selects the desired control
function (heating, cooling,
ventilation, defrosting)

Fig. 2-153:

2-96
 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:

2-97
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Back-up heating (optional) Control unit

The back-up heating is located in the module (Fig. 2-158:):
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:).
Do not switch on the back-up heating
when the air conditioner is set to
”cooling”.

Fig. 2-158:

Pos. Element Function

1 Indicator lamp heating ON

2 Indicator lamp blower ON

3 Indicator lamp heating

4 Indicator lamp cooling

5 Switch heating ON
Fig. 2-156:
6 Switch blower ON

7 Indicator lamp blower level 3

8 Indicator lamp blower level 2

9 Indicator lamp blower level 1

Fig. 2-157:

2-98
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

OPERATIONAL PRACTICES State of operator’s workplace

Working operation - Safety Inspect and fasten your seat belts.

Adjust the operator’s seat for comfortable reach all
instructions 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.
Personnel Clean off any earth, mud, snow, ice, grease and oil
Any work with the machine must be executed only adhering to your working footwear before operating
by reliable, skilled and well trained personnel in the machine. There is otherwise a risk of slipping
good healthy condition. Statutory minimum age off the pedals and initiating inadvertent
limits must be observed. movements.
Never operate the machine while impared with Clean and secure all windows and doors.
drugs or alcohol. Clean and adjust all mirrors for optimum vision.
Read the sections "Fundamental safety Start the engines only from the operator’s
instructions" and "Operation, safety instructions" in compartment.
this Operation and Maintenance Manual carefully Operate the machine only while sitting on the
and observe the instructions given in this sections. operator’s seat.
Observe all job site safety requirements.

State of the machine

State of the site Operate the machine only if all protective and
Inspect the site for underground gas, power and safety oriented devices, such as removable safety
water lines before starting work. Any damage to devices, emergency shut-off equipment, sound-
such lines is a risk to life! proofing elements and exhausters, are in place
and fully functional.
Clear all obstacles from the path of the machine.
Do not operate the machine,
Sound the horn to warn persons in the immediate
vicinity before starting work.  when several track rollers or upper rollers have
been removed;
Stop work if anyone is in the hazard range of the
machine. Make sure all persons have left the  when one or several swing gearboxes have
hazard range before resuming work. failed or been removed;
 when one or several teeth on the backhoe or
Machine stability on the shovel are worn or missing;
Never operate the machine unless it is standing on  when parts of the hardfacing layer on the
a reasonably horizontal, flat surface. The stability backhoe or on the shovel are worn or missing.
of the machine is otherwise at risk.
Working under these circumstances results in
When working or traveling on a slope is required, heavy wear and possibly in severe damage and
do not exceed the maximum machine inclination thus in high repair costs.
for working operation and for traveling (refer to
Such circumstances are considered by CGM HMS
Operation and Maintenance Manual section
as "abusive utilization".
“Maximum machine inclinations”).
CGM HMS refuses to assume the guarantee for
Ensure that the attachment has adequate
damage and consequential damage caused by an
clearance below overhead power lines and
abusive utilization of the machine.
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.

2-99

Before starting work
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.
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 ma-
chine 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 infor-
mation on special configurations of your machine.
2-100
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Warming up the hydraulic system
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”.
 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:

2-101

Working operation – basics
This section gives you basic information about the
functions of the joystick controls. For further de-
tailed information refer to section “Operation Tech-
niques” 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”.
2-102
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Working on level ground
CGM HMS recommends operating the machine on
level and stable ground. Doing so ensures maxi-
mum productivity and prevents machine compo-
nents 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 undercar-
riage 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 “Max-
imum machine inclinations”).
If the machine begins to sideslip on a slope, im-
mediately lower the attachment and the load to the
ground and turn the machine facing downhill.
Operate the machine slowly, accelerate and de-
celerate 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 hy-
draulic shovel with the attachment positioned uphill
or downhill, never sideways.
When traveling up and down a slope or when trav-
eling over rough terrain reduce travel speed mode
to slow (refer to Operation and Maintenance Man-
ual 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 over-
load the machine.
 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 Fig. 2-160:
structure, the joystick must be moved in the
direction opposite the swinging movement
(reversing).

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:

2-103
 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:

2-104
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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:

2-105
 EM024061-1
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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:

2-106
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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:

2-107
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OPERATION

OPERATION TECHNIQUES
Machine operation with backhoe attachment, Best Practices

Machine Stability When working with the attachment in a cross direc-

tion 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, “Re-
stricted Operation” for further detailed information.

Do not overfill / overload the bucket, the machine

may tip over.

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 sec-
Fig. 2-170: tion “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: If it is unavoidable to work on soft and yielding

ground, operate the machine at reduced bucket
The hydraulic shovel must always be operated in a
loads to avoid tipping of the machine.
way, that its stability is always ensured and the
danger of tipping over is avoided.
When working on high-density and coarse materi-
Machine stability is greater when the bucket is
al, operate the machine at reduced bucket loads to
parallel with the tracks (Fig. 2-170:).
avoid overloading and damaging components of
When working with the bucket parallel to the
the machine.
tracks, the final drives should be in the rear posi-
tion, for the following reasons:
Stand attachment down to the ground during
 The travel motors and final drives are protect- breaks in working operation.
ed from falling rocks etc.
 When the hydraulic shovel is operated on Do not operate the hydraulic shovel in water or in
muddy ground and the tracks are covered with mud deeper than the breather valves of the final
mud, the sprocket runs on a clean track when drives. Refer to section “Restricted Operation”.
backing up.

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OPERATION

Know the situation on site

To maximize productivity of the machine, it is im- Conditions favorable to hydraulic backhoes:

portant that the operator understand characteris- (Preferred option for overburden and softer materi-
tics of the material they are digging and how to al)
adjust their operating style accordingly.  Low to moderate bench heights (Refer to sec-
tion “Bench Heights – Recommendations for
Material penetrability: BH-machines”)
 Easily penetrable material:  Truck spotted either on top of bench or on the
All loose, free flowing material and all materials floor below the backhoe
which can be excavated without blasting.
 Tight load area
 Difficult to penetrate material:
Blasted or unblasted material containing large  Short swing – 60°
chunks, wet clayey soil and overburden.  Well-shot material

Material flow: Conditions unfavorable to hydraulic backhoes:

 Free flowing / loose.  High benches
 Sticky / in situ.  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 ma-
chine. 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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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 circum-
stances (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 BH-
machines, table”.

Fig. 2-176:

2-111
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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.
 Clear separation of loading and hauling
equipment.
Fig. 2-177:  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 load-
ing 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.
 15 – 20% higher productivity when trucks are
spotted on the floor below the excavator vs. on
top of bench.

Fig. 2-178:
 5% higher productivity when excavator swings
60º vs. 90º.
 Higher productivity when positioned as close to
edge as safely possible.

Fig. 2-179:

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OPERATION

Truck on lower level — drive-by loading (Fig.

2-180:):

Advantage:
 Truck spotting time is eliminated, for the high-
est productivity, because the next truck does
not need to reverse for positioning.

Disadvantages:
 More than 90° swing angle.
 Loading through the gate could be more diffi-
cult due to limited space for dumping.

Fig. 2-180: 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 Stick Truck body loading Recommended

Model length edge @ 4 to 5 pass bench height
match
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

2-113

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.
2-114
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OPERATION
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 attach-
ment.
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 effi-
cient performance.
 Loosen hard material and rocks with the buck-
et, not with the stick crowding thrust.
 Avoid digging with corner tooth to avoid tor-
sional forces into attachments.
 Avoid contacting mechanical stops and cylin-
ders end of stroke.
Refer to Operation and Maintenance Manual chap-
ter “Backhoe Operation - Restricted Operation” for
further details.
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Digging and loading a truck

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 al-
lows 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,
Fig. 2-182: decrease the down pressure as you move the
stick toward the cab.
 Maintain a bucket attitude that ensures a con-
tinuous 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 struc-
Fig. 2-183: ture back and begin the next loading cycle.

2-115

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 ac-
cordance with the following rules.
Fig. 2-184:
Fig. 2-185:
2-116
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Rules for “Double Benching”
Material:
Loose, well blasted and easy to dig material is
absolutely essential for Double Benching.
Boom down function should be used in float posi-
tion 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 dam-
ages.
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.
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 for-
ward (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 back-
wards (arrow, 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.
 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, sta-

ble, 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 sec-
tion “Backhoe Operation - Restricted Operation”.
Fig. 2-187:

2-117
 EM024061-1
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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:

2-118
 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 dur-

ing operation, excessive force will occur on the
inside of the cylinder (Fig. 2-192:).
This will reduce the life of the cylinder and struc-
tures.
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:

2-119
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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 oper-
ate 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 re-
lief valves protect the attachment from excessive
force.

Fig. 2-196:

2-120
 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 pen-
etrability 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 operation-
al/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 re-
ducing 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:

2-121
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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 ma-

chine to pry material in the bank or for excavation
(Fig. 2-201:).
Doing so may damage the machine and the at-
tachment.
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 posi-

tioned parallel with the tracks and over the front
idlers (Fig. 2-202:).

Fig. 2-202:

2-122
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OPERATION

Machine stability is reduced when the load is

swung to the side and when operating the attach-
ment 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 dam-
age the attachment or frame.

Fig. 2-204:

Do not propel the machine while the bucket is en-

gaged in the material (Fig. 2-205:).
This operation will potentially damage components
of the attachment.

Fig. 2-205:

2-123
 EM024061-1
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OPERATION

Do not allow the boom to hit the ground when ex-

cavating below grade (Fig. 2-206:).

Fig. 2-206:

Do not swing the machine while the bucket is en-

gaged 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 be-

tween 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,
 curling the bucket with rocks between stick and
bucket.

Fig. 2-208:

2-124
 EM024061-1
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OPERATION

Do not swing a load over a truck cab or over per-

sonnel (Fig. 2-209:).

Fig. 2-209:
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 down-
hill. 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
Fig. 2-210:
ascending steep slopes. If the hydraulic oil has not
warmed-up sufficiently, performance may be ef-
fected.

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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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 ma-
chine 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:

2-126
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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:

2-127
 EM024061-1
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OPERATION

When initiating material penetration with the buck-

et, 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:

2-128
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OPERATION

Machine operation with face shovel attachment - Best Practices

Machine stability
When working with the attachment in a cross direc-
tion 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, “Re-
stricted Operation” for further detailed information.

Do not overfill / overload the face shovel, the ma-

chine may tip over.

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 sec-
Fig. 2-221:
tion “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.

When working on soft ground or on high density

Fig. 2-222: material, operate the machine at reduced bucket
The hydraulic shovel must always be operated in a loads.
way, that its stability is always ensured and the
danger of tipping over is avoided. Stand attachment down to the ground during
Machine stability is greater when the bucket is breaks in working operation.
parallel with the tracks (Fig. 2-221:).
When working with the bucket parallel to the Do not operate the hydraulic shovel in water or in
tracks, the final drives should be in the rear posi- mud deeper than the breather valves of the final
tion, for the following reasons: drives. Refer to section “Restricted Operation”.
 The travel motors and final drives are protect-
ed 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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OPERATION

Know the situation on site

To maximize productivity of the machine, it is im-

portant that the operator understand characteris-
tics 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:).
 A flat slope with an angle ≤ approx. 60° and
free flowing, loose, blasted material (Fig.
2-224:).

Fig. 2-223:
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.

Fig. 2-224:

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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 reloca-
tion 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

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
Fig. 2-226:

(These are rules of thumb, they are a guide only,

values depend on the material conditions).

Fig. 2-227:

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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

Fig. 2-228: (This is a rule of thumb, a guide only, value de-

pends on the material conditions).

Fig. 2-229:

Bench Heights – Recommendations for FS - Machines, table

Flat Slope ≤ ~ 60°

Steep Slope > ~approx. 60°
Minimum Free flowing / loose
Sticky / in situ material
material
Tough digging Easy digging
Rule of thumb 75% of max.
Bucket Height Cab Roof Height Max. vertical reach
Model vertical reach
6015 FS ~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

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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.

Fig. 2-230:

 The 45° position towards the digging face al-

lows 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.

Fig. 2-231:

 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. 2-232:

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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, re-
sults in cleanup delays, dozer standby re-
quired, 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.
 Poor visibility of truck driver to the shovel
means difficult positioning.

Fig. 2-235:

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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.
 Good floor conditions that are easy to main-
tain.
 Support equipment can clean the excavated
area behind the shovel without interfering with
the loading action.
Fig. 2-236:
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 disad-
vantages 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.

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OPERATION

Digging and Loading

Digging
 Maintain a digging face which avoids any ma-
jor slides which could cause an accident.
 Always check the digging face for large boul-
ders, 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 shov-
el lip to contact the bank on each pass. A full
face cut combined with a deep bank penetra-
tion will result in a well filled shovel.
 Use the float function of the boom while pene-
trating the material.
 Always keep the shovel as close as possible to
the work area. Short boom trips - high efficien-
cy.
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 buck-
et, not with the stick crowding thrust.
 Do not swing the bucket into the material; pen-
Fig. 2-240: etrate only after swing is complete
 Never penetrate the material with an open
bucket.

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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 po-
tential rock fall and large and oversize materi-
al.

Fig. 2-242:

 For the 2nd and the subsequent passes (the

truck is in position) dig again from top to bot-
tom maintain smaller swing angles.
This minimizes truck loading time.

Fig. 2-243:

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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 cylin-
ders.

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:

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 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 At-

tachment

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 are difficult but possible (Fig.

Drop cuts 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 re-
duced service life of the components can be
expected.
Fig. 2-252: Drop cut = Digging down from current level to the
next level down, creating a ramp in the process.

2-140
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Handling Oversized Boulders / Over-

hangs

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 under-
cut. 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 Park the machine in a location that is smooth, sta-
ble, 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:).

Fig. 2-255:

2-142
 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 pos-
sible 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 dur-

ing operation, excessive force will occur on the
inside of the cylinder.
This will reduce the life of the cylinder and struc-
tures.
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 pen-
etrability 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 operation-
al/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 re-
ducing 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 cyl-
inder. 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
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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 be-

tween 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 ex-
cessive 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 re-

moving anchored rocks or other solid objects,
since such operations may result in severe dam-
age 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 ma-

chine to pry material in the bank or for excavation
(Fig. 2-281:).
Doing so may damage the machine and the at-
tachment.

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 piec-

es (Fig. 2-283:). Doing so could damage the at-
tachment.

Fig. 2-283:

Machine stability is reduced when the load is

swung to the side and when operating the attach-
ment 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 posi-

tioned 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 loos-

en 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 en-
gaged 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 en-

gaged in the material (Fig. 2-291:).
This operation will potentially damage components
of the attachment.

Fig. 2-291:

2-154
 EM024061-1
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OPERATION

Do not propel the machine longer than 5 minutes

with the propel motors to the front (Fig. 2-292:).

Fig. 2-292:
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 down-
hill. 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 neu-
tral.
Fig. 2-293: 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 ef-
fected.

Always ascend the slope at a 90 degree angle

(Fig. 2-294:).

Fig. 2-294:

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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 may cause the machine to slide or tip over
(Fig. 2-343:).
If the direction must be changed, move the ma-
chine 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:

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 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, careful-
ly 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

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 move-
ments.
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 opera-
tor’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 by-
standers to clear the area before moving the ma-
chine 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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 under-
ground 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 ma-
chine.
Rocks and moisture of the surface material may
drastically affect the machine's traction and ma-
chine'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, sec-
tion “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 ma-
chine takes, before initiating the full traveling
movement.
Safe operation on steep slopes may require spe-
cial machine configuration. Excellent skill of the
operator and proper attachment for specific appli-
cations 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 POSI-
TION (Fig. 2-300:).
In this BASIC POSITION (Fig. 2-300:) the coun-
terweight (3) is positioned above the final drives
(4). Fig. 2-300:
The operator’s cab (1) is above the left idler (2).
Forwards means: Machine movement in direction
of the idlers.
Backwards means: Machine movement in direc-
tion 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 posi-
tion of the upper structure with regard to the un-
dercarriage, pedals (112 and 113) should be de-
pressed 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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 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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”.

2-160
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Traveling – Basic Movements Traveling movement is controlled by means of the

Fig. 2-302:
Travel straight forward/backward
travel pedals (112 and 113, Fig. 2-302:). The travel
pedals return automatically to their neutral posi-
tions when released.
During traveling, an acoustic warning signal
sounds (Travel Alarm).
All instructions with regard to travel direction con-
trol 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 gen-
tly. 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.

Traveling straight backward

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

2-161
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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. Do-
ing 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, re-
lease 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, re-
lease 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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 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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
 backwards from pos. 2 to pos. 3
Fig. 2-309:
 forwards from pos. 3 to pos. 4

The same procedure should be adopted if the hy-

draulic 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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OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Counter-rotation turns / Turning Note:

Counter rotational turns/turning on the spot in a
on the spot 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 fol-
lowed 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 sta-
tionary.

Counter-rotation turn to the right / Turning on

the spot
Fig. 2-311:
 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 ma-
chine 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 re-
turn in neutral position.

Fig. 2-312:

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 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 op-
eration.
Whenever loading operation is interrupted, rest the
attachment on the ground. This avoids slight
movement of the machine and possible conse-
quential damage of lowered ladder, in case ignition
remains engaged.
All instructions with regard to traveling speed regu-
lation 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 pos-
sible with this gear.
 Switch (72) to the right = fast gear.
All forward/reverse travel movements are pos-
sible 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 travel-

ing gear brakes can also be applied with switch
(63, Fig. 2-313:).
Actuate this switch only when the hydraulic shovel Fig. 2-314:
is stationary. Do not use this switch while the hy-
draulic 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.

2-165
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 hy-
draulic 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 hy-
draulic shovel is stationary.
 Bring shovel in a position shown in Fig. 2-317: 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. 2-318:

Fig. 2-315:

2-166

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, im-
mediately dump the load and turn the machine
uphill.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Traveling speed on ramps and slopes-
change
 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 hy-
draulic shovel is stationary.
 Depress travel pedals (112 and 113, Fig.
2-319:) fully to the limit stop.
 Regulate the travel speed only with the en-
gines 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 ped-
als (112 and 113) to stop the shovel.
Fig. 2-319:
2-167
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 head-

room, e. g. under cable bridges or high-tension
cables.
Lower the attachment when traveling underneath Fig. 2-320:
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 at-

tachment (Fig. 2-320:):
 Fully extend boom cylinder (1).
 Retract bucket cylinder (2). Fig. 2-321:
 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.

2-168

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:).
Fig. 2-322:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Track roller temperature – check
After traveling for 15 minutes without interruption,
stop the hydraulic shovel and check the tempera-
ture of the track rollers.
If you use an infrared thermometer, you can meas-
ure 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 dis-
tance. This will rapidly cool down the track rollers.
Fig. 2-323:
2-169
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OMM 6060, 6060FS(3 847 031.02)-EN
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, careful-
ly 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:

2-170
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 cylin-
ders 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 cyl-
inder clevis bolts.

Do not travel too steep ramps. Doing so can ex-

ceed 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”
Fig. 2-329: for information about maximum inclinations.

2-171
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 ma-
chine 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 ma-
chine less stable.

Fig. 2-332:

2-172
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 materi-

al. 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 dam-
age 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:

2-173
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

Maximum Machine Inclinations

The machine must not exceed the inclinations indi-
cated for working, traveling and servicing opera-
tions 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 in-
sufficient lubrication. In the event of extreme incli-
nations the machine can topple over.
The working performance of the machine is espe-
cially 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 slew-
ing uphill.
For the building of ramps, the values specified in
the table "Maximum inclinations during working
operations" may be exceeded. In this case, how-
ever, 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.

Type 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%

Maximum machine inclinations during maintenance operations:

forward inclination rearward inclination side inclination

0° - 2° / 3.4% 0° - 2° / 3.4% 0° - 2° / 3.4%

2-174

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).
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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:
2-175
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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:

2-176
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

After daily operation

Parking the machine Escaping oil pollutes the environment.
 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.  Repair leaks immediately (or have them
 Shut off the engines. repaired).
 Shift both control levers into all directions  Report oil accidents to the responsible person.
todepressurize the hydraulic cylinders.  Check the upper structure, undercarriage and
 Withdraw the key from the electrical system the attachment for damage and all steel
key-switch. components for cracks or fractures.
 Close the cab window.  Report detected damage immediately to the
responsible person.
 Lock the cab door and all lockable hatches and
covers on the machine.  Clean off gross dirt, ice and snow from the fins
and the fan wheel of the hydraulic oil cooler.
 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.
 Fill up the fuel tanks.
 Inspect the engines, the hydraulic system, the
track rollers, upper rollers, idlers and
gearboxes visually for leaks.

2-177

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.
Fig. 2-339:
2-178
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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
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 cab-
protection roof (FOPS).

Main control valves – at-
tach/remove the handrail
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 sys-
tem. If you do not use the safety equipment pro-
vided you may fall down and seriously hurt your-
self.
Before starting work at the main control valves:
 Bring the surface of the walkway (1, Fig. 2-
190) to a horizontal position by moving the at-
tachment. The GET must hit the ground.
 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 us-
ing the wingscrews.
Fig. 2-340:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Securing the machine
Risk of injury
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 pressure-
resistant 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. Trouble-
free 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.
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.
2-179

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 non-
moving 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
Application of GLEITMO 815
 Clean off grease, oil, dirt and corrosion protec-
tion 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 sur-
face.
 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) On-board crane - Monitoring,

The on-board crane is designed for warning and control elements
lifting heavy parts only. (Fig. 2-341:)
Do not lift persons.
Observe all national directives as well
as specific regulations relevant to
crane operation.

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 Function

1 Monitoring Alternator
lamp
2 Warning lamp Engine oil pressure
3 Warning lamp Engine temperature
4 Monitoring Air filter
lamp
5 Key-switch Electrical system
ON/OFF
6 Button Start engine of drive unit
7 Monitoring Preheating system
lamp (option)
8 Knob Engine speed variation
9 Monitoring Crane in operation
lamp
10 Warning lamp Malfunction
11 Button EMERGENCY STOP
12 Button Emergency lowering of
winch
21 Control lever Extending and retracting
of boom extension
22 Control lever Folding the boom
23 Control lever Swinging the boom
24 Control lever Winch up / down

2-181
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

On-board crane- Putting into On-board crane - Drive unit

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).
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:

2-182

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.
Fig. 2-343:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION
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.
2-183
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 col-
umn (arrow, Fig. 2-194).
To switch the LCD-display on, press key “PWR”
on the display housing. Fig. 2-345:

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:). Operator Assist System (if
Additional information can be found in the manuals equipped)
of the camera manufacturer (see Volume 5 of the There is several literature available covering the
Technical Documentation "Components"). Operator Assist System. Please contact your Cat
dealer for assistance.

Reference Literature
Media-Id- Title
Number
M0083817 “Operator Assist System -
Operation and Maintenance
Manual, Supplemental Infor-
mation”
AEXQ2311-01 “Operator Assist Retrofit Kit –
Flyer”

Fig. 2-344:

2-184
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

NOTES

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2-185
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
OPERATION

2-186
 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 Operating personnel

+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.

Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.

Part 4 REPAIR WORK 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

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

3-2

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 sequenc-
es, 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 servic-
ing 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.
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 hy-
draulical 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 hand-
rails provided when climbing onto or off the ma-
chine.
Always keep ladders, steps, platforms and hand-
rails in a non-slip, safe state and remove any oil,
grease, soil, clay, snow, ice and other foreign mat-
ter 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
Prior to commencing work, clean your working
area, if necessary and possible, with a steam-jet
(rubber parts and electric components with com-
pressed air - refer to information label).
Exhaust pipes and turbo chargers in the engine
compartments are covered with special heat insu-
lating 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 us-
ing 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 harm-
ful, 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

Handling flammable liquids
When handling flammable liquids:
 never smoke,
 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 va-
porize 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 speci-
fications 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 wa-
ter 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Visible oil losses
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 sepa-
rately from other waste.
Relieving residual pressure in the hy-
draulic system
Only unpressurized hydraulic systems may be
opened. Even when a machine is parked on a hor-
izontal 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 pres-
sure 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 un-
dertaken 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 sys-
tem is depressurized.
Escaping oil is an environmental hazard.

Non-polluting disposal
Dispose of oils, greases, cooling liquids, deter-
gents, solvents and oil-containing components,
such as filters, cleaning rags, replaced wearing
parts and unusable machine parts, without pollut-
ing 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, "environ-
mental-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 con-
tain 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 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Engine exhaust gases
Start and operate combustion engines only on
well-ventilated premises.
In closed rooms, exhaust gases must be evacuat-
ed 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.
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 immediate-
ly.
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 watch-
straps 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 con-
tact with electrical conductors or contacts, the bat-
tery 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

Handling of cold-starting fluid (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 be-
fore 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 / sup-
plier 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 pres-
sure 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 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Filters
Replace / clean all filter elements or filter cartridg-
es within the specified periods.
All filters are coordinated carefully with the equip-
ment. Original CGM-HMS GmbH parts must be
used to ensure smooth running and a long service
life of the engine and the hydraulic units.
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 devic-
es.
Never start up the drive motors while work is being
done on the machine.
Carry out performance tests with the machine.

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 han-
dling 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 sub-
stances or liquids increase the risk of fire and ex-
plosion. This is also valid for pressure vessels con-
taining 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 mainte-
nance operations, they must be completely re-
moved 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.
 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Place suitable fire guardings (fire barriers) if open
fire or flying sparks cannot be avoided during re-
pair work.
If necessary, also cover the ground with fire-
protective 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 ves-
sels can explode if exposed to high temperatures
(above 49°C / 120°F) or in the event of damage.
Protect the pressure vessels against damage be-
fore 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 extin-
guishing 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 elec-
trical 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 ma-
chine. If possible, use a steam-jet cleaner for
cleaning.
3-7
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

3-8

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 Ser-
vicing plans.
Plan Do all jobs ....
V ...once prior to initial commissioning.
N ...after initial commissioning and du-
ring the running-in period (after 100
OH).
T ...every 10 OH or every working shift 2)
W ...every 60 OH or weekly .2 )
A ...after every 250 OH.
B ...after every 500 OH.
C ...after every 1000 OH.
D ...after every 5000 OH.
E ...after every 10000 OH.
OH = Bh = Operating hours
Change of engine oil
Refer to chapter “Engine oil service interval table”
for more information. Also refer to SEBU6250 Cat-
erpillar Machine Fluid Recommendations.
2
Whichever comes first.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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“ sec-
tion.
The numerals mentioned in the "Oil / Grease" col-
umn in the inspection and Servicing plans have the
following meaning:
I Oils for combustion engines and com-
pressors
II Oils for hydraulic systems
IIIa, b Oils for gearboxes
V Greases for bearings and swing rings
Cleaning jobs
Cleaning jobs, especially on cooling systems, must
be done at shorter intervals if the machine is ex-
posed 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 documenta-
tion for these components states intervals deviat-
ing from the above-mentioned intervals.
In such case, only the maintenance intervals speci-
fied by CGM-HMS GmbH shall apply.
3-9
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

3500 Engine Maintenance Inter-

val 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 replace-
ment of components due to normal wear and ag-
ing. Failure to adhere to proper maintenance in-
tervals 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 condi-
tions 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 Quantity/
No.
Engine Check oil level 2
Engine oil tank (if equipped) Check oil level 2
Cooling system
Cooling liquid Check level 2
Fuel system Fill in fuel
Electrical system
Battery Check liquid level (not applicable when 6
maintenance-free batteries build in)
Check state of charge
Lighting Check operation
Monitoring, warning and control elements Check function of monitoring, warning and
control elements
Check emergency OFF function
Board Control System (BCS) Check function
Slewing system Perform „Slew brake test“ (see chapter „Ser-
vice – Slew brake test screen“)
Hydraulic system
Pressure accumulators Check, fill in the correct nitrogen pressure
- track tensioning system (see Service Manual, chapter 8)
- hydraulic ladder
- pilot system
- engine-off attachment lowering
- service station (fast fill arm)
Hydraulic oil reservoir Check oil level
Hydraulic system Check pressure (see „Service Manual“)
Hydraulic cylinders Vent (see chapter “Venting hydraulic system“)
Check function of working attachment and
traveling movement
Pump drive gearbox and cooling system Check oil level 2
- Pre-chambers, expansion reservoir Check oil level 2
Swing gearbox Check oil level 4
Travel gearbox (PN N3683483 only) Check oil level 2
- Spur gear section Check oil level 2x1
- Brake-chambers Check oil level 2x2
Travel gearbox (PNs N3683496 and Check oil level 2
N3749598 only)
- Hydraulic motor chambers Check oil level 2x2
Swing ring
Internal gearing Check grease filling 1
Undercarriage
Track roller Check for leaks and free movement 2x7
Check grease filling, fill with grease 3
Upper roller Check for leaks and free movement 2x2
Check grease filling, fill with grease 3
Track tensioning system Check pressure (see „Service Manual“) 2
Idler Check for leaks and free movement 2

3
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 2
For more detailed information see “On-board
crane” documentation in Volume “Compo-
nents”.
Escape ladder Check function
- Locking device Check function
- Ladder Check free movement
Emergency escape device / seat (if Check completeness and condition
equipped) Check for tightness
- Harness holding device on cab roof
Fall arrest static line on working attach- Check condition
ment (optional) Check function
Check proper fastening
All lines, fittings and connections Inspect visually for leaks, wearing marks
All articutated joints and hinges Grease

3-12
 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 Quantity/
No.
Engine
Belts Check tension, check condition
Engine mounts Inspect

when required:
Air filter primary element Clean / replace
Air filter secondary element Replace
Air filter pre cleaner Clean

Initial 250 service hours:

Engine valve lash Check / adjust

For more information on engine maintenance

work contact your Cat dealer.
Cooling system
Cooling fluid Check level
Carry out cooling liquid analysis after 250 OH
For more information contact your Cat dealer.
Radiator bearing fastening bolts Check for tightness (see „Service Manual“)
Hydraulic system
Hydraulic oil cooler
- bearing fastening bolts Check for tightness (see „Service Manual“)
Return-flow filter Replace 2x7
Magnetic rod Clean 1
Pressure accumulators Check function (see „Service Manual“)
- engine-off attachment lowering
- hydraulic ladder
- track tensioning system
- pilot system
- service station (fast fill arm)
Pump drive gearbox and cooling system Change oil 24
- Pre-chambers, expansion reservoir Change oil 2x13
- Gearbox oil filter (cooling circuit) Replace 2x1
- Fastening bolts Check for tightness (see „Service Manual“)

4
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 Quantity/

No.
Swing gearbox Change oil 44
Fastening bolts Check for tightness (see „Service Manual“)
Travel gearbox (PN N3683483 only) Change oil 24
- Spur gear section Change oil 2x14
- Brake-chambers Change oil 2x24
- Magnetic plugs Clean
Fastening bolts Check for tightness (see „Service Manual“)
Travel gearbox (PNs N3683496 and Change oil 24
N3749598 only)
- Hydraulic motor chambers Change oil 2x24
- Magnetic plugs Clean
Fastening bolts Check for tightness (see „Service Manual“)
Swing ring
Fastening bolts (swing ring, undercarriage Check for tightness (see „Service Manual“)
and upper structure)
Upper structure
Fastening bolts, especially at upper structure / Check for tightness (see „Service Manual“)
pedestal / operator´s cab
All lines, fittings and connections Inspect visually for leaks, wearing marks

3-14
 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) Page 1 of 3

Location Servicing work Quantity/ Plan Plan

No. T W
Hydraulic shovel Visual check / overall cleaning 
Undercarriage
- Tracks Inspect track tension visually 2  
- 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  
Face shovel
- Clam cylinder chambers Inspect, remove all accumulated de- 2x1  
bris, rocks, soil and so on.
- Mechanical stops on face shovels Check for wear  
rearwall and stick
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 2  
- Engine monitoring (Board Control Check monitoring lamps and BCS dis-  
System) play for fault messages
When required:
- Ether starting aid cylinder Replace
- Fuel system Prime
Cooling system
- Cooling fluid Check level 2  
- Radiator Check / clean 2  
Fuel system
- Fuel filter Drain off water 2x2  
- Water trap (optional) Drain off water 2x1  
- Fuel tanks Drain off water and sediment if neces- 2  
sary
Air-intake system Check BCS – indication 1  
Intake and clean-air lines Check for tightness and leaks 
- 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) Page 2 of 3

Location Servicing work Quantity/ Plan Plan

No. T W
Hydraulic system Check function of working and traveling  
movement
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 Check oil level 2  
system
- pre-chambers expansion reservoir Check oil level 2  
- Oil filter (tell-tale) Check 2x1 
Swing gearbox Check oil level 4  
Central lubricating system
- Grease container Check filling level  
- Lubricating points Check visually  
5
On-board crane (optional)
- 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 indi- Check 1
cator)
Reservoirs for used grease at the Check, depollute used grease 2 
A-frame
Fire extinguisher (if equipped) Inspect  
Escape ladder Check function  
- Locking device Check function  
- Ladder 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) Page 3 of 3

Location Servicing work Quantity/ Plan Plan

No. T W
Emergency escape device / seat Check completeness and condition  
(if equipped)
- Harness holding device on cab Check for tightness  
roof
Fall arrest static line on the at- Check condition  
tachment
Check proper fastening  
Check function  
Operator’s cab
- Window panes Clean  
- Mirrors Check/Clean/Adjust  
- Cameras (if equipped) Check/Clean/Adjust  
- ROPS structure Inspect for damage  
- Operator’s seat belt Check condition  
- Trainer’s seat belt Check condition  
Monitoring, warning and control Check function of monitoring, warning  
elements and control elements
Board Control System (BCS) Check function  
Electrical system
- Lighting Check operation  
- Horn Test  
- Travel Alarm Test  
- EMERGENCY OFF button Check function 6  
- CAN-BUS wiring connections Inspect 
- Switchgear cabinet breather filter Remove dust 
dust trap
Air conditioner (optional) Carry out all servicing work, see “Air 
Conditioning manual“
Automatic fire-extinguishing sys- Inspect  
tem (if equipped)

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 Plan B - after every 500 OH

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... 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
- and control spool Clean, then grease lightly 26   
- Pedal
- Control spool Clean, then grease lightly 3x26   
(machine with loading
shovel)
- Control spool Clean, then grease lightly 2x26   
(machine with backhoe
bucket)
Operator’s cab Check for tightness   
- Fastening bolts to cab mod- (see “Service Manual” for
ule 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

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 Plan B - after every 500 OH

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH Page 2 of 7
(at 10000, 20000, 30000, ... OH)
Location Servicing work Quant. / Plan Plan Plan Plan Plan
No. A B C D E
Servicing in acc. with plans W     
or T
Engine
Every 250 Service Hours:
Engine oil Carry out oil analysis (see: En- 2x1     
gine oil service interval table)
Engine oil and filter Change – severe duty (see: En- 27     
gine 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 27    
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 Check / adjust
Every 6000 Service Hours or 3 years:
Cooling system water tempera- Replace
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: For more information on en-
Overhaul considerations gine maintenance contact your
Cat dealer.
Engine oil tank (Reserve Oil
System)
- Filter Replace (see: Engine oil service 2x2     
interval table)
- Breather filter Replace 2x1   

7
see: “Refilling quantities – Oil“ table

3-20
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Plan A – after every 250 OH Plan B – after every 500 OH

(at 250, 750, 1250 … OH) (at 500, 1500, 2500 … OH)
Plan C – after every 1000 OH Plan D – after every 5000 OH
(at 1000, 2000, 3000, 4000 … OH) (at 5000, 15000, 25000 … OH)
Plan E – after every 10000 OH
(at 10000, 20000, 30000, … OH)
Page 3 of 7
Location Servicing work Quantity Plan Plan Plan Plan Plan
/ No. A B C D E
Cooling system Inspect visually for leaks     
Radiator
- Fastening bolts Check tightness   
- Rubber bearing Check condition   
Cooling system coolant sam- Obtain    
ple (Level 1)
Lines and hoses Check for leaks   
Inspect / Replace 
Hose clamps Check tightness     
Fuel system
Fuel filter Replace 2x3     
Fuel system primary filter Clean 2x1    
Water trap (optional) Clean 2x1     
- Filter element Replace 2x1   
Breather filter fuel tank Replace 2x1   
Fuel tank water and sediment Drain 2x1    
Fuel tank Clean 2 
Air-intake system
Main filter element Check / replace 2x48   
Secondary filter element Replace 2x49   
Air-intake lines and clean-air Check for tightness and leaks   
lines
Intercooler Check / Clean     
Hoses Replace  
Electrical system
Battery cable connections Check for tightness     
Battery Check fluid level (not applica- 6    
ble when maintenance-free
batteries build in)
Switchgear cabinet breather Clean 1    
filter
Replace 1   
Horn Inspect / Replace  

8
Replacement of main filter element after one year resp. after 3 cleaning cycles at the latest
9
Replacement of secondary filter element after one year resp. after 3 cleaning cycles of the main filter ele-
ment at the latest

3-21
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Plan A - after every 250 OH Plan B - after every 500 OH

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH Page 4 of 7
(at 10000, 20000, 30000, ... OH)
Location Servicing work Quantity Plan Plan Plan Plan Plan
/ No. A B C D E
Hydraulic system Check pressure settings (see   
„Service Manual“)
Oil cooler bearing
- Fastening bolts Check for tightness   
- Rubber bearing Check condition   
Return-flow filter Replace 2x7   
Magnetic rod Check / clean 1    
Bypass valve (hydraulic oil Check / clean filter sieve 6   
reservoir)
High-pressure filter for work- Check for contamination and 2x4   
ing hydraulics damage
Replace 2x4  
Filter for pilot control circuit Check for contamination and 4x1   
damage
Replace 4x1  
Filter for swing pump charge Check for contamination and 2x2   
circuit damage
Replace 2x2  
Filter for swing circuit Check for contamination and 2x1   
damage
Replace 2x1  
Filter for bearing flushing of Replace 2x1  
main pumps
Hydraulic oil reservoir Carry out oil analysis includ- 1    
ing particle count
(For more information regarding
particle count results, refer to
section: “Hydraulic Oil Analysis –
Understand Particle Count Re-
sults”)
Change oil 1 10 11 
- Breather filter Replace 2   
Pressure accumulators Check pressure (see „Service 1 
Manual“)
Cylinder (seals and guide Replace 
rings)

10
see “Refilling quantities – Oil“ table
11
Unless it is regularly analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the
latest

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

Plan A - after every 250 OH Plan B - after every 500 OH

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH Page 5 of 7
(at 10000, 20000, 30000, ... OH)
Location Servicing work Quantity Plan Plan Plan Plan Plan
/ No. A B C D E
Pump drive gearbox and Carry out oil analysis 2    
cooling circuit
Change oil * 2 12   
- Breather filter Clean 2x1   
Replace 2x1 
Pre-chambers and expansion Change oil * 2 x 5 12   
reservoirs
- Breather filter Clean 2x1   
Oil filter Check for contamination and 2x1   
damage
Replace 2x1  
Fastening bolts Check tightness (see „Service     
Manual“)
Swing gearbox Carry out oil analysis 4    
Change oil * 4 12   
Breather filter Clean / replace 4x1  
Travel gearbox Carry out oil analysis 2    
(PN N3683483 only)
Check oil level 2    
Change oil ** 2 12
- Magnetic rod Clean 2x6   
Spur gear section Check oil level 2x1    
Change oil ** 2 x 1 12
- Magnetic rod Clean 2x1   
Brake-chambers Check oil level 2x2    
Change oil ** 2 x 2 12  
Breather filter Clean / replace 2x3   
Travel gearbox Carry out oil analysis 2    
(PNs N3683496 and
N3749598 only)
Check oil level 2    
Change oil ** 2 12
- Magnetic rod Clean 2x6   
Hydraulic motor-chambers Check oil level 2x2    
Change oil ** 2 x 2 12
Breather filter Clean / replace 2x3   
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

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

Plan A - after every 250 OH Plan B - after every 500 OH

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH
(at 10000, 20000, 30000, ... OH)
Page 6 of 7
Location Servicing work Quantity Plan Plan Plan Plan Plan
/ No. A B C D E
Swing ring Check grease filling 1    
Gearing / pinion Check condition    
Fastening bolts (swing ring, Check for tightness (see  
undercarriage and upper „Service Manual“)
structure)
Replace (see „Service Manu-
al“) 13
Undercarriage Check wear (see „Service   
Manual“)
Diaphragm accumulator Check pressure (see „Service 2x1   
Manual”, chapter 8)
- Diaphragm Replace 2x1  
Piston accumulator Check pressure (see „Service 2x1   
Manual“, chapter 8)
Track roller (if not connected Check grease filling, lubricate 2x7   
to the central lubricating sys-
tem)
Central lubricating system Check function    
Oil filter (hydraulic circuit Check for contamination and 1   
grease pump) damage
Replace 1  
Grease filter (filling grease Check for contamination and 1   
container) damage
Replace 1  
Grease filter (grease lines) Check for contamination and 2   
damage
Replace 1  
Breather filter grease reser- Check / replace 1   
voir
Air conditioner resp. heat- Carry out all maintenance   
ing (optional) work acc. to the manufactur-
ers manual.
- Air suction filter mat Clean, replace if necessary 3   
- Fan motors brushes Inspect / Replace  
Hydraulic ladder
- greasing points Lubricate   
Service-Station (Fast fill arm)
- Arm bearing grease nipple Lubricate   
- Hydr. cylinder grease nipple Lubricate   

13
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 Plan B - after every 500 OH

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH
(at 10000, 20000, 30000, ... OH)
Page 7 of 7
Location Servicing work Quantity Plan Plan Plan Plan Plan
/ No. A B C D E
On-board crane (Option) 14
- Bearing Lubricate 4
- Joint (column / boom) Lubricate 2
– Cylinder bearing Lubricate 5
– Swing ring Grease 1
Hydraulic system Change oil 1 15
– Return-flow filter Replace 1
– Breather filter Replace 1
(see “On-Board Crane Opera-     
tion and Maintenance Manu-
al”)
Crane drive engine Clean 1
Change oil 1 15
- Oil filter Replace 1
– Fastening bolts Check for tightness 1
– Fuel filter Replace 1
– Air filter Replace 1
– Battery cable connection Check for tightness 2
(see “Crane Drive Engine     
Operation and Maintenance
Manual”)
Steel components 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 pene-
trant, magnetic powder or
ultrasonic test.
Modules Check for tightness (see   
- Fastening bolts “Service Manual”)
All articulated joints and Lubricate   
hinges

14
Do all servicing jobs at least once a year and when necessary
15
see “Refilling quantities – Oil“ table
16
„Structural Inspection Reports“ for inspections every 500 OH can be downloaded from SIS-Web, Media-ID-
No. BI644777.

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

LUBRICATING CHART – GREASE

Fig. 3-1:

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

Lubricating chart – Grease (legend)

No. Greasing point Number Lubricant Grease every
properties .... operating hours
1 Central lubricating system – grease container 1 V 17 10
3 Track roller (if not connected to the central 2x7 Tribol 18 (*) 1000
lubricating system)
4 Hydraulic ladder V 17 1000
5 On-board crane 250
- Bearing 4 V 17 250
- Joint (column / boom) 2 250
- Cylinder bearing 5 250
- Swing ring 1 Graphite 250
spray
6 Monitoring, warning and control elements
- Joystick: plate, cardan joint, control spool 2 19 V 17 1000
- Pedal (machine with shovel attachment) 3 x 2 19 1000
- Pedal (machine with backhoe attachment) 2 x 2 19 1000

All other greasing points are supplied with grease by the central lubricating system.

Refill Capacities – Grease

Greasing point Lubricant Filling quant.
properties kg lb

Central lubricating system – grease container V 17 approx.1000 approx. 2204.6

(different containers available)

Internal gearing – Roller-bearing swing ring approx. 300 approx. 661

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

Upper rollers (permanent grease filling *) 4 x approx. 14 4 x approx. 30.9

(*) 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 CGM-
HMS product support or your local DPSC.

17
see " LUBRICANTS / CONSUMABLES " section.
18
Not in use when machine is equipped with undercarriage greasing system
19
apply a thin layer of low temperature grease

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)

No. Location Number Lubricant Check oil level Change oil
properties 20 every ... OH every ... OH
1 Engine (Standard) 2 I 10 See: Engine Oil
Service Interval
Table
Engine (With Reserve Oil 2 I 10 See: Engine Oil
System, if equipped) Service Interval
Table
3 Hydraulic system 1 II 10 10000 21
4 Pump drive gearbox and cool- 2 10 1000
ing system
III.a (mineral gearoil)
- Pre-chambers expansion 2x1 10 3000
reservoirs (synthetic gearoil)
5 Swing gearbox 4 III.b 10 1000
(mineral gearoil)
3000
(synthetic gearoil)
6 Travel gearbox 2 500 2000
(mineral gearoil)
- Spur gear section 2x1 500 6000
(Travel gearbox P/N N3683483 only) III.a (synthetic gearoil)
- Hydraulic motor chambers 2x2 500
7 On-board crane (optional)
- Crane drive engine 1 I 10 250 22
- Hydraulic oil reservoir 1 II 10 1000 23

20
see "LUBRICANTS / CONSUMABLES" section
21
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.

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 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 Reserve Oil System Oil change Max. oil change Oil filter change
filters with extra oil tank interval with- interval with SOS interval *
used approx. 500 L out SOS
(132 USgal)
# 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 RE-
FILL 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 sam-
pling 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.

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 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
I
Engine oil tank (if equipped) 2 x approx. 500 2 x approx. 132
I
Hydraulic system approx. 9400 approx. 2483
II
Hydraulic oil reservoir approx. 7100 approx. 1876
II
Pump drive gearbox 2 x approx. 85 2 x approx. 22.5
- Pre-chambers (working pumps) 8 x approx. 1,5 8 x approx. 0.4
III.a
- Pre-chambers (hydraulic pumps) 4 x approx. 0.4 4 x approx. 0.1
- Pre-chambers (cooling oil pumps) 2 x approx. 0.2 2 x approx. 0.05
Swing gearbox 4 x approx. 38 4 x approx. 10
III.b
Travel gearbox (PN N3683483) 2 x approx. 145 2 x approx. 38.3
- Spur gear section 2 x approx. 10 2 x approx. 2.6
III.a
- Brake chambers 4 x approx. 0,5 4 x approx. 0.13
Travel gearbox (PNs N3683496 and 2 x approx. 165 2 x approx. 43.5
N3749598) III.a
- Hydraulic motor chambers 4 x approx. 3,5 4 x approx. 0.93
On-board crane (optional)
- Crane drive engine approx. 5.5 approx. 1.45
I
- Hydraulic oil reservoir approx. 50 approx. 13.2
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

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

LUBRICANTS / CONSUMABLES recommend that the fluid be changed out to elimi-

nate any fluid incompatibility issues.
Notes on the selection of oils and
greases Alternative oils and greases
The oils and greases filled into the machine must
Original CGM-HMS GmbH oils and meet at least the specifications mentioned in the
greases lubricants tables of the CGM-HMS GmbH Opera-
tion and Maintenance Manual.
Besides regular and careful maintenance, the qual-
ity of the oils and greases used in the machine has In the event of damage to the machine or to its
a decisive influence on high performance, reliability units and assemblies caused by the use of alterna-
and long service life of a machine and of its units tive oils and greases that are not compatible with
and assemblies. CGM-HMS GmbH specifications, CGM-HMS
GmbH does not assume any responsibility and
The lubricants tables in the CGM-HMS GmbH Op- does not accept any warranty claims.
eration and Maintenance Manual contain specifica-
tions 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 re-
quirements 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 sam-
pling that is stated in the Operation and Mainte-
nance 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 im-
portant 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 publica-
tion 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
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

I. Oils for combustion engines

Fig. 3-3:

3-33
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

II. Fluids for hydraulic system

Fig. 3-4:

3-34
 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 lubrica-
tion 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:

3-39
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

SERVICING WORK The engines, the hydraulic oil reservoir, the pump
drive gearboxes, the swing gearboxes and the
Hose line for oil and cooling liq- radiators (engine cooling liquid) are moreover
uid changes equipped with automatic drain valves (1, Fig.
3-11:)
Collect escaping oil and cooling liquid These automatic drain valves permit oil- and cool-
and discard without polluting the en- ing-liquid changes without polluting the environ-
vironment. ment.

Carry out oil changes when the ma-

chine 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 connect-
ed 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 pres-
sure. Fig. 3-11:

Change oil or cooling liquid as follows:

 Place a collecting recipient for used oil or cool-
ing 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:

3-40

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 harm-
ful contact with engine oil.
Wear protective gloves and firm work-
ing clothing.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Attention, Ether!
The engine compartment can be
equipped with pressure vessels con-
taining cold-starting fluid (ether).
Ether is toxic and highly flammable;
the vessels are under pressure. These
pressure vessels can explode if ex-
posed to high temperatures (above
49°C / 120°F) or in the event of dam-
age.
Protect the pressure vessels against
damage before beginning to work in
or close to the engine compartment.
Secure the machine as described in section “Se-
curing 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 spray-
washed with steam-jet cleaners or
high-pressure cleaners. It will be dam-
aged.
Therefore cover all the insulating ma-
terial with plastic foils before using
steam-jet cleaners or high-pressure
cleaners inside the engine compart-
ments.
Do not clean the pumps of the Oil Re-
serve System with high pressure
cleaning systems. High pressure
cleaning will damage the pumps.
3-41

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 avoid-
ed.
For maximum engine service life, make a thorough
inspection of the engine compartment before start-
ing 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. Re-
pair damaged guards or replace missing
guards.
 Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of sys-
tem 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 com-
ponents 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
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 connec-
tions.
 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 addi-
tional 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 start-
ing motor. Check the condition and the electro-
lyte 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.

Belts - Inspect/Replace
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 unnec-
essary 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 compo-
nents.
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 adjust-
ment, 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Fuel Injector - Inspect/Adjust
Note: Perform this procedure when the engine
valve lash is inspected.
The Electronic Control Module pro-
duces 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 re-
moved 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 injec-
tor 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 pro-
gram, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is re-
quired for determining nitration and oxidation lev-
els.
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 compo-
nents to contact the skin.
Before you take the oil sample, complete the La-
bel, 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 sam-
ple.
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 op-
eration.
Fig. 3-12:
The 169-8373 Fluid Sampling Bottle is recom-
mended for use with the sampling valve. The fluid
sampling bottle includes the parts that are needed
for obtaining oil samples. Instructions are also pro-
vided.
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 analy-
sis 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 de-
signed to accept sampling bottles. Disposable tub-
ing 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.

3-44
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Engine Valve Lash – Water Pump - Inspect

Check/Adjust
Note: For procedures on adjusting the valve lash
and adjusting the valve bridge, see Systems Oper-
ation/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 rec-
ommended 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 be-
ing performed. To help prevent possi-
ble injury, do not use the starting mo-
tor to turn the flywheel.
Hot engine components can cause
burns. Allow additional time for the
engine to cool before measur-
ing/adjusting valve lash clearance.
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other poten-
tial damage to the engine.
Visually inspect the water pump for leaks. If leak-
ing 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 Opera-
tion/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 Speci-
fications manual. For the procedure to set the
valve lash, see the engine’s Systems Opera-
tion/Testing and Adjusting manual.

3-45
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Engine oil level – Check level /  Draw out dipstick a second time. The oil level
should now lie between the marks (arrows,
top up Fig. 3-14:). If the oil level is at the "min" mark
The engine oil temperature and oil temperature are or below, top up with engine oil through filler
constantly monitored by the BCS (Fig. 3-13:) when tube (2, Fig. 3-15:).
the machine is in operation.
The actual engine oil pressure is constantly dis-
played 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.

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:
 express coupling (9) for the right hand engine,
 Park the machine on a horizontal surface and
secure against inadvertent movements. (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 coun-
terweight.
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 reser-
voirs 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

Engine oil - Change
Risk of scalding from hot engine oil.
The engines may also be hot.
Wear protective gloves and firm work-
ing 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)”.
3-48
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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:
 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 Fig. 3-20:
abt. 2 minutes.
 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) Draining off the oil

- Drain / Fill oil
Risk of scalding from hot engine oil.
The engines oil reservoirs may also
be hot.
Wear protective gloves and firm work-
ing 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)”.
 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 inter-
val 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
Fig. 3-24:
hose line of the service vehicle.
 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 work-
ing 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".
Collect escaping oil and discard with-out polluting
the environment
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.

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:).
Fig. 3-27:
 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
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Engine oil filter – Replace Engine crankcase breather –

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".
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. Fig. 3-29:
Thereafter:
 Allow engines to run at idling for a short while
 Loosen clamp (1, Fig. 3-29:). Slide the clamp
and check filters for tightness and leaks before
down on tube (2).
shutting off the engines.
 Loosen clamps (3). Remove both breathers as
 Check oil level after abt. 10 minutes and top
a unit.
up, if required.

Fig. 3-28:
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.

3-53

Cold-starting fluid (ether) - Re-
place the pressure vessel
Read and observe: "Inspection and servicing -
Safety instructions"
Risk of injury
Cold-starting fluid is composed main-
ly of ether.
Ether is toxic when the mists and va-
pors are inhaled. Ether is harmful to
the eyes, the skin, the respiratory sys-
tem 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 dam-
age.
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 pres-
sure vessels with cold starting fluid
(ether).
Provide for sufficient ventilation of the
surroundings.
Do not eat, drink or smoke when re-
placing an empty vessel.
Do not inhale the vapors of escaping
cold-starting fluid (ether).
Avoid skin contact. Wear suitable pro-
tective gloves and goggles.
3-54
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
If the machine is used in low temperatures, the
engine may be equipped with a cold-starting de-
vice.
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 ves-
sel.
 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 me-
tering valve and tighten by hand.
 Fasten the clamp round the pressure vessel.
Even apparently empty pressure vessels can con-
tain 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 Temperature

Risk of scalding from hot cooling liq- The cooling liquid circuit is controlled by a thermo-
uid. stat. The max. admissible temperature is ca. 100°
C (212°F).
Shut off the engines and allow to cool
In case of higher temperatures, the BCS displays a
down.
warning on the screen (Fig. 3-31:).
Read and observe: "Inspection and
servicing - Safety instructions".

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:

3-55
 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 re-
quired.

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 cool- Fig. 3-32:
ing liquid, if required (see “Cooling liquid – Top
up”).

Fig. 3-33:

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

Cooling liquid – Top up

Fill cooling liquid through filler tube (1, Fig. 3-34:)
or through express couplings of the Service-
Station (2 and 3, Fig. 3-35:) into the cooling system
(see “Topping up cooling liquid using the Service-
Station”).
The caps of the expansion reservoirs (1, Fig.
3-34:) are accessible from above.
Risk of scalding from hot cooling liq-
uid under pressure.
Before opening the cap: Release
pressure by lifting the red lever on top
of the cap.
Fig. 3-35:
Open cap cautiously after releasing
pressure. For topping up of the cooling system use specially
prepared cooling liquid CAT ELC, CGM-HMS
GmbH SAP Part No. 4275599 only.
 First release pressure from the expansion res- This gives an anti-freeze protection down to -37 °C
ervoir by lifting up the red lever integrated in / -34.6°F.
cap (1). For use at lower temperatures, ask the CGM-HMS
 When the pressure has been released turn cap GmbH Service or your CAT-dealer.
into the "open" position and remove. After filling in cooling liquid allow the engines to run
for short period to eliminate air voids before top-
ping up with cooling liquid to the lower edge of the
Do not fill in cold cooling liquid when filler tube.
the engine is at operating tempera-  Remove hose from express coupling.
ture. The express coupling closes automatically.
Before refilling, allow engine to cool  Screw on protective cap.
down to below 50° C (122°F).
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 tight-
ness.

Fig. 3-34:

3-57
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 ser-
vice 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 pres-
sure 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.
Fig. 3-36:
 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" sec-
tion.
 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

Cooling liquid - Change
Risk of scalding from hot cooling liq-
uid under pressure.
Open cap of expansion reservoir cau-
tiously after releasing pressure.
Wait until cooling liquid has cooled
down.
Do not fill in cold cooling liquid when
the engine is at operating tempera-
ture.
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).
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Drawing off cooling liquid
Cooling liquid can be drained from the cooling sys-
tem 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 pres-
sure 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:
3-59
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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.
Fig. 3-38:
 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 Fig. 3-39:
neck (1, 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 anti-
freeze concentration is sufficient for the expected
temperatures.
Check the cooling liquid in the cooling system reg-
ularly to ensure that the ELC is sufficiently concen-
trated to prevent corrosion under the correspond-
ing 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 liq-
uid”.

3-60

Cooling System Supplemental
Coolant Additive (SCA) – Add
Cooling system coolant additive con-
tains 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 concen-
tration can form deposits on the higher tempera-
ture 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 concen-
tration 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 sup-
plemental coolant additive concentration.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable con-
tainers before opening any compartment or disas-
sembling any component containing fluids. Refer
to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” and to Special Publi-
cation, GECJ0003, “Cat Shop Supplies and Tools”
for tools and supplies suitable to collect and con-
tain fluids on Caterpillar products.
Dispose of all fluids according to applicable regula-
tions 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 Convention-
al Coolant
This maintenance procedure is required for con-
ventional coolants such as DEAC. This mainte-
nance is NOT required for cooling systems that are
filled with Extended Life Coolant.
Test the Concentration of the SCA
NOTICE
Do not exceed the recommended six percent sup-
plemental coolant additive concentration.
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OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Test the concentration of the SCA with the 8T-
5296 Coolant Conditioner Test Kit.
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 al-
low 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 Rec-
ommendations” topic. The proper concentration of
SCA depends on the type of coolant that is used.
For the proper concentration of SCA, refer to Spe-
cial Publication, SEBU6251, “Caterpillar Commer-
cial 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. 294-
7420 Test Kit contains the refill ampoules for the
298-5311 Coolant Nitrite Test Kit. Use the instruc-
tions 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.
3-61

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 al-
low 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 Rec-
ommendations” topic. For the proper concentration
of SCA, refer to Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engine Fluids Rec-
ommendations”.
4. Clean the cooling system filler cap. Install the
cooling system filler cap.
3-62
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Cooling System Water Tempera-
ture 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 partial-
ly opened position can cause overheating or over-
cooling 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 tempera-
ture 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 incor-
rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera-
ture 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 As-
sembly 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 regu-
lator housing.

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 stat-
ed in the Maintenance Interval Schedule.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant in-
stead 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
Type of coo- Level 1 Level 2
lant
Cat DEAC Every 250 Yearly(1)(2)
(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 cool-
ants 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 analy-
sis 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 pos-
sible 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, per-
form consistent samplings that are evenly spaced.
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OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 cool-
ant 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 immedi-
ately 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, “Re-
fill Capacities and Rec Recommendations” or con-
sult 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 analy-
sis 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) - Ob-
tain” 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 Recommenda-
tions” or consult your Caterpillar dealer.
3-63
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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 Fig. 3-40:
instructions" chapter.

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 de-
tached.
Engine damage may occur if the en-
gine 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, pri-
mary air filter elements and secondary air filter
elements.
Insufficient air-intake performance, caused by a
contaminated air filter, is displayed on the BCS-
screen with the engines running at high speed.
In case that an air filter is contaminated, the con-
tamination indicator near the air filter housing (ar-
row, Fig. 3-41:) will give an electrical signal to the
BCS.
The Board Control System (BCS) notifies the op-
erator that the air filters need service (arrow, Fig.
3-42:).
New air filter elements should always be at hand to
shorten shovels downtimes.
Fig. 3-42:
Service the air filters only with the engines
stopped. Engine damage can occur.

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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 Fig. 3-43:
damaged dust valves.
(1) Dust valve
 Make sure that all of the tubes within the pre
(2) Clamp
cleaner are free of dirt (Fig. 3-44:). Clean the
(3) Lower precleaner bowl
tubes, if necessary with a stiff brush.

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 rub-
ber may not seal properly.

Fig. 3-44:

3-65
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Primary air filter element - Inspect

/ replace
The Board Control System (BCS) notifies the op-
erator 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 re-
moval.
 Do not remove secondary filter element (2).
Fig. 3-45:
 Visually check secondary filter element for
damage and replace if damaged.

Note: Do not remove secondary filter element un-

less a change-out is necessary. Replace the sec-
ondary 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 con-
tact 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, mak-

ing 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 ser-

vice 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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Secondary air filter element - Re- Air-intake lines - Inspect

place At regular intervals:
Removal and installation  Inspect air-intake lines for leaks and hose
clamps for tightness. If there are leaks, or
 Replace the secondary filter elements (2, Fig.
holes, or damage, replace immediately.
3-46:) every three primary filter changes. After
one year of operation at the latest.  Replace hoses between filter housing and
engine (clean-air lines) according to the
Never clean the secondary filter ele- maintenance plan.
ment, but always renew. During all work on the air-intake system ensure
proper sealing to prevent unfiltered air from reach-
ing the engines.
 Remove cover (4, Fig. 7) and primary filter
element (3) as described in section “Primary
air filter element, inspect / replace“.
 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 de-
scribed in section “Primary air filter element -
Inspect / replace“.

Fig. 3-46:

3-67

FUEL SYSTEM
Fuel system - Safety instructions
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 "Se-
curing 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.
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 posi-
tion “0”.
 To open the ball valve, shift lever in position
“I”.
Read and observe the "Fuel system – Safety in-
structions” chapter.
Fig. 3-47:
3-68
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INSPECTION AND SERVICING
Fuel System – Prime
Personal injury or death may result
from failure to adhere to the following
procedures.
Fuel leaked or spilled onto hot surfac-
es 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.
Prime the fuel system in order to purge trapped air
and in order to fill the fuel filter.
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 posi-
tion in order to prime the fuel system.
 Hold priming pump switch (arrow, Fig. X) up-
ward in order to activate the electric fuel prim-
ing 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 at-
tempts, consult your Cat dealer.
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Fuel filter – Replace Fuel system – Vent

Read and observe the "Inspection
and servicing – Safety instructions"
chapter.
Collect escaping fuel and discard without polluting
the environment.
Venting the fuel filters:
 Switch on primary fuel pump with switch (ar-
row, 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:
Venting the fuel tanks:
 Shut off the fuel supply valves between fuel
The fuel tanks are vented with breather valves
tanks and engines. (arrow, Fig. 3-51:).
 Unscrew filters (Fig. 3-49:).
 Do not fill new filter with fuel. This prevents
the injection system from being contaminated
Breather filter fuel tanks - Re-
by unfiltered fuel after fuel filter change.
 Apply clean diesel fuel to the new filter gasket
place
and screw it onto the filter head by hand.  Replace breather filters regularly according to
Continue to tighten filter by a further ½ to ¾ the maintenance plan.
turn. To do so unscrew cap (1, Fig. 3-51:) of breath-
er valve and replace with a new one. The filter
Tightening the filter element with a element is integrated in the cap.
tool may damage or deform the filter
head.

 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:

3-69
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Fuel tanks – Clean

 Use up as much fuel as possible.
Explosion hazard due to fuel vapors.
 Check how much fuel remains in the tank and
Read and observe the "Inspection and
place a collecting recipient of sufficient size
servicing, Safety instructions" chap-
under the drain plugs of the tanks.
ter.
 Shut off the fuel supply valves (arrow, Fig.
3-52:). To do so, shift lever of the ball valve
Do not use white spirit, paraffin oil or other sol-
from position “I” to position “0”.
vents.
For flushing and cleaning use diesel fuel.  Loosen drain plug (5, Fig. 3-53:) at the bottom
of the fuel tank and drain off fuel.
Avoid skin contact.
Skin contact with diesel fuel may cause skin injury.  Flush tank with diesel fuel.
Wear firm working clothing.  Inspect fuel tank inside for damages.
Wear protective gloves or use a barrier cream.  Screw drain plug back (5) in place.
Fuel must be prevented from penetrat-
ing into the soil. Keep fuel for filtering
and re-use or discard without pollut-
ing 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.
Fig. 3-54:
 Remove filling hose.
The express coupling closes automatically.
 Screw on protective cap.
 Open fuel supply valves (arrow, Fig. 3-52:).
To do so, shift lever of the ball valve from posi-
tion “0” to position “I”.

Fig. 3-55:

Fig. 3-56:

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Water trap (option) - Clean / re- Servicing

place Draining off water
Water contained in the fuel is removed by the wa- Carry out the following works in accordance with
ter trap (Fig. 3-57:). 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 wa-
ter 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:

3-72
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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 emp-
ty.
 Remove cover (5).
 Remove spring holder (7) and filter element (6)
from filter housing (4).
 Check / replace filter element (6)
 Clean filter housing (4) using diesel fuel.
 Check cover sealing and replace,if necessary.
 Insert filter element (6) and spring housing (7)
into filter housing (4).
 Fasten cover (5) on filter housing (4).
Check for proper sealing.
Fig. 3-59:
 Clean recipient (1) and filter housing (4).
 Loosen flange (2).
 Take off recipient (1) and clean with diesel fuel
 Check cover sealing and replace, if necessary.
 Attach recipient (1) with flange (2) at filter
housing (4).
Check for proper sealing.

3-73

Hoses and Clamps - In-
spect/Replace
Hoses and clamps must be inspected periodically
and replaced at the recommended interval to en-
sure safe and continuous operation of the engine.
Failure to replace a fuel hose at the recommended
change interval may result in a hazardous situa-
tion. Take proper safety precautions before in-
specting 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 inju-
ry or possible death. Leaks that are the size of a
pin hole are included. Refer to Operation and
Maintenance Manual, “General Hazard Infor-
mation” for more information.
Note: Ensure that the hose is compatible with the
application.
3-74
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Inspect the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the
following conditions. Replace any hose which ex-
hibits 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 cover-
ing
 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 cou-
pling 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 loos-
en 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.

Replace the Hoses and the Clamps
Note:
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable con-
tainers before opening any compartment or disas-
sembling 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.
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 sys-
tem components are cool. Loosen the
cooling system pressure cap slowly in
order to relieve the pressure.
Personal injury can result from remov-
ing 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 re-
placed. 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 Specifica-
tions, 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 gas-
kets on the filler cap. Inspect the gasket seat.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 remov-
ing 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.
Contact with high pressure fuel may
cause fluid penetration and burn haz-
ards. High pressure fuel spray may
cause a fire hazard. Failure to follow
these inspection, maintenance and
service instructions may cause per-
sonal injury or death.
Note:
Do not bend or strike high pressure lines. Do not
install bent or damaged lines, tubes or hoses. Re-
pair 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. Thor-
oughly clean the area around a fuel system com-
ponent that will be disconnected. Fit a suitable
cover over any disconnected fuel system compo-
nents.
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.
3-75

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 Specifica-
tions, 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 en-
gine with fuel.
 Start the engine. Inspect the fuel system for
leaks.
3-76
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OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 re-
placed.
 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 Specifica-
tions, SENR3130, “Torque Specifications”
“Hose Clamps” for information about selecting
and installing the proper hose clamps.
 Refill the lubrication system. Refer to this Op-
eration and Maintenance Manual, “Engine Oil
Level - Check” in order to ensure that the lubri-
cation 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 Specifica-
tions, 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.

ELECTRICAL SYSTEM
Electrical system - Safety instruc-
tions
Risk of injury caused by battery acid
and gases.
Read and observe the "Inspection and
servicing – Safety instructions" chap-
ter.
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, regu-
lator 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Electrical circuit diagrams
The electrical circuit diagrams and wiring diagrams
are annexed to the spare-parts list. Further infor-
mation 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 elec-
trical components.
Fuses and their function are listed on a sheet in-
side 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 per-
taining fuses, connection cables and contacts must
be checked.
Xenon-working floodlights are operat-
ed 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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 EM024061-1
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INSPECTION AND SERVICING

Xenon floodlight projector (op-

tional) - 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 bal-
last unit. The ballast unit is integrated in the flood-
light 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 life-
threatening risk, if a person comes
into contact with any of the live com-
ponents. 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 fol-
lowing 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 be-
fore 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 opera-
tion and obscure the reflector.
If the fingers have nevertheless come into contact
with the glass bulb, the fingerprints must be re-
moved 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 elec-
trical wiring is damaged.
Have damaged projectors be replaced by a quali-
fied 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.
 Remove four screws (1, Fig. 3-60) and with-
draw the reflector (2) from the projector hous-
Fig. 3-60 ing.
 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

3-79
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Lighting systems in LED technol-

ogy - 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 (light-
emitting 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.
Fig. 3-63
For this reason, the housings must
not be covered up and cleaning rags
or similar things placed over them.

The high-performance LEDs in these lights have a

very long service life and can therefore not be re-
placed. 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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 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Battery- Check the state of Checking charge of batteries

charge The acid temperature must be 20 ° C / 68°F.
 Unscrew caps of the battery (Fig. 3-65:).
Warning! Battery Posts, terminals and
related accessories contain lead and  Measure the acid density of the battery using a
lead compounds, chemicals known to commercial acid tester (Fig. 3-65:).
cause cancer and reproductive harm. The acid density measured is in direct correla-
Risk of injury caused by battery acid tion with the battery charge.
and gases.
Wear goggles, working gloves and
firm working clothing. Acid density
kg / dm3 Charge
Do not eat, drink or smoke when han-
Normal Tropical
dling batteries.
condi- condi-
Wash hands after handling. tion tions
Read and observe the "Inspection and 1,28 1,23 fully charged
servicing – Safety instructions" chap- 1,20 1,12 half charged, recharge
ter. 1,12 1,08 discharged, recharge
immediately

Checking the battery fluid level

On closed / sealed (so called „maintenance-free“)
(Not applicable in case of maintenance-free batter-
batteries, the charging status can be checked us-
ies)
ing a charge meter. Ask your Caterpillar dealer for
 Unscrew caps (Fig. 3-65:). 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 con-
tacts 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:

3-81

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 han-
dling batteries.
Wash hands after handling.
Read and observe the "Inspection and
servicing – Safety instructions" chap-
ter.
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.
Fig. 3-66:
3-82
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
 Shut off the engines before removing the bat-
teries to avoid damaging the alternator and the
regulator.
 Turn key in key-switch to position "0" and with-
draw.
 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 vas-
eline on the battery terminal posts and clamp-
ing 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.
After putting the machine back to operation:
 Check battery cabling for tightness, retighten if
necessary.
 Check battery holders and wing nuts for tight-
ness, retighten if necessary.
 Repeat these checks regularly.

Battery charge inside the ma-
chine - 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 protec-
tion 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 dis-
charged and replace the batteries if they are defec-
tive.
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 cross-
section of at least 70 mm2.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 nec-
essary 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 con-
stant (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:
3-83
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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:

3-84
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Checking and cleaning the filter ele-

ment
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 ele-
ment immediately.

 Check element seal. If damaged, replace filter

element too.
Cleaning with compressed air allows the filter ele-
ment to be re-used immediately.
 Blow filter element (Fig. 3-71:) dry with com-
pressed air by moving the compressed-air pis- Fig. 3-70:
ton up and down inside it.
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:

3-85
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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.

Fig. 3-72:
Inspect
 Check CAN Bus wiring inside the cab module
(Fehler! Verweisquelle konnte nicht gefun-
den werden. and Fehler! Verweisquelle
konnte nicht gefunden werden.) for damage.

Note:
Damaged wiring needs to be replaced immediate-
ly. Contact your Cat dealer. Bring the machine
back to operation only after the repair is complet-
ed.

 Inspect wiring connections (arrows, Fehler!

Verweisquelle konnte nicht gefunden wer-
den. and Fehler! Verweisquelle konnte nicht
gefunden werden.). All connections must be
interconnected to the stop and secured.

Fig. 3-73:

3-86

HYDRAULIC SYSTEM
Hydraulic system - Safety instruc-
tions
Risk of injury caused by hydraulic
fluid under high pressure. Never open
hydraulic connections while the sys-
tem is pressurized. Depressurize the
hydraulic system section before start-
ing any work on the section.
Risk of burning caused by hot hydrau-
lic components (e.g. hydraulic oil res-
ervoir, 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 work-
ing clothing.
Secure the machine as described in
the "Securing the machine“ section.
Read and observe the "Inspection and
servicing – Safety instructions" chap-
ter.
Before working on the hydraulic system, make
sure that the system is without pressure and that
the residual pressures have also been eliminated.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 residu-
al pressure in parts of the hydraulic system, as e.g.
the primary pressure resulting from the last hy-
draulic 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 re-
quired, the necessary measures described
must be combined.
 Open the depressurized system section with
caution.
Fig. 3-74:
Fig. 3-75:
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 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Examples of system sections: The following screen appears on the BCS display:
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

Attachment circuits – Depressur-

ize
 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 in- Fig. 3-77:
stalled.
To continue depressurization mode:
 If the E stop was hit, reset it.
 move a joystick (115 or 116, Fig. 3-74) or
 Park the hydraulic shovel on level ground.
 a pedal (111) or
 Set the attachment on the ground.
 Shut off the engines.  a thumbwheel (118)
 Sit in the operator’s seat to activate the seat within the next 15 seconds.
switch (105, Fig. 3-72). Otherwise depressurization mode will be deac-
 Switch on the electric system with the key tivated.
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.

3-88

 In one second release “clam close” function.
 In one second actuate “clam open” function.
 In one second release “bucket dump” function.
 In one second actuate “bucket curl” function.
 In one second release all the functions.
The attachment circuits are depressurized.
Before starting any maintenance work on the hy-
draulic 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 “Pres-
sure checking and setting” in the Service Manual
of this machine.
Hydraulic system sections – De-
pressurize
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 “De-
pressurizing, bleeding and flushing the hydraulic
system” in the Service Manual of this machine.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Hydraulic oil level – Check
 Bring hydraulic oil to operating temperature
(abt. 50 °C / 122°F).
 Park the machine on a horizontal surface.
 Stand attachment on the ground as shown on
the sign (2, Fig. 3-79:).
The oil level must be between the “min” and “max”
marks of the sign (2, Fig. 3-79:) near the inspection
glass (1).
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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 EM024061-1
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 Stand attachment on the ground as shown on

the sign (Fig. 3-81:).
 Sign (2, Fig. 3-82:) is attached beside the hy-
draulic 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)”.

 Unscrew cap of express coupling (10).

Fig. 3-81: 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 / CONSUMA-
BLES”).
The acoustic warning signal “Travel Alarm”
sounds.
 Disconnect the filling hose; the express cou-
pling closes automatically.
 Screw protective cap back in place

Fig. 3-82:

If necessary, fill in hydraulic oil through the return-

flow 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 / CONSUMA-
BLES”).
 Before fitting the cover (19), check the sealing
ring and replace, if damaged.
Fig. 3-84:
 Fit cover together with sealing ring.

3-90
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Hydraulic Oil Analysis – Under-

stand Particle Count Results Tooling and Equipment
Refer to Special Publication M0080900 “Contami-
nation Control Guidelines, Filtration Procedure for
CGM-HMS recommends to carry out particle Hydraulic Mining Shovel Hydraulic Oil” for the se-
counting in any regularly performed oil analysis. lection of the required tools suitable for your ma-
In case the result of the particle count shows val- chine:
ues of above than “ 19 / 16 / 13 ”, an off-board  Hydraulic Oil Filtration Skid,
filtration of the hydraulic fluid is recommended.
The string “ 19 / 16 / 13 “ is a three factor code  Analyzer Group,
which shows levels of Particle Count Range ac-  Suction and Return Adapters,
cording to ISO 4406. This code represents fluid
cleanliness.  Hoses.
The three factor codes “ X / Y / Z “ represent three
different particle sizes:
Reference Literature
 X = particle size equal or larger than 4 microns,
Media-Id- Title
 Y = particle size equal or larger than 6 microns, Number
 Z = particle size equal or larger than 14 microns. M0080900 “Filtration Procedure for Hydraulic
Mining Shovel Hydraulic Oil”
The numbers in the code sample above represent
a particle number range, listed in ISO 4406: M0073390 “Tool Operating Manual 514-4590
 X : “19“ = 2500 – 5000 particles in 1 ml of fluid, to 514-4596 Hydraulic Oil Filtra-
tion Skid for Hydraulic Mining
 Y : “16” = 320 – 640 particles in 1 ml of fluid, Shovels”
 Z : “13” = 40 – 80 particles in 1 ml of fluid. NEHS0799 “Tool Operating Manual for 170-
This is the cleanliness level of new oil. 8500 Analyzer Group”
Note: This data shows only particle size, not the PEGJ0045 “Reporting Particle Count by ISO
specific particle composition (metal or not metal). Code”
For more detailed information about the particle PEGJ0047 “How to take a good S.O.S. Oil
composition a spectrographic analysis may help. Sample”
Please contact your Cat dealer for assistance. SEBF8482 “Obtaining an Oil Sample for
Analysis”
If the contamination values are above the recom-
mended values (“ 19 / 16 / 13 “), please perform
off-board filtration during the next and the after
next planned maintenance to confirm oil cleanli-
ness.

For more information about the filtration procedure

please refer to section “Reference Literature” and
ask your Cat dealer for assistance.

3-91
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Remove return flow filter elements

Hydraulic oil return-flow filters,  Remove covers (3, Fig. 3-86:) together with
sealing rings (5).
Replace
 Unscrew ring nuts (6) and remove retaining
disk (7).
Risk of scalding caused by hot hy-  Remove press parts (8) with o-rings (10).
draulic oil.
 Withdraw filter elements (9) with o-rings (11)
The hydraulic oil reservoir itself may from filter-baskets (12).
also be hot.
 Inspect filter elements for damage.
Wait until the hydraulic oil has cooled
If no damages are visible, insert new filter ele-
down before starting work on the
ments (9) with new o-rings (11) into filter-
filters.
basket (12), (see: “Install return flow filter ele-
Read and observe the "Inspection ments”).
and servicing – Safety instructions"
If a filter element (9) is damaged, remove filter-
chapter.
basket (12) and inspect / clean, (see: “Remove
filter-basket, inspect / clean”).
Shut off the engines.
Skin contact with hydraulic oil may cause skin inju-
ry. 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 ele- Fig. 3-85:
ments (9, Fig. 3-86:) are heavily contaminated;
 after repairs on the hydraulic system;
 in case of damage.

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 fil-
ings 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 Fig. 3-87:
wrench (torque = 79 Nm / 58.3 lbf ft).

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 contamina-
tion and foreign objects and eliminate the fail- Fig. 3-88:
ure. Otherwise there is a risk of serious dam-
age in the hydraulic system.
 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 - Remove return flow filter elements

Replace (from machine no.
340173 / DHN60173)
Risk of scalding caused by hot hy-
draulic 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 inju-
ry. 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.
 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 ele-
ments (9) with new o-rings (11) into filter-
basket (12), (see: “Install return flow filter ele-
ments”).
If a filter element (9) is damaged, remove filter-
basket (12) and inspect / clean, (see: “Remove
filter-basket, inspect / clean”).

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 ele- Fig. 3-89:
ments (9, Fig. 3-90:) are heavily contaminated;
 after repairs on the hydraulic system;
 in case of damage.

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 fil-
ings 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
Fig. 3-91:
(5). Tighten bolts (18) crosswise using a torque
wrench (torque = 79 Nm / 58.3 lbf ft).

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 contamina-
tion and foreign objects and eliminate the fail-
Fig. 3-92:
ure. Otherwise there is a risk of serious dam-
age in the hydraulic system.
 Replace o-ring (15) located in the filter brack-
ets 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 hy-
draulic 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 inju- Fig. 3-93:
ry. 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.

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 Fig. 3-94:
required.
 Insert bypass valves and fasten with bolts (1).

Replacing the bypass valves and seal-

ing rings
 Remove bypass valves as described under
"Cleaning the filter screens".
 Re-assemble the bypass valves with a new o-
ring (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

Hydraulic oil tank breather filters
- Replace
Risk of scalding caused by hot hy-
draulic 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 inju-
ry. 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Replacing the filter elements
Two breather filters (Fig. 3-95:) on top of the hy-
draulic 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 condi-
tions 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 con-
taminated.
To replace the filter elements:
 Unscrew bolts (2, Fig. 3-95:) and remove hold-
ing 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) - Replacing the filter element

Check / replace
Risk of scalding caused by hot hy-
draulic 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 imme-
diate vicinity carefully.
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 coun-
terclockwise 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 sys-
tem into operation.

Check for contamination and damage

 Unscrew filter housing (4, Fig. 3-96:) by coun-
terclockwise 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 paraf-
fin oil and check for contamination and dam-
age.
 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 or-
der.
 Screw in the filter housing (4) to stop. Then Fig. 3-96:
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 sys-
tem into operation.

3-98
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Hydraulic oil filters for working Replacing the filter elements

hydraulics – Check / replace  Place a suitable collecting recipient under the
To filter the hydraulic oil on the high-pressure side filter housings (Fig. 3-97:).
of the working hydraulic system, the machine is  Collect escaping hydraulic oil and used filter
equipped with eight high-pressure filters (arrows, elements. Discard without polluting the envi-
Fig. 3-97:). ronment.
The filters are attached to the valve block in front  Unscrew filter housing (5) by counterclockwise
of the hydraulic oil tank, they are accessible from rotation. Pour out the oil.
the pump compartment.
 Disengage filter element (2) with a slight turn
Risk of scalding caused by hot hy- from the centering spigot in the filter head.
draulic oil.
 Check filter housing (5) as well as used filter
The filter housings themselves may surface for debris.
also be hot.
 Clean filter housing (5) and the sealing faces
Wear protective gloves and firm
at the filter head with white spirit or paraffin oil.
working clothing.
 Check sealing ring (3) and support ring (4) on
Skin contact with hydraulic oil may
cause skin injury. Avoid skin contact. the filter housing for position and damage. Re-
place, if necessary.
Read and observe the "Inspection
and servicing – Safety instructions"  Install the new filter element (2) with a new
chapter. seal (1) on the spigot again by slightly turning
it.
 Shut off the engines.
 Screw in the filter housing (5) to stop. Then
 Depressurize the hydraulic system. turn out the filter housing by an 1/8 turn so that
 Clean the filter block and the filter housings the filter housing is not stuck due to pressure
carefully. pulsation and can be easily loosened in case
of maintenance works.
Check for contamination and damage  Check high-pressure filters for leaks after put-
 Unscrew filter housing (5, Fig. 3-97:) by coun- ting the hydraulic system back into operation.
terclockwise rotation. Pour out the oil.
 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 paraf-
fin oil and check for contamination and dam-
age.
 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 dam-
aged.
 Re-assemble the filter element in reverse or-
der.
 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 Fig. 3-97:
pulsation and can be easily loosened in case
of maintenance works.
 Check for leaks after putting the hydraulic sys-
tem into operation.

3-99
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Filters for swing pump charge Replacing the filter elements

circuit – Check / replace  Detach flanges (4, Fig. 3-98: and Fig. 3-99:).
The hydraulic shovel has four high-pressure filters  Remove filter housings (5) and pour out used
(Fig. 3-98:) for the charging circuits of the swing oil.
pumps.  Disengage filter element (6) with a slight turn
Two high-pressure filters each are installed beside from the centering spigot in the filter head.
the pump drive gearbox.
 Clean filter housing (5) and the sealing faces
Replace filter elements regularly according to the at the filter head with white spirit or paraffin oil.
maintenance plans and when the contamination
indicator (1) indicates a contamination, a red sec-  Install the new filter element (6) with a new,
tor is visible then through transparent cap (2). lightly oiled o-ring (7) on the filter heads spigot
by slightly turning it.
Risk of scalding caused by hot hy-
draulic oil.  Attach the filter housing (5) with a new, lightly
oiled sealing ring (8) to filter head.
The filter housings themselves may
also be hot.  Remount flanges (4).
Wear protective gloves and firm  Check for leaks after putting the hydraulic sys-
working clothing. tem into operation.
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 imme-
diate 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 paraf-
fin oil and check for contamination and dam-
age.
 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 dam-
aged.
 Re-assemble the filter element in reverse or-
der.
 Attach the filter housing (5) ) to filter head.
 Remount flanges (4).
 Check for leaks after putting the hydraulic sys-
tem into operation.
Fig. 3-99:

3-100
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Filters for swing circuits - Re- Replacing the filter elements

place
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 hy-
draulic 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.
 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 hous-
ing 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 sys-
tem into operation.

 Depressurize the hydraulic system.

 Clean the filter housings as well as the imme-
diate 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 paraf-
fin oil and check for contamination and dam-
age.
 If significant contamination or foreign objects
are detected, contact your Cat dealer service
immediately.
Fig. 3-100:
 Replace filter element (3) if it is damaged.
 Check seals (2 and 4) and replace, if dam-
aged.
 Re-assemble the filter element in reverse or-
der.
 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 sys-
tem into operation.

3-101

Bearing flushing for main pumps
- Replace filter
Bearing flushing, function
The hydraulic shovel has two bearing flushing cir-
cuits for the main hydraulic pumps.
The bearing flushing circuit removes air pockets in
the housing of the main pumps and reduces inter-
nal temperature. This also increases life expectan-
cy 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".
Shut off the engines.
Relieve the hydraulic system totally from pressure.
Avoid potentially harmful skin contact with hydrau-
lic oil.
Wear protective gloves and firm protective cloth-
ing.
Collect escaping hydraulic oil, used filter elements
and oil impregnated cleaning rags and discard
without polluting the environment.
3-102
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
 Relieve pressure from filter housing. To do so,
loosen screw plug (7, Fig. 3-102:).
 Unscrew filter housing (5) without spilling hy-
draulic 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 fil-
ter 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 mainte-
nance 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.
Fig. 3-101:
Fig. 3-102:

Hydraulic oil – Change
Risk of scalding caused by hot hy-
draulic oil.
The hydraulic oil reservoir itself may
also be hot.
Read and observe the "Inspection and
servicing – Safety instructions" chap-
ter.
Shut off the engines.
Skin contact with hydraulic oil may cause skin inju-
ry. 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 sam-
pling that is stated in the Operation and Mainte-
nance 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 im-
portant 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 publica-
tion 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 elimi-
nate any fluid incompatibility issues.
3-103

Drawing off hydraulic oil
 Bring the hydraulic oil to operating temperature
(abt. 50 ° C / 122°F).
 Retract the hydraulic cylinders as far as possi-
ble 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 re-
quired capacity refer to the "Refilling quantities
- Oil" table.
 Unscrew the hose line; the oil drain valve clos-
es automatically.
 Screw protective cap back in place.
Fig. 3-103:
3-104
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Drawing off hydraulic oil using the Ser-
vice 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 auto-
matically.
 Screw on protective cap.
Fig. 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 spe-
cial 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
Fig. 3-105:
or special flushing and cleaning fluids without pol-
luting the environment and separately from other
waste.

 Close the shut-off valves in the suction pipes

at the hydraulic tank (arrows, Fig. 3-105:).
 Detach the return-flow filters, see chapter “Hy-
draulic oil return-flow filters, replace”.
 Detach the bypass valves, see chapter “By-
pass 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.
Fig. 3-106:
 Clean the inside of the hydraulic oil tank with
diesel fuel or special flushing and cleaning flu-
id.
Remove all sediments and also the residues of
the cleaning agent thoroughly.
 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 (ar-
rows, Fig. 3-105:).

3-105

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 / CONSUMA-
BLES”).
 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:).
Fig. 3-107:
Fig. 3-108:
3-106
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 / CONSUMA-
BLES”).
The acoustic warning signal “Travel Alarm”
sounds.
 The oil level is also displayed on the BCS-
screen (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. 3-109:
Fig. 3-110:

Hydraulic system – Vent
Hydraulic pumps, hydraulic motors, hydraulic cyl-
inders, travel brake valves, suction lines of hydrau-
lic pumps, oil cooler manifolds and the servo con-
trol system must be vented
 after assembly on site and prior to initial com-
missioning,
 before each recommissioning of the hydraulic
shovel, e.g. after extensive repair work to the
hydraulic system or after prolonged down-
times,
 after each hydraulic oil change,
 after replacement of hoses or lines.
Venting / filling the hydraulic compo-
nents
 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 move-
ments of the attachment are a sign of en-
trapped air in the system. Remaining air pock-
ets 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 ex-
treme piston positions. In other words, the pis-
ton rod (1, Fig. 3-111: and Fig. 3-112:) must be
either completely retracted or completely ex-
tended.
Fig. 3-111:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Fig. 3-112:
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 piston-
side port (4).
When oil is admitted for the first time to the cyl-
inder, 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).
3-107
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Hydraulic oil cooler – Clean Cleaning

The hydraulic oil coolers are located in the oil
Risk of injury from rotating cooler fan cooler module.
blades.
Clean the hydraulic oil coolers at regular intervals.
Shut off the engines.
 Shut off the engines.
Never start cleaning work until the
cooler fan blades have stopped turn-  Remove any accumulated dirt.
ing.  Clean the fan blades (2).
The hydraulic oil coolers reach the  Clean the radiators with a jet of water or com-
same temperature as the hydraulic oil. pressed air from outside to inside.
Risk of burning.
 Leave hydraulic oil coolers to dry.
Allow the hydraulic oil cooler to cool
down.  Check the hydraulic motors (1) for free move-
ment.
Wear protective gloves and firm pro-
tective clothing. 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 con-
taminated 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 maxi-
mum 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 con- Pedal

trols - Clean / lubricate At regular intervals acc. to the maintenance plans:
 Remove old grease and dirt from the control
Joystick
spools and the actuator plate of the pedals (ar-
At regular intervals acc. to the maintenance plans:
rows, Fig. 3-115:).
 Loosen gaiter and move upwards.
 Apply a thin layer of low temperature grease
 Apply a thin layer of low temperature grease on the control spools of the pedals to prevent
on the control spools, the actuator plate above jamming of the control spools.
and the cardan joint of the joysticks (arrows,
Fig. 3-114:) to prevent jamming of the joy-
sticks.
 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 - Emer- Extract from the German regulations

gency lowering
To permit the attachment to be lowered in an
emergency, the machine is equipped with a pres-
sure accumulator (arrow, Fig. 3-116:).
The pressure accumulator is located in the module
beneath the operator’s cab.
Fig. 3-116:
Pressure-accumulator inspection regu-
lations
The following regulations are appli-
cable only in Germany. Please ob-
serve the relevant regulations in force
in your own country.
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 "Druckbehälterverord-
nung (DruckbehV)" [Pressure Vessel Regulations].
Their installation, equipment and operation are
governed by the "Technische Regeln Druck-
behälter (TRB)" [Technical Rules for Pressure
Vessels]. The pressure vessels of hydraulic accu-
mulators 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 pres-
sure 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.

Group Inspections prior to commissioning Regular

at the factory at the place of use inspections
II Pressure testing Inspection certificate Inspection schedule to be
p  l bar Prototype and pressure test (Check of correctness and drawn up by end user, based
and certified by the manufacturer correct installation) on experience with type of
p·x l  200 issued by an expert operation and fluid.

3-110
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

PUMP DRIVE GEARBOX

Risk of scalding caused by hot gear-

box oil. The gearbox housings may be
hot too.
Shut off the engines.
Skin contact with gearbox oil is a po-
tential 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”.

Fig. 3-117:
Pump drive gearbox – Check oil
level / Top up with oil
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:).
Fig. 3-118:
Do not screw in.
 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 / CONSUM-
ABLES”).
 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

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 reser-
voir (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 inspec-
tion glass (3).
 Screw breather filter back in place.
Fig. 3-119
3-112
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Pump drive gearbox oil sample -
Obtain
Risk of scalding caused by hot gear-
box oil. The gearbox housings may be
hot, too.
Skin contact with gearbox oil is a po-
tential 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 sam-
ple, refer to:
 Special Publication, SEBU6250, “Caterpil-
lar Machine Fluids Recommendations”
“S·O·S Oil Analysis”,
 Special Publication, PEGJ0047, “How To
Take A Good Oil Sample”.
 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 op-
erating 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. Fig. 3-120:
The coupling closes automatically.
 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 Fig. 3-121:
”max” mark on dipstick (1, 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 cor-
rect 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 Pump drive gearbox breather

oil valve - Replace
The pump drive gearbox is vented through a
Draining off oil breather valve, mounted on top of the gearbox
housing (arrow, Fig. 3-123:).
 Prepare a collecting recipient for used oil.
 Replace breather valve in accordance with the
Choose the required capacity in accordance
servicing plan.
with the "Refilling quantities - Oil" table.
 Clean area around the breather to prevent
 Unscrew plugs (7, Fig. 3-122) and drain off oil.
contamination of the gearbox.
 Screw plugs (7) back in place.
 Unscrew breather filter and replace by a new
one.
Filling in oil
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 - Re-

place
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 fil-

ters - Replace
In the oil cooling circuit of each pump drive gear-
box there is a filter element (Fig. 3-125:).
Check filter tell-tale (1, Fig. 3-126:) regularly - at
operating temperature - for indication of contami-
nation.
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 Fig. 3-125:
remove filter element (5).
 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 Swing gearbox - Check oil level /

Risk of scalding caused by hot gear-
box oil. The gearbox housings may be
hot too.
Shut off the engines.
Skin contact with gearbox oil is a po-
tential 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”.
Top up with oil
 Park the machine as described under "Secur-
ing 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 low-
er mark on dipstick (1).
 Top up with gearbox oil through the opening of
plug (4), if required.
(oil grade see: „LUBRICANTS / CONSUMA-
BLES“).
To reach plug (4) remove cover plate above
swing gearbox.
 Screw dipstick (1) back in place.

Swing gearbox oil sample - Ob-

tain

Risk of scalding caused by hot gear-

box oil. The gearbox housings may be
hot, too.
Skin contact with gearbox oil is a po-
tential health hazard. Protect the skin
from contact with gearbox oil. Wear
protective gloves and firm working
clothing. Fig. 3-128:

Obtain an oil sample of the swing drive oil through

the opening for the oil level dipstick (1, Fig.
3-128:).
Swing gearbox - Vent
Refer to CGMHMS publication “Service Manual for
Oil Samples and Oil Analysis” for more information. The gearbox is vented through breather filter (2,
Fig. 3-128:).
Clean breather filter in accordance with the servic-
For additional information about taking an oil sam- ing plan.
ple, refer to:
 Unscrew breather filter (2), clean in white spirit
 Special Publication, SEBU6250, “Caterpil-
or paraffin oil and blow dry with compressed
lar Machine Fluids Recommendations”
“S·O·S Oil Analysis”, air.
 Special Publication, PEGJ0047, “How To  Screw breather filter (2) back in place.
Take A Good Oil Sample”.

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 op-
erating 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 ac-
cessible from below the undercarriage.
The use of the oil draining hose is described in
the "Hose line for oil and cooling liquid chang-
es" chapter.
 Drain off gearbox oil.
 Remove hose. The oil drain valve closes au-
tomatically.
 Fill in fresh gearbox oil, see: “Filling in new oil / Fig. 3-131:
Topping up”.

Fig. 3-129:

3-118
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Fill in new oil / Top up

(oil grade see: „LUBRICANTS / CONSUMA-
BLES“).
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 res-
ervoir (arrow, Fig. 3-134:).
 Connect other end of the filling hose to ex-
press coupling at the swing gearbox (1, Fig.
3-135:).
Fig. 3-133:
 Open ball valve at filling hose (Fig. 3-133:) and
fill swing gearbox with gearbox oil.
 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 Spur gear section – Check oil level /

(GEARBOX P/N 3683483)
Risk of scalding caused by hot gear-
box oil. The gearbox housings may be
hot too.
Shut off the engines.
Skin contact with gearbox oil is a po-
tential health hazard. Protect the skin
from contact with gearbox oil. Wear
protective gloves and firm working
clothing.
Top up with oil
 Check oil level at the inspection glass (2, Fig.
3-137:).
The oil level should reach the center of the in-
spection glass. Top up with oil if required
through the bore of plug (4).
Oil grade see: “LUBRICANTS / CONSUMA-
BLES”.

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 / CONSUMA-
BLES”.
To identify the gearbox part number (P/N) check
the name plate attached to the gearbox.

Travel gearbox - Check oil level / Fig. 3-137:

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 / CONSUMA-
BLES”.
 Screw checking plug (1) back in place.
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 / CONSUMA-
BLES”.

Fig. 3-136:
Fig. 3-138:

3-120

Travel gearbox - Change oil
Carry out oil change when oil is nearly at operating
temperature. All suspended particles and contami-
nations 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
 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 / CONSUMA-
BLES”.
 Screw plugs (1 and 3) back in place.
Fig. 3-139:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 / CONSUMA-
BLES”.
 Screw plug (4) back in place.
Fig. 3-140:
3-121
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Brake housing - Change oil Travel gearbox breather filter –

Drain off oil Replace
 Place a collecting recipient for used oil under  Unscrew breather filters (1 and 5, Fig. 3-142:)
the brake housing. and clean in white spirit or paraffin.
Choose the required capacity in accordance
with the "Refilling quantities - Oil" table.
 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).
Fig. 3-142:
Oil grade see: “LUBRICANTS / CONSUMA-
BLES”.
 Screw plug (6) and breather filter (5) back in
place. Travel gearbox oil sample – Ob-
tain

Risk of scalding caused by hot gear-

box oil. The gearbox housings may be
hot, too.
Skin contact with gearbox oil is a po-
tential 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:
Fig. 3-141:  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 sam-

ple, refer to:
 Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “S·O·S Oil
Analysis”,
 Special Publication, PEGJ0047, “How To Take
A Good Oil Sample”.

3-122

TRAVEL GEARBOX
(GEARBOX P/N 3683496)
Risk of scalding caused by hot gear-
box oil. The gearbox housings may be
hot too.
Shut off the engines.
Skin contact with gearbox oil is a po-
tential 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 / CONSUMA-
BLES”.
To identify the gearbox part number (P/N) check
the name plate attached to the gearbox.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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: „“LUBRI-
CANTS / CONSUMABLES”.
Fig. 3-143:
Fig. 3-144:
3-123

Hydraulic motor chamber - Brake hous-
ing – Check oil level / Top up with oil
 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 / CONSUMA-
BLES”.
Fig. 3-145:
3-124
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Travel gearbox oil sample – Ob-
tain
Risk of scalding caused by hot gear-
box oil. The gearbox housings may be
hot, too.
Skin contact with gearbox oil is a po-
tential 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 sam-
ple, refer to:
 Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “S·O·S Oil
Analysis”,
 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 contami-
nations 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 Fig. 3-146:
plug at the bottom side of the hollow wheel (ar-
row) and drain off the oil completely.
Slackening plug (3) allows the oil to run out
more readily.
 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. Fig. 3-147:
Driving longer distances may damage
the gearbox.
Remember, the gearbox is without oil.

 Unscrew screw plug (3).

 Fill in oil through bore of plug (3) until it flows
out of the bore.
Oil grade see: “LUBRICANTS / CONSUMA-
BLES”.
 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 hous- Travel gearbox breather filter –

ing - Change oil Replace
Draining off oil  Unscrew breather filters (1 and 5, Fig. 3-150:)
 Place a collecting recipient for used oil under and clean in white spirit or paraffin.
the hydraulic motor chamber.
Choose the required capacity in accordance
with the "Refilling quantities - Oil" table.
 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 / CONSUMA-
BLES”.
 Screw plug (6) and breather filter (5) back in
place. Fig. 3-150:

Fig. 3-149:

3-126

TRAVEL GEARBOX
(GEARBOX P/N 3749598)
Risk of scalding caused by hot gear-
box oil. The gearbox housings may be
hot too.
Shut off the engines.
Skin contact with gearbox oil is a po-
tential 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 / CONSUMA-
BLES”.
To identify the gearbox part number (P/N) check
the name plate attached to the gearbox.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 re-
quired 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: „“LUBRI-
CANTS / CONSUMABLES”.
Fig. 3-151:
Fig. 3-152:
3-127

Hydraulic motor chamber - Brake hous-
ing – Check oil level / Top up with oil
 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 / CONSUMA-
BLES”.
Fig. 3-153:
3-128
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Travel gearbox oil sample – Ob-
tain
Risk of scalding caused by hot gear-
box oil. The gearbox housings may be
hot, too.
Skin contact with gearbox oil is a po-
tential 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 sam-
ple, refer to:
 Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “S·O·S Oil
Analysis”,
 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 contami-
nations 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 Fig. 3-154:
plug at the bottom side of the hollow wheel (ar-
row) and drain off the oil completely.
Slackening plug (1) allows the oil to run out
more readily.
 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 / CONSUMA-
BLES”. 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 hous- Travel gearbox breather filter –

ing – Change oil Replace
Draining off oil  Unscrew breather filters (1 and 5, Fig. 3-154)
 Place a collecting recipient for used oil under and clean in white spirit or paraffin.
the hydraulic motor chamber.
Choose the required capacity in accordance
with the "Refilling quantities - Oil" table.
 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 / CONSUMA-
BLES”.
 Screw plug (6) and breather filter (5) back in
place. Fig. 3-158:

Fig. 3-157:

3-130

CRAWLER TRACKS
Cleaning
Clean tracks, track and upper rollers, sprockets
and idlers regularly and whenever required. Clean-
ing 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.
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. 3-159:
Track roller fastening - Check
Check fastening bolts (4, Fig. 3-156) regularly for
tightness:
 Tighten bolts with a torque wrench to the pre-
scribed tightening torque (see "Service Manu-
al“).
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Upper roller fastening - Check
 Check fastening bolts (3, Fig. 3-156) regularly
for tightness.
 Tighten bolts with a torque wrench to the pre-
scribed tightening torque (see "Service Manu-
al“).
Fig. 3-160:
Undercarriage – Check for leaks
and free movement
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 mount-
ing bolts.
Listen for any abnormal noises while you are mov-
ing slowly in an open area.
If abnormal wear exists or abnormal noises or
leaks are found, consult your Caterpillar dealer.
3-131
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Track roller - Lubricate

(Not applicable at machines equipped with under-
carriage lubricating system).
The track rollers (Fig. 3-158) have a lifetime
grease filling with Tribol® (see chapter “LUBRI-
CANTS / 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 Fig. 3-161:
line.
 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:

3-132
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Track tensioning system Technical data

Design Track tensioning pres- appr. 7000 kPa / 1015
sure psi
Each crawler track is kept automatically and con-
Pressure limiting valve appr. 33000 kPa / 4786
stantly tensioned by a hydraulic track tensioning
psi
system. After starting one or both engines the track
Gas pressure in dia- appr. 5000 kPa / 725
tensioning system is pressurized.
phragm accumulator psi
Prior to start of operation and after repair work on (nitrogen filling pres-
the track tensioning system make sure that the sure)
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:

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 limit-
ing valves (3) to the limit stop.

Fig. 3-163:

1 Pressure accumulator
2 Pressure cylinder
3 Pressure limiting valve
4 Mini- measuring port
5 Stop cock valve

The tensioning system is under permanent pres-

sure of ca. 7000 kPa / 1015 psi which keeps both
tracks permanently tensioned. Pressure losses are
compensated as soon as the engines have been Fig. 3-164:
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.

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”).

3-133

Pressure-accumulator inspection
regulations
The following regulations are appli-
cable only in Germany. Please ob-
serve 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 "Druckbehälterverord-
nung (DruckbehV)" [Pressure Vessel Regulations].
Their installation, equipment and operation are
governed by the "Technische Regeln Druck-
behälter (TRB)" [Technical Rules for Pressure
Vessels]. The pressure vessels of hydraulic accu-
mulators 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:
Tab. 3-1
Group Inspections prior to commissioning
at the factory at the place of use
IV Preliminary inspection by an Acceptance inspection by an
p  l bar expert expert
p·x l  1000 Prototype and pressure test
certified by the manufacturer
(type approval) or the expert
3-134
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Checking the gas charging pres-
sure 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 re-
quired by the "Pressure Vessel Regulations".
Before checking the gas charging pressure (nitro-
gen filling pressure) in the pressure accumulator,
the track must first be slackened, i.e. the hydraulic
part of the tensioning system must be depressur-
ized. See under "Function".
Regular
inspections
Internal inspection:
every 10 years for non-
corrosive 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 Internal gearing

The internal gearing (1, Fig. 3-166:) and the pinion
Read and observe: "Inspection and (2) are enclosed in a housing (3, Fig. 3-167:). The
servicing - Safety instructions. 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 cloth-
ing.

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 im-
mediately to prevent damage to the swing ring. Fig. 3-166:

Greases and greasy cleaning rags must not be The grease is pumped to the greasing port of the
allowed to pollute the environment. Discard grease trough by the distributor (Fig. 3-165:). The
grease and greasy cleaning rags separately from amount of grease used up during operation is re-
other waste without polluting the environment. plenished by the central lubricating system.
The housings have a check opening which is
closed with a cover (2, Fig. 3-167:). For checking,
Bearing races the cover must be removed.
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. 3-167:

Fig. 3-165:

3-135

Swing ring grease filling – Check
Read and observe: "Inspection and
servicing - Safety instructions.
Shut off the engines
Wear protective gloves and firm protective cloth-
ing.
At regular intervals
 check internal gearing and teeth of swing
mechanism pinion for condition
 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 dam-
aged by continued swing movements.
Fig. 3-168:
3-136
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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,
 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.
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: "Ser-
vice Manual").

CENTRAL LUBRICATING SYS-
TEM
Central lubrication system - De-
sign
The hydraulic shovel is equipped with an automatic
central lubricating system which provides grease
regularly to all greasing points except those men-
tioned in the "Lubricating chart - Grease".
The central lubricating system is activated when
the electrical system is switched on with the key-
switch 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 electro-
hydraulically by one of the controllers of the CAMP
system.
Fig. 3-169:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 contami-
nated.
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 func-
tion 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. 3-170:
3-137
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Central lubrication system - Func-

tion
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 struc-
ture and attachment, pump (3) supports the under-
carriage (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
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Grease container – Fill up Grease container breather filter -

Always refill the grease container in time to avoid Check / replace
air from penetrating into the greasing system. Air in Check / replace the breather filter of the grease
the greasing may cause malfunctions. container at regular intervals.
Fill up the grease container through the service
 Unscrew wing nut on top of the breather filter.
station (Fig. 3-173:).
A description of the Service Station (Fast fill arm)  Withdraw cover (1, Fig. 3-174:) and filter ele-
can be found in Part 2 of this manual, chapter ment (2).
“Service Station (fast fill arm)”.  Check the filter element (2) and replace if it is
 Switch on the indicator system with toggle soiled or damaged.
switch (23, Fig. 3-173:). Monitoring lamp (22)  Replace sealing rings of the filter element.
lights up.  Re-install breather filter.
 Unscrew the cap of the express coupling (11).
 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:

3-139
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Greasing pressure - Check Grease line - Unblock

Check regularly (accord. to the maintenance plan), In the event of faults at the central greasing system
whether the oil pressure indicated by pressure inform the responsible maintenance personnel
gauge (3, Fig. 3-175:) at the hydraulic oil filter is 55 immediately. Detailed information about the central
– 6000 kPa / 798 - 870 psi. greasing system can be found in the “Technical
The pressure is depending on temperature and Handbook” chapter 11.
viscosity of the oil and may vary. Even when the grease pump isn’t active, there can
This oil pressure is reduced so that the pressure be residual pressures in the grease lines up to
indicated by pressure gauge (2) is 3500 – 4000 3000 kPa (435 psi).
kPa / 507 – 580 psi and by pressure gauge (1) is Relieve this residual pressure before opening a
4900 – 5100 kPa / 711 – 740 psi. grease line.
The necessary greasing pressure of 32000 kPa / Put the hydraulic shovel back into operation only
4641 psi for the upper structure and 18000 kPa / after the greasing system works properly and after
2611 psi for the lower carriage is generated by having actuated the unloaded attachment for abt. 5
means of a pressure translator. minutes. This is necessary in order to supply suffi-
The greasing pressure for upper structure and cient amounts of grease to the cylinder bearings.
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 mainte-
nance personnel. The central greasing system has
to be checked.
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

Oil filter (hydraulic circuit grease
pump) - Replace
Risk of scalding caused by hot hy-
draulic 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 work-
ing clothing.
Skin contact with hydraulic oil may
cause skin injury. Avoid skin contact.
Read and observe the "Inspection and
servicing - Safety instructions" chap-
ter.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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 op-
eration.
Fig. 3-176:
3-141
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Grease filter (filling the grease

container) - Check / replace Replacing the filter element
A grease filter (arrow, Fig. 3-177:) is installed in the
Shut off the engines. grease filling line to the grease container.
Switch off the electrical system. Replace filter element regularly according to the
Skin contact with grease may cause maintenance plans.
skin injury. Avoid skin contact.  Unscrew filter housing (4).
Read and observe the "Inspection and  Withdraw filter element (2) from housing.
servicing - Safety instructions" chap-
 Remove the grease.
ter.
 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
Checking for contamination and dam- sealing rings (1 and 3).
age  Check for leaks after putting the filter into op-
 Unscrew the filter housing (4, Fig. 3-177:). eration.
 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 reassem-
ble 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
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Grease filter (grease lines) -

Check / replace Replacing the filter element
Two grease filters (Fig. 3-178:) are installed in the
Risk of injury by grease under pres- greasing lines to the grease distributors.
sure. Replace filter element regularly according to the
Shut off the engines. maintenance plans.
Switch off the electrical system.  Unscrew filter housing (4).
Skin contact with grease may cause  Withdraw filter element (2) from housing.
skin injury. Avoid skin contact.
 Remove the grease.
Read and observe the "Inspection and
servicing - Safety instructions" chap-  Clean filter housing and contact faces at the
ter. 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 op-
Checking for contamination and dam- eration.
age
 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 reassem-
ble 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

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 OPER-
ATE”.
Accumulated grease and oil on an
engine is a fire hazard. Keep the en-
gine 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 spray-
washed with steam-jet cleaners or
high-pressure cleaners. It will be dam-
aged. Therefore cover all the insulat-
ing material with plastic foils before
using steam-jet cleaners or high-
pressure cleaners inside the engine
compartments.
3-144
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Periodic cleaning of the engines is recommended.
Steam cleaning the engines will remove accumu-
lated 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 elec-
trical 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 clear-
ance.
Use the travel pedals to move the machine for-
ward. The travel alarm should sound.
Release the travel pedals in order to stop the ma-
chine.
Use the travel pedals to move the machine back-
ward. The travel alarm should sound.
Stop the machine.
Lower the work tool to the ground.
Stop the engines.
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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. Fig. 3-179:

The maximum air pressure for cleaning purposes Radiators located in the counterweight:
must be reduced to 205 kPa (30 psi) when the air 1 – Engine intake air aftercooler
nozzle is deadheaded. 2 – Engine cooling liquid
Do not clean radiators with a wire brush or similar
hard objects.
Pressurized air is the preferred method for remov-
ing loose debris. Direct the air in the opposite di-
rection of the air flow. Hold the nozzle approxi-
mately 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 purpos-
es must be less than 275 kPa (40 psi). Use pres-
surized 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 Fig. 3-180:
core with detergent and hot water. Thoroughly
rinse the core with clean water. Radiators located in the oil cooler module:
In case of firmly adhering dirt, remove radiator and 3 – Hydraulic oil coolers
clean. 4 – Pump drive gearbox oil coolers
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, connec-
tions, clamps and seals.
Make repairs, if necessary.

3-145
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Aftercooler Core - Clean/Test Reservoirs for used grease at the

Note: A-frame - Empty
Adjust the frequency of cleaning according to the Remove used grease from the reservoirs (Fig.
effects of the operating environment. 3-182:) regularly according to the maintenance
Inspect the aftercooler for these items: damaged plans.
fins, corrosion, dirt, grease, insects, leaves, oil and Do not re-use the grease because it is polluted.
other debris. Clean the aftercooler, if necessary. Dispose off used grease as well as cleaning rags
For air-to-air aftercoolers, use the same methods without polluting the environment and separately
that are used for cleaning radiators. from other waste.
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, connec-
tions, clamps and seals.
Make repairs, if necessary.
Contact your Caterpillar dealer for more infor-
mation.

Fig. 3-182:

Fig. 3-181:

Radiators located in the counterweight:

1 – Engine intake air aftercooler
2 – Engine cooling liquid

3-146

Air conditioning filter – Clean
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.
 Clean or replace filter mats.
 Close housing.
Fig. 3-183:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Attachment - Check for cracks
Check the welded joins of the attachment regular-
ly.
Inspections must be carried out acc. to the "Struc-
tural Inspection Reports" every 500 OH.
"Structural Inspection Report" forms for those in-
spections 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:).
Fig. 3-184:
Fig. 3-185:
3-147

Clam cylinder chamber - Check
for soiling
In unfavourable circumstances during working
operation loose material can reach the clam cylin-
ders chambers in the shovel rear wall.
To avoid damage to the clam cylinders and their
hydraulic lines and hoses, inspect the clam cylin-
der chambers before starting each working shift.
Fig. 3-186:
 Lift up the rubber cover plate of the clam cylin-
der 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
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. 3-187:
 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 ma-
chine (arrow, Fig. 3-188:).
Hand tools may be needed in order to adjust
the mirrors.

Fig. 3-188:

3-149

Seat belt – Inspect
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 dam-
age.
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 exten-
sion, 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).
Fig. 3-189:
3-150
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Seat belt – Replace
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 installa-
tion 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 exten-
sion, also perform this replacement procedure for
the seat belt extension.
Fig. 3-190:
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
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 op-
erator greater visibility while machine operation.
The cameras can be positioned for best view but
as a minimum should optimize the operator's visi-
bility 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 Fig. 3-191:
cameras.
Note: In order to access the cameras it may be
Note: The cameras are equipped with an internal
necessary to use a portable access system (lad-
heater to help counteract the effects of condensa-
der, stair assembly, man lift, or other portable ac-
tion, snow, or ice.
cess system) that is suitable and compliant to local
regulations. The cameras are sealed units. The cameras are
not affected by high-pressure spray.
Make sure that the cameras are in proper working
condition and that the cameras are clean. For more information on the camera system refer
to:
Adjust the cameras for the best visibility close to
the machine. - Operation and Maintenance Manual, “Monitoring
Cameras - Function”,
Check/Clean/Adjust all cameras at the beginning
of each work period and check/clean/adjust the - Camera manufacturer documentation which can
cameras when you change operators. be found in volume 5 “Components” of the shovels
Technical Documentation.
 Park the machine on a level surface.
 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.

3-151

Horn – Inspect / Replace
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.
Note:
Use a working platform or a man lift machine for
work carried out in great height. Wear your per-
sonal protective equipment and approved fall pro-
tection equipment.
Fig. 3-192:
3-152
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING
Inspect
 Park the machine.
 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 connec-
tion 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 vi-
cinity of the horn.
If the horn does not sound or sounds inade-
quately / too quiet, it must be replaced imme-
diately.
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) (Tight-
ening torque = 79Nm / 58 lbf ft).
 Connect the electrical connector to the power
cable.
 Check the function.
Note:
Wear hearing protection in the immediate vi-
cinity of the horn.
Fig. 3-193:
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Hydraulic ladder – pressure ac-

cumulator
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 accumula-
tor (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:

3-153
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

Pressure-accumulator inspection Pressure accumulator - Checking

regulations the gas charging pressure
The following regulations are applica- After commissioning (new installation or repair),
ble only in Germany. Please observe the gas charging pressure in the pressure vessel
the relevant regulations in force in must be checked at least once during the first
your own country. 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
Extract from the German regulations either, the testing interval can be fixed at once
The accumulator vessel must not be subjected to pressure test each year.
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 "Druckbehälterverord-
nung (DruckbehV)" [Pressure Vessel Regulations].
Their installation, equipment and operation are
governed by the "Technische Regeln Druck-
behälter (TRB)" [Technical Rules for Pressure
Vessels]. The pressure vessels of hydraulic accu-
mulators 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 Inspections prior to commissioning Regular

at the factory at the place of use inspections
III Preliminary inspection by an Acceptance inspection by an Inspection schedule to be
p  l bar expert expert drawn up by end user, based
and Prototype and pressure test on experience with type of
p·x l  200 certified by the manufacturer operation and operating flu-
bars (type approval) or the expert ids.
p·x l  1000
bars

3-154
 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 sys-
tem.
Crane engine
More and detailed information about the diesel
engine can be found in the Operating and Mainte-
nance Manual for the crane engine.
 Before each shift check engine oil level. If nec-
essary top up with engine oil through opening
of dipstick (3, Fig. 3-197:).
 After each shift fill up fuel tank (1).
Fig. 3-197:
 Regularly check batteries (4) and cable con-
nections.
 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.

Hydraulic system
For more and detailed information, see crane op-
erating instructions.
 Prior to each deployment, check the hydraulic
oil level at the inspection glass (1, Fig. 3-198:);
Fig. 3-198:
top up with hydraulic oil if necessary.
 Check contamination of hydraulic oil filter regu-
larly at contamination indicator (4).
 Regularly, but at least once a year replace the
hydraulic oil filter (3) and the breather filter (2).

3-155
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

On-board crane - Lubricate On-Board crane fastening bolts -

Servicing work Check tightness
 Lubricate all bearings regularly and as re-
quired, and spray swing ring with a graphite The hydraulic driven on-board crane (Optional) is
spray (Fig. 3-199:). 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
1 bearing 4 lube points
safety relevant components, they carry all loads
2 joint (column/boom) 2 lube points and forces of the crane.
3 cylinder bearing 5 lube points
Check tightness of all fastening bolts:
4 swing ring Graphite spray
 in regular intervals according to the mainte-
nance 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 fas-
tening bolts M20, quality 10.9, lightly oiled is: 557
Nm.

Fig. 3-199:

Fig. 3-200:

3-156
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

PUTTING THE HYDRAULIC Battery storage

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, re-
tracting the piston rods of the hydraulic cylin-
ders as far as possible.
 Set all control element to "0".
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 fol-
lowing 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 out-
side.

 Clean the machine.

 Carry out a visual inspection of the hydraulic
shovel. Recommissioning
 Remove coarse dirt, snow and ice from the fins  Remove the covers.
and fan wheel of the hydraulic oil cooler.  Degrease / clean all protected components.
 Carry out engines preservation. Ask your Cat  Remove engines preservation. Ask your Cat
dealer for assistance dealer for assistance.
 Protect all bright metal parts (e.g. piston rods)  Check the fuel level in tanks.
from rust and dirt.
 Check track tension (visual inspection).
 Check anti-freeze concentration of the cooling
 Check level and condition of the cooling liquid
liquid to avoid freezing during the cold season.
in the cooling system.
 Fill up the fuel tanks.
 Check grease filling in grease container.
 Remove the batteries; see: "Battery storage".
 Oil level - drive engines,
 Secure the machine against unauthorized - swing gearboxes,
starting by: - pump drive gearboxes,
withdrawing the key from the key-switch, - travel gearboxes.
locking the cab door,
 Check oil level in hydraulic oil reservoir.
securing all lockable hatches.
 Check battery acid density and level.
 Cover up all openings.
 Install batteries and reconnect.
 Function checks: - upper structure holding
brake,
- track brake,
- lighting system,
- signaling equipment.
 Vent the hydraulic system.

3-157
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

3-158
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

NOTES

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3-159
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INSPECTION AND SERVICING

3-160
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK

4 REPAIR WORK

Operation and Maintenance Manual Target group

Part 1 INTRODUCTION Operating personnel

+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.

Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.

Part 4 REPAIR WORK 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

4-1
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK

4-2

REPAIR WORK - SAFETY IN-
STRUCTIONS
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 instruc-
tions attached to the machine.
The descriptions of job sequences provide only
experienced personnel with the necessary instruc-
tions.
The Operation and Maintenance Manual must be
kept with the machine at all times.
Repair personnel
Repair personnel must have know-how and expe-
rience relevant to repairing this or comparable
machines.
In the absence of such know-how, meticulous
training must be given by experienced repair per-
sonnel, 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 re-
place 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
Dismantling components
Never do dismantling while the machine is at op-
erating temperature.
Oils, greases, or coolants may have a high tem-
perature 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 oth-
er 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 ex-
posed 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 ma-
chine parts with a grease film.
On completing the work, re-assemble all protec-
tive devices, covers and noise- and vibration-
insulation 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 mon-
oblock 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 com-
ponents in order to carry out inspections or repairs Fig. 4-1:
such as welding work.
Dangerous situations can also exist in other spac-
es which are not very often visited or which are
badly ventilated. In these spaces, harmful or flam-
mable gases can accumulate unnoticed.

Work in such spaces may only be carried out by

specially qualified persons who have been in-
structed 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
Fig. 4-2:
risk of fire.
 Use your personal protective equipment, e.g.
respiratory mask.
 Use a safety harness and have a second per-
son stand by with a rescue rope attached to
the harness.
 Evacuate the gases produced during welding.

Fig. 4-3:

4-4

REPAIR WORK, FIRE AND EX-
PLOSION HAZARD
Safety instructions
Prior to commencing work, obtain
information on the national and corpo-
rate rules for the prevention of acci-
dents and avoiding fires.
Pay particular attention to hazards
caused by combustible and easily
flammable substances.
Obtain information on the safe han-
dling 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 sub-
stances or liquids increase the risk of fire and ex-
plosion. This is also valid for pressure vessels con-
taining 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 mainte-
nance operations, they must be completely re-
moved 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.
 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
Place suitable fire guardings (fire barriers) if open
fire or flying sparks cannot be avoided during re-
pair work.
If necessary, also cover the ground with fire-
protective 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 ves-
sels can explode if exposed to high temperatures
(above 49°C / 120°F) or in the event of damage.
Protect the pressure vessels against damage be-
fore 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 extin-
guishing 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 elec-
trical 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 ma-
chine. If possible, use a steam-jet cleaner for
cleaning.
4-5

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 con-
taining cold-starting fluid (ether).
Ether is toxic and highly flammable;
the vessels are under pressure. These
pressure vessels can explode if ex-
posed 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 spray-
washed with steam-jet cleaners or
high-pressure cleaners. It will be dam-
aged.
Therefore cover all the insulating ma-
terial with plastic foils before using
steam-jet cleaners or high-pressure
cleaners inside the engine compart-
ments.
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.
4-6
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
Overhaul Considerations
Reduced hours of operation at full load will result in
a lower average power demand. A decreased av-
erage 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 deci-
sion is being made on the proper time for an en-
gine 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 mainte-
nance requirements must be followed.
Oil Consumption as an Overhaul Indi-
cator
Oil consumption, fuel consumption, and mainte-
nance 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 suit-
able 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 con-
sumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpil-
lar 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 consump-
tion.
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 applica-
tions, load factors, site conditions and mainte-
nance practices.

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 with-
out the risk of a major catastrophe due to en-
gine 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recom-
mends a scheduled engine overhaul by your Cat-
erpillar dealer before the engine fails. This will pro-
vide 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, Cylin-
der Packs, Oil Pump, and Fuel Transfer Pump
These components should be inspected according
to the instructions that are found in various Cater-
pillar reusability publications. The Special Publica-
tion, 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 con-
sumption 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 Every 1,420,000 L (375,000 US gal) of

Piston Rings, Crankshaft Bearings, Valve Rota- Fuel or 6750 hours
tors, and Crankshaft Seals 1. Prepare the machine for maintenance. Refer to
The following components may not last until the Operation and Maintenance Manual, “Prepare the
second overhaul. Machine for Maintenance”.
 Thrust bearings 2. Refer to Disassembly and Assembly manual for
removal and installation instructions
 Main bearings
Caterpillar recommends this maintenance for the
 Rod bearings following engine components. Consult your Cater-
pillar dealer for further information.
 Valve rotators
The quantity of consumed fuel is a better indicator
 Crankshaft seals for this service interval than service hours. If the
load factor is higher, the number of service hours
 Nonmetallic fuel lines (if equipped) for service interval will be lower. If the load factor is
Caterpillar Inc. recommends the installation of new lower, the number of service hours for service in-
parts at each overhaul period. terval will be higher. The following list contains
Inspect these parts while the engine is disassem- components that should be rebuilt or replaced with
bled for an overhaul. a remanufactured product.
Inspect the crankshaft for any of the following con-
ditions: Engine Components – Rebuild/Install Reman
 Deflection  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 crank-
shaft 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 Install New Components

Fuel or 13,500 hours  All seals, Gaskets and O-rings
Refer to this Operation and Maintenance Manual in  Camshaft Bearings
order to determine the maintenance interval for a
major overhaul.  Engine Mounts
The need for a major overhaul is determined by  Updated Engine Software
several factors.
 Fuel Pressure Regulating Valve
 An increase of oil consumption
 Fuel Priming Pump
 An increase of crankcase blowby
 Gear train bushings, Bearings and thrust
 The total amount of fuel consumption plates
 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
An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may  Piston Rings,
need to be serviced. An increase in the levels of
 Wiring Harness
noise and vibration indicates that rotating parts
require service.
Note: It is possible for oil analysis to indicate a Reuse (Clean and Inspect for Reusability)
decrease of wear metals in the lube oil. The cylin- Inspect the following components according to the
der liners may be worn so that polishing of the bore instructions that are in Caterpillar reusability publi-
occurs. Also, the increased use of lube oil will di- cations. Refer to Guidelines for Reusable Parts
lute the wear metals. and Salvage Operations, SEBF8029, “Index of
Monitor the engine as the engine accumulates Publications on Reusability or Salvage of Used
service hours. Consult your Caterpillar dealer Parts”.
about scheduling a major overhaul.  Aftercooler Core
Note: The driven equipment may also require ser-
vice when the engine is overhauled. Refer to the  Camshaft
literature that is provided by the OEM of the driven  Camshaft Lifters
equipment.
 Connecting Rods
For the major overhaul, all of the bearings, seals,
gaskets, and components that wear are disassem-  Crankshaft
bled. The parts are cleaned and inspected. If nec-
 Cylinder Block
essary, the parts are replaced. The crankshaft is
measured for wear. The crankshaft may require  Cylinder Liners
regrinding. Alternatively, the crankshaft may be
 Damper
replaced with a Caterpillar replacement part.
Your Caterpillar dealer can provide these services  Fan Drive (if equipped)
and components. Your Caterpillar dealer can en-  Gear Train
sure that the components are operating within the
appropriate specifications.  Pistons
If you elect to perform an overhaul without the ser-  Piston Pins
vices of a Caterpillar dealer, be aware of the fol-
lowing recommendations.  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 in-
structions on cleaning the cores, see this Opera-
tion 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 instruc-
tions on removal and installation of components,
see the Service Manual, "Disassembly and As-
sembly" module.

4-10

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 pollut-
ing the environment. These substances must not
be allowed to penetrate into the soil.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
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 condi-
tions - 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 opera-
tion and round-the-clock work).
Hydraulic hoses must be replaced, if one of the
following defects is detected during a visual in-
spection:
 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 re-
main under pressure.
The accumulators are completely safe in opera-
tion. 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, de-
pressurize 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 accumu-
lator was damaged or if the admissible operat-
ing temperature or operating pressure was ex-
ceeded.
 Never remove or paint over warning and in-
formation plates, rating plates or type identifi-
cation markings. Replace illegible or damaged
plates immediately.

4-12

WELDING AND FLAME CUTTING
WORKS - SAFETY INSTRUC-
TIONS
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 weld-
ing work on heavily loaded components. The quali-
ty 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 pre-
vention 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,
 protective gloves,
 protective mask and,
 a fall-arrest system for persons working at
height.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
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 pro-
cess 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 non-
combustible materials.
If works in the vicinity of combustible materials
cannot be avoided, further persons with fire-
fighting equipment must be present on site as fire-
guards.
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 venti-
lated 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 pro-
duced may damage your health.
4-13

Tanks, pressure vessels and pressure
accumulators
Any work on vessels containing or having con-
tained
 combustible or combustion-accelerating sub-
stances,
 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 as-
signed 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 com-
partment.
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 tem-
peratures.
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 be-
fore they have been covered up safely against
accidental contact or flying sparks. Have the pres-
sure accumulators removed from the machine, if
safe protection cannot be ensured.
4-14
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
Slewing rings and articulated joints
The welding current must not flow through ball-
bearing 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 pre-
cautions 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 elec-
tric lines as possible.
If it is not possible to implement all of the above-
mentioned precautions, all connectors must be
removed from the electronic modules before be-
ginning any welding work.
 Protect withdrawn terminals and connectors
from short circuits and soiling. Cover up termi-
nals 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 emanat-
ing 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.

Welding on the counterweight
Counterweights may contain a build-up of flamma-
ble 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,
 Flame cutting,
 Grinding,
 Drilling, milling and
 All other mechanical work that generates heat
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 com-
pressed air until the flammable gases are fully
displaced.
For more information on the correct flushing pro-
cedure please refer to Special Instruction
M0078482 and contact your local Caterpillar deal-
er.
Fig. 4-4:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
Welding on components of the attach-
ment and on other fully or partly closed
steel structures
Components may be equipped with pipelines rout-
ed inside. These lines can contain combustible
substances such as hydraulic oil or lubricating
grease which may be set on fire by welding opera-
tions.
 Check whether pipes or hosepipes are con-
nected to the steel component.
 Depressurize these lines.
 Open the screwed connections and empty the
lines routed inside the component.
 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
More detailed information concerning the state-of-
the-art execution of welding operations can be
found in the Service Manual "Welding for mainte-
nance and repair".
For problems or queries please contact the compe-
tent service personnel.
If parts of the machine have to be removed or dis-
mantled, please read and observe the chapters:
"Assembly of attachment, safety instructions",
"Inspection and servicing, safety instructions",
"Repair, safety instructions".
4-15

DISPOSAL AT THE END OF THE
SERVICE LIFE
Dismantling and removal instruc-
tions
Before beginning work, think about the risks in-
volved, e.g.:
 Most of the machine components have con-
siderable 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 hydrau-
lic 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
REPAIR WORK
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 re-
move these flammable gases, the hollow spaces
must be purged carefully with compressed air be-
fore 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 forma-
tion 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 flam-
mable 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 Further hazardous substances

polluting the environment  Batteries contain lead and acid.
Before stripping down the machine at the end of its  Electronic modules are located in switch cabi-
service life observe the following instructions: nets of the cab module, the engine module, the
The assemblies of the machine contain various control column.
operating fluids or lubricants. These substances
may pollute the environment (so-called hazardous  Pressure accumulators contain nitrogen under
substances) and must therefore be disposed of high pressure and possibly remainders of hy-
properly. draulic oil.
Observe the national laws and regulations govern-  Lamps of Xenon working lights contain mercu-
ing the non-polluting disposal of these substances.
ry.
Remove all operating fluids from the systems, re- The required electronic control circuits are in-
move all lubricants and dispose of these sub- tegrated in the housings of the working lights.
stances properly.
 Fuel system:  The fluorescent lamps of the maintenance
fuel tanks, fuel filters, fuel lines, filling station. lighting (discharge types) contain mercury.
Auxiliary attachment and units, such as an on-  Insulating material of cables can contain PVC.
board crane or an auxiliary heater have their
own fuel tanks with the correpsonding line sys-  The fire extinguishing system (if installed) con-
tems. tains trigger charges (ATTENTION, explosion
risk) on the extinguishing agent containers.
 Hydraulic oil: Pressure accumulators, extinguishing gas and
hydraulic oil reservoir, hydraulic cylinders, hy- extinguishing powder.
draulic motors, hosepipes, piping, hydraulic For more detailed information please refer to
pumps, hydraulic valves, hydraulic oil filter, fill- the manufacturer's safety datasheets.
ing 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, distribu-
tors, 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 dis-
posed 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 manufac-
turer, dealer or by other specialized companies.
In the European Community, the final consumer is
obliged by law to dispose off used batteries in des-
ignated waste collections centers.
Observe the current regulations and laws of your Fig. 4-5:
country with regard to the handling of damaged or The symbols in Fig. 4-5: have the following mean-
used batteries. ing:
 Crossed-out waste bin=
Do not dispose of batteries with normal house-
hold waste.
 Pb……=
Chemical symbol for lead.
 Circle of bent arrows=
Recycling symbol, ingredients of the battery
can be reused.

4-18
 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 Target group

Part 1 INTRODUCTION Operating personnel

+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.

Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.

Part 4 REPAIR WORK 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

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 moni-
toring and control system for hydraulic mining hy-
draulic 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 Plat-
form.
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 cabi-
nets in the module below the operator’s cab, the
pump compartment and the engine compartment.
The exchange of data between sensors, control-
lers, 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 trou-
ble-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 in-
struments as well as they are archived and can be
called up as and when required.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
Fig. 5-1:
Benefits for the operator
Because BCS automatically warns of any abnor-
mal 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 infor-
mation from the BCS archive.
The housing – installed in the control column in-
side 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 trouble-
shooting.
5-3

The keys 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 be-
low the active area "Service". Touching the "Ser-
vice" 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 ac-
cess to the previous screen page.
Pressing the bottom key in the row confirms an
input (like “Enter”).
Fig. 5-2:
5-4
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
Other elements on the front side
(located on top of the column of keys on the right
side)
The green LED lights up when the electrical sys-
tem of the machine is switched on, operating volt-
age 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 illu-
mination of the keypad.

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 self-
tests 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 ac-
cess 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.
Fig. 5-3:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
Active areas are shown on the screen as three-
dimensional graphics. In the basic configuration –
not activated - they seem to project out of the user
interface. When touched, they appear to be low-
ered.
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 fin-
gertips!
Note:
Do not remove the film visible on the screen sur-
face. This is a polarization film which makes the
displayed graphics much better visible.
5-5

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 in-
formation is displayed in the red “failure row” be-
low.
1 Left engine monitoring.
2 Central lubrication system monitoring.
3 The number of dumpers you loaded is dis-
played here (if counted with the key in the
right joystick).
4 Connection to Remote Service System (op-
tional).
5 Hydraulic system monitoring.
Fig. 5-4:
5-6
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
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.
9 Hydraulic ladder, turns to red color if low-
ered. 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.

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 de-
grees Celcius, left arrowhead-shaped sym-
bol slides up and down displaying the cur-
rent temperature. The symbol showing a
halfed arrowhead is a trailing pointer dis-
playing the maximum temperature. Slide to
“0” with your fingertip.
Fig. 5-5:
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
2 Hydr. Oil = Hydraulic oil temperature in de-
grees 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 de-
grees Celcius, left arrowhead-shaped sym-
bol slides up and down displaying the cur-
rent temperature. The symbol showing a
halfed arrowhead is a trailing pointer dis-
playing the maximum temperature. Slide to
“0” with your fingertip.
5-7
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX

Information given on the start

screen, lower section
1 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”).
2 Button “Setup”.
Tapping with your fingertip opens a login
window that permits access to the BCS sec-
tion that is exclusively for service personnel.
A password is needed to get access.
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 infor-
mation 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.

Note: 6 Clock.
Can be adjusted in the “Setup” section by
Modifying parameters in BCS must be carried out
service personnel.
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-ID-
No. BI644793-01 “BCS Passcodes” for more in-
formation.

Fig. 5-6:

5-8
 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 1 This symbol appears on the main screen
switches or by operating the battery circuit breaker, when the Emergency Stop function has
the main screen changes and displays the reset been activated.
button (1, Fig. 5-7:). The machine is inactivated
then, engines cannot be started.
Call the responsible service personnel immediate-
ly. 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 24Volt-
switch cabinet (X1) must be pressed. The switch
cabinet is located in the cab module.
After pushing the reset button, the green LED in-
side the push switch lights up. This signalizes that
the Emergency Stop function is back in function
again.

Fig. 5-7:

5-9

Swing circuit lock-out function
If the system detects an error with the swing func-
tion the swing circuit lock-out screen pops up on
the main page displaying the faulty component(s).
Call the responsible service personnel immediate-
ly. The fault has to be located and eliminated.
The pop-up window disappears after touching an-
ywhere in the window. It will stay in the background
until another fault happens or the operator navi-
gates 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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
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 cor-
relates with the three conditions mentioned above.

Information given on the “Ser-
vice” screen
1 Tapping on the photo of the engine opens a
screen displaying current engine data (see
“Engine data screen”).
Same result when tapping on button “En-
gine” or pressing key “1” on the housing.
2 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 “Hy-
draulic” or pressing key “3” on the housing.
3 Tapping on the photo of the lubrication con-
trol opens a screen displaying current lubri-
cation data (see “Lubrication data screen”).
Same result when tapping on button “Lubri-
cation” or pressing key “5” on the housing.
Fig. 5-9:
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OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
4 Tapping on the photo of the control lever
(joystick) opens a screen displaying control
elements adjusting data (see “Controls ad-
justment data screen”).
Same result when tapping on button “Ser-
vosystem” or pressing key “7” on the hous-
ing.
5 Tapping on this button opens the “View doc-
uments” 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.
5-11

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
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ANNEX
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 USB-
stick after tapping this button (see: “Saving
data to an USB-stick”).
5 Tapping on this button opens a window dis-
playing all the faults / malfunctions the sys-
tem 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 hy-

draulic system.
2 All data displayed can be saved to an USB-
stick 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

Lubrication data screen
1 This screen displays data related to the cen-
tral lubrication system.
Here are information about the status of the
lubricating system of the upper structure.
2 If the system detects faults or malfunctions
in the lubrication system of the upper struc-
ture they are marked here with a red dot.
Call the responsible service personnel.
Fig. 5-12:
5-14
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ANNEX
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 under car-
riage 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.
 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 ser-
vice 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

Tapping the button with the door icon “Exit” leaves
Technical documentation for the machine is stored the current screen and opens the previous screen.
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
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX

Signal table screen

1 To identify and localize sensors and units on
the machine, some photos were attached. If
This is a listing of all the signal sources that are you tap on a “Name” and then the button
connected to the BCS- and CAMP-system. “Location” became readable, a photo is
In the “Status” column small icons visualize the available. Otherwise the button is greyed.
signal status: green=ok; red=malfunction.
In Fig. 5-15: ID 110 “Main Pump 1/3 Pres-
In column “Code” you can find the identifier for the sure” is marked and button “Location” (1) is
sensor or unit that helps the maintenance person- readable. When tapping on it, a photo ap-
nel to localize the sensor in the electric schematics pears and shows where the sensor is locat-
(in this example the identifier for the sensor is ed (see Fig. 5-16:).
“3B22”) .
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 ap-
pears showing where the sensor “3B22” is located
at the machine.

Fig. 5-16:

5-18

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 Tapping on button “Config.” opens a window
listing all the signal sources available for
BCS and CAMP (Fig. 5-18:).
2 Listing of the four signal sources selected:
ID, Name, actual value and value at cursor
in the diagram.
Fig. 5-17:
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ANNEX
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 (chan-
nel 1-4)
8 Tapping the button with the door icon “Exit”
leaves the current screen and opens the
previous screen.
5-19

Signal table screen, diagram con-
figuration
Button “Config.” has been tapped, a window ap-
pears 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
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ANNEX
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 selec-
tion.
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, accord-
ing 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

Slew brake test screen
The slew brake test screen (Fig. 5-20:) is available
after logging in to the Setup-Level I-Menu (pass-
word required).
A slew brake test must be performed during com-
missioning of the machine and after repair work or
maintenance work carried out on the slewing sys-
tem.
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 work-
place 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 instruc-
tions (4) given on the screen.
Fig. 5-20:
5-22
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OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
1 Preconditions to be fulfilled before perform-
ing 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.
2 Button to start the test.
Hydraulic pressures in the units of the
3
slewing systems, left hand and right hand.
Instructions to perform the slew brake test.
4
5 Instruments displaying hydraulic pressure
in left hand / right hand slewing system.
6 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 inter-
faces. 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 diagno-
sis software with access to the CAN bus.
This connection is reserved for service per-
sonnel. Fig. 5-21:

3 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
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ANNEX

Saving data to a USB stick

All screens which have the “USB-stick-button” (1, Save data:
Fig. 5-22:) offer the functionality to store data for
external use. Plug a USB stick into the USB jack (see: “BCSIII,
interfaces”).
All data related to the current screen will be stored
to a USB stick. In this example all data from the To save the data, tap on button (1, Fig. 5-22:).
“Service, left engine” screen will be saved to a file. The BCS system checks the USB interface before
Fileformat is RTF (Rich Text Format). saving the data. If no USB stick is detected, a new
The file name will be automatically created follow- window appears showing the folder structure on
ing this pattern: the CF-card as well as the message “Please plug a
USB stick”..
“Shovel type+serial number+screen name.rtf”.
If a USB stick is found, a new window appears, see
For example: next page (Fig. 5-23:).
“RH120172_Engine_LH.rtf”.
If this file already exists, an extension with incre-
ment numbers will be added to the file name:
“RH120172_Engine_LH_(1).rtf”.
“RH120172_Engine_LH_(2).rtf”.
……

Fig. 5-22:

5-24
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX

Saving data to a USB stick, con-

tinued
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” but-
ton (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, con-

tinued
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 win-
dow 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

BCSIII, cleaning
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.
Never use solving or scouring clean-
ing 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.
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX
BCSIII, disposal
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-type-
lamps (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.
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

TROUBLESHOOTING
Instructions on troubleshooting
Faults are often due to the machine not being cor-
rectly operated or serviced.
For this reason, it is vital to read through the rele-
vant 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 after-
sales service.
Describe the fault and all accompanying cir-
cumstances 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 re-
ported to date and outlines their possible causes
and rectifying measures. In exceptional cases, a
described fault may also have a different cause.
5-28
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ANNEX
Layout of the fault table
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 out-
lined 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 trouble-
shooting is given in the Operation and Mainte-
nance Manual. If there is no entry, the CGM HMS
GmbH after-sales service should be consulted
 EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
ANNEX

FAULT TABLES
Combustion engine - Fault table

Fault Remedial action

Engine fails to start or starts only with difficulty Check P
Engine does not turn Adjust E
Replace W
Engine starts, but runs enevenly or intermittently Top up A
Reduce S
Engine gets too hot, temperature warning activated Clean R
Engine not working at full power
Engine not working on full cylinder papacity
Engine without oil pressure or oil pressure too low 1) Contact the
CGM HMS GmbH
Engine oil comsumption too high Service
Engine emits blue smoke
Engine emits white smoke
Engine emits black smoke
Engine cannot be stopped
Engine throttled down strongly
Cause Chapter ref.
  Oil level too low Engine oil level A
    Oil level too high Engine oil level S
   Engine inclination too big Engine Op. P
Instr.
 Engine oil of wrong SAE-class Lubricants W
    Fuel quality not corresponding to specification Engine Op. W
Instr.
     Air filter contaminated / turbo-charger defective Air intake syst. P
 Fuel filter contaminated Fuel filter P/W
   Charge-air line leaking P
 Radiator / cooling fins contaminated Cooler cleaning R
 Cooling fan or water pump defective or loose Engine Op. P/W
Instr.
 Cooling air gets too hot / heat buid-up P
 Battery defective or discharged Battery P
 Cable connections in starter circuit loose or corroded P
 Starter defective or pinion not in mesh P
  Shut-off relay jamming 1)
      Incorrect valve setting Engine Op. E
Instr.
    Injection line leaking P
       Injection valve defective Engine Op. P/W
Instr.
 Combustion engine blocked on output side 1)
 PMS malfunction 1)
     Celect coding lamp flashing/lit 1)
 Celect defective (software error) 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

Check P
No boom function Adjust E
Replace W
No bucket function Top up A
Reduce S
No backhoe function Clean R
No stick function
Working movements too slow
Power loss in working hydraulics 1) Contact the
CGM HMS GmbH
Uncontrolled working movements Service
Cause Abschnitt
 Electronic hydraulic shovel control not activated/defective Working P
      Malfunction of pressure-relief valve 1)
  Servo system pump defective 1)
      Malfunction of primary / sencondary pressure-relief valves 1)
 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)
 Malfunction of solenoid valves 1)
  Malfunction of control spool 1)
 Engine coupling defective

5-30
 EM024061-1
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ANNEX

Track drive – Fault table

Fault Remedial action

No forward travel and no reversing travel

Check P
Maximum travel speed cannot be reached Adjust E
Replace W
Insufficient traction power Top up A
Reduce S
Clean R

1) Contact the
CGM HMS
Service
Cause Chapter ref.
   Malfunction of pressure-relief valves 1)
   Servo system pump defective 1)
   Malfunction of travel valve (pedal) 1)
 Engine nominal speed too low 1)
  Malfunction of control spool 1)
 ECO-power switch in 80%-position Traveling P
 Insufficient engine power 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 clean-
ing
 Engine coolant temperature too high (warning lamp lit and PMS 1)
fault indicator lamp flashing)

5-31
 EM024061-1
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ANNEX

Swing mechnism – Fault table

Fault Remedial action

No swing possible
Check P
No righthand or lefthand swinging Adjust E
Replace W
Swing performance insufficient Top up A
Reduce S
Uncontrolled swinging movement Clean R
1) Contact the
CGM HMS
Service
Cause Chapter ref.
 Electronic hydraulic shovel control not activated / defective Working P
 Limiting switch optional, ramp-type ladder not complete retracted Operation P
 Upper structure holding brake applied P
  Pressure-relief valve adjusted too low level / defective 1)
 Servo system pump defective 1)
  Malfunction in feed-pressure circuit of swing pump 1)
 Malfunction in high-pressure circuit of swing system 1)
  Malfuction of moment-regulating valve 1)
  Malfunction in swing pump displacement cylinder 1)
 Excessive leakage in swing motor 1)

5-32
 EM024061-1
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ANNEX

Central lubricating system – Fault table

Fault Remedial action

Grease pump not working, the BCS does not indicate a warning
Automatic circuit breaker on
Check P
Grease pump not working, pilot lamp lit Adjust E
Replace W
Grease pump working, no grease delivered Top up A
Reduce S
Greasing pressure too high or too low Clean R
Vent L
1) Contact the
CGM HMS GmbH
Service
Cause Chapter ref.
  Timer defective P/W
 Lines between timer and hydraulic motor defective P/W
  Hydraulikmotor defektive P/W
    Grease pump defective P/W
 Grease sieve clogged P/R
 Distributor defective P/W
 Grease container empty P/A
 Grease pump does not suck grease P/L
 Leaky lines P/L
 Non-return valve defective P/W
 Pressure switch defective E

5-33
 EM024061-1
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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 installa-
tion of seats for operators in conformity with ISO
7096 ensures that the weighted vibration accelera-
tions 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; Sec-
tion 3.6.3.1, resp. the "Lärm - und Vibrations-Arbeits-
schutzverordnung" 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
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ANNEX

ABBREVIATIONS

A Ampere (SI base unit of electric current)

abt. about
AC Alternating Current i Transmission ratio
acc. according to i.e. id est = that is
Ah Ampere hours (SI base unit of quantity of IFN ISO service rating, blocked
electricity) IN Rated current
ANSI American National Standards Institute, Inc.
in Inch (unit of distance), 1 in = 25,4 mm
API American Petroleum Institute
Incl. Including, inclusive of
approx. / approximately
appr. ISO International Standardization Organization

bar unit of pressure, 1 bar = 14.5 psi kg Kilogram (unit of weight), 1 kg = 2.2 lb
Bh = OH = Operating hour kg/dm3 Kilograms per cubic decimeter (= unit of
specific density)
km/h Kilometers per hour
CAMP Control and Monitoring Platform
kPa Kilopascal (unit of pressure), 100kPa =
CE Communauté Européenne = European
1bar = 14.5psi
community
kNm KiloNewtons per meter (1 kNm = 1000 Nm)
CECE Committee for european Construction
= unit of torque
Equipment (Defines a measure for bucket,
grab or scoop filling) kW Kilowatt (1 kW = 1.36 hp)
CEN European Standardization Committee
CGM Caterpillar Global Mining l Liter (unit of volume), 1 liter = 0.26 gal
cm centimeter (= 1/100 m) LAN Local Area Network
cm3/rev Cubic centimeters per revolution lb pound (unit of mass), 1 lb = 0.45 kg
CCW counterclockwise lbf Poundforce (unit of force), 1 lbf = 4,45 N
CW clockwise lb/in² Pounds per square inch (= psi)
LED Light-emitting diode
dB(A) Decibel (sound intensity according to l/min Liters per minute
measuring method A) LpA Sound pressure at workplace
dia. Diameter LwA Sound power level of the machine in sta-
DIN German Industrial Standard tionary operation

ECM Electronic Control Module on engines m Meter (unit of distance), 1 m = 3.28 ft

eff. effective MA Tightening torque
e.g. for example mA Milliampere (=1/1000 A)
ELC Extended Life Coolant max. maximal, maximum
etc. etcetera MDG Mining Design Guidelines (Australian
Standards in Mining Industries)
Fig. Figure, serial number of illustration min. minimal, minimum
FMI Failure Mode Identifier, description of min-1 Revolutions per minute
malfunctions according to SAE J1939 mm Millimeter (=1/1000 m)
FOPS Falling objects protective structures
FS Rock shovel (attachment) N, kN Newton, kiloNewton (unit of force)
ft foot (unit of distance), 1 ft = 0.30 meter NLGI National Lubricating Grease Institute (USA)
NLGI– Consistency – lubricant classification acc.
gal gallon (unit of volume), 1 gal = 3.78 liters Klasse To DIN 51 818
GET Ground Engaging Tool Nm Newtonmeter (unit of torque)
GmbH German legal business form No. Number

HD Heavy duty OH Operating hour

HMS Hydraulic Mining Shovels OMM Operation and Maintenance Manual
Hydr. Hydraulic, Hydraulics oz ounce (unit of volume) 1 oz = 0.03 liter
Hp Horse power (unit of power), 1 Hp = 0,75
kW
Hz Hertz (unit of frequency)

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ANNEX

ABBREVIATIONS

PDF Portable Document Format (trademark of

ADOBE Inc.)
PMS Pump Managing System
P/No. Part number
PPE Personal Protection Equipment
PS Metric horsepower (1 PS = 0.74 kW)
psi pund per sqare inch (unit of pressure),
1 psi = 0.069 bar
PLC Programmable logic controller

Qty. Quantity

R, r Radius
resp. Respectively
RTF Rich Text Format, text based file format
ROPS Roll-over protective structures
rpm Revolutions per minute (= min-1)

SAE Society of Automotive Engineers (USA)

sec./s. Second
SCA Supplemental Coolant Additive
SM Service Manual
SN CGM HMS GmbH part number
SPN Suspect Parameter Number, description of
malfunctions according to SAE J1939
SW Width across flats

t Metric ton (= 1000 kg)

tm Tons by meters (obsolescent unit of swing
torque)
typ. Typical

U/min Revolutions per minute

U.S./ United States Environmental Protection
EPA Agency
USB Universal Serial Bus, interface for fast data
exchange

V Volt (unit of electric voltage)

VDMA Association of German Machinery and
Systems Manufacturers

W Watt (unit of electric power)

°C Degrees Celsius (temperature)

°F Degrees Fahrenheit (temperature)
> greater than
< less than

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PRODUCT SPECIFICATION SHEET

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NOTES

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OMM 6060, 6060FS(3 847 031.02)-EN
INDEX

6 INDEX

Operation and Maintenance Manual Target group

Part 1 INTRODUCTION Operating personnel

+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.

Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.

Part 4 REPAIR WORK 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

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INDEX

6-2

3 machines, table ............................................ 114
3500 Engine Maintenance Interval Schedule -
Notes ........................................................... 3-10
A Board-Control-System (BCS) ........................... 2-9
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 Combustion engine - Fault table ..................... 5-29
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 . 2-
48
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 3-
102
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 BH-
machines ................................................... 2-112
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INDEX
Bench Heights – Recommendations for BH-
Bench Heights – Recommendations for FS -
Machines, table ............................................ 133
Bench Heights on Steep Slopes ................... 2-132
BOARD-CONTROL-SYSTEM .......................... 5-3
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) .... 3-
151
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 . 2-
141
Code table screen ........................................... 5-21
Cold-starting fluid (ether) – Replace the pressure
vessel .......................................................... 3-54
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

DESCRIPTION OF THE HYDRAULIC SHOVEL 2-
6 Engines - Start ................................................ 2-93
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 FIRE AND EXPLOSION HAZARD .......... 1-15, 2-5
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 3-
50
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
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INDEX
Engines - Shut off ........................................... 2-95
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 .. 2-
144
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 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

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 Notes on the selection of oils and greases ..... 3-32
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 ................................................................... 3-156
Know the situation on site ............................. 2-131
L OPERATION - SAFETY INSTRUCTIONS ....... 2-3
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
EM024061-1
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INDEX
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
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
ON-BOARD CRANE, DRIVE UNIT (optional) .... 3-
155
Operating hours meter (if equipped) ............... 2-51
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

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 . 3-
112
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 ... 3-
114
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 .. 2-
82
R Swing ring – Instructions ............................... 3-135
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 Travel gearbox – Check the oil level / Top up with
Safety films and warning messages – Overview
and Description ........................................... 2-10
6-6
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INDEX
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 .. 2-
48
Swing circuit lock-out function ........................ 5-10
SWING GEARBOX ....................................... 3-117
Swing gearbox - Check oil level / Top up with oil 3-
117
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 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 3-
120, 3-123
oil ............................................................... 3-127
TRAVEL GEARBOX (GEARBOX P/N 3683483) 3-
120

TRAVEL GEARBOX (GEARBOX P/N 3683496) 3-
123
TRAVEL GEARBOX (GEARBOX P/N 3749598) 3-
127
Travel gearbox breather filter - Replace ....... 3-130
Travel gearbox breather filter – Replace . 3-122, 3-
126
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 . 2-
168
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
EM024061-1
OMM 6060, 6060FS(3 847 031.02)-EN
INDEX
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
6-7
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