Hydraulic Mining Shovel

Cat® 6020B

01. Introduction

Cat® 6020B – Backhoe Version Service Training

778 kW
1043 HP

220 t
12 m³
(1:1)
2
Cat® 6020B – Main Assembly Groups Service Training

Cat® 6020B – Component locations Service Training

4 (1) Bucket
(2) Stick
(3) Boom
3 (4) Cabin
(5) Superstructure
2 (6)Counterweight
5 (7)Undercarriage
6
1
7

2
5
6
1
7
4
 Cat® 6020B – Backhoe Version Service Training

Cat® 6020B – Main Dimensions Service Training

5,900
7,160
6,285

5,680

5,030

6,940

1,85
6

5,840
7,600

16,970
6,285

Weight: 220 t
Track ground contact surface: 2 x 5.8m X 0.8m = 9.28m²
Ground pressure: 23t/m²
940

800
5,500
6,240

6
 Cat® 6020B – Main Parts Service Training

Working Attachment

Superstructure

Undercarriage

Cat® 6020B – Layout of Superstructure Service Training

Air conditioner unit

Fuel tank
Power module

Counterweight
Hydraulic tank

Cab module

Cab stairways

Platform left
Access ladder

Engine radiator

Hydraulic oil cooler

Cover panel
Maintenance walkway
Platform right
Central greasing
system
8
Cat® 6020B – Layout of Undercarriage Service Training

1. Load Roller
2. Carry Roller
3. Track Frame
4. Final Drive / Sprocket / Travel Motors
5. Idler Wheel
6. Track Chain with 49 track pads
7. Car body
8. Swing bearing

6
7 4

5 1

Cat® 6020B – Undercarriage Transport Dimensions Service Training

Carbody Assembly
Weight: 17.8 t

Crawler Assembly (Standard RH Shown)

Weight: 27.8 t Each (Standard track 800mm)
Weight: 30.2 t Each (Wide track 1000mm)

10
Cat® 6020B – Attachment Service Training

Stick
Cylinder
Boom

Boom
Cylinder

Bucket
Cylinder Stick

Bucket

11

Cat® 6020B – Pressures Service Training

12
Cat® 6020B – Cabin Interior Service Training

• Class-leading cab visibility

– Safer machine positioning & truck-loading
via large windshield & side windows
– Reduced crawler link damage via floor
window
• Enhanced operator training
– Patented three-seat design with
unobstructed view of digging environment
from all seats
– Additional E-stop button that can be
reached from both trainer seats
• Reduced operator fatigue
– Extremely quiet cab environment
– Ergonomic operator seat and controls

13

Cat® 6020B – Layout of Controls Service Training

14
 Cat® 6020B – Layout of Controls Service Training

Monitoring
Hand Lever and performance
Main Machine
Foot Pedals Fault Memory
Interface Display Camera System
+
BCS
Parameter
setting
CLLI-BUS
(Safety-CAN)
Main CAN-Open- Main CAN-Open-
Bus Bus

Servo Controller
Drive Controller
Auxiliary System
32 bit
32 bit

Servo System Pump Contamination Engine Speed

Attachment, Request and Temperature Fan Control
Swing Drive, Pump Control Monitoring Monitoring Air Filter
Cylinder Cut off Contamination CAT Engine
Hydraulic and Engine Start, Stop,
Gearbox Idle
Fuel level
Monitoring Batter
Charge, engine
coolant level 15

Cat® 6020B – Pump identification Service Training

10
1. Main pump 1
7
2. Main pump 2
3. Main pump 3 1 5
4. Main pump 4 2 6
5. Main pump 5 9

6. Main pump 6 8

7. Air conditioning pump 12

8. Pilot (servo) pump 11

3
9. PTO pump
4
10. Oil cooling control pump
11. Engine fan drive pump 13

12. Hydraulic fan drive pump

13. PTO gearbox

16
 Cat® 6020B – MinestarTM Service Training

The Cat 6020B Hydraulic Mining Shovel can be equipped with an optional MineStar system.
The Cat MineStar system helps manage material tracking, real-time fleet management, machine
health systems, autonomous, equipment, etc.
MineStar utilizes four of the Cat MineStar system configurable capability sets to scale the system
to your mine site needs:

• Health

• Fleet

• Terrain

• Detect

17

Minstar (cont.) Service Training

There is a standard pre-wired harness (12-pin connector) located in the main electrical cabinet,
below the operator's station.
If MineStar is installed on the 6020B, the MineStar controller (ECM) and the MineStar radio will
also be located at the main electrical cabinet. The MineStar antenna will be located on the cab.

The MineStar controller pulls active events and all sensor data (pressures, temperatures, etc)
from the machine CAN Bus and relays the information via radio, Local Area Network (LAN), or
cellular to the main office for additional information.
18
Cat® 6020B – Boarding ladder Service Training

Upright position Lowered position for machine entry/exit.

The ladder must be in the upright position for the proximity switch to send a signal to the
Board Control System (BCS) allowing the machine to swing and travel.
NOTE: Always use three points of contact when entering or exiting a machine.

19

Cat® 6020B – Boarding ladder lights Service Training

(1) The boarding ladder can be illuminated with a flood lamp on the cab roof for
entry and exit by the following methods:
(2) switch inside the operator's station Located in the corner of the cab wall. The
light remains ON for a fixed time
(3) With a pull rope located on the platform of the ladder Located near the
boarding ladder and can be switched ON from the ground.

20
Battery Main Switch cabinet Service Training

The boarding ladder raise/lower switches on the

upper structure are located in the battery main
switch cabinet at the power module.

(1) The upper switch raises the boarding ladder.

(2) The lower switch lowers the boarding ladder.

1
NOTE: Pushing the buttons once will fully raise and
lower the boarding
ladder.

21

Emergency ladder Service Training

22
Emergency stop switches Service Training

The battery main switch is located in the

battery main switch cabinet at the power
module.
(1) The battery main switch can be switched
2 into the OFF position by pushing the switch
located on the door of the main switch
cabinet.

The emergency shut-off function can be

triggered from six different locations on the
1 machine.

(2) An emergency shut-off switch is located in

the front panel of the battery main switch
cabinet at the power module.

NOTE: Do not press switch the battery main switch with

the engine running, may cause damage.
Use the emergency stop button in case of emergency.

23

Emergency stop switches Service Training

(1) Inside the cab, on the switch control panel

(2) Inside the cab, at the base of the trainer’s seat

NOTE: The emergency stop switches do not shut off the electrical system, they only stop the engine.

24
Emergency stop switches Service Training

(1) Located inside the power module, pump

1 compartment
(2) Located inside the power module, engine
compartment
(3) From the ground, an emergency pull switch
between the power module and the
counterweight engages switch (4).

25

Emergency shut-off - reset Service Training

(1) The emergency shut-off reset button is located in

the battery main switch cabinet at the power module.
The machine can only be put back into operation when
all emergency shut-off switches are back into their
basic position (not actuated) and must be pressed after
2 any of the emergency stop switches have been
activated.
(2) In order to reset the emergency shut-off reset
1 button, pull the red knob outward.
The emergency shut-off switch on the rear side of the
power module is reset after pulling out the blue knob.
If the ground level emergency stop has been activated,
the blue knob must be pushed in.
Once pushed, a green LED located inside the switch
will be illuminated.

26
 Starter/battery isolator switches Service Training

(1) Battery disconnect Isolation switch: isolates the entire electrical system when the battery disconnect
switch is turned to the OFF position.
(2) The starter disconnect Isolation switch: Isolates the engine starter electrical system from the batteries,
the engine cannot be started, all sections of the electrical system are supplied with voltage as the battery
remains connected to the electrical system when the starter disconnect switch is turned to the OFF position.
Do not disengage switches with the engine running, damage to electrical components may occur

4 3

2 When the battery isolator switch is turned to the ON

position, a green LED (3) located near the switch is
illuminated.

When the starter disconnect switch is turned to the ON

position, a green LED (4) located near the switch is
1 illuminated.

NOTE: The power supply of the electronic control units of the engine and of the machine are shut off after a brief delay.
The delay ensures the current operating data can be saved and the systems shut down properly.

27

Air Filters Service Training

• 2 air filters are mounted inside the power module. One is accessible from the machine's
centre and one is accessible from the counterweight side through an access door.
• The engine is equipped with two dry air filters , consisting of cyclone pre pre-cleaners located
on the deck of the power module.

28
Air Filters (cont) Service Training

(1) Air filter housing cover

3 (2) Primary air filter element
2
(3) Secondary air filter element
1 (4) Dust trap

• The primary air filter can be

replaced or cleaned.
• Always replace the secondary
air filter when needed.
• Clean the dust trap regularly in
order to prevent dirt from
building inside the air pre-
cleaner housing.

Refer to the Operation and Maintenance Manual for service intervals and for more information.

29

Engine Fuel and Oil Filters Service Training

(1) The primary fuel filter is mounted inside the power module, near the engine,
Primary Fuel filter also serves as a water separator. Separated water is gathered in the clear bowl on the
bottom of the filter and should be monitored daily for signs of water.
(2) Two secondary fuel filters are attached directly to a filter head at the engine.
(3) Two engine oil filters

1 2

Refer to the Operation and Maintenance Manual for service intervals and for more information. regarding the fuel filters
and the two engine oil filters
30
Machine Fluid level checks Service Training

Engine oil level check

The level of the engine oil should be between the

minimum and maximum marks on the level gauge.

Engine coolant level check

• The engine coolant is checked at the coolant

expansion tank
• The sight gauge is located inside the engine
compartment access door.
• The coolant level should be between the FULL and
LOW marks.
31

Machine Fluid level checks Service Training

Hydraulic oil level check

• The hydraulic oil temperature must be approximately
122ºF (52ºC) and all implements must be in their
central positions in order to accurately check the
hydraulic oil level.
• The hydraulic oil level must be between minimum
and maximum on the level indicator

PTO oil level check

• The level gauge (arrow) for the pump drive gearbox is
accessible through a small door on the right side wall of
the power module.
• When checking the pump gearbox oil, it is important to
remove the level gauge and reinsert the gauge until the
thread reaches the top of the tube.
NOTE: The PTO must be checked with the engine in the OFF position

32
 Machine Fluid level checks Service Training

Swing gearbox - oil level check

• When checking the swing gearbox oil, it is important to
remove the level gauge and reinsert the gauge until the
thread reaches the top of the tube.

Travel gearbox - oil level check

• In order to accurately check the travel gearbox oil fill plug
must be positioned at the top of the travel gearbox and
drain plug at the bottom.
• The gearbox oil should reach up to the lower edge of the
level plug opening.
• When checking the travel gearbox oil, make sure the
machine is on a flat, level surface.

33

Service station refilling Service Training

The service station is accessible from the ground below the upper structure, near the counterweight.
The service station is comprised of two sections:

Section (A):
(1): Diesel fuel Used for filling
(2): Engine coolant Used for filling and draining.
There is also a filling point on top of the machine.

Section (B):
(3): Engine oil Used for filling and draining
(4): Gear box oil for pump drive gearbox (PTO) Used for filling and
draining
(5): Hydraulic oil Used for filling and draining
(6): Hydraulic fluid monitoring lamp (full) Used for monitoring
(7): Battery charging Socket
3 4 5 7 There are also couplings for the filling of grease and swing gear
6
lubricant.
34