M0083817-01 (en-us)

August 2019

Operation and
Maintenance
Manual
Supplemental Information

6060, 6060 FS, and 6090 FS Hydraulic

Mining Shovel
Operator Assist System
DHN 60100-UP (6060)
DH3 60098-UP (6060 FS)
DM6 90015-UP (6090 FS)
DHS 90012-UP (6090 FS)

Use this Supplement with the original Operation and Maintenance Manual. This supplement does
not apply to 6060 FS AC machines.

PUBLICATIONS.CAT.COM
 i06558969

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
M0083817-01 3
Table of Contents

Table of Contents
Foreword ........................................................... 4

Operation Section

Machine Operation ............................................ 5

Index Section

Index.................................................................. 8
4 M0083817-01
Foreword

Foreword
Literature Information
This manual should be stored in the operator's
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, and maintenance recommendations.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your product.
Continuing improvement and advancement of
product design might have caused changes to your
product which are not included in this publication.
Read, study and keep this manual with the product.
Whenever a question arises regarding your product,
or this publication, please consult your Cat dealer for
the latest available information.

Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.

Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, product controls, attachment
controls, and programming information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the product.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the product and its capabilities.

Maintenance
The maintenance section is a guide to equipment
care.
M0083817-01 5
Operation Section
Machine Operation

Operation Section Controls

Machine Operation
i07045557

Operator Assist Systems

SMCS Code: 7008
The Operator Assist (OA) system is designed to
smoothly reduce the velocity of attachment cylinders,
near the end of stroke, to minimize or eliminate
mechanical impacts. This system reduces operator
fatigue, increases cylinder seal life, bolt joint life, and
structural durability.
There are two types of protection functions provided:
Cylinder snubbing – Slows the velocity of all
cylinders as the cylinders approach the end of stroke.
Linkage snubbing – Slows the velocity of cylinders
as the linkage approaches impact points between the Illustration 1 g06208123
bucket and stick.
(1) Right joystick
(2) Keypad
System Description:
The OA system uses sensors mounted on the main
Keypad
frame body, boom, stick, and bucket to measure the
The keypad is mounted inside the operator cabin on
angles of the attachment. OA uses these inputs to
limit the cylinder strokes to avoid mechanical the lower front face of the control tower. The keypad
contacts. provides primary fault indication and system status.
The top row of four buttons is functional. The second
OA is automatically enabled when a machine is row of four buttons is for future use.
started. A machine without OA installed or OA
installed but disabled, will have the following: Three indicator lamps are provided above each of the
buttons to indicate the status of operator assist
1. Each function Indicator Lamp will be ON to indicate system functionality. Descriptions of each indicator
that each function is disabled. lamp are provided below.

2. System Notification indicator lamp will be OFF.

3. Toggle buttons will be disabled.

Illustration 2 g06208219
Front shovel keypad configuration
6 M0083817-01
Operation Section
Operator Assist Systems
Illustration 3 g06208221
Backhoe keypad configuration
Illustration 4 g06208963
The indicator lights above each button are described
in the following method:
(A) Left light
(B) Middle light
(C) Right light
System Notification Button (3)
System Notification Button – This
button toggles the maintenance mode
between enabled and disabled.
When indicator light (A) is illuminated, the
maintenance mode is enabled. Maintenance mode
disables the cylinder and linkage snubbing function
and limits boom, stick, and bucket linkage velocities
to 50% of maximum joystick command.
When indicator light (B) is illuminated, a system fault
is present. When a system fault is present, the
corresponding attachment (boom, stick, bucket)
indicator lamp will be illuminated. Machine
performance will be modified as per the attachment
description below.
Indicator light (C) is not used.
Boom Snubbing Button (4)
Boom Snubbing Button – This
button toggles boom cylinder
snubbing between enabled and
disabled.
When indicator light (A) is NOT illuminated, boom
snubbing is enabled. Pressing the boom snubbing
button when indicator light (A) is NOT illuminated will
have no effect.
When indicator light (A) is illuminated, the boom
snubbing has been manually disabled by the
operator and the boom joystick command is not
limited. Pressing the boom snubbing button when
indicator light (A) is illuminated will Enable boom
snubbing.
If indicator light (A) is blinking, then there is a fault in
the boom cylinder snubbing function and the joystick
boom command is limited to 75%.
Pressing the boom snubbing button when indicator
light (A) is blinking will disable the joystick command
limiting, which allows full cylinder velocity end of
stroke boom collisions, and end of stroke bucket
collisions. The operator is required to limit end of
stroke velocity when boom snubbing is disabled.
Indicator lights (B) and (C) are not used.
Stick Snubbing Button (5)
Stick Snubbing Button – This
button toggles stick cylinder
snubbing between enabled and
disabled.
When indicator light (A) is NOT illuminated, stick
snubbing is enabled. Pressing the stick snubbing
button when indicator light (A) is NOT illuminated will
have no effect.
When indicator light (A) is illuminated, the stick
snubbing has been manually disabled by the
operator and the stick joystick command is not
limited. Pressing the stick snubbing button when
indicator light (A) is illuminated will Enable stick
snubbing.
If indicator light (A) is blinking, then there is a fault in
the stick cylinder snubbing function and the joystick
stick command is limited to 50%.
Pressing the stick snubbing button when indicator
light (A) is blinking will disable the joystick command
limiting, which allows full cylinder velocity end of
stroke stick collisions, and end of stroke bucket
collisions. The operator is required to limit end of
stroke velocity when boom snubbing is disabled.
Indicator lights (B) and (C) are not used.
M0083817-01 7
Operation Section
Operator Assist Systems

Bucket Snubbing Button (6) Joystick

Bucket Snubbing Button – This
button toggles bucket cylinder
snubbing between enabled and
disabled.
When indicator light (A) is NOT illuminated, bucket
snubbing is enabled. Pressing the bucket snubbing
button when indicator light (A) is NOT illuminated will
have no effect.
When indicator light (A) is illuminated, the bucket
snubbing has been manually disabled by the
operator and the bucket joystick command is not
limited. Pressing the bucket snubbing button when
indicator light (A) is illuminated will Enable bucket
snubbing.
Illustration 5 g06209060
If indicator light (A) is blinking, then there is a fault in
the bucket cylinder snubbing function and the joystick Right joystick Type 1
bucket command is limited to 50%.
Pressing the bucket snubbing button when indicator
light (A) is blinking will disable the joystick command
limiting, which allows full cylinder velocity end of
stroke bucket collisions, and end of stroke bucket to
stick collisions. The operator is required to limit end
of stroke velocity when boom snubbing is disabled.
When indicator light (C) is NOT illuminated, bucket to
stick snubbing is enabled. Pressing the bucket
snubbing button when indicator light (C) is NOT
illuminated will have no effect. Bucket to stick
snubbing only applies to front shovel machines.
If indicator light (C) is blinking, then there is a fault in
the bucket to stick snubbing function and the boom
joystick command is limited to 75%, and the stick and Illustration 6 g06209054
bucket joystick commands are limited to 50%.
Right joystick Type 2
Pressing the bucket snubbing button when indicator
light (C) is blinking will disable the joystick command Operator Assist Override Button (7) – The
limiting, which allows full cylinder velocity end of operator assist override button is on the right joystick.
stroke bucket collisions, and end of stroke bucket to Press and hold the bottom of the rocker switch for
stick collisions. The operator is required to limit end Type 1, or press and hold the left side of the rocker
of stroke velocity when boom snubbing is disabled. switch for Type 2, to override all snubbing.

Indicator light (B) is not used.
The override will work only when boom, stick, or
bucket is in an active snubbing range when the
override button is pressed. The override will not
activate when holding down the override button and
then moving the boom, stick, or bucket into a
snubbing range.
The override function allows the cylinders to extend
or retract fully to achieve specific activities, such as
bucket shaking to release carryback material, end
stroking cylinders to allow full pump pressure testing,
or warming the hydraulic oil.
8 M0083817-01
Index Section

Index
F
Foreword ........................................................... 4
Literature Information .................................... 4
Maintenance .................................................. 4
Operation ....................................................... 4
Safety............................................................. 4

I
Important Safety Information............................. 2

M
Machine Operation ............................................ 5

O
Operation Section.............................................. 5
Operator Assist Systems................................... 5
Controls ......................................................... 5

T
Table of Contents .............................................. 3
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
M0083817 CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow”, the
©2019 Caterpillar “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used
All Rights Reserved herein, are trademarks of Caterpillar and may not be used without permission.

10 August 2019