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Cat 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015811 – PDF DOWNLOAD
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Description
Cat 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015811 – PDF DOWNLOAD
FILE DETAILS:
Cat 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015811 – PDF DOWNLOAD
Language : English
Pages : 326
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015811 – 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 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015811 – PDF DOWNLOAD
TITLEPAGE..................................................................................................................................................................... 3 1 INTRODUCTION................................................................................................................................................................ 15 PREFACE .................................................................................................................................................................. 17 About this Operating Instructions .................................................................................................................................... 17 Further machine documentation ........................................................................................................................................ 17 WARRANTY ................................................................................................................................................................. 18 FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................................................................................... 19 Warnings and symbols ................................................................................................................................................. 19 DESIGNATED USE, UNAUTHORIZED USE ......................................................................................................................................... 20 Noise emission information ........................................................................................................................................... 21 Vibration information ................................................................................................................................................ 21 ORGANIZATIONAL MEASURES .................................................................................................................................................. 22 Selection and qualification of personnel; basic responsibilities ..................................................................................................... 23 Safety instructions governing specific operational phases ............................................................................................................ 23 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 24 Warning of special dangers ........................................................................................................................................... 25 Gas, dust, steam and smoke ........................................................................................................................................... 25 Hydraulic equipment .................................................................................................................................................. 26 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 27 NOTES .................................................................................................................................................................... 29 2 OPERATION................................................................................................................................................................... 31 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 33 Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 34 FIRE AND EXPLOSION HAZARD................................................................................................................................................. 35 DESCRIPTION OF THE HYDRAULIC SHOVEL ...................................................................................................................................... 36 Hydraulic shovel layout .............................................................................................................................................. 37 Undercarriage ........................................................................................................................................................ 38 Superstructure ....................................................................................................................................................... 38 Drive ................................................................................................................................................................ 38 Hydraulic system ..................................................................................................................................................... 38 Control and Monitoring Platform (CAMP) ............................................................................................................................... 38 Board-Control-System (BCS) ........................................................................................................................................... 39 Demand control / Zero-flow regulation................................................................................................................................. 39 Automatic reset to idling............................................................................................................................................. 39 Electrical system .................................................................................................................................................... 39 Signs ................................................................................................................................................................ 40 Entering and leaving the machine, Safety instructions ................................................................................................................ 48 Access ladder lighting ............................................................................................................................................... 48 Swinging ladder ...................................................................................................................................................... 49 Folding ladder (optional) ............................................................................................................................................ 50 Emergency exit in driver’s cab and escape ladder ..................................................................................................................... 51 Switching the cab interior lighting on and off ....................................................................................................................... 52 Switching the maintenance lights on and off .......................................................................................................................... 53 Emergency shut-off function .......................................................................................................................................... 54 Shutting off the supply voltage (battery main switch) ................................................................................................................ 55 Driver’s seat ....................................................................................................................................................... 56 Reducing operators exposure to vibrations ............................................................................................................................ 58 Trainer's / instructor's seat ........................................................................................................................................ 58 Windscreen washer .................................................................................................................................................... 58 Fire extinguisher..................................................................................................................................................... 59 Automatic fire-extinguishing system (optional) ....................................................................................................................... 60 Harness (optional) ................................................................................................................................................... 61 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 64 Engine 1 (LH), control and monitoring ................................................................................................................................ 71 Engine 2 (RH), control and monitoring ................................................................................................................................ 73 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 92 Reducing the operator's exposure to noise ............................................................................................................................ 92 Refuelling ........................................................................................................................................................... 92 Back-up heating (option), filling in fuel ............................................................................................................................ 93 Service station (tanklift) ........................................................................................................................................... 93 Switching the electrical system on and off ........................................................................................................................... 99 Engines, emergency shut-off .......................................................................................................................................... 99 Preheating system for engine and hydraulic oil (optional) ............................................................................................................100 Fuel preheating system (optional) ....................................................................................................................................101 STARTING AND STOPPING THE ENGINES ........................................................................................................................................102 Starting the engines .................................................................................................................................................102 Starting the left-hand engine.........................................................................................................................................102 Starting the right-hand engine........................................................................................................................................102 Engines – adjusting the speed ........................................................................................................................................103 Starting the engines at low temperatures .............................................................................................................................103 Shutting off the engines .............................................................................................................................................104 Shutting off the left-hand engine.....................................................................................................................................104 Shutting off the right-hand engine....................................................................................................................................104 AIR CONDITIONER (OPTIONAL) ...............................................................................................................................................105 Back-up heating driver’s cab (optional) ..............................................................................................................................106 Back-up heating (optional) ...........................................................................................................................................107 MAXIMUM MACHINE INCLINATIONS, INFORMATION ................................................................................................................................108 TRAVELLING, SAFETY INSTRUCTIONS ..........................................................................................................................................109 TRAVELLING ...............................................................................................................................................................110 Superstructure basic position ........................................................................................................................................110 Travelling forwards/backwards ........................................................................................................................................110 Superstructure holding brake .........................................................................................................................................114 Track parking brake ..................................................................................................................................................114 TRANSPORTING THE MACHINE .................................................................................................................................................115 Transport - Safety instructions ......................................................................................................................................115 WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................116 WORKING OPERATION ........................................................................................................................................................118 Before starting work .................................................................................................................................................118 Activating the electronic excavator control ..........................................................................................................................118 Swinging the superstructure ..........................................................................................................................................119 Braking the superstructure ...........................................................................................................................................119 Working ..............................................................................................................................................................120 Emergency lowering of the equipment ..................................................................................................................................121 After daily operation ................................................................................................................................................122 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................123 Securing the machine .................................................................................................................................................124 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................125 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................126 On-board crane, monitoring, warning and control elements .............................................................................................................126 On-board crane, putting into operation ...............................................................................................................................127 On-board crane, drive unit ...........................................................................................................................................127 On-Board crane, – blocking the boom in position of rest ..............................................................................................................128 On-board crane, checking .............................................................................................................................................128 NOTES ....................................................................................................................................................................129 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 ........................................................................................................................................................155 Lubricating chart – Grease (legend) ..................................................................................................................................156 Filling quantities - Grease...........................................................................................................................................156 INSPECTION PLAN - OIL ....................................................................................................................................................157 Inspection plan – Oil (legend) .......................................................................................................................................158 Filling quantities - oil .............................................................................................................................................159 Filling quantities - other............................................................................................................................................159 LUBRICANTS / CONSUMABLES .................................................................................................................................................160 Notes on the selection of oils and greases ...........................................................................................................................160 Avoid mixing of different hydraulic fluids ...........................................................................................................................160 I. Oils for combustion engines and compressors .......................................................................................................................161 II. Oils for hydraulic system (selection) ............................................................................................................................162 III.a Oils for pump distribution gearboxes ...........................................................................................................................163 III.b Oils for swing gearboxes .......................................................................................................................................164 III.c Oils for travel gearboxes ......................................................................................................................................165 V. Greases for bearings and swing rings ..............................................................................................................................166 Fluid grease for idlers, track rollers and support rollers ...........................................................................................................167 SERVICING WORK ...........................................................................................................................................................168 Hose line for oil and cooling liquid changes .........................................................................................................................168 ENGINE ...................................................................................................................................................................169 Engine - Safety instructions .........................................................................................................................................169 Engine oil, checking the oil level / topping up .....................................................................................................................170 Engine oil reservoir, checking the oil level .........................................................................................................................171 Changing the engine oil ..............................................................................................................................................172 Engine oil reservoir, changing the oil ...............................................................................................................................174 Replacing the oil filters ............................................................................................................................................176 Eliminator filter and centrifuge .....................................................................................................................................177 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................179 COOLING SYSTEM ...........................................................................................................................................................180 Radiators ............................................................................................................................................................181 Checking cooling-liquid level ........................................................................................................................................181 Topping up cooling-liquid ............................................................................................................................................182 Cooling liquid change ................................................................................................................................................183 Water filter change...................................................................................................................................................185 AIR-INTAKE SYSTEM ........................................................................................................................................................186 Main filter elements .................................................................................................................................................186 Safety filter element ................................................................................................................................................189 Air-intake lines .....................................................................................................................................................190 Dust collection ......................................................................................................................................................190 FUEL SYSTEM ..............................................................................................................................................................191 Fuel system - Safety instructions ....................................................................................................................................191 Replacing the fuel filters ...........................................................................................................................................191 Fuel filters, draining water .........................................................................................................................................193 Fuel tank, replace breather filter ...................................................................................................................................194 Cleaning the fuel tanks ..............................................................................................................................................194 ELECTRICAL SYSTEM .......................................................................................................................................................196 Electrical system - Safety instructions ..............................................................................................................................196 Alternator - Instructions ............................................................................................................................................196 Electrical circuit diagrams ..........................................................................................................................................196 Electrical system switch-cabinets ....................................................................................................................................196 Replacing lamps and bulbs ............................................................................................................................................196 Xenon floodlight projector, replacing the lamp .......................................................................................................................197 Lighting systems in LED technonogy, instructions .....................................................................................................................199 Battery ..............................................................................................................................................................200 Charging batteries inside the machine, safety instructions ...........................................................................................................202 Switchgear cabinet ...................................................................................................................................................203 HYDRAULIC SYSTEM .........................................................................................................................................................205 Hydraulic system - Safety instructions ...............................................................................................................................205 Depressurizing the hydraulic system ..................................................................................................................................205 Checking the hydraulic oil level .....................................................................................................................................206 Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................208 Bypass valves (hydraulic oil reservoir) ..............................................................................................................................210 Replacing the hydraulic oil return-flow filters (filter housing) .....................................................................................................211 Bypass valves (filter housing - cooling system) ......................................................................................................................212 Breather filter ......................................................................................................................................................213 Filter (control circuit) .............................................................................................................................................214 High-pressure filter for working hydraulics ..........................................................................................................................215 High-pressure filters for the servo circuit ..........................................................................................................................216 High-pressure filters for pump-flushing circuit ......................................................................................................................217 High-pressure filters for feeding circuits and swing pumps ...........................................................................................................218 High-pressure filters for swing circuit ..............................................................................................................................219 Changing the hydraulic oil ...........................................................................................................................................220 Avoid mixing of different hydraulic fluids ...........................................................................................................................220 Venting the hydraulic system..........................................................................................................................................223 Cleaning the hydraulic oil cooler.....................................................................................................................................224 Electronic excavator control..........................................................................................................................................225 Pressure accumulator - Emergency lowering.............................................................................................................................226 PUMP TRANSFER GEARBOX ....................................................................................................................................................227 Checking the gearbox oil level / Topping up with oil .................................................................................................................227 Changing the gearbox oil .............................................................................................................................................227 Gearbox venting ......................................................................................................................................................229 Pre-chambers .........................................................................................................................................................229 Pump transfer gearbox lube oil filters ...............................................................................................................................230 SWING GEARBOX ............................................................................................................................................................231 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................231 Changing the gearbox oil .............................................................................................................................................232 Gearbox venting ......................................................................................................................................................232 TRAVEL GEARBOX ...........................................................................................................................................................233 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................233 Travel gearbox - Changing the oil ....................................................................................................................................233 Preliminary gearbox - Draining off oil ...............................................................................................................................234 CRAWLER TRACKS ...........................................................................................................................................................235 Track tensioner ......................................................................................................................................................237 Pressure-accumulator inspection regulations ..........................................................................................................................239 Checking the gas charging pressure in the pressure accumulator........................................................................................................239 SWING RING ...............................................................................................................................................................240 Swing ring - Instructions.............................................................................................................................................240 Bearing races.........................................................................................................................................................240 CENTRAL LUBRICATING ......................................................................................................................................................242 Design ...............................................................................................................................................................242 Function .............................................................................................................................................................243 Filling up the grease container ......................................................................................................................................244 Breather filter ......................................................................................................................................................244 Checking the greasing pressure .......................................................................................................................................245 Unblocking a grease line .............................................................................................................................................245 Oilfilter for hydraulic circuit grease pump replace ..................................................................................................................246 Grease filter replace (Filling the grease container) .................................................................................................................247 Grease filter replace (Grease lines) .................................................................................................................................248 OTHER MAINTENANCE ........................................................................................................................................................249 Engine ...............................................................................................................................................................249 Equipment ............................................................................................................................................................250 Hydraulic ladders ....................................................................................................................................................251 Pressure-accumulator inspection regulations ..........................................................................................................................252 Extract from the German regulations...................................................................................................................................252 Checking the gas charging pressure in the pressure accumulator........................................................................................................252 ON-BOARD CRANE, DRIVE UNIT ...............................................................................................................................................253 On-board crane, lubricating ..........................................................................................................................................254 On-Board crane, checking tightness of fastening bolts ................................................................................................................254 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING ........................................................................................................255 Putting the hydraulic shovel out of operation ........................................................................................................................255 Battery storage ......................................................................................................................................................255 Recommissioning ......................................................................................................................................................255 NOTES ....................................................................................................................................................................257 4 REPAIR WORK.................................................................................................................................................................259 REPAIR WORK - SAFETY INSTRUCTIONS ........................................................................................................................................261 CONFINED SPACES - SAFETY INSTRUCTIONS ....................................................................................................................................262 REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................263 REPAIR WORK, ENGINE ......................................................................................................................................................264 HYDRAULIC SYSTEM .........................................................................................................................................................265 Repair instructions ..................................................................................................................................................265 Hydraulic hoses – Instructions ......................................................................................................................................265 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................266 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................267 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................270 Dismantling and removal instructions .................................................................................................................................270 Risk of deflagrations ................................................................................................................................................270 Risk of fire .........................................................................................................................................................270 Disposing of the machine without polluting the environment ...........................................................................................................271 Further hazardous substances .........................................................................................................................................271 Appropriate disposal of batteries ....................................................................................................................................272 NOTES ....................................................................................................................................................................273 5 ANNEX.......................................................................................................................................................................275 BOARD-CONTROL-SYSTEM .....................................................................................................................................................277 BCS III, what’s that? ................................................................................................................................................277 The keys on the front side ...........................................................................................................................................278 Other elements on the front side .....................................................................................................................................278 BCSIII, the start screen .............................................................................................................................................279 Information given on the start screen, top section ...................................................................................................................280 Information given on the start screen, central section ...............................................................................................................281 Information given on the start screen, lower section .................................................................................................................282 Information given on the “Service” screen ............................................................................................................................283 Engine data screen ...................................................................................................................................................284 Hydraulic data screen ................................................................................................................................................285 Lubrication data screen ..............................................................................................................................................286 Controls adjustment data screen ......................................................................................................................................287 View documents screen ................................................................................................................................................288 Signal table screen ..................................................................................................................................................289 Signal table screen, location ........................................................................................................................................290 Signal table screen, diagram .........................................................................................................................................291 Signal table screen, diagram configuration ...........................................................................................................................292 Code table screen ....................................................................................................................................................293 BCS III, interfaces ..................................................................................................................................................294 USB interface, data storage ..........................................................................................................................................294 Saving data to a USB stick ...........................................................................................................................................295 Saving data to a USB stick, continued ................................................................................................................................296 Saving data to a USB stick, continued ................................................................................................................................297 BCSIII, cleaning .....................................................................................................................................................298 BCSIII, disposal .....................................................................................................................................................298 TROUBLESHOOTING ..........................................................................................................................................................299 Instructions on troubleshooting ......................................................................................................................................299 Layout of the fault table ............................................................................................................................................299 Possible causes ......................................................................................................................................................299 Measures .............................................................................................................................................................299 Section ..............................................................................................................................................................299 FAULT TABLES .............................................................................................................................................................300 Combustion engine - Fault table ......................................................................................................................................300 Working hydraulics – Fault table .....................................................................................................................................301 Track drive – Fault table ............................................................................................................................................302 Swing mechnism – Fault table .........................................................................................................................................303 Central lubricating system – Fault table .............................................................................................................................304 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................305 Vibration data .......................................................................................................................................................305 ABBREVIATIONS ............................................................................................................................................................306 ABBREVIATIONS.........................................................................................................................................................307 TECHNICAL DATA ...........................................................................................................................................................309 Product Specification Sheet ..............................................................................................................................................311 NOTES ....................................................................................................................................................................317 6 INDEX.......................................................................................................................................................................319
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