CATERPILLAR 6090 RH400 Hydraulic Shovel Operating Instruction Manual – PDF DOWNLOAD
FILE DETAILS:
CATERPILLAR 6090 RH400 Hydraulic Shovel Operating Instruction Manual – PDF DOWNLOAD
Language : English
Pages : 320
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CATERPILLAR 6090 RH400 Hydraulic Shovel Operating Instruction Manual – PDF DOWNLOAD
PREFACE:
About this Operating Instructions:
- These operating instructions are designed to famil- iarize the operator with the machine and its
desig- nated use. - The operating instructions contain important in- formation 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 avail- able 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, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
▪ maintenance (inspection, servicing, repair) and / or
▪ transport.
- In addition to the operating instructions and the mandatory rules and regulations for
accident pre- vention 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 min- ing-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 per- sonnel. - 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 transla-
tion may give rise to questions which Bucyrus HEX will be pleased to answer. - The operating instructions are not work instruc- tions for carrying out major repairs.
Such work is willingly done for you by the Bucyrus HEX after-
sales service.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CATERPILLAR 6090 RH400 Hydraulic Shovel Operating Instruction Manual – PDF DOWNLOAD
1 INTRODUCTION 1-1
PREFACE 1-3
About this Operating Instructions 1-3
Further machine documentation 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE, UNAUTHORIZED USE 1-6
Noise emission information 1-7
Vibration information 1-7
ORGANIZATIONAL MEASURES 1-8
Selection and qualification of personnel; basic responsibilities 1-9
Safety instructions governing specific operational phases 1-9
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-10
Warning of special dangers 1-11
Gas, dust, steam and smoke 1-11
Hydraulic equipment 1-12
FIRE AND EXPLOSION HAZARD 1-13
NOTES 1-15
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE HYDRAULIC SHOVEL 2-6
Hydraulic shovel layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Control and Monitoring Platform (CAMP) 2-8
Board-Control-System (BCS) 2-9
Demand control / Zero-flow regulation 2-9
Automatic reset to idling 2-9
Electrical system 2-9
Signs 2-10
Entering and leaving the machine, Safety instructions 2-18
Access ladder lighting 2-18
Swinging ladder 2-19
Folding ladder (optional) 2-20
Emergency exit in driver’s cab and escape ladder 2-21
Switching the cab interior lighting on and off 2-22
Switching the maintenance lights on and off 2-23
OPERATING INSTRUCTIONS 6090 / RH400
Table of contents
vi BA RH400(3 725 058.00)-EN
Emergency shut-off function 2-24
Shutting off the supply voltage (battery main switch) 2-25
Driver’s seat 2-26
Reducing operators exposure to vibrations 2-28
Trainer’s / instructor’s seat 2-28
Windscreen washer 2-28
Fire extinguisher 2-29
Automatic fire-extinguishing system (optional) 2-30
Harness (optional) 2-31
MONITORING, WARNING AND CONTROL ELEMENTS 2-34
Engine 1 (LH), control and monitoring 2-41
Engine 2 (RH), control and monitoring 2-43
PUTTING THE MACHINE INTO OPERATION 2-62
Reducing the operator’s exposure to noise 2-62
Refuelling 2-62
Back-up heating (option), filling in fuel 2-63
Service station (tanklift) 2-63
Switching the electrical system on and off 2-69
Engines, emergency shut-off 2-69
Preheating system for engine and hydraulic oil (optional) 2-70
Fuel preheating system (optional) 2-71
STARTING AND STOPPING THE ENGINES 2-72
Starting the engines 2-72
Starting the left-hand engine 2-72
Starting the right-hand engine 2-72
Engines – adjusting the speed 2-73
Starting the engines at low temperatures 2-73
Shutting off the engines 2-74
Shutting off the left-hand engine 2-74
Shutting off the right-hand engine 2-74
AIR CONDITIONER (OPTIONAL) 2-75
Back-up heating driver’s cab (optional) 2-76
Back-up heating (optional) 2-77
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-78
TRAVELLING, SAFETY INSTRUCTIONS 2-79
TRAVELLING 2-80
Superstructure basic position 2-80
Travelling forwards/backwards 2-80
Superstructure holding brake 2-84
Track parking brake 2-84
TRANSPORTING THE MACHINE 2-85
Transport – Safety instructions 2-85
WORKING OPERATION – SAFETY INSTRUCTIONS 2-86
WORKING OPERATION 2-88
Before starting work 2-88
Activating the electronic excavator control 2-88
OPERATING INSTRUCTIONS 6090 / RH400
Introduction
BA RH400(3 725 058.00)-EN vii
Swinging the superstructure 2-89
Braking the superstructure 2-89
Working 2-90
Emergency lowering of the equipment 2-91
After daily operation 2-92
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-93
Securing the machine 2-94
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-95
ON-BOARD CRANE (OPTIONAL) 2-96
On-board crane, monitoring, warning and control elements 2-96
On-board crane, putting into operation 2-97
On-board crane, drive unit 2-97
On-Board crane, – blocking the boom in position of rest 2-98
On-board crane, checking 2-98
NOTES 2-100
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-7
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Plan V 3-11
Plan N 3-13
Plan T and W 3-15
Plan A – E 3-17
LUBRICATING CHART 3-24
Lubricating chart – Grease (legend) 3-25
Filling quantities – Grease 3-25
INSPECTION PLAN – OIL 3-26
Inspection plan – Oil (legend) 3-27
Filling quantities – oil 3-28
Filling quantities – other 3-28
LUBRICANTS / CONSUMABLES 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids 3-29
I. Oils for combustion engines and compressors 3-30
II. Oils for hydraulic system (selection) 3-31
III.a Oils for pump distribution gearboxes 3-32
III.b Oils for swing gearboxes 3-33
III.c Oils for travel gearboxes 3-34
V. Greases for bearings and swing rings 3-35
Fluid grease for idlers, track rollers and support rollers 3-36
SERVICING WORK 3-37
Hose line for oil and cooling liquid changes 3-37
ENGINE 3-38
Engine – Safety instructions 3-38
OPERATING INSTRUCTIONS 6090 / RH400
Table of contents
viii BA RH400(3 725 058.00)-EN
Engine oil, checking the oil level / topping up 3-39
Engine oil reservoir, checking the oil level 3-40
Changing the engine oil 3-41
Engine oil reservoir, changing the oil 3-43
Replacing the oil filters 3-45
Eliminator filter and centrifuge 3-46
Cold-starting fluid (ether) – Replacing the pressure vessel 3-48
COOLING SYSTEM 3-49
Radiators 3-50
Checking cooling-liquid level 3-50
Topping up cooling-liquid 3-51
Cooling liquid change 3-52
Water filter change 3-54
AIR-INTAKE SYSTEM 3-55
Main filter elements 3-55
Safety filter element 3-58
Air-intake lines 3-59
Dust collection 3-59
FUEL SYSTEM 3-60
Fuel system – Safety instructions 3-60
Replacing the fuel filters 3-60
Fuel filters, draining water 3-62
Fuel tank, replace breather filter 3-63
Cleaning the fuel tanks 3-63
ELECTRICAL SYSTEM 3-65
Electrical system – Safety instructions 3-65
Alternator – Instructions 3-65
Electrical circuit diagrams 3-65
Electrical system switch-cabinets 3-65
Replacing lamps and bulbs 3-65
Xenon floodlight projector, replacing the lamp 3-66
Lighting systems in LED technonogy, instructions 3-68
Battery 3-69
Charging batteries inside the machine, safety instructions 3-71
Switchgear cabinet 3-72
HYDRAULIC SYSTEM 3-74
Hydraulic system – Safety instructions 3-74
Depressurizing the hydraulic system 3-74
Checking the hydraulic oil level 3-75
Changing the hydraulic oil return-flow (hydraulic oil reservoir) 3-77
Bypass valves (hydraulic oil reservoir) 3-79
Replacing the hydraulic oil return-flow filters (filter housing) 3-80
Bypass valves (filter housing – cooling system) 3-81
Breather filter 3-82
Filter (control circuit) 3-83
High-pressure filter for working hydraulics 3-84
High-pressure filters for the servo circuit 3-85
High-pressure filters for pump-flushing circuit 3-86
High-pressure filters for feeding circuits and swing pumps 3-87
OPERATING INSTRUCTIONS 6090 / RH400
Introduction
BA RH400(3 725 058.00)-EN ix
High-pressure filters for swing circuit 3-88
Changing the hydraulic oil 3-89
Avoid mixing of different hydraulic fluids 3-89
Venting the hydraulic system 3-92
Cleaning the hydraulic oil cooler 3-93
Electronic excavator control 3-94
Pressure accumulator – Emergency lowering 3-95
PUMP TRANSFER GEARBOX 3-96
Checking the gearbox oil level / Topping up with oil 3-96
Changing the gearbox oil 3-96
Gearbox venting 3-98
Pre-chambers 3-98
Pump transfer gearbox lube oil filters 3-99
SWING GEARBOX 3-100
Gearbox – Checking the oil level / Topping up with oil 3-100
Changing the gearbox oil 3-101
Gearbox venting 3-101
TRAVEL GEARBOX 3-102
Gearbox – Checking the oil level / Topping up with oil 3-102
Travel gearbox – Changing the oil 3-102
Preliminary gearbox – Draining off oil 3-103
CRAWLER TRACKS 3-104
Track tensioner 3-105
Pressure-accumulator inspection regulations 3-107
Checking the gas charging pressure in the pressure accumulator 3-107
SWING RING 3-108
Swing ring – Instructions 3-108
Bearing races 3-108
CENTRAL LUBRICATING 3-110
Design 3-110
Function 3-111
Filling up the grease container 3-112
Breather filter 3-112
Checking the greasing pressure 3-113
Unblocking a grease line 3-113
Oilfilter for hydraulic circuit grease pump replace 3-114
Grease filter replace (Filling the grease container) 3-115
Grease filter replace (Grease lines) 3-116
OTHER MAINTENANCE 3-117
Engine 3-117
Equipment 3-118
LADDERS (OPTIONAL) 3-119
Pressure-accumulator inspection regulations 3-120
Extract from the German regulations 3-120
Checking the gas charging pressure in the pressure accumulator 3-120
OPERATING INSTRUCTIONS 6090 / RH400
Table of contents
x BA RH400(3 725 058.00)-EN
ON-BOARD CRANE, DRIVE UNIT 3-121
On-board crane, lubricating 3-122
On-Board crane, checking tightness of fastening bolts 3-122
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-123
Putting the hydraulic shovel out of operation 3-123
Battery storage 3-123
Recommissioning 3-123
NOTES 3-125
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
CONFINED SPACES – SAFETY INSTRUCTIONS 4-4
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
HYDRAULIC SYSTEM 4-7
Repair instructions 4-7
Hydraulic hoses – Instructions 4-7
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-8
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-9
DISPOSAL AT THE END OF THE SERVICE LIFE 4-12
Dismantling and removal instructions 4-12
Risk of deflagrations 4-12
Risk of fire 4-12
Disposing of the machine without polluting the environment 4-12
Further hazardous substances 4-13
Appropriate disposal of batteries 4-14
NOTES 4-15
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
The keys on the front side 5-4
Other elements on the front side 5-4
BCSIII, the start screen 5-5
Information given on the start screen, top section 5-6
Information given on the start screen, central section 5-7
Information given on the start screen, lower section 5-8
Information given on the “Service” screen 5-9
Engine data screen 5-10
Hydraulic data screen 5-11
Lubrication data screen 5-12
Controls adjustment data screen 5-13
View documents screen 5-14
Signal table screen 5-15
Signal table screen, location 5-16
OPERATING INSTRUCTIONS 6090 / RH400
Introduction
BA RH400(3 725 058.00)-EN xi
Signal table screen, diagram 5-17
Signal table screen, diagram configuration 5-18
Code table screen 5-19
BCS III, interfaces 5-20
USB interface, data storage 5-20
Saving data to a USB stick 5-21
Saving data to a USB stick, continued 5-22
Saving data to a USB stick, continued 5-23
BCSIII, cleaning 5-24
BCSIII, disposal 5-24
TROUBLESHOOTING 5-25
Instructions on troubleshooting 5-25
Layout of the fault table 5-25
Possible causes 5-25
Measures 5-25
Section 5-25
FAULT TABLES 5-26
Combustion engine – Fault table 5-26
Working hydraulics – Fault table 5-27
Track drive – Fault table 5-28
Swing mechnism – Fault table 5-29
Central lubricating system – Fault table 5-30
HYDRAULIC CIRCUIT DIAGRAM 5-31
Vibration data 5-31
ABBREVIATIONS 5-32
ABBREVIATIONS 5-33
TECHNICAL DATA 5-35
NOTES 5-37
6 INDEX 6-
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