CAT 6090 FS Hydraulic Shovel Operation and Maintenance Manual EM028265 – PDF DOWNLOAD
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CAT 6090 FS Hydraulic Shovel Operation and Maintenance Manual EM028265 – PDF DOWNLOAD
Language : English
Pages : 402
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT 6090 FS Hydraulic Shovel Operation and Maintenance Manual EM028265 – PDF DOWNLOAD
ALL PRODUCTS FOREWORD
Literature Information
- This manual should be read carefully before using this product for the first time and before performing maintenance. This manual should be stored in the product literature holder or in the product literature storage area. Immediately replace this manual if lost, damaged, or unreadable.
- This manual may contain safety information, operation instructions, transportation information, lubrication information, and maintenance information. Some photographs or illustrations in this publication show details or attachments that can be different from your product. Guards and covers might have been removed for illustrative purposes.
- Continuing improvement and advancement of product design might have caused changes to your product, which are not included in this publication. Whenever a question arises regarding your product, or this publication, consult your dealer for the latest available information.
Safety
The safety section, if present, lists basic safety precautions. In addition, this section identifies the text and locations of safety messages used on the product. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance, and repair on this product.
Operation
The operation section, if present, is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, controls, attachment controls, transportation, and towing information (if applicable). 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, if present, is a guide to equipment care. Proper maintenance and repair are essential to keep the equipment and systems operating correctly. As the owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual. The Maintenance Interval Schedule lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the “When Required” service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or “one safe source” for all maintenance procedures
Maintenance
Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty, or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT 6090 FS Hydraulic Shovel Operation and Maintenance Manual EM028265 – PDF DOWNLOAD
TABLE OF CONTENTS
1 INTRODUCTION ____ 1-1
ALL PRODUCTS FOREWORD __ 1-1
Literature Information 1-1
Safety ___________ 1-1
Operation ________ 1-1
Product Information _ 1-1
Maintenance ______ 1-1
Maintenance Intervals ____ 1-1
Product Capacity ___ 1-1
California Proposition 65 Warning ________ 1-2
PREFACE _________ 1-3
About this Operation and Maintenance Manual ____ 1-3
Further machine documentation 1-3
WARRANTY _______ 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols ___ 1-5
Declaration of Conformity _ 1-5
Noise emission information 1-6
Vibration information 1-6
Visibility Information 1-6
Restricted Visibility _ 1-7
DESIGNATED USE UNAUTHORIZED USE 1-8
ORGANIZATIONAL MEASURES 1-9
Selection and qualification of personnel; basic responsibilities _____________________________ 1-10
Safety instructions governing specific operational phases ________________________________ 1-10
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables ___________________________ 1-11
Warning of special dangers ___ 1-12
Gas dust steam and smoke _ 1-12
Hydraulic equipment ____ 1-13
FIRE AND EXPLOSION HAZARD ________ 1-14
NOTES ___________ 1-16
2 OPERATION _______ 2-1
OPERATION – SAFETY INSTRUCTIONS ___ 2-3
Visibility aids ______ 2-4
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
Upper structure ____ 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
Safety films and warning messages _____ 2-10
ANSI – compliant safety messages set ___ 2-11
Safety messages (ANSI) – Description ___ 2-17
Additional messages (ANSI) – Description 2-21
Entering and leaving the machine – Safety instructions __________________________________ 2-25
Access ladder – Lighting _ 2-25
Folding ladder – Function 2-26
Emergency exit in operator’s cab and escape ladder ____________________________________ 2-27
Cab interior lighting – Switch on and off __ 2-28
Maintenance lights – Switch on and off ___ 2-29
Emergency shut-off – Function 2-30
Putting the machine back into operation reset of emergency shut off function ________________ 2-31
Battery isolator switch – Shut off supply voltage ___ 2-32
Starter isolator switch- Shut off starter voltage ____ 2-32
Operator’s seat ___ 2-33
Reducing operators exposure to vibrations 2-35
Trainer’s / instructor’s seat ___ 2-35
Windscreen washer 2-35
Operating hours meter (if equipped) _____ 2-35
Fire extinguisher __ 2-36
Automatic fire-extinguishing system _____ 2-36
MONITORING WARNING AND CONTROL ELEMENTS __________________________________ 2-38
Engine 1 (LH) control and monitoring ___ 2-45
Engine 2 (RH) control and monitoring ___ 2-47
PUTTING THE MACHINE INTO OPERATION _____ 2-66
Electrical Storm Injury Prevention _______ 2-66
Reducing the operator’s exposure to noise 2-66
Refueling ________ 2-67
Diesel fuel – recommendations 2-67
Back-up heating (option) – filling in Diesel fuel ____ 2-67
Service station (Fast fill arm) – Function __ 2-68
Emergency off switch ___ 2-69
Electrical system – Switch on and off ____ 2-74
Engines – Emergency shut-off _ 2-74
ENGINES – STARTING AND STOPPING __ 2-76
Engines – Start ___ 2-76
Starting the left-hand engine __ 2-76
Starting the right-hand engine _ 2-76
Engines – Adjust speed _ 2-77
Engines – Start at low temperatures _____ 2-77
Engines – Shut off _ 2-78
Shutting off the left-hand engine ________ 2-78
Shutting off the right-hand engine _______ 2-78
AIR CONDITIONER (OPTIONAL) ________ 2-79
Back-up heating operator’s cab (optional) 2-80
Back-up heating (optional) ___ 2-81
OPERATIONAL PRACTICES __ 2-82
Working operation – Safety instructions ___ 2-82
Before starting work ____ 2-83
Machine Operating Temperature Range __ 2-83
Warming up the hydraulic system _______ 2-83
Electronic hydraulic shovel control (pilot control) – activate _______________________________ 2-84
Working operation – basics ___ 2-85
OPERATION TECHNIQUES ___ 2-91
Machine operation with face shovel attachment – Best Practices ___________________________ 2-91
Face Shovel Operation – Restricted Operation ___ 2-105
TRAVELING ______ 2-120
Traveling – Safety Instructions 2-120
Before starting traveling 2-121
Traveling – Basic Movements 2-123
Counter-rotation turns / Turning on the spot _____ 2-126
Track Parking Brake – set/release _____ 2-127
Traveling speed – adjust 2-127
Traveling uphill and downhill on ramps and steep slopes ________________________________ 2-128
Traveling over long distances 2-130
Traveling – Best Practices __ 2-132
Traveling – Restricted Operation ______ 2-133
Maximum Machine Inclinations ________ 2-136
TRANSPORTING THE MACHINE _______ 2-138
Transport – Safety instructions ________ 2-138
Emergency lowering of the attachment __ 2-139
After daily operation ___ 2-140
ASSEMBLING ATTACHMENT – SAFETY INSTRUCTIONS _______________________________ 2-141
Safety line on boom ___ 2-141
Main control valves – attach/remove the handrail _ 2-142
Securing the machine __ 2-142
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___________ 2-143
ON-BOARD CRANE (OPTIONAL) _______ 2-144
On-board crane – monitoring warning and control elements _____________________________ 2-144
On-board crane – putting into operation _________ 2-145
On-board crane – drive unit __ 2-145
On-Board crane – blocking the boom in position of rest _________________________________ 2-146
On-board crane – checking __ 2-146
Monitoring cameras – Function ________ 2-147
Operator Assist System (if equipped) ___ 2-147
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 T and W ____ 3-17
Plan A – E _______ 3-18
LUBRICATING CHART ___ 3-26
Lubricating chart – Grease (legend) _____ 3-27
Filling quantities – Grease 3-27
INSPECTION PLAN – OIL _ 3-28
Inspection plan – Oil (legend) _ 3-29
Filling quantities – oil ____ 3-30
Filling quantities – other __ 3-30
LUBRICANTS / CONSUMABLES ________ 3-31
Notes on the selection of oils and greases 3-31
I. Oil for combustion engines 3-32
II. Fluid for hydraulic system ________ 3-33
III.a Oil for pump drive gearboxes and travel gearboxes ________________________________ 3-34
III.b Oils for swing gearboxes 3-35
V. Greases for bearings swing rings and track system ________________________________ 3-36
Coolant for use on all combustion engines 3-37
SERVICING WORK _ 3-38
Hose line for oil and cooling liquid changes ______ 3-38
ENGINE __________ 3-39
Engine – Safety instructions __ 3-39
Walk-Around Inspection _ 3-40
Engine oil level – Check / top up ________ 3-41
Engine oil reservoir – Check oil level ____________ 3-42
Engine oil – Change 3-43
Engine oil reservoir – Fill in / drain off oil __ 3-45
Engine oil reservoir – Replace oil filters __ 3-47
Centrifuge oil cleaning system – Maintain 3-48
Cold-starting fluid (ether) – Replace the pressure vessel _________________________________ 3-50
Engine Oil Sample – Obtain __ 3-51
Engine Mounts – Inspect _ 3-52
Belts – Inspect/Replace __ 3-52
COOLING SYSTEM _ 3-53
Cooling liquid radiators – Check / Clean __ 3-54
Cooling-liquid level – Check ___ 3-54
Cooling-liquid – Top up __ 3-55
Cooling liquid – Change __ 3-57
Water filter – Change ____ 3-59
AIR-INTAKE SYSTEM ____ 3-60
Main filter elements – Check / Clean ____ 3-60
Secondary filter element – Check / Replace ______ 3-63
Air-intake lines – Check __ 3-64
Dust collection – Function 3-64
FUEL SYSTEM ____ 3-65
Fuel system – Safety instructions _______ 3-65
Fuel tank supply valve – Function _______ 3-65
Fuel filters – Replace ____ 3-65
Fuel filters – Drain water _ 3-67
Fuel tank breather filter – Replace _______ 3-68
Fuel tanks – Clean _ 3-68
Hoses and Clamps – Inspect/Replace ____ 3-70
ELECTRICAL SYSTEM ___ 3-73
Electrical system – Safety instructions ____ 3-73
Alternator – Instructions __ 3-73
Electrical circuit diagrams 3-73
Electrical system switch-cabinets _______ 3-73
Lamps and bulbs – Replace __ 3-73
Xenon floodlight projector (if equipped) – Replace the lamp _______________________________ 3-74
Lighting systems in LED technology – Instructions _ 3-76
Battery – Check the state of charge ______ 3-77
Battery – Remove / Install 3-78
Battery charge inside the machine – Safety instructions __________________________________ 3-79
Switchgear cabinet filters – Clean _______ 3-80
CAN-Bus wiring connections – Inspect ___ 3-82
HYDRAULIC SYSTEM ___ 3-83
Hydraulic system – Safety instructions ___________ 3-83
Hydraulic system – Depressurize _______ 3-83
Attachment circuits – Depressurize ______ 3-84
Hydraulic system sections – Depressurize 3-85
Hydraulic oil level – Check 3-85
Hydraulic oil return-flow filters (hydraulic oil reservoir) – Replace ___________________________ 3-87
Bypass valves (hydraulic oil reservoir) – Check / Replace ________________________________ 3-89
Hydraulic oil return-flow filters (filter housing cooling system) – Replace______________________ 3-90
Bypass valves (filter housing – cooling system) – Check / Replace _________________________ 3-91
Hydraulic tank breather filter – Replace ___ 3-92
Filter (control circuit main pumps) – Replace ______ 3-93
High-pressure filter for working hydraulics – Check / Replace _____________________________ 3-94
High-pressure filters for the pilot control circuit – Check / Replace __________________________ 3-95
High-pressure filters for pump-flushing circuit – Check / Replace ___________________________ 3-96
High-pressure filters for feeding circuits and swing pumps – Check / Replace _________________ 3-97
High-pressure filters for swing circuit – Check / Clean / Replace ___________________________ 3-99
Hydraulic oil – Change _ 3-100
CGM-HMS Hydraulic Fluid __ 3-100
Hydraulic oil tank – Clean ___ 3-101
Hydraulic system – Vent 3-103
Hydraulic oil cooler – Clean _ 3-104
Electronic shovel controls – Clean / Lubricate ___ 3-105
Pressure accumulator – Emergency lowering ____ 3-106
PUMP DRIVE GEARBOX 3-107
Pump drive gearbox – Check oil level / Top up with oil __________________________________ 3-107
Pump drive gearbox – Change gearbox oil ______ 3-108
Pump drive gearbox breather valve – Replace ___ 3-109
Pump drive gearbox – pre-chambers expansion reservoir _______________________________ 3-109
Pump drive gearbox oil sample – Obtain 3-110
Pump drive gearbox lube oil filters – Clean / Replace ___________________________________ 3-110
SWING GEARBOX 3-111
Swing gearbox oil sample – Obtain _____ 3-111
Swing gearbox – Check oil level / Top up with oil _ 3-111
Swing gearbox – Vent __ 3-111
Swing gearbox oil – Change _ 3-112
TRAVEL GEARBOX (GEARBOX P/N SAP 1522923) ____________________________________ 3-114
Travel gearbox – Check oil level / Top up with oil _ 3-114
Travel gearbox oil sample – Obtain ____ 3-116
Travel gearbox oil – Change _ 3-117
Travel gearbox breather filter – Clean/Replace ___ 3-118
CRAWLER TRACKS ____ 3-119
Tracks – Clean __ 3-119
Carbody-crawler frame fastening bolts and disks – Replace ______________________________ 3-119
Track roller fastening – Check ________ 3-120
Upper roller fastening – Check ________ 3-120
Undercarriage – Check for leaks and free movement ___________________________________ 3-120
Track tensioning system 3-121
Pressure-accumulator inspection regulations ____ 3-122
Checking the gas charging pressure in the pressure accumulator _________________________ 3-122
SWING RING _____ 3-123
Swing ring – Instructions 3-123
Swing ring grease filling – Check ______ 3-124
Swing ring bolts – Check for tightness __ 3-124
CENTRAL LUBRICATING SYSTEM _____ 3-125
Central lubrication system – Design ____ 3-125
Central lubrication system – Function ___ 3-126
Grease container – Fill up ___ 3-127
Grease container breather filter Check / replace __ 3-127
Greasing pressure – Check _ 3-128
Grease line – Unblock __ 3-128
Oil filter (hydraulic circuit grease pump) – Replace 3-129
Grease filter (filling the grease container) – Check / replace _____________________________ 3-130
Grease filter (grease lines) – Check / replace ____ 3-131
OTHER MAINTENANCE WORK ________ 3-132
Engine – Clean __ 3-132
Radiator – Clean _ 3-133
Reservoirs for used grease at the A-frame – Empty ____________________________________ 3-134
Air conditioning filter – Clean _ 3-134
Attachment – Check for cracks ________ 3-135
Clam cylinder chamber – Check for soiling ______ 3-135
Window panes – Clean _ 3-136
Mirror – Clean / adjust position ________ 3-136
Seat belt – Inspect ____ 3-137
Seat belt – Replace ____ 3-137
Cameras – Check/Clean/Adjust (If equipped) ____ 3-138
Horn – Inspect / Replace 3-139
Hydraulic ladders – Pressure accumulator ______ 3-140
Pressure-accumulator inspection regulations ____ 3-141
Extract from the German regulations ___ 3-141
Pressure accumulator – Checking the gas charging pressure _____________________________ 3-141
ON-BOARD CRANE – DRIVE UNIT ______ 3-142
On-board crane – Lubricate __ 3-143
On-Board crane fastening bolts – Check tightness 3-143
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING _______ 3-144
Putting the hydraulic shovel out of operation ____ 3-144
Battery storage __ 3-144
Recommissioning 3-144
NOTES __________ 3-145
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
NOTES ____________ 4-1
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
ABBREVIATIONS __ 5-37
ABBREVIATIONS __ 5-38
PRODUCT SPECIFICATION SHEET _____ 5-39
NOTES 5-41
6 INDEX 6-1
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