CAT 6090 FS Hydraulic Shovel Operation & Maintenance Manual EM028265-2 – PDF DOWNLOAD

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
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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
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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
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NOTES 2-148
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
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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
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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
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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
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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
EM028265-2

ABBREVIATIONS 5-37
ABBREVIATIONS 5-38
PRODUCT SPECIFICATION SHEET 5-39
NOTES 5-41
6 INDEX 6-1