MEJORAS DE FABRICA PALA 6060FS CAT

6060 606 0 / 6060 6060 FS – History History and and Improve Improvement ments s Presenter Name

2014 Improvements

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2014 Improvements

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New Air Cleaner Installation for 3512C engines •

Due to some some proble problems ms in in extr extreme emely ly dust dusty y envir environm onmen ents ts the the air air clea cleaner ners s for for 3512 3512 C engines are changed – – –

Installation Installation was successfully successfully tested in Mauretania Mauretania Clean arrangement arrangement with better service accessibility accessibility on on upper deck Standard from unit unit 340191 340191 (Mid (Mid 2014)

Proven Cat air-filterbox used on mining trucks

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Options to become standard in 2014

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Operators Cab – – – –

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Heating ventilating and air-conditioning system in cab Emergency rescue seat at cab Roller blinds at all windows External sun shields at side and rear Windows



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Attachment – –

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LED high brightness working flood lights at boom (FS & BH) Guards for shovel cylinders (FS)



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Swing ring –

Two greasing pinions for the internal gearing of the swing ring supplied by the automatic lubrication system •

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Two additional pinions which are made of felt will be installed inside the slew ring. These pinions are connected to the central lubrication system. The grease is distributed through holes in each tooth of that pinions. This system ensures that the slew ring teeth will be directly lubricated over their entire height which will reduce wear.

Dirt wipers at swing ring to prevent build-up of debris between swing ring and carbody . from material spillage in the area underneath the slew ring during slewing.

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2012 Improvements MDG updates

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2012 Improvements MDG updates Undercarriage

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Undercarriage

Old

New

• Revised hose routing on track frames • All hoses are separated by clams • No use of spiral wrap

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Undercarriage

• Revised hose routing track tensioning

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Undercarriage • Improved hose routing

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2012 Improvements MDG updates Superstructure

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Superstructure OLD

• Differen Differentt hydr hydraulic aulic concept concept for travelling travelling • More More space space on sup supers erstru tructu cture re

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NEW

Superstructure

• Slew Slew gear gear box box cov cover ers s • Ne New w rout routin ing gs ser ervo vo lin lines es

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2012 Improvements MDG updates Cab

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Cab

• Working lights have been moved to side and are installed underneath the FOPS structure • Lights are accessible from walkway 

Improved serviceability

• LED lights instead of Xenon • New stainless steel panel and new switches on control tower 16


2012 Improvements MDG updates Cab Module & Access/Egress

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Cab Module & Access/Egress • Revised design of access to cab • Step and handrail design • Revised design of emergency egress • Extended back protection • New control device • Walkway in front of cab has been removed

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Cab Module & Access/Egress

• Revised walkway and handrail design • Additional toeboards

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Access System

• Revised handrail design • New step design

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Cab Module

• All hydraulic controls on the cab module have been removed completely •

con ro s move o e attachment and to the main control plate between the pumps

Optional feature

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Cab Module

• New door handles • Filter openings in door have been closed •

oses or a er con ro have been removed

• Pressure vessel is now installed from underneath

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Cab Module • Working lights mounted on plate which can be opened from inside 

better serviceability

• Plugs for main harness going to controls on attachment

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Cab Module

• Pressure vessel for ladder control and servo system are mounted underneath the cab module 

Good serviceability



Well protected against damage



less risk

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2012 Improvements MDG updates Oil Cooling Module

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Oil Cooling Module

• Self closing gate on opening to attachment

450 mm

1100 mm 450 mm

• Removable handrail for walkway behind valves on attachment • Redesigned handrails and kickboards to meets Australian and ISO Standards • New door handles

125 mm

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Oil Cooling Module

• Additional pressure vessel for servo circuit in oil cooling module

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2012 Improvements MDG updates Counterweight

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Counterweight

450 mm

1100 mm 450 mm

125 mm

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• Redesigned handrails and kickboards to meets Australian and ISO Standards

Counterweight – Engine oil extension

• Tank for engine oil exchange interval extension moved from cab and oil cooler module to counterweight • Pumps and Filters moved from underneath the engine to counterweight 

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Better serviceability


Counterweight

• New door handles • Spyhole • Doors can only be opened by using a tool

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Counterweight • Fully enclosed muffler covers instead of meshed material

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Counterweight – Fan drive

• New hydraulic lines for fan drive • Shorter hoses • No contact between hoses/hoses and hoses/steel structures

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2012 Improvements MDG updates Service Station

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Service Station •

Completely redesigned service station – Improved hose routing • Use of pipes instead of hoses

– More functions • • • • • • • • •

Coolant (including pressure relief) Hydraulic oil Gear box oil Slew gear box oil Grease Diesel Engine oil Engine oil extension Liquid ammonia (Tier 4 final preparation)

– Height of service arm has been lowered for safe and easy refueling

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Service Station • Completely retracts into safe position

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2012 Improvements MDG updates Engine Module

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Engine Covers • Covers for exhaust system • Mitigates risk of injuries • Covers hot surfaces to prevent fires

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Coolant Tanks • Stainless steel covers for coolant extension tanks • Pressure relief caps on coolant tanks • Pressure can also be relieved from service station

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Engine Module • Redesigned handrails and toeboards • Improved sealing between engine and pump compartment

1,100 mm

• Material according to AS specifications 450 mm 125 mm 450 mm

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Engine Module • New walkways in pump bay

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2012 Improvements MDG updates Hydraulics

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Hydraulics – Former Problems

OLD

• Former hose routing design was not in line with MDG 15/41 • Many hose were rubbing and were not probably supported • Accessibility with old concept was limited

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OLD

Hydraulics • Entire hydraulic system has been redesign • 3D hose routing tools have been used

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Hydraulics

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Hydraulics

NEW NEW

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2012 Improvements MDG updates Hydraulics – Swing System

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Hydraulics – Swing System • New hose routing concept • Swing blocking valves moved underneath the walkway • New blocks on swing motors for improved serviceability • Block directly mounted to swing motor

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Hydraulics – Swing System NEW

OLD

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2012 Improvements MDG updates Hydraulics – Travel System

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Hydraulics – Travel System

• Redesigned travel system • Improved hose routing • Less hoses • More space on superstructure • More efficient hydraulic system • Less heat will be created

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Hydraulics – Travel System

OLD

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NEW

2012 Improvements MDG updates Hydraulics – Leak Oil

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Hydraulics – Leak Oil

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Hydraulics – Leak Oil

Old

New

• New leak oil collector design • Revised hose routing • New fittings for sensors on pumps

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2012 Improvements MDG updates Hydraulics – Control System

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Hydraulics – Control System (Old)

Former Problems: • Hose routing on mounting plate very untidy • Hoses going to attached are cannot be routing probably • Hose routing in accordance with MDG 41 not possible 57


Hydraulics – Control System (New) • New location in pump module

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Hydraulics – Control System Pilot Valve Block 2

Solenoid Valve (SIL)

Pilot Valve Block 1

Proportional Valve Pump Regulation

Flushing Valve

Swing Balance Valve Proportional Valve Travel 59


Pressure Adjustment Swing Proportional Valve Swing

Hydraulics – Control System

Swing Park Brake 50 bar Pump Regulation 50 bar

Pilot 60 bar

Supply for small valve blocks Tank Swing 35 bar 2nd Speed 50 bar

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Pump Travel Brake 30 bar


Pilot 35 bar

Hydraulics – Control System Pilot 50 bar Track Tensioning 80 bar Ladder / Service Arm / Grease Tank 80 bar

Pump Tank

X2 Main Pumps Pilot 100 bar 61


Travel Boost 40 bar

Clam Boost 40 bar


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Hydraulics – Control System Pilot System Filter • 60 bar test point on LH engine bay • 100 bar test point on RH engine bay

Gear Oil Filter PTO

Main Pump Bearing Flushing Filter

• New arrangement of filter for better serviceability and improved hose routing

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2012 Improvements MDG updates Attachment

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Hydraulics – Attachment

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Attachment

• Flexible mounting base for handrails on attachment

• Additional walkways behind main control valves • Removable handrail

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Attachment

• Fall arrest kit on boom

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2012 Improvements MDG updates Electrics

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Electrics

• Battery Battery and and starte starterr Isolat Isolator or Station Station on on main main deck deck • Easi Easily ly acce access ssib ible le • Close Close to the batte battery ry box box • Shor Shortt cab cable le leng length th

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Electrics

• Clear Clear and and durabl durable e labeli labeling ng of of sensor sensor cables cables

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Electrics

• Addition Additional al circuit circuit breaker breaker for alter alternato nators rs

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Electrics

• New electrical cabinet on main control plate for improved cable routing

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2012 Improvements MDG updates Fuel Tank

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Fuel Tank Capacity Increase •

Use of the additional engine oil tanks installed in the cab and oil cooler module (for oil change interval extension) as fuel tanks – Additional fuel capacity: 1,200 l

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Additional engine oil tanks in counterweight


2011 Improvements

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2011 Improvements New Control and Monitoring Platform (CAMP) Including new Boad Control System (BCS)

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Control And Monitoring Platform CAMP BCS III

CAN bus II CAN bus I

J1939

Drive train controller LH 78

J1939

Servo controller


Auxiliary Controller

Drive train controller RH

Board Control System – BCS III

Control Tower in ergonomic position for the operator Cleary labeled push buttons 79


Interfaces: USB, CAN BUS Lan (TPC/IP)

BCS Display with 12” high resolution touch screen

BCS III – Operator Comfort •

Large 12” touch screen – –

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Monitoring of operating data – –

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PDF documents on board

Beside the factory setting 3 further settings can be defined and stored

Various languages can be selected On screen PDF documentation –

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Detailed description of fault First action suggestions

Joystick characteristics adjustable to operator preferences –

• •

Approx. 30 analogue and 50 digital sensors Comparison with set values and indication of deviating values

Visual and acoustic warnings – – –

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Intuitive handling Adjustable brightness for night operation

Operating instruction

Service assistance / Caterpillar Confide ntial: Yellow / WHEREVER THERE’S MINING

Trouble shooting assistance

2010-2011 Improvements

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Second Horn on oil cooler module • •

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Standard scope of supply Field conversion kit available

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Track tensioning system • • •

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Flexible connection of push tube to slider Push tube supported by additional ring Will be implemented in serial production by 2011



Bucket Clam Cylinder • • • •

Increase of piston diameter from 220 mm to 250 mm Retraction force increased by 39 % Current cylinder: 3684640 / New Cylinder: 3713737 Currently under field test; serial production will follow after successful field tests ∅250

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New manhole covers for attachment

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Service lights • • • • •

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New LED maintenance lights All machines since March 2010 are equipped with these lights Better light output Solid material



Fans Oil Cooling System • •

The metal fans have been replaced by plastic fans Less weight of the fans leads to increased life expectancy of fan drive system

OLD

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NEW


New installation plate on cab module •

Clear arrangement of components

•

Pre-assembly possible

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Installation of pipes instead of hoses where worthwhile

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2010-2011 Improvements Modified Hose Arrangement •

Exte Extens nsiv ive e usag usage e of brac bracke kets ts and and cla clamp mps s for for fixe fixed d hose hose rou routi ting ng

•

In steel steel struct structure ure integr integrate ated d hose hose conn connect ection ion brack brackets ets bet betwe ween en modul modules es – Easier assembly / disassembly of of modules – Shorter hoses for for better handling

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2010-2011 Improvements Self-aligning roller bearings

PTO • Modified PTO – New bearing bearing of input shaft shaft – New oil dipstick dipstick – New Shaft sealing sealing ring

OLD Fitting key

– Gearing instead instead of fitting key

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Part-No: – Old: 3691273 3691273 – Modification Kit: 6004320 – New: 3705643 3705643 / 3705638 3705638

cylinder roller bearings Groove ball bearings

NEW

Gearing instead of fitting key 91


2010-2011 Improvements New pre-assembled installation plate •

Various servo control components and hydraulic filters are pre-assembled on a new installation plate – Easier assembly/disassembly – Easier service due to clear arrangement

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2010-2011 Improvements Cat ® Air Cleaners for Cat ® 3512C engines New brackets

CAT Air-Filterbox with precleaner

Easy to maintain! new steel pipes 93


New silicon adapters


Main Valve Block • • • •

Main valve block completely reworked Optimized pipe routing Easy replacement through standardized pipes Optimization of all pipes through – – – Natural frequency analysis

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Main Pumps • •

Improvement by BoschRexroth Enlargement contact area on the sliding shoe / retainer plate by: – Downsizing of piston bore diameter on the retainer plate – Restriction on sliding shoe diameter

•

Pum s are alread in field test

OLD since 04/1996 95


NEW starting 03/2010

2010-2011 Improvements Hydraulic oil tank was optimized to increase air release • •

•

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During testing it was found that large amounts of large bubbles 20mm and above were entering the main pumps Baffles allows a better flow of oil to increase the air release from the return oil (Even when flow rate is extremely high or oil brand and grade are not optimum) Baffle plates are a bolt on type package for easy field upgrade



Hydraulic Tank Design • •

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Bolted hydraulic tank Bolted to both tank and excavator


2010-2011 Improvements Steel Structure • •

Reinforced engine module frame for better support engine mounting and hydraulic tank Increased stability of steel structure

•

Reduced counterweight due to longer superstructure frame – Same stability and dynamic forces during swing like A-version

New Old

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2010-2011 Improvements Fuel Tank Capacity Increase (Field Solution) • • • • •

Increase of fuel tank capacity to guarantee sufficient capacity for 24 operating hours even at very high engine utilization Temporary field solution/upgrade with additional tank on top of standard tank Headroom in engine module still sufficient Tank volume increased by 768 l (each side) Total useful tank volume on even ground approx. 13000 l original tank

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complete tank modification


Fuel Tank Design • •

Revised design due to cracks at the corner of the rear and front plate on the fuel tanks Repair procedure available

OLD: R = 25 mm

OLD: t = 8 mm

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NEW: R = 63mm

NEW: t =12 mm

2010-2011 Improvements New Pump Drive Coupling • • •

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Different design/supplier Same design like on RH400 First units equipped with new coupling for field testing



Handrails • •

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New design of handrail mountings Solid base material


History

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CAT 6060 History

The RH340 was developed on basis of the 6050 / 6050 FS model. The later upgrade to the RH340B is now called 6060 / 6060 FS

Cat® 6050 – Base Specs – – – – –

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Bucket capacity: 26 m³ Breakout force: 1500 kN Crowd force: 1890 kN Operating weight: 505 t Engine output: 1680 kW


CAT 6060 History

2004 – RH340 prototypes compared to 6050 / 6050 FS • New patented attachment and bucket design concept • Increased operating weight – Increased counterweight – Revised superstructure frame – Larger undercarriage

• • • • •

Shorter stick on backhoe machines Larger boom cylinders on face shovel machines Increased working pressure (320 bar) Increased digging forces longer undercarriage – 7 bottom rollers (6050: 6)

•

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New final drive 1300 Nm (6050: 1130 Nm)


CAT 6060 History

2004 – RH340 - Prototypes • bucket capacity: 34 m³ • breakout force: FS: 1500 kN / BH: 1240 kN • crowd force: FS: 1910 kN / BH: 1270 kN • Operating weight: FS: 552 t / BH: 547 t • En ine: 1880 kW – Cummins K1500E

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CAT 6060 History

2004/2005 – RH340 • Engine Option: Cummins QSK 45 with 2240 kW (340003) • Larger oil cooling module (+ 20 % cooling capacity) • Revised FS bucket and FS stick design • Revised BH boom structure design with man hole and new welding procedures 2005/2006 –RH340 • First machine with electric drive (340018) • Reinforced superstructure frame • New stick and bucket cylinders with increased piston diameter on Face Shovel machines – Breakout force: 1640 kN – Crowd force: 2240 kN

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CAT 6060 History

2007 – 6060 / 6060 FS (RH340B) • longer superstructure main frame (+ 300 mm) • longer engine module to fit Caterpillar 3512C engine • higher counterweight for 3512C charge air coolers • increased tank volume diesel and hydraulic oil • new main um s – 4 x 1300 l/min (RH340: 4 x 912 l/min)

• •

new pump transfer gearbox new valve blocks – 4 units (twice RH120E installation)

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Two engine alternatives – Cummins QSK45 (2240 kW) – Caterpillar 3512C (2240 kW)

•

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Upgrade to B-version only for diesel machines


Comparison: A-Version vs. B-Version Dimensions A-Version

B-Version

Length of engine module

3600 mm

3950 mm

Tail overhang

7350 mm

7700 mm

Tail swing radius

7580 mm

7955 mm

Hei ht of counterwei ht

3675 mm

3975 mm

Face shovel

552.000 kg

566.600 kg

Backhoe

547.000 kg

567.500 kg

Operating weights

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Remarks had to be extended due to the longer engine blocks of the CAT engines

The CAT en ines have char e air cooling which requires additional radiator space

Comparison: A-Version vs. B-Version Hydraulics A-Version

B-Version

Pump transfer gear

Same as RH200

New design

Main pumps

4 bent axis axial piston pumps

4 double pumps in swash plate design

Displacement of main pumps

1000 cm³

892 cm³ *

* The nominal capacity of x cm³ = cm³ s reduced to 892 cm³ to achieve a max. flow of 5200 l/min

Drive speed of main pumps

925 rpm

1457 rpm

Max. oil flow, each main pump

925 l/min

1300 l/min

All other pumps remain unchanged.

Max. total oil flow of main pumps

3700 l/min

5200 l/min

2 (like RH 200)

4 (twice RH 120E)

Hydraulic tank capacity

6100 l

7100 l

approximate

Total volume of hydraulic oil

8400 l

9400 l

Approximate

Main valve blocks

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Remarks Revised domensions, ratios and speeds

Necessary to cope with the higher oil flow

CAT 6060 History

2008 – Cat® 6060 • Larger (deeper) oil pan for QSK45 engines 2009 – Cat® 6060 • First RH340 electric drive according to CSA Standards for Canada • Reinforced desi n of backhoe boom 2010 – Cat® 6060 • Reinforced engine module frame • Revised hydraulic tank design • Revised fuel tank design • Improved hose routing • Pre-assembled installation plates for servo control components • …… 111


Ke Features of CAT 6060 Attachment Update

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CAT 6050 vs. CAT 6060: Attachment Comparison

New patented attachment design • •

Reduced stress in critical areas Reduced weight which can be added as additional payload – – – – –

Welds are out of high stress areas Material is where it needs to be Thinner plates where material is not required No internal stiffener plates Counter welded from inside

– All parts are designed in FE system

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CAT 6050 vs. CAT 6060: Attachment Comparison Cat® 6050

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Cat® 6060

Boom crack at first machine

Boom crack at the first Cat ® 6060 Backhoe • • •

Cause: weld defect Change of manufacturing/welding procedure Reinforcement of bottom chord

•

Due to these improvements the problem was solved

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CAT 6050 vs. CAT 6060: Attachment Comparison

Cat® 6050 (Former design)

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Cat® 6060

CAT 6060: Stick Design

• • • •

The first FS stick design caused problems with the geometry of the attachment All following units were equipped with a new designed stick The stick on 340003 has been exchanged New stick design well proven in 48 units

es gn • Straight bottom cord

New design • Curved bottom cord

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Ma or H draulic U rades A-Version compared to B-Version

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Comparison: A-Version vs. B-Version Cat ® 6060 – A-Version

Cat ® 6060 – B-Version

•

•

2 Valve blocks – Same like RH 200

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4 Valve blocks – Same like RH120E but twice

Comparison: A-Version vs. B-Version Cat ® 6060 – A-Version

Cat ® 6060 – B-Version

• •

• •

Bent axis main pumps 1000 cm³

Swash plate double pumps Nominal 1040 cm³ Reduced to 890 cm³ – Less stress on pumps

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MEJORAS DE FABRICA PALA 6060FS CAT

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