CAT 6090, 6090FS Hydraulic Shovel Operation & Maintenance Manual BI015760 – PDF DOWNLOAD

Description

CAT 6090, 6090FS Hydraulic Shovel Operation & Maintenance Manual BI015760 – PDF DOWNLOAD

FILE DETAILS:

CAT 6090, 6090FS Hydraulic Shovel Operation & Maintenance Manual BI015760 – PDF DOWNLOAD

Language : English
Pages : 334
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6090, 6090FS Hydraulic Shovel Operation & Maintenance Manual BI015760 – PDF DOWNLOAD

PREFACE:
About this Operation and Maintenance Manual:

• This Operation and Maintenance Manual is de- 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 efficien- cy. Observing these instructions
  helps to prevent hazardous situations, to reduce repair costs and downtimes and to
  increase the reliability and ser- vice life of the machine.
• The Operation and Maintenance Manual must be supplemented by the respective national rules
  and regulations for accident prevention and environ- mental protection.
• The Operation and Maintenance Manual must always be available in the operator’s cab
  of the machine.

The Operation and Maintenance Manual must be read and put into practice by any person in
charge of carrying out work with or on the machine, such as
■ operation, including setting-up, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
■ maintenance (inspection, servicing, repair) and / or
■ transport.

• In addition to the Operation and Maintenance Manual and the mandatory rules and
  regulations for accident prevention and environmental protec- tion in the user’s country and
  at the place where the machine is to be used, the generally recog- nized technical
  rules for safe and proper working must be observed ¹.
• The Operation and Maintenance Manuals are di- rected to the mining-machine specialist. They
  can- not provide basic know-how. This can be acquired, for example, in several days’ instruction by
  a quali- fied Caterpillar Global Mining Hydraulic Mining Shovels (CGM HMS) mechanic
  or by attending a CGM HMS training course for operators or mainte- nance personnel.
• The CGM HMS after-sales service will be pleased to deal with any queries you may have after read-
  ing through the Operation and Maintenance Manu- als.
• The operating and maintenance instructions are not work instructions for carrying out major
  repairs. Such work is willingly done for you by the CGM
  HMS after-sales service.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT 6090, 6090FS Hydraulic Shovel Operation & Maintenance Manual BI015760 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-1
About this Operation and Maintenance Manual 1-1
Further machine documentation 1-1
WARRANTY 1-2
FUNDAMENTAL SAFETY INSTRUCTIONS 1-3
Warnings and symbols 1-3
DESIGNATED USE, UNAUTHORIZED USE 1-4
Noise emission information 1-5
Vibration information 1-5
ORGANIZATIONAL MEASURES 1-6
Selection and qualification of personnel; basic responsibilities 1-7
Safety instructions governing specific operational phases 1-7
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-8
Warning of special dangers 1-9
Gas, dust, steam and smoke 1-9
Hydraulic equipment 1-10
FIRE AND EXPLOSION HAZARD 1-11
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
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
Superstructure 2-8
Drive unit 2-8
Hydraulic system 2-8
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
Signs 2-10
Entering and leaving the machine, Safety instructions 2-18
Access ladder lighting 2-18
Folding ladder 2-19
Emergency exit in operator’s cab and escape ladder 2-20
Switching the cab interior lighting on and off 2-21
Switching the maintenance lights on and off 2-22
Emergency shut-off function 2-23
BI015760
OMM 6090, 6090FS(3 847 002.04)-EN
TABLE OF CONTENTS
vi
Putting the machine back into operation, reset of emergency shut off function 2-24
Battery isolator switch, shutting off supply voltage 2-25
Starter isolator switch, shutting off starter voltage 2-25
Operator’s seat 2-26
Reducing operators exposure to vibrations 2-28
Trainer’s / instructor’s seat 2-28
Windscreen washer 2-29
Operating hours meter 2-29
Fire extinguisher 2-30
Automatic fire-extinguishing system (optional) 2-31
Harness (optional) 2-32
MONITORING, WARNING AND CONTROL ELEMENTS 2-36
Engine 1 (LH), control and monitoring 2-43
Engine 2 (RH), control and monitoring 2-45
PUTTING THE MACHINE INTO OPERATION 2-64
Electrical Storm Injury Prevention 2-64
Reducing the operator’s exposure to noise 2-64
Refueling 2-65
Back-up heating (option), filling in Diesel fuel 2-65
Service station (tanklift) 2-66
Emergency off switch 2-67
Switching the electrical system on and off 2-72
Engines, emergency shut-off 2-72
STARTING AND STOPPING THE ENGINES 2-74
Starting the engines 2-74
Starting the left-hand engine 2-74
Starting the right-hand engine 2-74
Engines – adjusting the speed 2-75
Starting the engines at low temperatures 2-75
Shutting off the engines 2-76
Shutting off the left-hand engine 2-76
Shutting off the right-hand engine 2-76
AIR CONDITIONER (OPTIONAL) 2-77
Back-up heating operator’s cab (optional) 2-78
Back-up heating (optional) 2-79
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-80
TRAVELLING, SAFETY INSTRUCTIONS 2-82
TRAVELLING 2-83
Superstructure basic position 2-83
Travelling forwards/backwards 2-83
Superstructure holding brake 2-87
Track parking brake 2-87
TRANSPORTING THE MACHINE 2-88
Transport – Safety instructions 2-88
BI015760
OMM 6090, 6090FS(3 847 002.04)-EN
TABLE OF CONTENTS
vii
WORKING OPERATION – SAFETY INSTRUCTIONS 2-89
WORKING OPERATION 2-91
Before starting work 2-91
Activating the electronic shovel control 2-91
Swinging the superstructure 2-92
Braking the superstructure 2-92
Working operations 2-93
Emergency lowering of the equipment 2-94
After daily operation 2-95
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-96
Safety line on boom 2-96
Main control valves – attach/remove the handrail 2-97
Securing the machine 2-97
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-98
ON-BOARD CRANE (OPTIONAL) 2-99
On-board crane, monitoring, warning and control elements 2-99
On-board crane, putting into operation 2-100
On-board crane, drive unit 2-100
On-Board crane, – blocking the boom in position of rest 2-101
On-board crane, checking 2-101
Monitoring cameras 2-102
NOTES 2-103
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
Plan V 3-11
Plan N 3-13
Plan T and W 3-15
Plan T and W 3-16
Plan A – E 3-17
LUBRICATING CHART 3-24
Lubricating chart – Grease (legend) 3-25
Filling quantities – Grease 3-25
INSPECTION PLAN – OIL 3-26
Inspection plan – Oil (legend) 3-27
Filling quantities – oil 3-28
Filling quantities – other 3-28
LUBRICANTS / CONSUMABLES 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids 3-29
I. Oil for combustion engines and compressors 3-30
II. Fluid for hydraulic system 3-31
III.a Oil for pump drive gearboxes and travel gearboxes 3-32
BI015760
OMM 6090, 6090FS(3 847 002.04)-EN
TABLE OF CONTENTS
viii
III.b Oils for swing gearboxes 3-33
V. Greases for bearings, swing rings and track system 3-34
Coolant for use on all combustion engines 3-35
SERVICING WORK 3-36
Hose line for oil and cooling liquid changes 3-36
ENGINE 3-37
Engine – Safety instructions 3-37
Engine oil, checking the oil level / topping up 3-38
Engine oil reservoir, checking the oil level 3-39
Engine oil, change 3-40
Engine oil reservoir, filling in / draining off the oil 3-42
Eliminator filter and centrifuge 3-45
Cold-starting fluid (ether) – Replacing the pressure vessel 3-47
COOLING SYSTEM 3-48
Radiators 3-49
Cooling-liquid level, check 3-49
Cooling-liquid, topping up 3-50
Cooling liquid change 3-52
Water filter, change 3-54
AIR-INTAKE SYSTEM 3-55
Main filter elements 3-55
Secondary filter element 3-58
Air-intake lines, check 3-59
Dust collection, function 3-59
FUEL SYSTEM 3-60
Fuel system – Safety instructions 3-60
Fuel tank supply valve, function 3-60
Fuel filters, replace 3-60
Fuel filters, draining water 3-62
Fuel tank breather filter, replace 3-63
Fuel tanks, clean 3-63
ELECTRICAL SYSTEM 3-65
Electrical system – Safety instructions 3-65
Alternator – Instructions 3-65
Electrical circuit diagrams 3-65
Electrical system switch-cabinets 3-65
Replacing lamps and bulbs 3-65
Xenon floodlight projector, replacing the lamp 3-66
Lighting systems in LED technology, instructions 3-68
Battery, checking the state of charge 3-69
Battery, removing and installing 3-70
Charging batteries inside the machine, safety instructions 3-71
Switchgear cabinet 3-72
HYDRAULIC SYSTEM 3-74
Hydraulic system – Safety instructions 3-74
Hydraulic system, depressurizing 3-74
Hydraulic oil level, check 3-75
BI015760
Hydraulic oil return-flow filters (hydraulic oil reservoir), replace 3-77
Bypass valves (hydraulic oil reservoir) 3-79
Hydraulic oil return-flow filters (filter housing cooling system), replace 3-80
Bypass valves (filter housing – cooling system) 3-81
Hydraulic tank breather filter, replace 3-82
Filter (control circuit main pumps), replace 3-83
High-pressure filter for working hydraulics, replace 3-84
High-pressure filters for the servo circuit, replace 3-85
High-pressure filters for pump-flushing circuit 3-86
High-pressure filters for feeding circuits and swing pumps 3-87
High-pressure filters for swing circuit, replace 3-88
Changing the hydraulic oil 3-89
Avoid mixing of different hydraulic fluids 3-89
Venting the hydraulic system 3-92
Cleaning the hydraulic oil cooler 3-93
Electronic shovel control 3-94
Pressure accumulator – Emergency lowering 3-95
PUMP DRIVE GEARBOX 3-96
Checking the gearbox oil level / Topping up with oil 3-96
Pump drive gearbox, Changing the gearbox oil 3-97
Pump drive gearbox breather 3-98
Pre-chambers, expansion reservoir 3-98
Pump drive gearbox lube oil filters, clean / replace 3-99
SWING GEARBOX 3-100
Swing gearbox – checking the oil level / topping up with oil 3-100
Swing gearbox, changing the gearbox oil 3-101
Swing gearbox venting 3-101
TRAVEL GEARBOX 3-102
Travel gearbox – checking the oil level / topping up with oil 3-102
Travel gearbox – changing the oil 3-102
CRAWLER TRACKS 3-104
Tracks – cleaning 3-104
Carbody-crawler frame fastening bolts and disks, replace 3-104
Track tensioner 3-105
Pressure-accumulator inspection regulations 3-107
Checking the gas charging pressure in the pressure accumulator 3-107
SWING RING 3-108
Swing ring – Instructions 3-108
Bearing races 3-108
CENTRAL LUBRICATING SYSTEM 3-110
Design 3-110
Function 3-111
Filling up the grease container 3-112
Breather filter 3-112
Checking the greasing pressure 3-113
Unblocking a grease line 3-113
Oil filter for hydraulic circuit grease pump, replace 3-114
Grease filter replace (Filling the grease container) 3-115
TABLE OF CONTENTS
Grease filter replace (Grease lines) 3-116
OTHER MAINTENANCE 3-117
Engine 3-117
Reservoirs for used grease at the A-frame, emptying 3-118
Heating and air conditioning, check 3-118
Working equipment, check welding seems 3-119
Clam cylinder chamber, check for soiling 3-119
Window panes – cleaning 3-120
Mirror – cleaning / adjusting position 3-120
HYDRAULIC LADDERS (OPTIONAL) 3-121
Pressure-accumulator inspection regulations 3-122
Extract from the German regulations 3-122
Checking the gas charging pressure in the pressure accumulator 3-122
ON-BOARD CRANE, DRIVE UNIT 3-123
On-board crane, lubricating 3-124
On-Board crane, checking tightness of fastening bolts 3-124
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-125
Putting the hydraulic shovel out of operation 3-125
Battery storage 3-125
Recommissioning 3-125
NOTES 3-127
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
HYDRAULIC SYSTEM 4-7
Repair instructions 4-7
Hydraulic hoses – Instructions 4-7
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-8
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-9
DISPOSAL AT THE END OF THE SERVICE LIFE 4-12
Dismantling and removal instructions 4-12
Risk of deflagrations 4-12
Risk of fire 4-12
Disposing of the machine without polluting the environment 4-13
Further hazardous substances 4-13
Appropriate disposal of batteries 4-14
BI015760
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM, OPERATOR LEVEL 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
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 mechanism – Fault table 5-32
Central lubricating system – Fault table 5-33
Engine control module, displaying stored fault codes 5-34
HYDRAULIC CIRCUIT DIAGRAM 5-36
Vibration data 5-36
BI015760
ABBREVIATIONS 5-37
ABBREVIATIONS 5-38
PRODUCT SPECIFICATION SHEET 5-39
NOTES 5-41
6 INDEX 6-1

Customer Support: [email protected]

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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