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Cat 6090 RH400 Hydraulic Shovel Operation Instructions Maintenance Manual BI651406 – PDF DOWNLOAD
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Description
Cat 6090 RH400 Hydraulic Shovel Operation Instructions Maintenance Manual BI651406 – PDF DOWNLOAD
FILE DETAILS:
Cat 6090 RH400 Hydraulic Shovel Operation Instructions Maintenance Manual BI651406 – PDF DOWNLOAD
Language : English
Pages : 320
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6090 RH400 Hydraulic Shovel Operation Instructions Maintenance Manual BI651406 – PDF DOWNLOAD
PREFACE
About this Operating Instructions
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency.
- Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine. The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The operating instructions must always be available in the driver’s cab of the machine. The operating instructions 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, troubleshooting 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 operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1. The operating instructions are directed to the mining- machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel
- The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
- All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer.
- The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat 6090 RH400 Hydraulic Shovel Operation Instructions Maintenance Manual BI651406 – PDF DOWNLOAD
1 INTRODUCTION................................................................................................................................................................ 13 PREFACE .................................................................................................................................................................. 15 About this Operating Instructions .................................................................................................................................... 15 Further machine documentation ........................................................................................................................................ 15 WARRANTY ................................................................................................................................................................. 16 FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................. 17 DESIGNATED USE, UNAUTHORIZED USE ......................................................................................................................................... 18 Noise emission information ........................................................................................................................................... 19 Vibration information ................................................................................................................................................ 19 ORGANIZATIONAL MEASURES .................................................................................................................................................. 20 Selection and qualification of personnel; basic responsibilities ..................................................................................................... 21 Safety instructions governing specific operational phases ............................................................................................................ 21 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 22 Warning of special dangers ........................................................................................................................................... 23 Gas, dust, steam and smoke ........................................................................................................................................... 23 Hydraulic equipment .................................................................................................................................................. 24 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 25 NOTES .................................................................................................................................................................... 27 2 OPERATION................................................................................................................................................................... 29 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 31 Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 32 FIRE AND EXPLOSION HAZARD................................................................................................................................................. 33 DESCRIPTION OF THE HYDRAULIC SHOVEL ...................................................................................................................................... 34 Hydraulic shovel layout .............................................................................................................................................. 35 Undercarriage ........................................................................................................................................................ 36 Superstructure ....................................................................................................................................................... 36 Drive ................................................................................................................................................................ 36 Hydraulic system ..................................................................................................................................................... 36 Control and Monitoring Platform (CAMP) ............................................................................................................................... 36 Board-Control-System (BCS) ........................................................................................................................................... 37 Demand control / Zero-flow regulation................................................................................................................................. 37 Automatic reset to idling............................................................................................................................................. 37 Electrical system .................................................................................................................................................... 37 Signs ................................................................................................................................................................ 38 Entering and leaving the machine, Safety instructions ................................................................................................................ 46 Access ladder lighting ............................................................................................................................................... 46 Swinging ladder ...................................................................................................................................................... 47 Folding ladder (optional) ............................................................................................................................................ 48 Emergency exit in driver’s cab and escape ladder ..................................................................................................................... 49 Switching the cab interior lighting on and off ....................................................................................................................... 50 Switching the maintenance lights on and off .......................................................................................................................... 51 Emergency shut-off function .......................................................................................................................................... 52 Shutting off the supply voltage (battery main switch) ................................................................................................................ 53 Driver’s seat ....................................................................................................................................................... 54 Reducing operators exposure to vibrations ............................................................................................................................ 56 Trainer's / instructor's seat ........................................................................................................................................ 56 Windscreen washer .................................................................................................................................................... 56 Fire extinguisher..................................................................................................................................................... 57 Automatic fire-extinguishing system (optional) ....................................................................................................................... 58 Harness (optional) ................................................................................................................................................... 59 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 62 Engine 1 (LH), control and monitoring ................................................................................................................................ 69 Engine 2 (RH), control and monitoring ................................................................................................................................ 71 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 90 Reducing the operator's exposure to noise ............................................................................................................................ 90 Refuelling ........................................................................................................................................................... 90 Back-up heating (option), filling in fuel ............................................................................................................................ 91 Service station (tanklift) ........................................................................................................................................... 91 Switching the electrical system on and off ........................................................................................................................... 97 Engines, emergency shut-off .......................................................................................................................................... 97 Preheating system for engine and hydraulic oil (optional) ............................................................................................................ 98 Fuel preheating system (optional) .................................................................................................................................... 99 STARTING AND STOPPING THE ENGINES ........................................................................................................................................100 Starting the engines .................................................................................................................................................100 Starting the left-hand engine.........................................................................................................................................100 Starting the right-hand engine........................................................................................................................................100 Engines – adjusting the speed ........................................................................................................................................101 Starting the engines at low temperatures .............................................................................................................................101 Shutting off the engines .............................................................................................................................................102 Shutting off the left-hand engine.....................................................................................................................................102 Shutting off the right-hand engine....................................................................................................................................102 AIR CONDITIONER (OPTIONAL) ...............................................................................................................................................103 Back-up heating driver’s cab (optional) ..............................................................................................................................104 Back-up heating (optional) ...........................................................................................................................................105 MAXIMUM MACHINE INCLINATIONS, INFORMATION ................................................................................................................................106 TRAVELLING, SAFETY INSTRUCTIONS ..........................................................................................................................................107 TRAVELLING ...............................................................................................................................................................108 Superstructure basic position ........................................................................................................................................108 Travelling forwards/backwards ........................................................................................................................................108 Superstructure holding brake .........................................................................................................................................112 Track parking brake ..................................................................................................................................................112 TRANSPORTING THE MACHINE .................................................................................................................................................113 Transport - Safety instructions ......................................................................................................................................113 WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................114 WORKING OPERATION ........................................................................................................................................................116 Before starting work .................................................................................................................................................116 Activating the electronic excavator control ..........................................................................................................................116 Swinging the superstructure ..........................................................................................................................................117 Braking the superstructure ...........................................................................................................................................117 Working ..............................................................................................................................................................118 Emergency lowering of the equipment ..................................................................................................................................119 After daily operation ................................................................................................................................................120 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................121 Securing the machine .................................................................................................................................................122 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................123 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................124 On-board crane, monitoring, warning and control elements .............................................................................................................124 On-board crane, putting into operation ...............................................................................................................................125 On-board crane, drive unit ...........................................................................................................................................125 On-Board crane, – blocking the boom in position of rest ..............................................................................................................126 On-board crane, checking .............................................................................................................................................126 NOTES ....................................................................................................................................................................128 3 INSPECTION AND SERVICING....................................................................................................................................................131 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................133 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................137 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................139 Plan V ...............................................................................................................................................................141 Plan N ...............................................................................................................................................................143 Plan T and W .........................................................................................................................................................145 Plan A – E ...........................................................................................................................................................147 LUBRICATING CHART ........................................................................................................................................................154 Lubricating chart – Grease (legend) ..................................................................................................................................155 Filling quantities - Grease...........................................................................................................................................155 INSPECTION PLAN - OIL ....................................................................................................................................................156 Inspection plan – Oil (legend) .......................................................................................................................................157 Filling quantities - oil .............................................................................................................................................158 Filling quantities - other............................................................................................................................................158 LUBRICANTS / CONSUMABLES .................................................................................................................................................159 Notes on the selection of oils and greases ...........................................................................................................................159 Avoid mixing of different hydraulic fluids ...........................................................................................................................159 I. Oils for combustion engines and compressors .......................................................................................................................160 II. Oils for hydraulic system (selection) ............................................................................................................................161 III.a Oils for pump distribution gearboxes ...........................................................................................................................162 III.b Oils for swing gearboxes .......................................................................................................................................163 III.c Oils for travel gearboxes ......................................................................................................................................164 V. Greases for bearings and swing rings ..............................................................................................................................165 Fluid grease for idlers, track rollers and support rollers ...........................................................................................................166 SERVICING WORK ...........................................................................................................................................................167 Hose line for oil and cooling liquid changes .........................................................................................................................167 ENGINE ...................................................................................................................................................................168 Engine - Safety instructions .........................................................................................................................................168 Engine oil, checking the oil level / topping up .....................................................................................................................169 Engine oil reservoir, checking the oil level .........................................................................................................................170 Changing the engine oil ..............................................................................................................................................171 Engine oil reservoir, changing the oil ...............................................................................................................................173 Replacing the oil filters ............................................................................................................................................175 Eliminator filter and centrifuge .....................................................................................................................................176 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................178 COOLING SYSTEM ...........................................................................................................................................................179 Radiators ............................................................................................................................................................180 Checking cooling-liquid level ........................................................................................................................................180 Topping up cooling-liquid ............................................................................................................................................181 Cooling liquid change ................................................................................................................................................182 Water filter change...................................................................................................................................................184 AIR-INTAKE SYSTEM ........................................................................................................................................................185 Main filter elements .................................................................................................................................................185 Safety filter element ................................................................................................................................................188 Air-intake lines .....................................................................................................................................................189 Dust collection ......................................................................................................................................................189 FUEL SYSTEM ..............................................................................................................................................................190 Fuel system - Safety instructions ....................................................................................................................................190 Replacing the fuel filters ...........................................................................................................................................190 Fuel filters, draining water .........................................................................................................................................192 Fuel tank, replace breather filter ...................................................................................................................................193 Cleaning the fuel tanks ..............................................................................................................................................193 ELECTRICAL SYSTEM .......................................................................................................................................................195 Electrical system - Safety instructions ..............................................................................................................................195 Alternator - Instructions ............................................................................................................................................195 Electrical circuit diagrams ..........................................................................................................................................195 Electrical system switch-cabinets ....................................................................................................................................195 Replacing lamps and bulbs ............................................................................................................................................195 Xenon floodlight projector, replacing the lamp .......................................................................................................................196 Lighting systems in LED technonogy, instructions .....................................................................................................................198 Battery ..............................................................................................................................................................199 Charging batteries inside the machine, safety instructions ...........................................................................................................201 Switchgear cabinet ...................................................................................................................................................202 HYDRAULIC SYSTEM .........................................................................................................................................................204 Hydraulic system - Safety instructions ...............................................................................................................................204 Depressurizing the hydraulic system ..................................................................................................................................204 Checking the hydraulic oil level .....................................................................................................................................205 Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................207 Bypass valves (hydraulic oil reservoir) ..............................................................................................................................209 Replacing the hydraulic oil return-flow filters (filter housing) .....................................................................................................210 Bypass valves (filter housing - cooling system) ......................................................................................................................211 Breather filter ......................................................................................................................................................212 Filter (control circuit) .............................................................................................................................................213 High-pressure filter for working hydraulics ..........................................................................................................................214 High-pressure filters for the servo circuit ..........................................................................................................................215 High-pressure filters for pump-flushing circuit ......................................................................................................................216 High-pressure filters for feeding circuits and swing pumps ...........................................................................................................217 High-pressure filters for swing circuit ..............................................................................................................................218 Changing the hydraulic oil ...........................................................................................................................................219 Avoid mixing of different hydraulic fluids ...........................................................................................................................219 Venting the hydraulic system..........................................................................................................................................222 Cleaning the hydraulic oil cooler.....................................................................................................................................223 Electronic excavator control..........................................................................................................................................224 Pressure accumulator - Emergency lowering.............................................................................................................................225 PUMP TRANSFER GEARBOX ....................................................................................................................................................226 Checking the gearbox oil level / Topping up with oil .................................................................................................................226 Changing the gearbox oil .............................................................................................................................................226 Gearbox venting ......................................................................................................................................................228 Pre-chambers .........................................................................................................................................................228 Pump transfer gearbox lube oil filters ...............................................................................................................................229 SWING GEARBOX ............................................................................................................................................................230 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................230 Changing the gearbox oil .............................................................................................................................................231 Gearbox venting ......................................................................................................................................................231 TRAVEL GEARBOX ...........................................................................................................................................................232 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................232 Travel gearbox - Changing the oil ....................................................................................................................................232 Preliminary gearbox - Draining off oil ...............................................................................................................................233 CRAWLER TRACKS ...........................................................................................................................................................234 Track tensioner ......................................................................................................................................................235 Pressure-accumulator inspection regulations ..........................................................................................................................237 Checking the gas charging pressure in the pressure accumulator........................................................................................................237 SWING RING ...............................................................................................................................................................238 Swing ring - Instructions.............................................................................................................................................238 Bearing races.........................................................................................................................................................238 CENTRAL LUBRICATING ......................................................................................................................................................240 Design ...............................................................................................................................................................240 Function .............................................................................................................................................................241 Filling up the grease container ......................................................................................................................................242 Breather filter ......................................................................................................................................................242 Checking the greasing pressure .......................................................................................................................................243 Unblocking a grease line .............................................................................................................................................243 Oilfilter for hydraulic circuit grease pump replace ..................................................................................................................244 Grease filter replace (Filling the grease container) .................................................................................................................245 Grease filter replace (Grease lines) .................................................................................................................................246 OTHER MAINTENANCE ........................................................................................................................................................247 Engine ...............................................................................................................................................................247 Equipment ............................................................................................................................................................248 LADDERS (OPTIONAL) .......................................................................................................................................................249 Pressure-accumulator inspection regulations ..........................................................................................................................250 Extract from the German regulations...................................................................................................................................250 Checking the gas charging pressure in the pressure accumulator........................................................................................................250 ON-BOARD CRANE, DRIVE UNIT ...............................................................................................................................................251 On-board crane, lubricating ..........................................................................................................................................252 On-Board crane, checking tightness of fastening bolts ................................................................................................................252 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING ........................................................................................................253 Putting the hydraulic shovel out of operation ........................................................................................................................253 Battery storage ......................................................................................................................................................253 Recommissioning ......................................................................................................................................................253 NOTES ....................................................................................................................................................................255 4 REPAIR WORK.................................................................................................................................................................257 REPAIR WORK - SAFETY INSTRUCTIONS ........................................................................................................................................259 CONFINED SPACES - SAFETY INSTRUCTIONS ....................................................................................................................................260 REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................261 REPAIR WORK, ENGINE ......................................................................................................................................................262 HYDRAULIC SYSTEM .........................................................................................................................................................263 Repair instructions ..................................................................................................................................................263 Hydraulic hoses – Instructions ......................................................................................................................................263 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................264 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................265 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................268 Dismantling and removal instructions .................................................................................................................................268 Risk of deflagrations ................................................................................................................................................268 Risk of fire .........................................................................................................................................................268 Disposing of the machine without polluting the environment ...........................................................................................................268 Further hazardous substances .........................................................................................................................................269 Appropriate disposal of batteries ....................................................................................................................................270 NOTES ....................................................................................................................................................................271 5 ANNEX.......................................................................................................................................................................273 BOARD-CONTROL-SYSTEM .....................................................................................................................................................275 BCS III, what’s that? ................................................................................................................................................275 The keys on the front side ...........................................................................................................................................276 Other elements on the front side .....................................................................................................................................276 BCSIII, the start screen .............................................................................................................................................277 Information given on the start screen, top section ...................................................................................................................278 Information given on the start screen, central section ...............................................................................................................279 Information given on the start screen, lower section .................................................................................................................280 Information given on the “Service” screen ............................................................................................................................281 Engine data screen ...................................................................................................................................................282 Hydraulic data screen ................................................................................................................................................283 Lubrication data screen ..............................................................................................................................................284 Controls adjustment data screen ......................................................................................................................................285 View documents screen ................................................................................................................................................286 Signal table screen ..................................................................................................................................................287 Signal table screen, location ........................................................................................................................................288 Signal table screen, diagram .........................................................................................................................................289 Signal table screen, diagram configuration ...........................................................................................................................290 Code table screen ....................................................................................................................................................291 BCS III, interfaces ..................................................................................................................................................292 USB interface, data storage ..........................................................................................................................................292 Saving data to a USB stick ...........................................................................................................................................293 Saving data to a USB stick, continued ................................................................................................................................294 Saving data to a USB stick, continued ................................................................................................................................295 BCSIII, cleaning .....................................................................................................................................................296 BCSIII, disposal .....................................................................................................................................................296 TROUBLESHOOTING ..........................................................................................................................................................297 Instructions on troubleshooting ......................................................................................................................................297 Layout of the fault table ............................................................................................................................................297 Possible causes ......................................................................................................................................................297 Measures .............................................................................................................................................................297 Section ..............................................................................................................................................................297 FAULT TABLES .............................................................................................................................................................298 Combustion engine - Fault table ......................................................................................................................................298 Working hydraulics – Fault table .....................................................................................................................................299 Track drive – Fault table ............................................................................................................................................300 Swing mechnism – Fault table .........................................................................................................................................301 Central lubricating system – Fault table .............................................................................................................................302 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................303 Vibration data .......................................................................................................................................................303 ABBREVIATIONS ............................................................................................................................................................304 ABBREVIATIONS.........................................................................................................................................................305 TECHNICAL DATA ...........................................................................................................................................................307 Product Specification Sheet...............................................................................................................................................308 NOTES ....................................................................................................................................................................313 6 INDEX.......................................................................................................................................................................315
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