Mejoras de Fabrica Pala 6060FS Cat

6060 / 6060 FS History and Improvements
Presenter Name
2014 Improvements
2 / Caterpillar Confidential: GREEN / WHEREVER THERE

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New Air Cleaner Installation for 3512C engines
Due to some problems in extremely dusty environments the air cleaners for 3512 C
engines are changed
Installation was successfully tested in Mauretania
Clean arrangement with better service accessibility on upper deck
Standard from unit 340191 (Mid 2014)
Proven Cat air-filterbox

used on mining trucks
3 / Caterpillar Confidential: GREEN / WHEREVER THERES MINING

Options to become standard in 2014
Operators Cab
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

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

Swing ring
Two greasing pinions for the internal gearing of the swing ring supplied by the automatic
lubrication system
Two additional pinions which are made of felt will be installed inside the slew ring. These pinions are
connected to the central lubrication system. The grease is distributed through holes in each tooth of
that pinions. This system ensures that the slew ring teeth will be directly lubricated over their entire
height which will reduce wear.
Dirt wipers at swing ring to prevent build-up of debris between swing ring and carbody
The slew bearing will be equipped with 2 dirt wipers. These will clean the top chord of the car body
from material spillage in the area underneath the slew ring during slewing.

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

Undercarriage
Improved hose routing

2012 Improvements
MDG updates
Superstructure

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Superstructure
OLD NEW
Different hydraulic concept for travelling

More space on superstructure

Superstructure
Slew gear box covers

New routing servo lines

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

2012 Improvements
MDG updates
Cab Module & Access/Egress

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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

Revised walkway and

handrail design
Additional toeboards

Access System
Revised handrail design

New step design

Cab Module
All hydraulic controls on

the cab module have been
removed completely
All controls moved to the
attachment and to the
main control plate
between the pumps
Optional feature

Cab Module
New door handles

Filter openings in door
have been closed
Hoses for ladder control
have been removed
Pressure vessel is now
installed from underneath

Cab Module
Working lights mounted on

plate which can be
opened from inside
better serviceability
Plugs for main harness

going to controls on
attachment

Cab Module
Pressure vessel for ladder control and

servo system are mounted underneath the
cab module
Good serviceability
Well protected against damage
less risk

2012 Improvements
MDG updates
Oil Cooling Module

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Oil Cooling Module
Self closing gate on opening

to attachment
Removable handrail for
450 mm walkway behind valves on
attachment
1100 mm Redesigned handrails and

kickboards to meets
450 mm
Australian and ISO Standards
New door handles
125 mm

Oil Cooling Module
Additional pressure vessel for servo circuit in

oil cooling module

2012 Improvements
MDG updates
Counterweight

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Counterweight
450 mm
1100 mm
450 mm
Redesigned handrails and kickboards to

meets Australian and ISO Standards
125 mm

Counterweight Engine oil extension
Tank for engine oil exchange interval extension moved

from cab and oil cooler module to counterweight
Pumps and Filters moved from underneath the engine to
counterweight
Better serviceability

Counterweight
New door handles

Spyhole
Doors can only be opened
by using a tool

Counterweight
Fully enclosed muffler covers instead of meshed

material

Counterweight Fan drive
New hydraulic lines for fan drive

Shorter hoses
No contact between hoses/hoses and
hoses/steel structures

2012 Improvements
MDG updates
Service Station

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Service Station
Completely redesigned service station

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

Service Station
Completely retracts into safe position

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

Coolant Tanks
Stainless steel covers for coolant

extension tanks
Pressure relief caps on coolant tanks
Pressure can also be relieved from
service station

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

Engine Module
New walkways in pump bay

2012 Improvements
MDG updates
Hydraulics

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Hydraulics Former Problems
OLD 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

Hydraulics
Entire hydraulic system has

been redesign
3D hose routing tools have
been used

Hydraulics

Hydraulics
NEW
NEW

2012 Improvements
MDG updates
Hydraulics Swing System

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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

NEW
OLD

2012 Improvements
MDG updates
Hydraulics Travel System

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Redesigned travel system

Less hoses
More space on superstructure
More efficient hydraulic system
Less heat will be created

OLD NEW

2012 Improvements
MDG updates
Hydraulics Leak Oil

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Hydraulics Leak Oil

Hydraulics Leak Oil
Old New
New leak oil collector design

Revised hose routing
New fittings for sensors on
pumps

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

Hydraulics Control System (New)
New location in pump module

Pilot Valve Block 2 Solenoid Valve Pilot Valve Block 1

(SIL)
Proportional Valve
Pump Regulation
Swing Balance Flushing Valve

Valve Pressure Adjustment
Proportional Valve Swing
Travel Proportional Valve
Swing
Swing Park Brake

50 bar
Pump Regulation
50 bar Pilot
60 bar
Supply for
small valve
blocks
Tank
Swing
35 bar
2nd Speed Pump
50 bar
Travel Brake
30 bar Pilot
35 bar
Pilot
50 bar
Track Tensioning
80 bar
Pump Ladder / Service Arm /
Grease Tank
80 bar
Tank
X2
Main
Pumps
Pilot
100 bar Travel Boost
40 bar Clam Boost
40 bar

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


2012 Improvements
MDG updates
Attachment

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Hydraulics Attachment

Attachment
Flexible mounting base for handrails on

attachment
Additional walkways behind main control valves

Removable handrail

Attachment
Fall arrest kit on boom

2012 Improvements
MDG updates
Electrics

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Electrics
Battery and starter Isolator Station on main deck

Easily accessible
Close to the battery box
Short cable length

Electrics
Clear and durable labeling of sensor cables

Electrics
Additional circuit breaker for alternators

Electrics
New electrical cabinet on main control plate for

improved cable routing

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
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 J1939
Drive train controller LH Servo controller Auxiliary Drive train controller RH

Controller
Board Control System BCS III
Interfaces: BCS Display with 12 high

USB, resolution touch screen
CAN BUS
Control Tower in ergonomic Lan (TPC/IP)
position for the operator
Cleary labeled push buttons

BCS III Operator Comfort
Large 12 touch screen

Intuitive handling
Adjustable brightness for night operation
Monitoring of operating data
Approx. 30 analogue and 50 digital sensors
Comparison with set values and indication of
deviating values
Visual and acoustic warnings
Type of warning is programmable
PDF documents on board
Detailed description of fault
First action suggestions
Joystick characteristics adjustable to operator
preferences
Beside the factory setting 3 further settings can be
defined and stored
Various languages can be selected
On screen PDF documentation
Operating instruction
Service assistance Trouble shooting assistance

2010-2011 Improvements

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Second Horn on oil cooler module

Standard scope of supply
Field conversion kit available

Track tensioning system

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

New manhole covers for attachment

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

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 NEW

New installation plate on cab

module
Clear arrangement of components
Pre-assembly possible

Installation of pipes instead of hoses where worthwhile

Modified Hose Arrangement

Extensive usage of brackets and clamps for fixed hose routing
In steel structure integrated hose connection brackets between modules

Easier assembly / disassembly of modules
Shorter hoses for better handling

Self-aligning roller bearings
PTO
Modified PTO
New bearing of input shaft OLD
New oil dipstick
New Shaft sealing ring Fitting key
Gearing instead of fitting key
Part-No: cylinder roller bearings
Old: 3691273
Groove ball bearings
Modification Kit: 6004320
New: 3705643 / 3705638
NEW
Gearing instead of fitting

key
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

Cat Air Cleaners for Cat 3512C engines
CAT Air-Filterbox with precleaner New brackets
Easy to
maintain!
new steel pipes New silicon adapters

Main Valve Block

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

Main Pumps
Improvement by BoschRexroth
Enlargement contact area on the sliding shoe / retainer plate by:
Downsizing of piston bore diameter on the retainer plate
Restriction on sliding shoe diameter
Pumps are already in field test
OLD since 04/1996 NEW starting 03/2010

Hydraulic oil tank was optimized to increase air release

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

Bolted hydraulic tank
Bolted to both tank and excavator

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

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 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 NEW: R = 63mm
OLD: t = 8 mm NEW: t =12 mm

New Pump Drive Coupling

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

Handrails
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

Bucket capacity: 26 m
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)
New final drive 1300 Nm (6050: 1130 Nm)

CAT 6060 History
2004 RH340 - Prototypes

bucket capacity: 34 m
breakout force: FS: 1500 kN / BH: 1240 kN
crowd force: FS: 1910 kN / BH: 1270 kN
Operating weight: FS: 552 t / BH: 547 t
Engine: 1880 kW
Cummins K1500E

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

CAT 6060 History
2007 6060 / 6060 FS (RH340B)

longer superstructure main frame (+ 300 mm)
longer engine module to fit Caterpillar 3512C engine
higher counterweight for 3512C charge air coolers
increased tank volume diesel and hydraulic oil
new main pumps
4 x 1300 l/min (RH340: 4 x 912 l/min)
new pump transfer gearbox
new valve blocks
4 units (twice RH120E installation)
Two engine alternatives
Cummins QSK45 (2240 kW)
Caterpillar 3512C (2240 kW)
Upgrade to B-version only for diesel machines

Comparison: A-Version vs. B-Version
Dimensions
A-Version B-Version Remarks
Length of engine module 3600 mm 3950 mm had to be extended due to the
longer engine blocks of the CAT
engines
Tail overhang 7350 mm 7700 mm

Tail swing radius 7580 mm 7955 mm
Height of counterweight 3675 mm 3975 mm The CAT engines have charge
air cooling which requires
additional radiator space
Operating weights
Face shovel 552.000 kg 566.600 kg
Backhoe 547.000 kg 567.500 kg

Hydraulics
A-Version B-Version Remarks
Pump transfer gear Same as RH200 New design Revised domensions, ratios
and speeds
Main pumps 4 bent axis axial 4 double pumps in
piston pumps swash plate design
Displacement of main pumps 1000 cm 892 cm * * The nominal capacity of

(2 x 520 cm = 1050 cm) is
reduced to 892 cm to
achieve a max. flow of 5200
l/min
Drive speed of main pumps 925 rpm 1457 rpm All other pumps remain
unchanged.
Max. oil flow, each main pump 925 l/min 1300 l/min
Max. total oil flow of main pumps 3700 l/min 5200 l/min
Main valve blocks 2 (like RH 200) 4 (twice RH 120E) Necessary to cope with the
higher oil flow
Hydraulic tank capacity 6100 l 7100 l approximate
Total volume of hydraulic oil 8400 l 9400 l Approximate

CAT 6060 History
2008 Cat 6060

Larger (deeper) oil pan for QSK45 engines
2009 Cat 6060

First RH340 electric drive according to CSA Standards for Canada
Reinforced design of backhoe boom
2010 Cat 6060

Reinforced engine module frame
Revised hydraulic tank design
Revised fuel tank design
Pre-assembled installation plates for servo control components


Key Features of CAT 6060
Attachment Update

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

Cat 6050 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

Cat 6050 Cat 6060

(Former design)

CAT 6060: Stick Design
The first FS stick design caused problems with the geometry of the
attachment
All following units were equipped with a new designed stick
The stick on 340003 has been exchanged
New stick design well proven in 48 units
Old design
Straight bottom cord
New design
Curved bottom cord

Major Hydraulic Upgrades
A-Version compared to B-Version

Cat 6060 A-Version Cat 6060 B-Version
2 Valve blocks 4 Valve blocks

Same like RH 200 Same like RH120E but twice

Cat 6060 A-Version Cat 6060 B-Version
Bent axis main pumps Swash plate double pumps

1000 cm Nominal 1040 cm
Reduced to 890 cm
Less stress on pumps

2013 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, their respective logos,
Caterpillar Yellow, the Power Edge trade dress as well as corporate and product
identity used herein, are trademarks of Caterpillar and may not be used without permission.

S MINING

Mejoras de Fabrica Pala 6060FS Cat

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Formats disponibles

6060 / 6060 FS History and Improvements

2 / Caterpillar Confidential: GREEN / WHEREVER THERE

Proven Cat air-filterbox

3 / Caterpillar Confidential: GREEN / WHEREVER THERES MINING

4 / Caterpillar Confidential: GREEN / WHEREVER THERES MINING

5 / Caterpillar Confidential: GREEN / WHEREVER THERES MINING

6 / Caterpillar Confidential: GREEN / WHEREVER THERES MINING

7 / Caterpillar Confidential: GREEN / WHEREVER THERE

8 / Caterpillar Confidential: GREEN / WHEREVER THERE

Revised hose routing on

9 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Revised hose routing

10 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Improved hose routing

11 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

12 / Caterpillar Confidential: GREEN / WHEREVER THERE

Different hydraulic concept for travelling

13 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Slew gear box covers

14 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

15 / Caterpillar Confidential: GREEN / WHEREVER THERE

Working lights have been moved to side and are

16 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Cab Module & Access/Egress

17 / Caterpillar Confidential: GREEN / WHEREVER THERE

Revised design of access to cab

18 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Revised walkway and

19 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Revised handrail design

20 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

All hydraulic controls on

21 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

New door handles

22 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Working lights mounted on

Plugs for main harness

23 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Pressure vessel for ladder control and

24 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Oil Cooling Module

25 / Caterpillar Confidential: GREEN / WHEREVER THERE

Self closing gate on opening

1100 mm Redesigned handrails and

26 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Additional pressure vessel for servo circuit in

27 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

28 / Caterpillar Confidential: GREEN / WHEREVER THERE

Redesigned handrails and kickboards to

29 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Tank for engine oil exchange interval extension moved

30 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

New door handles

31 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Fully enclosed muffler covers instead of meshed

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New hydraulic lines for fan drive

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34 / Caterpillar Confidential: GREEN / WHEREVER THERE

Completely redesigned service station

35 / Caterpillar Confidential: Yellow / WHEREVER THERES MINING

Completely retracts into safe position

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