Cat 6090, 6090FS Hydraulic Shovel Operating Instructions Manual BI651386

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN 09 / 2014

Operation and Maintenance Manual 6090, 6090FS Hydraulic Shovel

No.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Published by:

Caterpillar Global Mining HMS GmbH Dept. Technical Publications D-44149 Dortmund, Karl-Funke-Straße 36 Tel. 49 (0) 231 922-4340 Fax 49 (0) 231 922-5005 E-Mail documentation-HEX@cat.com https://mining.cat.com www.bucyrus-hex.de

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2014. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

Printed in Germany

ii

BI015760

OMM 6090, 6090FS(3 847 002.04)EN

The Operation and Maintenance Manual is in 6 sections; the sections are designed for different target groups: Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

iii

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

This page intentionally left blank.

iv

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

TABLE OF CONTENTS TABLE OF CONTENTS 1 INTRODUCTION ___________________________________________________________________ 1-1 PREFACE ________________________________________________________________________ 1-1 About this Operation and Maintenance Manual __________________________________________ 1-1 Further machine documentation ______________________________________________________ 1-1 WARRANTY ______________________________________________________________________ 1-2 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-3 Warnings and symbols _____________________________________________________________ 1-3 DESIGNATED USE, UNAUTHORIZED USE _____________________________________________ 1-4 Noise emission information__________________________________________________________ 1-5 Vibration information _______________________________________________________________ 1-5 ORGANIZATIONAL MEASURES ______________________________________________________ 1-6 Selection and qualification of personnel; basic responsibilities ______________________________ 1-7 Safety instructions governing specific operational phases __________________________________ 1-7 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ____________________________ 1-8 Warning of special dangers _________________________________________________________ 1-9 Gas, dust, steam and smoke ________________________________________________________ 1-9 Hydraulic equipment ______________________________________________________________ 1-10 FIRE AND EXPLOSION HAZARD ____________________________________________________ 1-11 NOTES _________________________________________________________________________ 1-13 2 OPERATION ______________________________________________________________________ 2-1 OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3 Operation and Maintenance Manual, where to store it in the operator’s cab ____________________ 2-4 FIRE AND EXPLOSION HAZARD _____________________________________________________ 2-5 DESCRIPTION OF THE HYDRAULIC SHOVEL __________________________________________ 2-6 Hydraulic shovel layout _____________________________________________________________ 2-7 Undercarriage ____________________________________________________________________ 2-8 Superstructure ___________________________________________________________________ 2-8 Drive unit ________________________________________________________________________ 2-8 Hydraulic system _________________________________________________________________ 2-8 Control and Monitoring Platform (CAMP) _______________________________________________ 2-8 Board-Control-System (BCS) ________________________________________________________ 2-9 Demand control / Zero-flow regulation _________________________________________________ 2-9 Automatic reset to idling ____________________________________________________________ 2-9 Electrical system __________________________________________________________________ 2-9 Signs __________________________________________________________________________ 2-10 Entering and leaving the machine, Safety instructions ____________________________________ 2-18 Access ladder lighting _____________________________________________________________ 2-18 Folding ladder ___________________________________________________________________ 2-19 Emergency exit in operator’s cab and escape ladder ____________________________________ 2-20 Switching the cab interior lighting on and off ___________________________________________ 2-21 Switching the maintenance lights on and off ___________________________________________ 2-22 Emergency shut-off function ________________________________________________________ 2-23

v

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

TABLE OF CONTENTS Putting the machine back into operation, reset of emergency shut off function _________________ 2-24 Battery isolator switch, shutting off supply voltage _______________________________________ 2-25 Starter isolator switch, shutting off starter voltage _______________________________________ 2-25 Operator’s seat __________________________________________________________________ 2-26 Reducing operators exposure to vibrations ____________________________________________ 2-28 Trainer's / instructor's seat _________________________________________________________ 2-28 Windscreen washer ______________________________________________________________ 2-29 Operating hours meter ____________________________________________________________ 2-29 Fire extinguisher _________________________________________________________________ 2-30 Automatic fire-extinguishing system (optional) __________________________________________ 2-31 Harness (optional) _______________________________________________________________ 2-32 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-36 Engine 1 (LH), control and monitoring ________________________________________________ 2-43 Engine 2 (RH), control and monitoring ________________________________________________ 2-45 PUTTING THE MACHINE INTO OPERATION ___________________________________________ 2-64 Electrical Storm Injury Prevention ___________________________________________________ 2-64 Reducing the operator's exposure to noise ____________________________________________ 2-64 Refueling _______________________________________________________________________ 2-65 Back-up heating (option), filling in Diesel fuel __________________________________________ 2-65 Service station (tanklift) ___________________________________________________________ 2-66 Emergency off switch _____________________________________________________________ 2-67 Switching the electrical system on and off _____________________________________________ 2-72 Engines, emergency shut-off _______________________________________________________ 2-72 STARTING AND STOPPING THE ENGINES ____________________________________________ 2-74 Starting the engines ______________________________________________________________ 2-74 Starting the left-hand engine _______________________________________________________ 2-74 Starting the right-hand engine ______________________________________________________ 2-74 Engines – adjusting the speed ______________________________________________________ 2-75 Starting the engines at low temperatures ______________________________________________ 2-75 Shutting off the engines ___________________________________________________________ 2-76 Shutting off the left-hand engine _____________________________________________________ 2-76 Shutting off the right-hand engine ___________________________________________________ 2-76 AIR CONDITIONER (OPTIONAL) _____________________________________________________ 2-77 Back-up heating operator’s cab (optional) _____________________________________________ 2-78 Back-up heating (optional) _________________________________________________________ 2-79 MAXIMUM MACHINE INCLINATIONS, INFORMATION ___________________________________ 2-80 TRAVELLING, SAFETY INSTRUCTIONS ______________________________________________ 2-82 TRAVELLING ____________________________________________________________________ 2-83 Superstructure basic position _______________________________________________________ 2-83 Travelling forwards/backwards ______________________________________________________ 2-83 Superstructure holding brake _______________________________________________________ 2-87 Track parking brake ______________________________________________________________ 2-87 TRANSPORTING THE MACHINE ____________________________________________________ 2-88 Transport - Safety instructions ______________________________________________________ 2-88

vi

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

TABLE OF CONTENTS WORKING OPERATION - SAFETY INSTRUCTIONS _____________________________________ 2-89 WORKING OPERATION ____________________________________________________________ 2-91 Before starting work ______________________________________________________________ 2-91 Activating the electronic shovel control _______________________________________________ 2-91 Swinging the superstructure ________________________________________________________ 2-92 Braking the superstructure _________________________________________________________ 2-92 Working operations _______________________________________________________________ 2-93 Emergency lowering of the equipment ________________________________________________ 2-94 After daily operation ______________________________________________________________ 2-95 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS_________________________ 2-96 Safety line on boom ______________________________________________________________ 2-96 Main control valves – attach/remove the handrail _______________________________________ 2-97 Securing the machine _____________________________________________________________ 2-97 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ____________ 2-98 ON-BOARD CRANE (OPTIONAL) ____________________________________________________ 2-99 On-board crane, monitoring, warning and control elements _______________________________ 2-99 On-board crane, putting into operation _______________________________________________ 2-100 On-board crane, drive unit ________________________________________________________ 2-100 On-Board crane, – blocking the boom in position of rest _________________________________ 2-101 On-board crane, checking ________________________________________________________ 2-101 Monitoring cameras _____________________________________________________________ 2-102 NOTES ________________________________________________________________________ 2-103 3 INSPECTION AND SERVICING _______________________________________________________ 3-1 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ________________________________ 3-3 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ____________________ 3-7 INSPECTION AND SERVICING PLANS - INSTRUCTIONS _________________________________ 3-9 Plan V _________________________________________________________________________ 3-11 Plan N _________________________________________________________________________ 3-13 Plan T and W ___________________________________________________________________ 3-15 Plan T and W ___________________________________________________________________ 3-16 Plan 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. Oil for combustion engines and compressors _______________________________________ 3-30 II. Fluid for hydraulic system _____________________________________________________ 3-31 III.a Oil for pump drive gearboxes and travel gearboxes ________________________________ 3-32

vii

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

TABLE OF CONTENTS III.b Oils for swing gearboxes _____________________________________________________ 3-33 V. Greases for bearings, swing rings and track system ________________________________ 3-34 Coolant for use on all combustion engines_____________________________________________ 3-35 SERVICING WORK ________________________________________________________________ 3-36 Hose line for oil and cooling liquid changes ____________________________________________ 3-36 ENGINE _________________________________________________________________________ 3-37 Engine - Safety instructions ________________________________________________________ 3-37 Engine oil, checking the oil level / topping up ___________________________________________ 3-38 Engine oil reservoir, checking the oil level _____________________________________________ 3-39 Engine oil, change _______________________________________________________________ 3-40 Engine oil reservoir, filling in / draining off the oil ________________________________________ 3-42 Eliminator filter and centrifuge ______________________________________________________ 3-45 Cold-starting fluid (ether) - Replacing the pressure vessel ________________________________ 3-47 COOLING SYSTEM _______________________________________________________________ 3-48 Radiators ______________________________________________________________________ 3-49 Cooling-liquid level, check _________________________________________________________ 3-49 Cooling-liquid, topping up __________________________________________________________ 3-50 Cooling liquid change _____________________________________________________________ 3-52 Water filter, change_______________________________________________________________ 3-54 AIR-INTAKE SYSTEM ______________________________________________________________ 3-55 Main filter elements_______________________________________________________________ 3-55 Secondary filter element ___________________________________________________________ 3-58 Air-intake lines, check _____________________________________________________________ 3-59 Dust collection, function ___________________________________________________________ 3-59 FUEL SYSTEM ___________________________________________________________________ 3-60 Fuel system - Safety instructions ____________________________________________________ 3-60 Fuel tank supply valve, function _____________________________________________________ 3-60 Fuel filters, replace _______________________________________________________________ 3-60 Fuel filters, draining water__________________________________________________________ 3-62 Fuel tank breather filter, replace _____________________________________________________ 3-63 Fuel tanks, clean _________________________________________________________________ 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 technology, instructions _______________________________________ 3-68 Battery, checking the state of charge _________________________________________________ 3-69 Battery, removing and installing _____________________________________________________ 3-70 Charging batteries inside the machine, safety instructions ________________________________ 3-71 Switchgear cabinet _______________________________________________________________ 3-72 HYDRAULIC SYSTEM _____________________________________________________________ 3-74 Hydraulic system - Safety instructions ________________________________________________ 3-74 Hydraulic system, depressurizing ____________________________________________________ 3-74 Hydraulic oil level, check __________________________________________________________ 3-75

viii

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

TABLE OF CONTENTS Hydraulic oil return-flow filters (hydraulic oil reservoir), replace _____________________________ 3-77 Bypass valves (hydraulic oil reservoir) ________________________________________________ 3-79 Hydraulic oil return-flow filters (filter housing cooling system), replace _______________________ 3-80 Bypass valves (filter housing - cooling system) _________________________________________ 3-81 Hydraulic tank breather filter, replace _________________________________________________ 3-82 Filter (control circuit main pumps), replace_____________________________________________ 3-83 High-pressure filter for working hydraulics, replace ______________________________________ 3-84 High-pressure filters for the servo circuit, replace _______________________________________ 3-85 High-pressure filters for pump-flushing circuit __________________________________________ 3-86 High-pressure filters for feeding circuits and swing pumps ________________________________ 3-87 High-pressure filters for swing circuit, replace __________________________________________ 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 shovel control ___________________________________________________________ 3-94 Pressure accumulator - Emergency lowering ___________________________________________ 3-95 PUMP DRIVE GEARBOX ___________________________________________________________ 3-96 Checking the gearbox oil level / Topping up with oil _____________________________________ 3-96 Pump drive gearbox, Changing the gearbox oil _________________________________________ 3-97 Pump drive gearbox breather _______________________________________________________ 3-98 Pre-chambers, expansion reservoir __________________________________________________ 3-98 Pump drive gearbox lube oil filters, clean / replace ______________________________________ 3-99 SWING GEARBOX _______________________________________________________________ 3-100 Swing gearbox - checking the oil level / topping up with oil _______________________________ 3-100 Swing gearbox, changing the gearbox oil_____________________________________________ 3-101 Swing gearbox venting ___________________________________________________________ 3-101 TRAVEL GEARBOX ______________________________________________________________ 3-102 Travel gearbox - checking the oil level / topping up with oil _______________________________ 3-102 Travel gearbox - changing the oil ___________________________________________________ 3-102 CRAWLER TRACKS ______________________________________________________________ 3-104 Tracks – cleaning _______________________________________________________________ 3-104 Carbody-crawler frame fastening bolts and disks, replace________________________________ 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 SYSTEM __________________________________________________ 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 Oil filter for hydraulic circuit grease pump, replace _____________________________________ 3-114 Grease filter replace (Filling the grease container) _____________________________________ 3-115

ix

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

TABLE OF CONTENTS Grease filter replace (Grease lines) _________________________________________________ 3-116 OTHER MAINTENANCE ___________________________________________________________ 3-117 Engine ________________________________________________________________________ 3-117 Reservoirs for used grease at the A-frame, emptying ___________________________________ 3-118 Heating and air conditioning, check _________________________________________________ 3-118 Working equipment, check welding seems ___________________________________________ 3-119 Clam cylinder chamber, check for soiling _____________________________________________ 3-119 Window panes - cleaning _________________________________________________________ 3-120 Mirror – cleaning / adjusting position ________________________________________________ 3-120 HYDRAULIC LADDERS (OPTIONAL) ________________________________________________ 3-121 Pressure-accumulator inspection regulations__________________________________________ 3-122 Extract from the German regulations ________________________________________________ 3-122 Checking the gas charging pressure in the pressure accumulator _________________________ 3-122 ON-BOARD CRANE, DRIVE UNIT ___________________________________________________ 3-123 On-board crane, lubricating _______________________________________________________ 3-124 On-Board crane, checking tightness of fastening bolts __________________________________ 3-124 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING _______ 3-125 Putting the hydraulic shovel out of operation __________________________________________ 3-125 Battery storage _________________________________________________________________ 3-125 Recommissioning _______________________________________________________________ 3-125 NOTES ________________________________________________________________________ 3-127 4 REPAIR WORK ____________________________________________________________________ 4-1 REPAIR WORK - SAFETY INSTRUCTIONS _____________________________________________ 4-3 CONFINED SPACES - SAFETY INSTRUCTIONS _________________________________________ 4-4 REPAIR WORK, FIRE AND EXPLOSION HAZARD _______________________________________ 4-5 REPAIR WORK, ENGINE ____________________________________________________________ 4-6 HYDRAULIC SYSTEM ______________________________________________________________ 4-7 Repair instructions ________________________________________________________________ 4-7 Hydraulic hoses – Instructions _______________________________________________________ 4-7 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ________________________________ 4-8 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS _______________________ 4-9 DISPOSAL AT THE END OF THE SERVICE LIFE _______________________________________ 4-12 Dismantling and removal instructions _________________________________________________ 4-12 Risk of deflagrations ______________________________________________________________ 4-12 Risk of fire ______________________________________________________________________ 4-12 Disposing of the machine without polluting the environment _______________________________ 4-13 Further hazardous substances ______________________________________________________ 4-13 Appropriate disposal of batteries ____________________________________________________ 4-14

x

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

TABLE OF CONTENTS NOTES _________________________________________________________________________ 4-15 5 ANNEX __________________________________________________________________________ 5-1 BOARD-CONTROL-SYSTEM, OPERATOR LEVEL _______________________________________ 5-3 BCS III, what’s that? _______________________________________________________________ 5-3 The keys on the front side __________________________________________________________ 5-4 Other elements on the front side _____________________________________________________ 5-4 BCSIII, the start screen_____________________________________________________________ 5-5 Information given on the start screen, top section ________________________________________ 5-6 Information given on the start screen, central section _____________________________________ 5-7 Information given on the start screen, lower section ______________________________________ 5-8 Emergency Stop, reset function ______________________________________________________ 5-9 Swing circuit lock-out function ______________________________________________________ 5-10 Information given on the “Service” screen _____________________________________________ 5-11 Engine data screen _______________________________________________________________ 5-12 Hydraulic data screen _____________________________________________________________ 5-13 Lubrication data screen ___________________________________________________________ 5-14 Controls adjustment data screen ____________________________________________________ 5-15 View documents screen ___________________________________________________________ 5-16 Signal table screen _______________________________________________________________ 5-17 Signal table screen, location ________________________________________________________ 5-18 Signal table screen, diagram _______________________________________________________ 5-19 Signal table screen, diagram configuration ____________________________________________ 5-20 Code table screen ________________________________________________________________ 5-21 Slew brake test screen ____________________________________________________________ 5-22 BCS III, interfaces ________________________________________________________________ 5-23 USB interface, data storage ________________________________________________________ 5-23 Saving data to a USB stick _________________________________________________________ 5-24 Saving data to a USB stick, continued ________________________________________________ 5-25 Saving data to a USB stick, continued ________________________________________________ 5-26 BCSIII, cleaning _________________________________________________________________ 5-27 BCSIII, disposal _________________________________________________________________ 5-27 TROUBLESHOOTING _____________________________________________________________ 5-28 Instructions on troubleshooting ______________________________________________________ 5-28 Layout of the fault table ___________________________________________________________ 5-28 Possible causes _________________________________________________________________ 5-28 Measures ______________________________________________________________________ 5-28 Section ________________________________________________________________________ 5-28 FAULT TABLES __________________________________________________________________ 5-29 Combustion engine - Fault table _____________________________________________________ 5-29 Working hydraulics – Fault table ____________________________________________________ 5-30 Track drive – Fault table ___________________________________________________________ 5-31 Swing mechanism – Fault table _____________________________________________________ 5-32 Central lubricating system – Fault table _______________________________________________ 5-33 Engine control module, displaying stored fault codes ____________________________________ 5-34 HYDRAULIC CIRCUIT DIAGRAM ____________________________________________________ 5-36 Vibration data ___________________________________________________________________ 5-36

xi

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

TABLE OF CONTENTS ABBREVIATIONS _________________________________________________________________ 5-37 ABBREVIATIONS _________________________________________________________________ 5-38 PRODUCT SPECIFICATION SHEET __________________________________________________ 5-39 NOTES _________________________________________________________________________ 5-41 6 INDEX ___________________________________________________________________________ 6-1

xii

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction 1 INTRODUCTION Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

1-1

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction

This page intentionally left blank.

1-2

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction PREFACE About this Operation and Maintenance Manual This Operation and Maintenance Manual is designed to familiarize the operator with the machine and its designated use.

The Operation and Maintenance Manual 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 Operation and Maintenance Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

The Operation and Maintenance Manual must always be available in the operator's cab of the machine.

The Operation and Maintenance Manual 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 Operation and Maintenance Manual 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 1 must be observed .

The Operation and Maintenance Manuals 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 Caterpillar Global Mining Hydraulic Mining Shovels (CGM HMS) mechanic or by attending a CGM HMS training course for operators or maintenance personnel.

The CGM HMS after-sales service will be pleased to deal with any queries you may have after reading through the Operation and Maintenance Manuals.

The operating and maintenance instructions are not work instructions for carrying out major repairs.

Such work is willingly done for you by the CGM HMS after-sales service.

Further machine documentation The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The Operation and Maintenance Manual, the spare-parts list and the Service Manuals are marked with the serial number of the machine.

The documentation supplied with your machine is rather comprehensive. Therefore, it has been split up in several volumes: Volume 1: the present Operation and Maintenance Manual, Volume 2: spare-parts catalog of the machine, Volume 3: cross reference list of spare-parts, Volume 4: electrical circuit diagram and key, Volume 5: documentation of the engine and of other components, Volume 6: Service Manual Part 1 Volume 7: Service Manual Part 2 Depending on the size of your machine, the documentation can also consist of more volumes.

If you cannot find the information you are looking for in the present Operation and Maintenance Manual please check also the other volumes of the documentation.

The Service Manual Part 1 also provides information on how to assemble the machine, on functions of the hydraulic system, on hydraulic circuit diagrams etc.

On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

1

Complies with VDMA recommendation "Operating instructions"

1-1

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction WARRANTY The warranty of CGM HMS presupposes among other things that the servicing works as described in the Operation and Maintenance Manual have been performed: by your Caterpillar dealer Service or by the CGM HMS Service or in a workshop authorized in writing by your Caterpillar dealer / by CGM HMS, and by using the original spare parts of CGM HMS. The proper execution of the servicing works must be documented on the CGM HMS Service checklists.

Do not operate the machine when components / assemblies are defective or missing, if one or several of such components of which more than one are installed in the machine have been removed.

In cases of doubt seek advice from the CGM HMS Service.

CGM HMS refuses to assume the guarantee for damage and consequential damage caused by an abusive utilization of the machine.

Therefore: Do not operate the machine, when several track rollers or support rollers have been removed; when one or several swing gearboxes have failed or been removed; when one or several teeth on the backhoe or on the shovel are worn or missing; when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by CGM HMS as "abusive utilization".

Why? The machines have been designed and built on the basis of detailed calculations and so that all of the components installed absorb the occurring forces and are thus loaded to an equal extent.

Example: If the machine is used for working with, for instance, one or even several track rollers removed, the forces must be absorbed by the remaining track rollers. These are then overloaded or loaded to a greater extent than calculated.

The consequences are higher wear and consequential damage to the track rollers, but also to other components of the machine: chassis, travel gearbox and crawler track.

1-2

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction FUNDAMENTAL SAFETY INSTRUCTIONS Complies with VDMA recommendation "Operating Instructions"

Warnings and symbols The following signs are used in the Operation and Maintenance Manual to designate instructions of particular importance: Precautionary rules and measures designed to protect the machine operator and other persons from lifethreatening danger or injuries and to prevent extensive damage.

Information and precautionary measures designed to prevent damage to the machine or other property.

1-3

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction DESIGNATED USE, UNAUTHORIZED USE The machine has been built in accordance with state-of-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property (acceptable risk) An acceptable risk is present, e.g.: loose material or material to be loaded may drop out of the bucket or backhoe while the working equipment is being swiveled.

The machine must be used only in technically perfect condition in accordance with its designated use and the instructions set out in the Operation and Maintenance Manual, and only by safetyconscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

With attached shovel equipment, the machine is to be used solely for loosening and loading of: sand, oil sand,

Using the hydraulic shovel or its attachments for purposes other than or extending beyond those stated above, e.g.: for lifting or transporting persons,

as a working platform, for lifting crane loads without the equipment being approved for this purpose, for driving in posts, sheetpiles supports, etc. without the equipment being approved for this purpose, for moving material to the side (sweeping), for breaking down rocks by beating with the shovel or the backhoe, for fitting or repairing of other machines is contrary to its designated use and considered as "unauthorized use".

gravel, blasted rock, ore, coal, and other raw materials.

With attached backhoe equipment, the machine can additionally also be used for excavating and loading of excavatable soils and other raw materials.

Operating the machine within the limits of the designated use also involves observing the instructions set out in the Operation and Maintenance Manual and complying with the inspection and maintenance directives.

1-4

Lifting eyes on the lower carriage - are settled for transporting with a crane only.

- must not be used for towing a machine.

Improper use may involve a life-threatening risk for operators or other personnel or may cause injury or extensive damage.

The manufacturer/supplier cannot be held liable for any damage resulting from other than the designated use. The risk involved in such misuse lies with the user.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction Noise emission information

Vibration information

Noise emission data are specified in acc. with ISO 6394.

Time-averaged A-weighted emission sound pressure level at operator’s position with the machine running at high idle: LAeq = XX dB.

On the condition that the hydraulic shovel is used within the limits of its designated use, the installation of seats for operators in conformity with ISO 7096 ensures that the weighted vibration accelerations awz (measured in compliance with ISO 2631 Part I) fulfilll the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG. The vibrations transferred are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. with the "Regulations for noise and vibration at the place of work", Section 4, as of 18.12.2008.

The effective value of the weighted acceleration to which the whole body is exposed, does not exceed 2 0.5 m/s .

The measurement uncertainty is ±3% (tolerance of the measuring instruments).

1-5

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction ORGANIZATIONAL MEASURES The Operation and Maintenance Manual must always be at hand at the place of use of the machine, e.g. by stowing them in the place provided for such purpose.

In addition to the Operation and Maintenance Manual, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment or traffic regulations.

The Operation and Maintenance Manual must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the Operation and Maintenance Manual and in particular the chapter on safety before beginning work. Reading the Operation and Maintenance Manual after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance.

Check - at least from time to time - whether the personnel is carrying out the work in compliance with the Operation and Maintenance Manual and paying attention to risks and safety factors.

For reasons of security, long hair must be tied back or otherwise secured, garments must be closefitting and no jewelry, such as rings, may be worn.

Injury may result from being caught up in the machinery or from rings catching on moving parts.

Use protective equipment wherever required by the circumstances or by law.

1-6

Personal protective equipment and the working clothing Depending on the cleaning, servicing and/or repair activities to be performed, the personal protective equipment and the working clothing may consist of the following items: fall arresters protective suit helmet goggles - e. g. for cleaning work - or for welding work protective gloves - e.g. for work on hot units - for grinding and welding work protective working gloves - e.g. for fitting work - for grinding and welding work ear protectors Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behavior of the machine during operation, stop the machine immediately and report the malfunction to the competent authority/person.

Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Use only the original spare parts of CGM HMS. They are the only ones to fulfilll the technical specifications of the machine.

Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the Operation and Maintenance Manual for routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction Selection and qualification of personnel; basic responsibilities Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorized personnel works on or with the machine.

Define the machine operator's responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

Work on chassis and brake systems must be performed by skilled personnel only, which has been specially trained for such work.

Work on hydraulic systems must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Safety instructions governing specific operational phases

Start the machine from the operator's seat only.

During start-up and shut-down procedures always watch the indicators in accordance with the Operation and Maintenance Manual.

Before setting the machine in motion, make sure that nobody is at risk.

Before starting work or travelling with the machine, check that braking, signaling and lighting systems are fully functional.

Before setting the machine in motion always check that the accessories have been safely stowed away.

In conditions of poor visibility and after dark always switch on the lighting system.

Persons accompanying the operator must be seated on the passenger seat provided for this purpose.

When crossing underpasses and bridges or when passing under overhead lines always make sure that there is sufficient clearance.

Always keep a distance from the working face and from slopes.

Avoid any operation that might be a risk to machine stability.

Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

On sloping terrain always adapt your travelling speed to the prevailing ground conditions.

Before leaving the operator's seat always secure the machine against inadvertent movement and unauthorized use. Shut off the engines.

Standard operation Avoid any operational mode that might be prejudicial to safety.

Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working area and the bearing capacity of the soil.

Take the necessary precautions to ensure that the machine is in a safe and reliable state.

Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional.

Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine's working behavior) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it.

In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified immediately.

1-7

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation and Maintenance Manual, including information on the replacement of parts and equipment.

These activities may be executed by skilled personnel only.

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and its safetyoriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the Operation and Maintenance Manual and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: removing the ignition key and attaching a warning sign.

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movements.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Never use machine parts as a climbing aid Wear a safety harness when carrying out maintenance work at heights above 1 m.

Wear an approved harness equipped with fall arresters and safety lines.

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

1-8

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair.

Never use aggressive detergents. Use lint-free cleaning rags.

Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switch-gear cabinets.

Ensure during cleaning of the machine that the temperature sensors of the fire-warning and firefighting systems do not come into contact with hot cleaning agents as this might activate the firefighting system.

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spray-washed with steam-jet cleaners or highpressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

After cleaning remove all covers and tapes applied for that purpose.

After cleaning, examine all fuel, lubricant, brake and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defect found must be rectified without delay.

Always tighten any screwed connections that have been loosened during maintenance and repair.

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of maintenance and repair work.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction Warning of special dangers

Gas, dust, steam and smoke

Electric energy

Always start and operate the engine in a wellvented area; If in an enclosed area, vent the exhaust to the outside; Do not modify or tamper with the exhaust system Diesel engine exhaust and some of its constituents are known to cause cancer, birth defects, and other reproductive harm Operate fuel-operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.

Observe the regulations in force at the respective site.

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

If your machine comes into contact with a live wire do not leave the machine drive the machine out of the hazard zone; warn others against approaching and touching the machine have the live wire de-energized do not leave the machine until the damaged or contacted line has been safely de-energized.

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

High-voltage system Flood lamps equipped with gas discharge lamps (Xenon) require a high-voltage supply (ca. 25 kV).

The high voltage is generated by a ballast unit.

Switch off the electrical system of the hydraulic shovel before touching the lamp or the ballast unit.

CALIFORNIA Proposition 65 Warning Diesel fuel and Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.

Electrical Storm Injury Prevention When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures: Mount the machine.

Dismount the machine.

If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

1-9

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction Hydraulic equipment

Ether

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

Depressurize all system sections and pressure pipes (hydraulic system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Hydraulic lines must be laid and fitted properly.

Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

The machine can be equipped with pressure vessels for cold-starting fluid (ether) installed in the engine compartment. Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the vessels against damage and high temperatures.

Do not store pressure vessels with cold-starting fluid (ether) on the hydraulic shovel.

Do not eat, drink or smoke when replacing pressure vessels with cold-starting fluid (ether). Observe the instructions on the pressure vessels.

Provide for sufficient ventilation (see also Part 3 "Inspection and servicing").

Do not open empty cold-starting fluid pressure vessels (ether). Have the vessels disposed of properly.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Noise During operation, all sound baffles of the machine must be closed.

Always wear the prescribed ear protectors.

Oil, grease and other chemical substances When handling oil, grease or other chemical substances, observe the product-related safety regulations (see safety specifications).

Be careful when handling hot consumables (risk of burning or scalding).

1-10

Transporting and recommissioning The machine must be loaded and transported only in accordance with the Operation and Maintenance Manual.

Use only appropriate means of transport and lifting gear of adequate capacity.

The recommisioning procedure must be strictly in accordance with the Operation and Maintenance Manual.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard.

Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid has been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substances can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Even battery gases can ignite in open flames or fire.

Avoid parking the hydraulic shovel in places where combustible substances such as coal dust or tar are present.

Place suitable fire guarding (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

If necessary, also cover the ground with fireprotective blankets.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Clean the hydraulic shovel before starting a job.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved.

open or smoldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

1-11

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction

This page intentionally left blank.

1-12

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

1-13

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Introduction

This page intentionally left blank.

1-14

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation 2 OPERATION Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

2-1

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

This page intentionally left blank.

2-2

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation OPERATION - SAFETY INSTRUCTIONS Operation and Maintenance Manual Never operate the machine before having read and understood the Operation and Maintenance Manual.

Pay special attention to: The "Fundamental Safety Instructions" and to all warning and instruction signs attached to the machine.

Familiarize yourself with the layout, the functioning and the sense of actuation of the control elements prior to starting up the machine.

Activate the control elements from the operator's seat only.

Keep the Operation and Maintenance Manual with the machine at all times.

Operating personnel The operating personnel must be fully informed of the operation and application of this or comparable machines.

The necessary know-how can be acquired in several days' instruction, e.g. by a Caterpiller Global Mining Hydraulic Mining Shovels (CGM HMS) mechanic or by attending a CGM HMS operator's training course.

Personal protective gear and working clothing Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation.

Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in control levers being inadvertently activated

Safety belt For machines with a safety belt for operating personnel: Check the safety belt attached to the operator's seat and to the trainer’s seat. In the event of damage or after an accident, have it replaced immediately.

Apply the safety belt before starting work.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the equipment and component combinations approved by CGM HMS. Clear-cut data are given in the technical specification.

Never install and commission other equipment and component combinations without CGM HMS having first inspected and approved the project.

Before starting work or travelling with the machine, check that the braking, signaling and lighting systems are fully functional.

Poor visibility may result in accidents. Always clean the windows and the glass covers of all lamps before starting the machine.

Check that all warning and instruction signs attached to the machine are present and legible.

Entering and leaving the machine Always face the machine when entering or leaving it.

Use only the ladders, steps, platforms and grab handles provided when entering and leaving the machine.

Always maintain a three point contact with the steps and grab handles.

Always keep ladders, steps and platforms in a non-slip, safe state and remove any oil, grease, soil, snow, ice and other foreign matter immediately.

2-3

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Hazard range The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its equipment and attachments or of swinging loads.

Persons within the hazard zone Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

Operation and Maintenance Manual, where to store it in the operator’s cab One copy of the Operation and Maintenance Manual for the machine must be available in the operator’s cab during operation.

Replace Operation and Maintenance Manual if lost, damaged or unreadable.

The binder with the Operation and Maintenance Manual can be stored in the tray (Fig. 2-1:).

Marshallers The marshaller must keep outside the hazard zone.

Have a marshaller to assist you: when you have no clear overview over the hazard zone of the machine, when reversing, when shunting.

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie/camera).

Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller.

Stop the machine immediately if you lose contact with the marshaller.

Securing the machine Secure the machine as described under "Securing the machine" before: mounting or dismantling the attachment, parking the machine after daily operation, carrying out any servicing or repair work.

2-4

Fig. 2-1:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid has been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Clean rubber or electrical with compressed air only.

Ensure sufficient ventilation.

Even battery gases can ignite in open flames or fire.

Avoid parking the hydraulic shovel in places where combustible substances such as coal dust or tar are present.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

Clean the hydraulic shovel before starting work.

Place suitable fire guarding (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved before starting work.

open or smoldering fire may occur.

2-5

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation DESCRIPTION OF THE HYDRAULIC SHOVEL

Fig. 2-2:

2-6

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Hydraulic shovel layout Fig. 2-2:

33 – Operator's cab

Undercarriage

34 – Control stand with BCS display

1 - Track drive

35 – Control cabinet cab module

2 – Idler

36 – Control cabinet with controllers

3 - Track roller

37 – Air conditioner

4 - Support roller

38 – Control cabinet (preheating system)

5 - Crawler track

39 – Control cabinet

6 - Track tensioner

40 – Starter batteries

7 - Swing ring

41 – Additional heating system (optional) 42 – Service-station (tank lift)

Superstructure

43 – Alternator with drive (optional)

11 – Engine left-hand side

44 – On-board crane (optional)

12 – Radiator (engine cooling liquid)

45 – Hydraulic system (on-board crane)

13 – Reservoir (engine cooling liquid)

46 – Grease container of central lubricating sys-

14 – Air-intake system

tem

15 – Exhaust system

47 – Tool cabinet (optional)

16 – Fuel Tank

51 – Hydraulic ladder

17 – Cooler (fuel)

52 – Stairway

18 – Engine oil reservoir (optional)

53 – Counterweight

19 – Hydraulic oil reservoir

54 – Emergency ladder

20 – Hydraulic oil cooler

55 – Battery isolator / starter isolator

21 – Filter housing (cooling system)

56 – Backup batteries in cab module

22 – Pump drive gearbox 23 – Working pump

Loading bucket

24 – Swing pump

61 – Boom

25 – Servo system pump

62 – TriPower linkage

26 – Gearbox circulating pump

63 – Stick

27 – Filling pump (swing circuit)

64 – Bottom-dump bucket

28 - Fan drive pump (engine radiator)

65 – Boom cylinder

29 - Fan drive pump (hydraulic oil cooler)

66 – Stick cylinder

30 – Cooling oil pump

67 – Tipping cylinder

31 – Swing gear

68 – Bottom-dump cylinder

32 – Travel block and rotor

69 – Control valves 70 – Quick-action valve

2-7

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Undercarriage The undercarriage of the hydraulic shovel serves as a stable base and for travelling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and superstructure are connected by means of a swing ring.

Superstructure The superstructure accommodates the drive and part of the hydraulic and electrical equipment.

Drive unit The drive unit comprises diesel engines, pump drive gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Hydraulic system All working and travelling movements are performed hydraulically. The movements are controlled by servo valves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the superstructure to the undercarriage is ensured by the rotor. The hydraulic system is overload-protected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

2-8

Control and Monitoring Platform (CAMP) The electronic CAMP system ensures the control and monitoring of all electrical and hydraulical functions of the hydraulic shovel.

Four interconnected electronic units ensure optimal use of the installed engine power. Microprocessors are used to adapt the power output of the hydraulic pumps optimally to actual operating conditions.

The machine is thus prevented from demanding more hydraulic power than the diesel engines can provide.

The desired working movements are detected by microcontrollers which permanently sense the position of hand levers and pedals.

As soon as movement is detected, the corresponding signals are transmitted to the electronic units. These units activate the drive control in order to provide the hydraulic energy needed for working. Only then do they activate the electrohydraulic valves which control the execution of the working movements.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Board-Control-System (BCS) The BCS is a micro-processor-controlled system for the acquisition and processing of measuring data.

Its function consists in collecting data of the hydraulic shovel operating conditions and to evaluate, store and display these data to the hydraulic shovel operator. For this purpose, the BCS is connected via a bus system to the Control and Monitoring Platform (CAMP). An interface with the outside world ensures the transfer of stored data and software updating.

The measured values (actual values) from the sensors and transducers installed in the hydraulic shovel are compared to the predefined reference values. Inadmissible deviations are indicated as fault messages on a display screen. Sensor or transducer defects or defective connecting cables are detected and indicated by plain-text messages.

The data from the engine electronics are acquired, processed and displayed in the same way.

Critical states of operation are brought to the operator's attention by means of optical and acoustic warning signals.

The display screen of the BCS is a touch-screen with a surface sensitive to the touch. This feature supports the hydraulic shovel operator or the service technician in navigating through the menus of the BCS software.

For further information in this respect, please refer to section 5 in this Operation and Maintenance Manual or to the brochure "Board-Control-System – Operating instructions"

Demand control / Zero-flow regulation In the fine-control range, swiveling of the hydraulic pumps, and thus the variation of oil flow, are proportional to control lever and pedal valve travel. This means that during the work, the pumps supply only as much hydraulic oil as required to perform the working movement. In the neutral position of the control levers, the pumps are automatically swiveled to zero flow.

These special features offer the following advantages: reduced fuel consumption minimum power losses reduced temperature of the hydraulic oil greater service life of hydraulic pumps and diesel engines.

Automatic reset to idling If no servo valves are actuated by the control pedals or levers for more than 8 seconds (factory-set value, adjustable), the engine is automatically set back to idling speed (factory setting ca. 1000 rpm, adjustable). This feature, too, contributes to reducing the fuel consumption.

Electrical system The electrical system operates on 24 volts.

Modifying parameters in BCS must be carried out by skilled, trained personnel only. Misuse could lead to serious damage on the shovel.

A passcode for BCSIII Service Level 1 and Level 2 is requested. Refer to Service Magazine 2014-005 “BCS Passcodes” available on the website

2-9

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Signs Warning and instruction signs Observe the warning and instruction signs attached to the machine.

Keep all the signs legible and clean.

Replace signs immediately if they have become illegible.

New warning and instruction signs can be ordered from the CGM HMS Spare Parts Service. The ordering part numbers are set out in the spare-parts list of the machine.

Fig. 2-3: - Fig. 2-8: show the location of warning and instruction signs on the machine.

2-10

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-3:

2-11

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-4:

2-12

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-5:

2-13

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-6:

2-14

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-7:

2-15

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-8:

2-16

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Machine number

Engine number

The identification plate with the machine number (Fig. 2-9:) is attached to the front side of the Aframe (arrow, Fig. 2-10:).

The data plate (arrow, Fig. 2-11:) of the diesel engines are located on the diesel engines opposite to the starter. It contains important information about the engine, like horsepower, engines serial number and rpm ratings.

Fig. 2-9: Fig. 2-11:

ECM dataplate This dataplates (Fig. 2-12:) are located on the Electronic Control Modules (ECM) of the engines.

The plates contain the serial number and part number, as well as engine and calibration data.

Fig. 2-10:

Fig. 2-12:

Component numbers Other larger units also have identification plates indicating, among other things, their serial number.

On steel components, the CGM HMS part number or the serial number may be stamped into the metal at a clearly visible place.

2-17

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Entering and leaving the machine, Safety instructions Risk of injury due to slipping.

Clean off oil, grease, soil, mud, snow, ice and other substances from footwear, grab handles, ladders and steps.

Keep ladders, steps, platforms and grab handles in a non-slippery condition.

For entering and leaving use only the ladders, steps, platforms and grab handles provided (see: illustration in Fig. 2-13:).

Always face the machine when entering or leaving it.

Always maintain a three point contact with the steps and the grab handles.

Access ladder lighting The access ladder of the machine can be illuminated.

From outside: The pull-switch (2, Fig. 2-14:) of the lighting system is located beneath the superstructure. The lights are switched on from the ground by means of the pull-rope.

From the cab: The switch is located besides the door (arrow, Fig. 2-15:).

The lighting remains on during a presettable ON time. The ON time of the lighting is factory-adjusted to three minutes.

Fig. 2-14:

Fig. 2-13:

Fig. 2-15:

2-18

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Folding ladder Raising resp. lowering the folding ladder (Fig. 2-16:).

Lowering the folding ladder (from the upper carriage) Start an engine.

Push lever of switch (1, Fig. 2-17:) downwards to position “ DOWN “ and hold.

The folding ladder is lowered (Fig. 2-16:).

The folding ladder can also be lowered when the engine is stopped.

Fig. 2-16:

Raising the folding ladder (from the upper carriage) Start an engine.

Push lever of switch (1, Fig. 2-17:) upwards to position “ UP “ and hold.

The folding ladder is raised (Fig. 2-18:).

Fig. 2-18:

Lowering the folding ladder (from the ground) Pull down rope (3, Fig. 2-19:).

The folding ladder is lowered (Fig. 2-16:).

Fig. 2-17:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-18:).

Fig. 2-19:

2-19

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Emergency exit in operator’s cab and escape ladder The sliding window (arrow, Fig. 2-20:) on the lefthand side of the operator’s cab serves as an alternative opening / emergency exit.

To open the sliding window from inside the cab: Lift latch (1).

Grasp handle (2) and slide window pane to the left.

The escape ladder (arrow, Fig. 2-21:) is located beside the operator´s cab.

Function of ladder locking as well as free movement of the ladder must be regularly checked according to the maintenance plans.

Before unlocking the ladder: Be sure that no person is near to the position the ladder moves to.

Fig. 2-20:

Pull out locking pin (1, Fig. 2-22:). The escape ladder is now unlocked and the release lever (2) is free to move.

Move release lever (2) away from the machine.

The escape ladder is now unlocked and moves down quickly to the ground.

Swing barrier (3) to the right and use the ladder to escape downwards.

Fig. 2-21:

Fig. 2-22:

2-20

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Switching the cab interior lighting on and off The cab interior lighting can be switched on and off with the switches (arrow, Fig. 2-23:), (96, Fig. 2-24:) and (arrow, Fig. 2-25:) The cab interior light is supplied with power even when the electrical system is shut down.

When leaving the machine, the interior light must therefore be switched off. The batteries could be discharged if the interior light is allowed to remain on for a prolonged period.

Fig. 2-23:

Fig. 2-24:

Fig. 2-25:

2-21

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Switching the maintenance lights on and off The maintenance lights in the various modules can be activated from a central point with the switches (arrow, Fig. 2-26:) or (95, Fig. 2-27:).

The individual modules are also equipped with switches, for example the engine module: Switch at the switchgear cabinet behind the hydraulic oil reservoir (1, Fig. 2-28:).

Fig. 2-26:

Fig. 2-27:

Fig. 2-28:

2-22

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Emergency shut-off function The emergency shut-off function can be triggered from five different places on the machine: by pressing the switch (red) on the front panel of the control column (35, Fig. 2-29:), by pressing the switch (red) on the drive regulators on the right-hand and on the left-hand side (Fig. 2-30:), by pressing the switch (red) on the control cabinet in the engine module (Fig. 2-31:), by pulling the pull-switch below the counterweight on the left (5, Fig. 2-32:), by pressing the switch (red) on the control box at the Service station (Fig. 2-33:).

The emergency shut-off function disconnects all power outputs of the electronic control units. In this case, all engines are shut off and all valves are deenergized so that no working movements can be performed anymore.

The power supply of the electronic control units of the engines (ECM) and of the machine (BCS, PLC) is, however, not interrupted. For this reason, the monitoring functions continue to remain active.

Other auxiliary functions such as: the fire extinguishing system, the service station (tank-lift) and, the radio, the cab interior lighting and the access ladder lighting remain functional as well.

The emergency shut-off function can also be triggered before maintenance operations are performed on the machine. For this purpose, one of the switches is depressed and secured with a padlock. Any inadvertent starting of the engine is thus prevented.

Emergency shut off switch in the operator’s cab

Fig. 2-29:

Emergency shut off switch at the engine compartments

Fig. 2-30:

(continued next page)

Emergency shut off switch on the control cabinet engine module

Fig. 2-31:

2-23

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Emergency shut off switches (continued) Emergency shut off pull switch between left fuel tank and counterweight

Putting the machine back into operation, reset of emergency shut off function The machine can only be put back into operation when all switches listed above are again in their basic position (i.e. not actuated).

Additionally the Reset button (arrow, Fig. 2-34:) has to be pushed. The Reset button is located in the front door of the 24 Volt-control cabinets in the cab module.

Fig. 2-32:

Emergency shut off switch on the Service station (tanklift)

Fig. 2-34:

Fig. 2-33:

2-24

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Battery isolator switch, shutting off supply voltage The battery isolator switch (1, Fig. 2-36:) is located inside the control cabinet on the deck of the engine module (Fig. 2-35:).

The supply voltage is shut off when the battery isolator switch has been turned to position “OFF”.

This function shuts off the complete electrical system of the machine by disconnecting the two poles from the batteries (battery main switch).

In this case, all engines are shut off so that no working movements can be performed anymore.

The power supply of the electronic control units of the engines and of the machine is shut off after a brief delay. The delay ensures that the current operating data can be saved and the systems shut down properly.

Lock the battery isolator switch in position “OFF” by means of a padlock.

The machine can only be put back into operation when the battery isolator switch is unlocked and switched in the “ON” position. A green LED located near the switch comes on.

Fig. 2-35:

Starter isolator switch, shutting off starter voltage The starter isolator switch (2, Fig. 2-37:) is located inside the control cabinet on the deck of the engine module (Fig. 2-35:).

After turning the “Starter Isolator” switch to position “OFF” the engines could not be started.

All other sections of the electrical system are supplied with voltage.

This is to ensure personal safety during testing and troubleshooting purposes.

Lock the starter isolator switch in position “OFF” by means of a padlock.

The engines can only be put back into operation when the starter isolator switch is unlocked and switched into the “ON” position. A green LED located near the switch comes on.

Fig. 2-36:

Fig. 2-37:

2-25

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Operator’s seat The operator’s seat (Fig. 2-38: and Fig. 2-39:) can be adjusted in several positions.

Fig. 2-38:

2-26

Never adjust the seat while driving. Concentrate on the road to avoid accidents.

Before carrying out any seat adjustments stop the machine and set the control levers to "0"

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-39:

2-27

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Reducing operators exposure to vibrations Vibrations, oscillations and movements of the machine cannot be avoided when the machine is in operation. They also have an effect on the operator.

These effects on the operator can however be avoided, if the operator's seat is adjusted correctly.

Therefore, make use of the seat's various adjustment features (see Fig. 2-38: and Fig. 2-39:): shock absorption (Absorber), body weight setting (Weight adjustment), horizontal movement damping (Fore/aft isolator).

Adjust the seat before beginning work to suit your personal requirements. Check whether all adjustments are functional. If this is not possible, have the seat checked and repaired as soon as possible.

Trainer's / instructor's seat For operator training / instructing purposes it is often required that a trainer / instructor accompanies the operator in the cab.

For the safety of the trainer / instructor during hydraulic shovel operation the cab is equipped with a second seat. This seat is installed behind the operator's seat (Fig. 2-40:).

Swing seat away from the cab wall.

Sit down on this seat and do not forget to fasten the seat-belt, if installed (Fig. 2-40:).

Do not leave this seat during the training / instruction session and /or as long as the machine is in operation.

Fig. 2-40:

2-28

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Windscreen washer

Operating hours meter

The fluid reservoir (1, Fig. 2-41:) of the windscreen washer is located in the cab module. The capacity of the reservoir is indicated under "Refilling quantities - Other".

Three operating hour meters (Fig. 2-42:) are located in the left front door of the “24 Volts switchgear cabinet” in the cab module.

1 2 3

LH engine hours meter RH engine hours meter Travel hours meter

Fig. 2-41:

Fig. 2-42:

2-29

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Fire extinguisher

Handling

The hydraulic shovel is equipped with two fire extinguishers (arrow Fig. 2-43:).

Fig. 2-44:

Fig. 2-43:

The hydraulic shovel operator and the maintenance personnel must inform themselves about how to handle the fire-extinguisher in order to be able to act fast and efficiently in case of beginning fires. Such instruction should be given by a qualified instructor.

Extinguishing agent Each fire-extinguisher is filled with 12 kg (26.4 lb) Glutex. This extinguishing agent is used for fighting fires of classes A, B and C. Fires are extinguished fast, perfectly and without residues.

2-30

Pull out securing pin (2, Fig. 2-44:).

Strike knob (3) hard, then release again.

Operate the extinguishing gun.

Inspection Have the extinguisher inspected at regular intervals by an expert. This is required by local authorities and insurance companies and is in the interest of your own safety.

Have the fire-extinguisher checked at the prescribed intervals by authorized testing agencies.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Automatic fire-extinguishing system (optional) The automatic fire-extinguishing system prevents fire from spreading. It is, however, assumed that the machine is thoroughly cleaned of combustible and easily flammable substances.

The hydraulic shovel operator and the maintenance personnel must familiarize themselves with the automatic fire-extinguishing system.

Such instruction should be given by a qualified instructor.

The fire-extinguishing system is activated automatically in an emergency.

Refill extinguishers immediately after use ready for further deployment.

In an emergency the fire-extinguishing system is actuated automatically.

Nevertheless particular extinguishing circuit e. g. engine 1 or 2 (LH or RH) can be actuated manually.

Inspection Have the extinguishing system inspected regularly by an expert. This is required by authorities and insurance companies and is in the interest of your own safety.

Have the fire-extinguishing system checked at the prescribed intervals by authorized testing agencies.

Manual activation Pull out ring (1, Fig. 2-45:) on activating unit for the corresponding extinguishing circuit.

Strike knob (2) hard.

(Fig. 2-46:) shows an activating unit in the operators cab.

Fig. 2-45:

Fig. 2-46:

2-31

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Harness (optional) Elements of the harness (Fig. 2-47:- Fig. 2-49:) Pos.

Designation

1

Back support (seat)

2

Shoulder belt

3

Shoulder belt

4

Loop (chest belt)

5

Loop (chest belt)

6

Loop (back support)

11

Holding device with fastening eye

12

Snap hook of fall arrester

13

Fall arrester

14

Hanging up line

15

Handbag with harness

16

Snap hook

17

Hook safety device

Fig. 2-48:

Fig. 2-49: Fig. 2-47:

Important hints Read and observe also: Operating instructions of the supplier.

Before using operator shall have received adequate training.

The harness must be used by one person only.

He is responsible for the appropriate use and maintenance.

Visual inspection is recommended prior to each use; if necessary it must be checked by an expert.

Harness must be checked annually (every 12 month) by an expert.

2-32

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Taking on harness Take harness out of handbag (15, Fig. 2-50:).

Pull back support (1, Fig. 2-51:) behind your body (Fig. 2-52:).

The loops (4 and 5) are in front of your body.

Fig. 2-52:

Fig. 2-50:

Pull loop (6) of the back support (1) between your legs to the front (Fig. 2-52:).

Pull loop (5, Fig. 2-53:) through loop (6).

Take on shoulder belts (2 and 3, Fig. 2-51:).

Fig. 2-53: Fig. 2-51:

2-33

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Pull loop (4, Fig. 2-53:) through loop (5).

Press the hooking safety device (17, Fig. 2-53:) of the snap hook (16).

Fig. 2-54:

Hang up loop (4, Fig. Fig. 2-55:) into snap hook (16).

Fig. 2-55:

Release hooking safety device (17, Fig. 2-56:).

Fig. 2-56:

2-34

If you have the harness put on in such a way in case of danger you can escape from the hydraulic shovel (Fig. 2-57:).

Fig. 2-57:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

This page was intentionally left blank.

2-35

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-58:

2-36

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-58:) BCS, Board-Control-System No. 1

2

Element BCS

Monitor

Function

Symbol

Electronic system Board Control System, acquisition and disfor measured data play of important operating data of the hyacquisition and pro- draulic shovel. cessing The surface of the monitor is sensitive to the touch (touch-screen technology). A touchscreen permits selecting menus and programs by touching graphic control symbols and to recall, for instance operating data of the hydraulic shovel.

For further information please refer to section 5 of this Operation and Maintenance Manual, chapter “Board-Control-System”.

BCS The monitor displays collected operating

data, warning messages and – if needed – instruction for help.

3

4

Push-button

Push-button

Navigation in menus Control of cursor movements, program selection within the BCS, confirmation of inputs / displayed values (Enter), quitting of menus / sub-menus Numeric keypad Input of numeric values.

2-37

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-59

2-38

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-59) BCS, Board Control System, display screen example (For further information please refer to section 5 of this Operation and Maintenance Manual, chapter “BoardControl-System”).

No. 1

2

3

4 5 6

Element

Function

Status line

Indicates activated functions and operating hours.

The symbols displayed are those of the switches in the control column

Touch-screen Monitor

BCS

Indicates collected operating data graphically and / or numerically, displays warning messages, fault messages and – if needed – instructions for help.

Pushbutton

Navigation in menus

Control of cursor movements, program selection within the BCS, confirmation of inputs / displayed values (Enter), quitting of menus / sub-menus

Push-button

Numeric keypad

Input of numeric values.

Touch-screen buttons Status line

Examples Fault messages

Symbol

Displays fault messages as a code number and as plain text. The "Fault" button permits displaying further fault messages stored in the system.

2-39

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-60:

2-40

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-60:)

Element

Function

Key-switch

Switches the electrical system on and off.

33

Buzzer (inside the control column)

Gives three acoustic warning signals if a fault is reported. The signals appear every 30 seconds.

34

Socket connectors

Connection of electronic devices for fault diagnosis purposes.

No. 32

35

Switch

Emergency shut-off

Symbol

De-energizes the outputs of the electronic control units: The engines are shut off, all valves are deenergized, working movements no longer possible. (see: "Emergency shut-off function").

2-41

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-61:

2-42

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-61:)

Engine 1 (LH), control and monitoring All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. 41

42

43

44

45

46

47

48

Element

Function

Push-button

Start

Starting of the engine. For starting, press the push-button face with the symbol.

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

Push-button

Idle

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol.

Warning lamp

Engine oil pressure

Lit up when the engine oil pressure is too low.

Warning lamp

Alternator

Lit up when the batteries are not being charged or in the event of an alternator defect.

Warning lamp

Engine oil temperature

Lit up when the engine oil temperature is too high.

Warning lamp

Cooling liquid temperature

Lit up when the engine cooling liquid temperature is too high.

Switch

Engine speed

Press switch face without symbol: the speed of the engine increases.

Symbol

Press the switch face with the symbol: the speed of the engine reduces.

49

50

Warning lamp

WARNING

Lamp is lit up in the event of a fault on the left engine 1. A periodic acoustic warning signal sounds and the BCS displays "PLEASE CHECK" as well as the fault description.

The engine can still be operated but the engine electronic unit possibly reduces engine power.

Contact the responsible service personnel soon.

Warning lamp

STOP

Lamp is lit up in the event of a critical fault on the left engine 1. A periodic acoustic warning signal sounds and the BCS displays "ENGINE STOP" as well as a fault description.

Shut off engine.

Contact the responsible service personnel immediately.

Warning lamp can display the faults stored in the fault memory of the left engine electronic unit as flashing sequences (see: Part 5 of this manual: "Engine Control Module, displaying stored fault codes”).

2-43

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-62:

2-44

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-62:)

Engine 2 (RH), control and monitoring All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. Element Function Symbol Push-button Start Starting of the engine. For starting, press the 51 push-button face with the symbol.

52

53

54

55

56

57

58

59

60

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

Push-button

Idle

Warning lamp

Engine oil pressure

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol..

Lit up when the engine oil pressure is too low.

Warning lamp

Alternator

Warning lamp

Engine oil temperature

Lit up when the batteries are not being charged or in the event of an alternator defect.

Lit up when the engine oil temperature is too high.

Warning lamp

Cooling liquid temperature

Lit up when the engine cooling liquid temperature is too high.

Switch

Engine speed

Warning lamp

WARNING

Warning lamp

STOP

Press switch face without symbol: the speed of the engine increases.

Press the switch face with the symbol: the speed of the engine reduces.

Lamp is lit up in the event of a fault on the right engine 2. A periodic acoustic warning signal sounds and the BCS displays "PLEASE CHECK" as well as the fault description.

The engine can still be operated but the engine electronic unit possibly reduces engine power.

Contact the responsible service personnel soon.

Lamp is lit up in the event of a critical fault on the right engine 2. A periodic acoustic warning signal sounds and the BCS displays "ENGINE STOP" as well as the fault description.

Shut off engine.

Contact the responsible service personnel immediately.

Warning lamp can display the faults stored in the fault memory of the right engine electronic unit as flashing sequences (see: Part 5 of this manual: "Engine Control Module, displaying stored fault codes”).

2-45

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-63:

2-46

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-63:) All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. 61

Element Push-button

Function Superstructure holding brake

Symbol

Blocks the superstructure.

Press this button when the superstructure is stationary.

Do not use this button while the superstructure is still in motion.

Risk of damage to the brake and the swing gearboxes.

Not connected.

62 63

Switch

Hydraulic shovel parking brake

Not actuated: The parking brake is applied automatically ca. 5 secs after the hydraulic shovel has stopped moving.

The parking brake is released automatically when the "Travel" function is activated.

Press the switch face with the symbol: The parking brake is applied permanently.

The hydraulic shovel cannot be moved.

Actuate this switch only when the hydraulic shovel is stationary.

Do not use this switch while the hydraulic shovel is still in motion.

Risk of damage to the brakes and the travel gearboxes.

64

Push-button

Central greasing system reset

Reset function of the central greasing system control (Press for at least 3 sec.).

Press switch face without symbol: Resets the control of the superstructure.

Press the switch face with the symbol: Resets the control of the undercarriage.

65

Push-button

Emergency lowering Lowering of the working equipment in an emergency situation. For instance, if the engines have failed.

For more information refer to chapter “Emergency lowering of the working equipment”.

66

Switch

Automatic speed reduction

Reduces the speed of the diesel engines to -1 about 1000 min , if no working movement is being executed during about 8 seconds.

2-47

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-64:

2-48

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-64:) All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. 71

72

Element

Function

Switch

Servo-control

Press the switch face with the symbol: The electro-hydraulic servo-control is enabled.

Switch

Travelling speed

Not actuated: st 1 travelling stage travelling forwards / backwards is possible

Symbol

Press the switch face with the symbol: nd 2 travelling stage, only parallel forward travel is possible. In case of backward travel and cornering, the machine switches back automatically into the st 1 travelling stage.

Not connected.

73 74

Monitoring lamps

Engine oil interval prolongation

Not connected.

75 76

81 82 83 84 85 86

Lamp is lit up, when the right or the left pump of the prolongation system is running.

Push-button

When the machine has to be maneuvered out of dangerous situations

Press the switch face with the symbol: The machine can be driven and the superstructure be swung although these functions are automatically deactivated.

Use this function only in dangerous situations to maneuver yourself or the machine out of hazard zones. Risk of damaging parts of the machine, e.g. the hydraulic ladder or the tanklift.

Switch

Flood lamps

Switches the flood lamps on the operator´s cab on and off.

Switch

Flood lamps

Switches the flood lamps on the hydraulic oil cooler module on and off.

Switch

Flood lamps

Switches the flood lamps on the cab module on and off.

Switch

Flood lamps

Switches the flood lamps on the boomon and off.

Switch

Flood lamps rear

Switches the flood lamps on the counterweight on and off.

Switch

Not connected.

2-49

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-65:

2-50

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-65:) All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No.

Element

Function

91

Push-button

Dumper count

Press the switch face with the symbol: Resets the loaded dumper count.

92

Switch

Windscreen wiper

Press the switch face with the symbol: Windscreen wiper in intermittent operation mode.

Symbol

Press the switch face without symbol: Windscreen wiper in permanent operation mode.

93

Pushbutton

Windscreen washer

Press the switch face with the symbol: Windscreen wiper in wipe/wash operation.

94

Switch

Rotary beacon (option)

Press the switch face with the symbol: Rotary beacon ON.

95

Switch

Lighting

Press the switch face with the symbol: Switches on the maintenance lights in the modules.

96

Switch

Lighting

Press the switch face with the symbol: Switches on the lights in the operator's cab.

97

Outlet

For connecting electrical driven devices, e. g. for charging small accumulators.

Operating voltage: 12 Volts.

Maximum power output: 120 Watts.

2-51

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-66:

2-52

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-66:) No. Element 101 Push-button

(Free for options)

102 Push-button

Stick floating position (shovel equipment only)

Function Symbol Can be used as a push-to-speak button on a radio, or to switch over from one camera to another one.

Button is pressed: The stick cylinders are pressurized on retracting.

Press button (102) only in position "0" of control lever (115).

103

Push-button

Boom floating position

Button is pressed: The boom cylinders are pressurized on retracting.

Press button (103) only in position "0" of control lever (116).

104 105

111 112 113 114 115

116

117 118

119

120

Push-button Push-button inside the seat

Pedal Pedal Pedal

Warning signal

Button is pressed: Acoustic warning signal / horn is activated.

Electronic hydraulic Button in the seat. shovel control (ser- The electronic hydraulic shovel control (servo-control) vo-control) is activated when the operators sits down on the seat.

The electronic hydraulic shovel control (servo-control) is deactivated when he leaves the seat.

Shovel trap (shovel Forwards – shovel trap is opened; equipment only) Backwards – shovel trap is closed.

Travel, left track Forwards – forward travel; Backwards – backward travel.

Travel, right track Forwards – forward travel; Backwards – backward travel.

Footrest Control lever

Forwards – raising the stick Backwards – lowering the stick.

To the left / right – swinging and braking of the superstructure.

Forwards – lowering the boom; Backwards – raising the boom.

To the left – backwards tipping of shovel / bucket; To the right – dumping of shovel / bucket.

Not used on this machine.

Control lever

Push-button Thumb wheel

Shovel trap (shovel equipment only)

Push-button

By-pass for the automatically switch off for stick- and /or backhoe cylinders (Option)

Thumb wheel

Turn Forwards – shovel trap is opened; Turn Backwards – shovel trap is closed.

Function can be overridden by Pedal 111.

(Thumb wheel is spring centered).

Lower half pushed – automatically stopped stick- and/or backhoe cylinders can be driven slowly to the limit stops.

Upper half pushed – Each press on the button increments the loaded dumper count for by "1". (Count reset with button (91)).

Not used on this machine.

2-53

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-67:

2-54

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-67:) (Engine 1 (left) monitoring) No.

Element

121

Monitoring device

Engine monitoring Indicates different parameters on the display (engine 1 left) (E) Use push buttons (C and D) to scroll through parameter list.

Indicator lamps (A and B) lit when an active fault occurs.

122

Thermometer

Engine temperature (engine 1 left)

123

Pressure gauge

Engine oil pressure Indicates the oil pressure in the diesel en(engine 1 left) gine lubricating system.

124

Warning device

Engine monitoring (engine 1 left)

Function

Symbol

Indicates the cooling-water temperature.

Gives an acoustic warning signal if a fault is reported, e.g.

Engine oil pressure too low, Engine temperature too high.

Lower the equipment to the ground and shut off engine immediately if the warning device (124) sounds. The warning device (124) continues to sound until the fault has been rectified.

Lights up when engine is in idle phase.

125

Indicator lamp

Idle (engine 1 left)

126

Warning lamp

Cooling water level Lights up when the cooling-water level is too (engine 1 left) low.

127

Warning lamp

Alternator (engine 1 left)

Lights up when the batteries are not recharged.

2-55

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-68:

2-56

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-68:) (Engine 2 (right) monitoring) No.

Element

131

Monitoring device

Engine monitoring Indicates different parameters on the display (engine 2 right) (E) Use push buttons (C and D) to scroll through parameter list.

Indicator lamps (A and B) lit when an active fault occurs.

132

Thermometer

Engine temperature (engine 2 right)

133

Pressure gauge

Engine oil pressure Indicates the oil pressure in the diesel en(engine 2 right) gine lubricating system.

134

Warning device

Engine monitoring (engine 2 right)

Function

Symbol

Indicates the cooling-water temperature.

Gives an acoustic warning signal if a fault is reported, e.g.

Engine oil pressure too low, Engine temperature too high.

Lower the equipment to the ground and shut off engine immediately if the warning device (134) sounds. The warning device (134) continues to sound until the fault has been rectified.

Lights up when engine is in idle phase.

135

Indicator lamp

Idle (engine 2 right)

136

Warning lamp

Cooling water level Lights up when the cooling-water level is too (engine 2 right) low.

137

Warning lamp

Alternator (engine 2 right)

Lights up when the batteries are not recharged.

2-57

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-69:

2-58

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-69:) (Options. Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

Nr. 140 141 142 143 144

Element Switch Switch Switch Switch Switch

Function Auxiliary heating (option) Auxiliary heating blower (option) Auxiliary heating (option) Fuel Pre-heating (option) Fuel Pre-heating (option)

Symbol

Auxiliary heating for operator's cab ON / OFF. Blower levels 1,2,3.

Auxiliary heating for operator's cab ON / OFF. Automatic regulation.

Switches the fuel pre-heating function of RH engine on and off.

Switches the fuel pre-heating function of LH engine on and off.

2-59

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-70:

2-60

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-70:) Air conditioner (Option. Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

No. 150 151 152

Element Rotary switch

Function

Knob

Blower of air conditioner Thermostat

Rotary switch

Selector

Symbol

Blower levels 1,2,3.

Presetting of desired temperature.

Selects the following functions: heating, cooling, ventilation, defrosting.

2-61

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Fig. 2-71:

2-62

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation (Fig. 2-71:) Air filter monitoring (Option. Depending on the options ordered with the machine, the described elements can be found on different positions on or near the control column).

No.

Element

191

Under pressure gauge

Air filters (left engine 1, outside)

192

Under pressure gauge

Air filters (left engine 1, inside)

193

Under pressure gauge

Air filters (right engine 2, outside)

194

Under pressure gauge

Air filters (right engine 2, inside)

Function

Symbol

Indicates the under pressure in the air filters.

Under pressure must be less than 25 inches (635 mm) water column.

Otherwise clean / replace the filter element.

Indicates the under pressure in the air filters.

Under pressure must be less than 25 inches (635 mm) water column.

Otherwise clean / replace the filter element.

Indicates the under pressure in the air filters.

Under pressure must be less than 25 inches (635 mm) water column.

Otherwise clean / replace the filter element.

Indicates the under pressure in the air filters.

Under pressure must be less than 25 inches (635 mm) water column.

Otherwise clean / replace the filter element.

2-63

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation PUTTING THE MACHINE INTO OPERATION

Reducing the operator's exposure to noise

Before daily start-up, carry out works in accordance with servicing plan T (see: Part 3 "Inspection and servicing")

All noise protection devices of the machine must be in place and fully functional when the machine is in operation. e.g. doors, flaps and cover of the engine compartments must be closed,

Increased fire and explosion hazard will exist.

Prior to your daily start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

access doors to the compartments of the radiator fans must not be left open, the cab door must be closed, the exhaust silencer must be checked for holes,

Electrical Storm Injury Prevention When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures: Mount the machine.

Dismount the machine.

If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

2-64

the screwed connections of all components fastened with bolts must be checked for tightness. Loose components tend to vibrate and to rattle, thus increasing the noise level.

Wear ear protectors when leaving the operator's cab with the engines on and running.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Refueling Refueling - Safety instructions Explosion hazard. Risk of fire.

Fuels and fuel gases are inflammable.

Avoid open flames and stop smoking.

Back-up heating (option), filling in Diesel fuel The Diesel fuel reservoir for the back-up heating system is located in the module below the operator’s cab (Fig. 2-72:).

Fill in clean Diesel fuel through the filler neck.

Fuel may cause skin injury. Wear protective gloves or use a barrier cream.

Stand working equipment on the ground.

Shut off the engines.

Fuel is to be filled in using the service station (tanklift), see the following chapter "Service station (tanklift), Fuel Tank".

Do not spill fuel and do not allow fuel to penetrate into the soil. Fuel pollutes the environment.

Wipe off spilt fuel immediately with cleaning rags or soak up with binding agents.

Fuel and cleaning material must be disposed of without polluting the environment.

Report fuel accidents immediately to the responsible person.

Check the grounding straps (equipotential bonding) at the tank lift regularly for proper fastening.

Grounding straps can remove voltages and prevent fire during Refueling only when properly fastened.

Fig. 2-72:

Diesel fuel – recommendations Diesel fuel must meet the “Caterpillar Specification for Destillate Fuel” and the latest versions of “ASTM D975” (Nr. 1-D or Nr. 2-D fuel) or “EN 590” in order to ensure optimum engine performance.

Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for the latest fuel information and for Cat fuel specification. This manual may be found on the Web at www.safety.cat.com or contact your Cat dealer.

Failures that result from the use of improper fuels are not Caterpillar factory defects. Therefore the costs of repairs would not be covered by a Caterpillar warranty.

2-65

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Service station (tanklift) The hydraulic shovel is equipped with a central service station (Fig. 2-73: resp. Fig. 2-74:) for Refueling. A service vehicle is needed for filling and/or draining of the fluids.

The service station is accessible from the ground below the uppercarriage.

Risk of injury. Always stay clear of the moving service station.

The service station is moved downwards and upwards by means of a hydraulic driven cylinder.

The up and down movement of the service station is initiated the switch (1, Fig. 2-74:). The switch is located in a control box at the hydraulic ladder (arrow).

To lower the service station:

Fig. 2-73:

Push momentary switch (1, Fig. 2-74:) downwards and hold until the service station is in its lower position.

To bring the service station in the upmost position: Push switch (1) upwards. Service station is moved upwards until it reaches its upmost position.

With switch (1) in its middle position, movement of the service station is stopped.

Fig. 2-74:

2-66

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Express couplings are provided for refilling / draining the following consumables (fluids).

Note: Connections used may vary depending on how the machine is equipped.

Pos. Fig. 2-75: 1

2 3 4 5 6

7

8 9 10

Consumable

Express coupling for

Diesel fuel for lefthand and right-hand fuel tank Cooling fluid for lefthand engine Cooling fluid for righthand engine Gearbox oil for left pump drive gearbox Gearbox oil for right pump drive gearbox Tank for engine oil interval prolongation left-hand engine.

Tank for engine oil interval prolongation left-hand engine.

Engine oil for left-hand engine Engine oil for righthand engine Hydraulic oil tank

Filling

11 Grease container 12 Swing gears 13-15 Not used

Filling and/or draining Filling and/or draining Filling and/or draining Filling and/or draining Filling and/or draining

Refilling and draining For filling in or for draining consumables / fluids, unscrew the cap of the corresponding express coupling (Fig. 2-75:).

Attach express coupling of filling hose from the service vehicle to the corresponding express coupling at the service station. Fill in or drain off consumable / fluid.

Take off filling hose and refit cap on the express coupling.

Emergency off switch The control box at the service station is equipped with an emergency off switch (Fig. 2-76:).

In case of emergency press the button. The electrical system is switched off.

Filling and/or draining Filling and/or draining Filling and/or draining Filling and/or draining Filling Filling

Fig. 2-76:

Fig. 2-75:

2-67

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Assemblies resp. Measuring device reservoirs Fuel tank BCS fuel indicator (Fig. 2-77:)

Remarks

Switch on the monitoring system by using toggle switch (23, Fig. 2-78:). The indicator light (22) comes on.

Fill in fuel using express coupling (1).

The indicator light (32) comes on when the LH fuel tank is full.

Stop filling when the fuel tank is full.

The indicator light (33) comes on when the RH fuel tank is full.

Stop filling when the fuel tank is full.

Switch off the monitoring system by using toggle switch (23), indicator light (22) is off.

Filling in fuel without using the service station Fuel can also be filled in by means of the filler neck in each fuel tank (1, Fig. 2-79:).

Unscrew cap of filler tube.

Fill in fuel through the filter sieve in the filler tube.

Do not remove the sieve!

A micro filter in the filling line is recommended.

Fig. 2-77:

Fig. 2-79:

Fig. 2-78:

2-68

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Assemblies resp. Measuring device reservoirs Pump drive gearDipstick (1, Fig. 2-80:) boxes

Remarks

Engines

Dipstick (1, Fig. 2-82:)

Engine oil tanks

Monitoring lamps (1 and 2, Fig. 2-83:)

Fill in gear oil using express couplings (4 and 5, Fig. 2-81:).

Stop filling when the oil reaches the "max" mark on the dipstick (see: Part 3, chapter "Pump drive gearbox Checking the gearbox oil level/Filling in oil").

Fill in engine oil using express couplings (8 and 9, Fig. 2-83:).

Stop filling when the oil reaches the "max" mark on the dipstick (see: chapter "Engine - engine oil level/filling in oil").

Small amounts of oil can be filled in through the filler neck (2, Fig. 2-82:) at the engine.

Fill in engine oil using express couplings (6 and 7, Fig. 2-83:).

Stop filling when monitoring lamps (1 and / or 2) lit up, (see: chapter "Engine , filling in oil").

Fig. 2-82: Fig. 2-80:

Fig. 2-83:

Fig.

2-81:

2-69

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Assemblies resp. Measuring device reservoirs

Remarks

Hydraulic oil tank

Checking the oil level: Extend the piston rods of stick and bucket cylinders halfway.

Stand working equipment on the ground (see Fig. 2-85:).

Check oil level at an oil temperature of ca. 50 °C / 122°F, with the engines stationary.

Fill in oil through express coupling (10, Fig. 2-86:) when the oil level in the inspection glass has dropped below the "min" mark.

Stop filling if the acoustic warning signal “Travel Alarm” sounds and oil reaches the "max" mark on the inspection glass (see: chapter "Hydraulic system - Checking the hydraulic oil level / Refilling hydraulic oil").

Fig. 2-84:

Fig. 2-85:

2-70

Inspection glass (1, Fig. 2-84:), sign (2. Fig. 2-84: and Fig. 2-85:)

Fig. 2-86:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Assemblies resp. Measuring device reservoirs

Remarks

Cooling system reservoir

Level indicator (4, Fig. 2-87:) Fill in cooling fluid using express couplings (2 and/or 3, Fig. 2-89:). Stop filling when the level indicator indicates maximum filling level. (see: chapter "Cooling system Cooling liquid").

Grease container – BCS display (Fig. 2-88:) BCS gives a warning if the grease container is nearly central lubricating empty. system Switch on the display system (optional) with the toggle switch (23), indicator lamp (22) comes on.

Fill in grease using express coupling (11, Fig. 2-90:).

Stop filling when the grease container is full, the indicator lamp (34) lights up.

On completion of filling, switch the display system off again with the toggle switch (23), indicator lamp (22) is off.

Fig. 2-87:

Fig. 2-89:

Fig. 2-90: Fig. 2-88:

2-71

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Switching the electrical system on and off The electrical system is switched on with keyswitch (32, Fig. 2-91:).

Insert key into key-switch and turn to the right.

If the electrical system cannot be switched on, check first whether the battery isolator switch is on (see: "Battery isolator switch, shutting off supply voltage").

Engines, emergency shut-off In an emergency, the engines can be stopped out of full load.

To do so: Depress the emergency shut-off switch (35, Fig. 2-92:). The engines are stopped. (see the chapter "Emergency shut-off function").

Switch off the electrical system with key-switch (32).

Fig. 2-92: Fig. 2-91:

2-72

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

This page intentionally left blank.

2-73

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation STARTING AND STOPPING THE ENGINES Starting the engines

Starting the left-hand engine

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Start and operate combustion engines only on well-ventilated premises. In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system and do not make any modifications to it.

All control levers and pedals must be in position "0".

Pull out all emergency shut-off switches.

Pull out both switches for the battery main switch.

Check for persons on the machine. Do not start engines until all persons have left the machine.

Activate the horn before you start the engines to give a warning signal to people around.

Start the engines one after another.

Switch on the electrical system with key-switch (32).

Warning lamps (44 – 47, Fig. 2-93:) and (54 – 57, Fig. 2-94:) light up.

The engine starts up only after the lubrication pressure has built up inside the engine.

An acoustic warning signal sounds.

Press button (41, Fig. 2-93:) to start the lefthand engine. Release button (41) as soon as the engine has fired.

Warning lamps (44 – 47) go out.

Press button (51, Fig. 2-94:) to start the righthand engine. Release button (51) as soon as the engine has fired.

Warning lamps (54 – 57) go out.

2-74

Fig. 2-93:

Starting the right-hand engine

Fig. 2-94:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Repeat the starting procedure if one of the engines does not fire. Repeat starting procedure not more often than three to four times. Do not operate the starter for more than 10 seconds.

If warning lamps (44 – 47, Fig. 2-93:) or (54 – 57, Fig. 2-94:) do not go out or when the BCS (Fig. 2-95:) displays a fault message after starting, the engine concerned must be stopped immediately.

Locate the cause of the fault and rectify before restarting the engine.

At low temperatures it is not possible to arbitrary adjust engine speed as long as the engines are cold.

This prevents the engines from too high speed.

Too high speed could seriously damage cold engines.

The engines are equipped with an automatic control for the warm-up phase. Engine electronic (ECM) controls the duration of the warm-up phase depending on the coolant, fuel and intake manifold temperatures.

At coolant temperature below -4°C (25°F) the warm-up phase can take up to ten minutes. During this warm-up phase it is impossible to increase engine speed.

BCS-display (arrow, Fig. 2-95:) shows “Engine in warm-up” during the warm-up-phase.

Engines – adjusting the speed Adjust the speed of the left-hand engine with switch (48, Fig. 2-93:).

Adjust the speed of the right-hand engine with switch (58, Fig. 2-94:).

Press the switch face without symbol the engine speed is raised up to maximum speed.

Press the switch face with the symbol the engine speed is reduced to idling speed.

Starting the engines at low temperatures If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is screwed into an electro-mechanical metering valve. When the engine is started at temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Ether is toxic and highly inflammable. Safety instructions and information concerning the handling of pressure vessels for cold-starting fluids (ether) can be found in the following chapters: "Fundamental safety instructions", "Inspection and servicing - Safety instructions", "Cold-starting fluid (ether) - Replacing the pressure vessel".

Fig. 2-95:

2-75

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Shutting off the engines

Shutting off the left-hand engine

During interruptions of the work and after the work, stand working equipment on the ground.

Do not shut off the engines before the working equipment rests on the ground.

Do not shut off the engine out of full load. The engine should be run at no more than one-half of the rated rpm for another 5 minutes to allow the lubricating oil and the cooling liquid to dissipate the combustion heat from the combustion chamber and from bearings and shafts.

Reduce the speed of the engines to idling by pressing the left side of the speed adjusting switches (48, Fig. 2-96:) and (58, Fig. 2-97:).

Press button (42, Fig. 2-96:) for the left-hand engine. The left-hand engine is stopped.

Warning lamps (44 – 47) light up.

Press button (52, Fig. 2-97:) for the right-hand engine. The right-hand engine is stopped.

Warning lamps (54 – 57) light up.

Switch off the electrical system with key-switch (32).

Warning lamps (44 – 47, Fig. 2-96:) and (54 – 57, Fig. 2-97:) go out.

The engines will be shut off with a delay of a few seconds. During this time, the current operating data are saved and the electronic units shut down.

Fig. 2-96:

Shutting off the right-hand engine

Fig. 2-97:

2-76

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation AIR CONDITIONER (OPTIONAL) Control unit (SIGMA dual) The air conditioning system (single or dual) is installed under the cab roof (Fig. 2-98:).

The illustration (Fig. 2-99:) shows a control unit for a dual air conditioner.

The control unit of a single air conditioning system contains the control elements only once.

Do not switch on the air conditioner when the backup heating is set to ”heating”.

Unit 1 Pos. Element 1 Rotary switch 2 3

Thermostat Rotary switch

Unit 2 Pos. Element 4 Rotary switch 5

Thermostat

6

Rotary switch

Function selects the intensity level of the blower (3 levels) sets the desired temperature inside the cab selects the desired control function (heating, cooling, ventilation, defrosting)

Fig. 2-98:

Function selects the intensity level of the blower (3 levels) sets the desired temperature inside the cab selects the desired control function (heating, cooling, ventilation, defrosting) Fig. 2-99:

2-77

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Back-up heating operator’s cab (optional) The back-up heating for the operator’s cab is located in the module below the operator’ cab (Fig. 2-100:). The heating consists of one or two heating units (1) and the Diesel fuel reservoir (2).

Switch on the back-up heating using switch (142, Fig. 2-101:). The pilot lamp above switch (142) lights up.

The heating system has an automatic regulation.

Do not switch on the back-up heating when the air conditioner is set to ”cooling”.

Fig. 2-100:

Fig. 2-101:

2-78

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Back-up heating (optional)

Control unit

The back-up heating is located in the module below the operator’ cab (Fig. 2-102:).

The heating system uses the engine cooling fluid.

Therefore full heating power is available after the engines reach their operating temperature.

Before switching on the blower, turn the valves (arrow, Fig. 2-102:) into direction of flow.

The back-up heating control elements are located at the control column unit (Fig. 2-104:).

(Fig. 2-104:):

Do not switch on the back-up heating when the air conditioner is set to ”cooling”.

Fig. 2-104:

Pos. Element

Fig. 2-102:

Function

1

Indicator lamp heating ON

2

Indicator lamp blower ON

3

Indicator lamp heating

4

Indicator lamp cooling

5

Switch

heating ON

6

Switch

blower ON

7

Indicator lamp blower level 3

8

Indicator lamp blower level 2

9

Indicator lamp blower level 1

Fig. 2-103:

2-79

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation MAXIMUM MACHINE INCLINATIONS, INFORMATION The machine must not exceed the inclinations indicated for working, travelling and servicing operations and during downtimes. The values specified in the tables below (next page) are valid for all types of working equipment.

If the maximum inclinations are exceeded, there is a risk of severe damage to the engines due to insufficient lubrication. In the event of extreme inclinations the machine can topple over.

The working performance of the machine is especially economical when the machine stands on firm and level ground.

A loss of performance and higher wear must be accepted when the machine works in an inclined position, e.g. when building a ramp or when slewing uphill.

For the building of ramps, the values specified in the table "Maximum inclinations during working operations" may be exceeded. In this case, however, a reduced service life of the components can be expected.

During downtimes, the machine must be parked in such a way that its inclination does not exceed 3° / 5.2 %.

Instruction sign “Maximum inclination” This sign (Fig. 2-105) is attached inside the operators cab.

Observe all the warning and instruction signs attached to the machine.

Keep the signs legible and clean.

Replace signs immediately if they have become illegible.

Fig. 2-105

2-80

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

Maximum machine inclinations during working operations:

forward inclination

rearward inclination

side inclination

5° / 8.7%

5° / 8.7%

5° / 8.7%

Maximum machine inclinations during travelling: Type

Engine

forward deg / %

rearward deg / %

side deg / %

6090

QSK60 20° / 36.4% 20° / 36.4% 20° / 36.4%

Maximum machine inclinations during maintenance operations:

forward inclination

rearward inclination

0° - 2° / 3.4%

0° - 2° / 3.4%

side inclination 0° - 2° / 3.4%

2-81

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation TRAVELLING, SAFETY INSTRUCTIONS Have the attachment raised only so far as to permit the machine to be driven under overhead power lines without any risk.

Close the cab door.

If the machine is fitted with a safety belt for the operator, fasten the belt.

If the superstructure is turned by more than 90° from the BASIC POSITION, the hydraulic shovel travels in the opposite direction to that selected.

If the position of the superstructure in relation to the undercarriage is not exactly known, touch the accelerator lightly to see which direction the machine takes, before initiating the full travelling movement.

Never drive across slopes.

Take the utmost care on slippery, greasy ground.

The engines must be at operating temperature before being subjected to full load.

If the machine is to be driven a longer distance, the superstructure must be secured against turning by means of the superstructure holding brake.

Sound the horn to warn persons in the immediate vicinity before starting travelling.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter).

Fig. 2-106:

2-82

Running-in specifications for components of the crawler tracks: Prior to initial commissioning and/or after repair work, run in the idlers, track rollers and support rollers as follow: Raise the working equipment (Fig. 2-106:).

Drive the hydraulic shovel in reverse approx. 50 m (164 ft).

Drive the hydraulic shovel in forwards approx. 50 m (164 ft).

Stop the hydraulic shovel.

Measure the temperature at each idler, track roller and support roller with an infrared thermometer. At a temperature of approx. 100° C (212°F) wait for idlers, track rollers and support rollers to cool down.

Repeat this running-in procedure up to 10 times.

Check all idlers, track rollers and support rollers for leaks.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation TRAVELLING Superstructure basic position Travel direction and sense of actuation of pedals (112 and 113, Fig. 2-108:) are identical only when the hydraulic shovel is in its BASIC POSITION (Fig. 2-107:).

Travelling forwards/backwards Travelling forwards: depress pedals (112 and 113) forwards.

The hydraulic shovel travels in the direction of the idler (2, Fig. 2-107:).

Travelling backwards: depress pedals (112 and 113, Fig. 2-108:) backwards.

The hydraulic shovel travels in the direction of the drive sprocket (4, Fig. 2-107:).

During travelling, an acoustic warning signal sounds (Travel Alarm).

Fig. 2-107:

If the superstructure is swung out of its basic position by more than 90° (Fig. 2-109:), the hydraulic shovel moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-108:) are depressed.

Fig. 2-109:

The pedals return automatically to their "0" positions when released.

Reverse the hydraulic shovel only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

Do not travel across slopes.

When travelling uphill or downhill, the travel drive must always be at the rear.

Travel only in the basic position of the hydraulic shovel and only forwards.

Be extremely careful on slippery and greasy ground.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter).

Fig. 2-108:

If the operator is not completely sure of the position of the superstructure with regard to the undercarriage, pedals (112 and 113) should be depressed slightly in order to find out which way the hydraulic shovel moves before initiating the full travelling movement.

All instructions with regard to travelling speed regulation and travel direction control are applicable only as long as the crawler tracks have sufficient grip and do not slip.

2-83

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Regulating the travelling speed Travelling on level ground Regulate the travelling speed with pedals (112 and 113, Fig. 2-110:) and Switch (72, Fig. 2-111:) to the left (slow gear).

All forward/reverse travel movements are possible with this gear.

Switch (72, Fig. 2-111:) to the right (fast gear).

The hydraulic shovel can be driven only parallel forwards with this fast gear.

The travel gearbox changes automatically into st the 1 gear as soon as another travelling function (e.g. reversing, cornering) is initiated.

Change speed range only when the hydraulic shovel is stationary.

Press engine speed regulator switches (48 and 58) to the left (full-throttled position).

Fig. 2-111:

Travelling uphill and downhill Read and observe the "Travelling Safety instructions" chapter.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter).

Depress pedals (112 and 113, Fig. 2-110:) fully to the limit stop.

Regulate the travel speed only with the engines speed control.

When travelling downhill, the travel retarder valve acts as a speed limiter.

The travel retarder valve works correctly if pedals (112 and 113) are fully depressed down to the limit stop.

Fig. 2-110:

2-84

Should the travelling speed become too high when travelling downhill release pedals (112 and 113) to stop the hydraulic shovel.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Cornering To take a right-hand corner forwards depress only pedal(112, Fig. 2-112:) forwards.

To take a left-hand corner forwards depress only pedal (113) forwards.

Turning To turn to the right depress pedal (112) forwards and pedal (113) backwards.

To turn to the left depress pedal (113) forwards and pedal (112) backwards.

Never use the working equipment to raise one side of the undercarriage and then turn the undercarriage by initiating the swinging and/or the travelling function.

This way of working is contrary to the hydraulic shovel 's designated use.

There is a risk of accident. Moreover, the tracks, swing gear, roller bearing swing ring, backhoe or bucket back-wall and the front part of the bucket are subjected to inadmissibly high stresses.

Fig. 2-113:

Fig. 2-112:

Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-113:).

Cornering to the left: forwards from pos. 1 to pos. 2 backwards from pos. 2 to pos. 3 forwards from pos. 3 to pos. 4 The same procedure should be adopted if the hydraulic shovel is to be driven out of depressions (Fig. 2-114:):

Cornering to the left Cornering to the right

Fig. 2-114:

from pos. 1 to pos. 2 from pos. 2 to pos. 3

2-85

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Travelling over long distances Travel only forwards with the hydraulic shovel in its basic position.

Travelling backwards over longer distances could damage parts of the undercarriage.

Read and observe the "Travelling – Safety instructions" chapter.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter).

When travelling, pay attention to sufficient headroom, e. g. under cable bridges or high-tension cables.

Keep the loading or the backhoe bucket close to the ground. For a more uniform loading of the tracks, the equipment must, however, be kept at a steep angle (Fig. 2-115:).

Fig. 2-115:

2-86

Loading bucket equipment (Fig. 2-115:): Fully extend boom cylinders (1) and retract bucket cylinders (2) and retract stick cylinders (3) to such an extent as to reach the position of the equipment (Fig. 2-115:).

Lower the equipment when travelling underneath obstacles.

If the equipment position must be changed: stop the hydraulic shovel, change the position, continue to travel.

After travelling for 15 minutes without interruption, stop the hydraulic shovel and check the temperature of the track rollers.

If the temperature does not exceed approx. 100° C (212°F): continue travelling.

In case of higher temperatures: Stop travelling. Resume travelling only after the track rollers have cooled down to approx. 40° C (104°F).

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Superstructure holding brake

Track parking brake

The hydraulic shovel is equipped with six superstructure holding brakes which are integrated in the swing gearboxes. The superstructure holding brakes lock the superstructure with respect to the undercarriage.

The gearbox brakes are holding brakes.

Do not press the button unless the superstructure is stationary. Do not use this button while the superstructure is still in motion. Risk of damage to the brakes and the swing gears.

Apply the holding brake: when the hydraulic shovel is parked,

The hydraulic shovel is equipped with four travelling gear brakes which are integrated in the travel drives.

The travelling gear brakes are parking brakes.

They protect the hydraulic shovel from rolling forwards or backwards. When the machine is parked, travel brakes are activated automatically. The brakes are deactivated during operation of the machine.

Note: As travel brakes are deactivated, machine could slightly move in direction of excavating during operation. Whenever loading operation is interrupted, stand working equipment on the ground. This avoids slight movement of the machine and possible consequential damage of lowered ladder, in case ignition remains engaged.

when travelling longer distances.

To apply the holding brakes, press switch (61, Fig. 2-116:).

Fig. 2-116: Fig. 2-117:

For Service and Maintenance purposes the travelling gear brakes can also be applied with switch (63, Fig. 2-117:).

Actuate this switch only when the hydraulic shovel is stationary. Do not use this switch while the hydraulic shovel is still in motion. Risk of damage to the brakes and the travel gearboxes.

Press the switch face with the symbol (63): The parking brake is applied permanently. The hydraulic shovel cannot be moved.

For more detailed information refer to the Service Manual, chapters eight and nine.

2-87

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation TRANSPORTING THE MACHINE Transport - Safety instructions The machine must be loaded and transported only after all safety regulations have been observed and complied with.

Entrust loading and transporting of the machine to a company experienced in the transport of heavy equipment.

The responsibility for loading and transporting lies with the transport company or their representative.

Remove oil, grease, soil, mud, snow, ice and other materials from the hydraulic shovel's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Secure the transport vehicle against rolling away.

Use only tying equipment of sufficient strength (the weights and dimensions of the hydraulic shovel are set out in the "Product Specification Sheet").

Transport The dimensions and the service weight of the fully assembled hydraulic shovel do not allow the hydraulic shovel to be transported in a disassembled state on a low-bed trailer over public roads.

Therefore, the components and modules must be dismantled beforehand.

Suspensions points as well as the center of gravity are marked on the modules (see example, Fig. 2-118:).

Dimensions and weights of the machines modules can be found in the annex, chapter “Product Specification Sheet” as well as in the “Service Manual”.

Detailed instructions for disassembling and assembling the machine can be found in the Service Manual.

Fig. 2-118:

2-88

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation WORKING OPERATION - SAFETY INSTRUCTIONS Read the sections "Fundamental safety instructions" and "Operation, safety instructions" carefully and observe the instructions given in them.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter.

Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life!

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements.

Sound the horn to warn persons in the immediate vicinity before starting work.

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk.

Ensure that the attachment has adequate clearance below overhead power lines and structures.

Trenches and working faces may give way. Keep well clear of them.

As travel brakes are deactivated, machine could slightly move in direction of excavating during operation.

Whenever loading operation is interrupted, stand working equipment on the ground. This avoids slight movement of the machine and possible consequential damage of lowered ladder, in case ignition remains engaged.

Do not operate the machine, when several track rollers or support rollers have been removed; when one or several swing gearboxes have failed or been removed; when one or several teeth on the backhoe or on the shovel are worn or missing; when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by CGM HMS as "abusive utilization".

CGM HMS refuses to assume the guarantee for damage and consequential damage caused by an abusive utilization of the machine.

Running-in instructions for hydraulic cylinders Compression of an oil/air compound in a hydraulic cylinder may result in detonations which might damage pistons and sealing rings.

Prior to initial commissioning and/or after repairs, run in the hydraulic cylinders as follows: Start up the engines and run at low speed.

The pressure-limiting valve in the hydraulic system must not respond In the first two working cycles, retract and extend the pistons of the hydraulic cylinders to max. ½ to ¾ (not to the limit stop).

Never change direction suddenly. The waiting time between changes of direction must be at least 4 seconds.

In the next eight working cycles, retract and extend the pistons of the hydraulic cylinders to the limit stop. The waiting time between changes of direction must be at least 4 seconds.

When all hydraulic cylinders have been run in, the hydraulic shovel can operate at a higher engine speed.

Warming up the hydraulic system At low temperatures, bring the engines down to moderate speed, then activate all hydraulic functions for about 10 minutes (bring to service temperature). For further instructions, see section "Lubricants".

If the BCS indicates problems with the cooling liquid temperature, engine oil pressure, coolant level, alternator or hydraulic oil filter control (with hydraulic oil at service temperature) light up: Lower the working equipment to the ground and shut off engines.

2-89

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Avoid extreme positions of the attachment Parts of the attachment may damage the machine if they are moved into extreme positions (see illustrations Fig. 2-119 - Fig. 2-120).

Work carefully, avoiding extreme positions of this kind.

Fig. 2-119

Fig. 2-120

2-90

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation WORKING OPERATION Before starting work Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded equipment for abt.

5 minutes.

This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts.

Warming up: At low outside temperatures it is necessary to run the hydraulic system up to operating temperature.

The temperatures at which warming up is necessary depend on the type of hydraulic oil used; see also "Oils for hydraulic systems".

Run the diesel engines at ca. 2/3 full speed and start to perform no-load working movements for abt. 10 minutes with the hydraulic shovel.

Activating the electronic shovel control The shovel can execute working movements only after the electronic shovel control (servo-control) has been activated.

The servo-control block is enabled by switch (71, Fig. 2-121:).

At the beginning of the work, the electronic shovel control (servo-control) is activated by a contact in the operator's seat (105): Electronic shovel control ON The operator is sitting on his seat.

Electronic shovel control is OFF The operator's seat is empty.

Note: During operation it is absolutely necessary that the operator keeps sitting on his seat.

Otherwise working movements may be interrupted suddenly, risk of damaging the holding brakes and the gearboxes.

Fig. 2-121:

2-91

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Swinging the superstructure Swinging of the superstructure is possible only when the superstructure holding brake is released and the hydraulic shovel operator is sitting on his seat and the hydraulic ladder is raised and the Service station (tanklift) is raised and the BCS swing circuit test was successful.

To swing the superstructure to the right move control lever to the right (115, Fig. 2-122:).

To swing the superstructure to the left move control lever to the left (115).

After releasing, the control lever returns automatically to position "0".

Releasing the control lever (115) is not sufficient to brake the superstructure automatically. In order to brake the superstructure, the control lever must be moved in the direction opposite the swinging movement (reversing).

Fig. 2-122:

Braking the superstructure The superstructure can only be braked by moving control lever (115) in the direction opposite the swinging movement (reversing).

The superstructure does not stop automatically by simply releasing the swing control lever (115).

To brake the superstructure, the swing control lever (115) must be moved in opposite direction.

In an emergency, activate the holding brake by pressing switch (61, Fig. 2-123:).

Fig. 2-123:

2-92

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Working operations When released, all control levers for working operation return automatically to position "0".

Level a surface only in the bucket's digging direction. Never "beat" or "sweep" with the bucket.

Do not level off a surface with the front shell of the bucket open.

Close bucket completely before beginning to dig.

Sound the horn to warn persons in the immediate vicinity before starting work.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter).

Extending and retracting the stick

Fig. 2-124:

To extend the stick: push control lever (115, Fig. 2-124:) forwards.

To retract the stick: pull control lever (115) backwards.

To retract the stick with pressure: (only on bottom-dump bucket equipment) depress button (102) and push control lever (115) backwards.

Opening and closing the bottom-dump bucket To open the bucket: press pedal (111, Fig. 2-124:) forwards or turn thumbwheel (118) backwards.

To close the bucket: press pedal (111) backwards or turn thumbwheel (118) backwards.

Pressing pedal (111) overrides turning the thumbwheel (118).

Raising and lowering the boom To raise the boom: pull control lever (116, Fig. 2-125:) backwards.

To lower the boom: push control lever (116) forwards.

To lower the boom with pressure: depress button (103) and push control lever (116) forwards.

Fig. 2-125:

Filling and emptying the bucket To fill/tip back the bucket: shift control lever (116, Fig. 2-125:) to the left.

To empty the bucket by dumping/tipping: shift control lever (116) to the right.

2-93

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Emergency lowering of the equipment In case of a failing out of the electronic hydraulic shovel control and / or the engines, lower the equipment as follows: Sit down on the operator’s seat. Switch inside seat (105, Fig. 2-126:) is activated then.

Switch on the electric system with switch (32).

Operate switch (71), hydraulic servo system is activated then.

Operate switch (65, Fig. 2-127:) and hold.

Push control lever (116) forwards to lower the working equipment to ground.

Contact the responsible service personnel as soon as possible.

Fig. 2-126:

Fig. 2-127:

2-94

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation After daily operation Parking the machine Park the machine on level and stable ground. This is particularly important in winter to avoid freezing of the tracks.

Stand the working equipment on the ground.

Shut off the engines.

Shift both control levers into all directions to depressurize the hydraulic cylinders.

Withdraw the key from the electrical system key-switch.

Close the cab window.

Lock the cab door and all lockable hatches and covers on the machine.

Clean the machine of coarse dirt as well as of combustible and easily flammable substances, if possible with a stream jet (rubber parts and electric components with compressed air - refer to information label). Otherwise, the fire and explosion hazard will exist.

Fill up the fuel tanks.

Inspect the engines, the hydraulic system, the track rollers, support rollers, idlers and gearboxes visually for leaks.

Escaping oil pollutes the environment.

Repair leaks immediately (or have them repaired).

Report oil accidents to the responsible person.

Check the superstructure, undercarriage and the working equipment for damage and all steel components for cracks or fractures.

Report detected damage immediately to the responsible person.

Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler.

2-95

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS Personnel Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM HMS. The operating manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Personal protective gear and working clothes Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear your personal protective equipment: a safety helmet, safety goggles, safety footwear and gloves.

Safety line on boom When carrying out work on the working equipment, for example on the boom (Fig. 2-128:), use a fall arrester. Falling down from great height may cause severe injuries. Connect the fall arrester to the safety line on the boom (arrow, Fig. 2-128:).

Tools and auxiliaries Tools, hoists, slings, trestles and other devices must be in a reliable, safe state.

Metal splinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Use only the steps, platforms and handrails when climbing onto or off the machine.

Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Carry out work on the attachment only if the machine is secured as described in the "Securing the machine" section.

Selecting the attachments

Fig. 2-128:

The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by CGM HMS for this type of machine.

Never install and commission other equipment and component combinations without CGM HMS first having inspected and approved the project in writing.

Protective roof against falling objects The machine is equipped with an integrated cabprotection roof (FOPS).

2-96

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Main control valves – attach/remove the handrail

Securing the machine

The handrail as well as the safety line fitted to the attachment ensure your safety when working on the main control valve block of the hydraulic system. If you do not use the safety equipment provided you may fall down and seriously hurt yourself.

Before starting work at the main control valves: Bring the surface of the walkway (1, Fig. 129) to a horizontal position by moving the attachment. The GET must hit the ground.

Put on your harness (part of PPE).

Lift the handrail (2) from its storage position (3) and fit it to the walkway (1).

Connect the safety line of your harness to the safety line on the attachment.

Carry out your work.

After completing your work detach the handrail (2) from the walkway (1), put the handrail into its storage position (3) and secure it with the wingscrews.

The machine must not be started by unauthorized persons.

Therefore, secure the machine.

Observe the accident prevention regulations.

Depressurize pipeline systems, on which work is to be carried out, by appropriate measures.

Protective shrouds of moving machine parts may only be opened or removed when the drive unit is stationary and protected against inadvertent starting.

Before carrying out fitting works, the machine and the equipment must be protected against inadvertent starting by placing chocks under the tracks and by standing the working equipment on the ground.

Hydraulic and lubricating systems: Close all open bores, pipe and hose connections with pressureresistant plugs.

Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of non re-usable oils without polluting the environment.

All components of CGM HMS machines have been carefully purpose-coordinated. Trouble-free operation and a long service life can only be achieved with original CGM HMS spare parts.

Respect the sequence of working operations when fitting or replacing the attachments. The sequence has been determined and tested by qualified experts.

Secure the machine as described below: before carrying out any fitting and modification work on the working equipment,

Parts of the machine may be damaged when moving the attachment with the handrail attached.

After completing work at the main control valves put handrail (2) into its storage position (3) and secure it using the wingscrews.

Risk of injury

before carrying out any servicing and repair work on the machine.

Park the machine on level and stable ground.

Stand the working equipment on the ground.

Shut off the engines.

Depressurize the hydraulic system.

Withdraw the key from the key-switch.

Fig. 2-129:

2-97

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) Use “GLEITMO 815” anti-corrosive agent only.

Other agents are not approved by CGM HMS. All pins and bearings (bushings and hubs) of the working equipment or in equipment components must be treated “GLEITMO 815” anti-corrosive agent before fitting.

“GLEITMO 815” permits easy fitting and dismantling, protects against rust, oxidation and similar wear, prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminum and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden.

“GLEITMO 815” is available from CGM HMS Spare-Parts-Service, part-no. 2764305.

2-98

Application of "GLEITMO 815" Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel.

Rust patches must be thoroughly removed, if any.

All parts must present a dry, bright metal surface.

Apply a thin layer of "GLEITMO 815" on pins and all bearings using a brush or a spray can.

Pin shafts and bearings must be completely covered by the protective layer.

If the protective layer of a pin already treated with "GLEITMO 815" is damaged, these areas must be touched up before fitting the part.

Fitting and securing of pins.

If the pin is too heavy to be fitted manually, apply "GLEITMO 815" at first only on abt. a quarter of the pin's length.

Then position pin by means of a lifting gear ready for fitting.

Apply "GLEITMO 815" on the remaining length of pin shaft, fit pin and secure.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation ON-BOARD CRANE (OPTIONAL) The on-board crane is designed for lifting heavy parts only.

Do not lift persons.

Observe all national directives as well as specific regulations relevant to crane operation.

On-board crane, monitoring, warning and control elements (Fig. 2-130:)

Personnel Crane work may be carried out only by operators who have the necessary know-how and the permission to operate cranes.

If such know-how or such permission is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM HMS. Incorrect operation of the crane may give rise to life-threatening situations.

Fig. 2-130:

Pos. Element 1 Monitoring lamp 2 Warning lamp 3 Warning lamp 4 Monitoring lamp 5 Key-switch 6 7

10 11 12

Button Monitoring lamp Knob Monitoring lamp Warning lamp Button Button

21

Control lever

22 23 24

Control lever Control lever Control lever

8 9

Function Alternator

Engine oil pressure Engine temperature Air filter Electrical system ON/OFF Start engine of drive unit Preheating system (option) Engine speed variation Crane in operation Malfunction EMERGENCY STOP Emergency lowering of winch Extending and retracting of boom extension Folding the boom Swinging the boom Winch up / down

2-99

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation On-board crane, putting into operation Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

Do not exceed the maximum lifting capacity (observe the lift capacity chart attached to the boom).

On-board crane, drive unit The drive unit (Fig. 2-131:) supplies the crane with hydraulic power. So the on-board crane is functional without the shovel’s engines running.

The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

The drive unit is equipped with an Emergency OFF push switch (arrow, Fig. 2-131:).

In case of emergency push the switch, the engine of the drive unit comes to standstill.

Prior to each deployment: Carry out all maintenance work as listed in the “Inspection and Servicing Plans “T” and “W”.

To start the drive unit: Turn key-switch (5, Fig. 2-130:) to position ON. Press button (6), engine will start.

The crane control unit is equipped with an Emergency OFF push switch (11).

In case of emergency push the switch, the engine of the drive unit comes to standstill.

After finishing work block the boom, then stop the engine (see chapter “On-board crane, - blocking the boom in position of rest”).

Fig. 2-131:

2-100

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation On-Board crane, – blocking the boom in position of rest Movements and accelerations produced by working operations of the machine can cause damage to the swing drive of the on-board crane, if the crane is not blocked.

The hydraulic on-board crane must therefore be blocked in its position of rest.

Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

To block the boom: Retract the boom completely.

Swing the boom in the direction of the blocking device (Fig. 2-132:) and lower it.

Withdraw the cotter pin at the tip of the boom.

Extend the boom carefully until the tip engages the blocking device (arrow, Fig. 2-132:).

Reinsert and lock the the cotter pin.

On-board crane, checking Extract from the inspection and testing regulations The on-board crane is approved in accordance with the Accident Prevention Regulations for Cranes (BGV D6, applicable only in Germany).

The on-board crane must be inspected regularly in accordance with the regulations in force in the country of use.

The inspections must be requested by the user of the crane. The expert or specialist entrusted with the inspection can be appointed at the user's discretion.

The user must ensure, however, that the appointed person meets the requirements.

The user is obliged to make available all documents required for the inspection and to ensure the smooth running of the inspection. He is furthermore obliged to provide, if required, crane operators and auxiliary personnel and the required test loads.

The result of the inspection is to be documented in an inspection record signed by the inspector.

The inspection record serves as proof on the part of the user that the inspections have been carried out. The inspection record must contain all data required for crane identification and for the performance of further regular inspections.

Fig. 2-132:

2-101

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation Monitoring cameras This hydraulic shovel can be equipped with two monitoring cameras: one mounted on the counterweight, looking backwards; one mounted on the hydraulic oil cooler module, looking to the right.

The two cameras and the belonging LCD-display are operational after the electrical system of the machine has been activated with the key operated switch.

The LCD-display is mounted near the control column (arrow, Fig. 2-133).

To switch the LCD-display on, press key “PWR” on the display housing.

Both cameras transmit their images to the same LCD-display. For toggling between the camera images being displayed, press the key in the left joystick (arrow, Fig. 2-134:).

Additional information can be found in the manuals of the camera manufacturer (see Volume 5 of the Technical Documentation "Components").

Fig. 2-133:

Fig. 2-134:

2-102

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

2-103

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Operation

This page intentionally left blank.

2-104

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing 3 INSPECTION AND SERVICING Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

3-1

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing

This page intentionally left blank.

3-2

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing INSPECTION AND SERVICING SAFETY INSTRUCTIONS Operating manual No inspection and servicing work must be carried out until the operating manual has been read and understood.

Pay special attention to: "Fundamental safety instructions" and all warnings and safety instructions attached to the machine.

The operating manual lists all jobs to be done. The descriptions of job sequences, however, provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Securing the machine Carry out servicing work only if the machine is secured as described in the section "Securing the machine".

Climbing onto and off the machine Use only the ladders, steps, platforms and handrails provided when climbing onto or off the machine.

Always keep ladders, steps, platforms and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately.

Always face the machine when climbing on and off.

Always maintain a three point contact with the steps and the grab handles.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

The necessary know-how can be acquired in a several day's instruction, e.g. by an Caterpillar Global Mining Hydraulic Mining Shovels (CGM HMS) mechanic or by attending a CGM HMS training course.

Personal protective equipment and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging / supporting devices to prevent them from moving, slipping or falling inadvertently.

Checking the state of tools Use only fully functional, reliable tools.

Select the right tool for the job.

Wrenches of the wrong size, for example, may slip and cause injury.

Cleaning jobs Prior to commencing work, clean your working area, if necessary and possible, with a stream jet (rubber parts and electric components with compressed air - refer to information label).

Exhaust pipes and turbo chargers in the engine compartments are covered with special heat insulating material. This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

Use only lint-free cleaning rags when working on the hydraulic system or the engines.

Cleaning agents and solvents may give off harmful, readily flammable vapors. Never work with such agents except on well ventilated premises; never inhale the vapors and never smoke.

Prevent solvents and cleaning agents from coming into contact with your skin.

Wear gloves.

Observe the instructions on the packaging.

3-3

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Handling flammable liquids

Visible oil losses

When handling flammable liquids: never smoke,

Have any visible leakage repaired immediately.

Escaping oil is an environmental hazard.

Soak up any oil that has escaped with a binding agent.

Sweep up binding agent and dispose of it separately from other waste.

keep away from unshielded light sources and naked flames, Fuel and other consumables often have low flash points and are readily ignited. Never attempt to extinguish burning liquids with water.

Use: dry powder, carbon dioxide or foam extinguishers.

Water used for extinguishing purposes would vaporize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing hazards.

Notify the fire brigade.

Fastening and securing elements Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

Spare parts Use only the original spare parts of CGM HMS. They are the only ones to fulfilll the technical specifications of the machine.

Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Never set foot within reach of the emerging oil jet.

Avoid contact with the skin. Wear gloves and firm protective clothing.

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with warm soapy water and apply a barrier cream. Never use fuels or solvents for cleaning the skin.

If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

3-4

Relieving residual pressure in the hydraulic system Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with its attachments supported on the ground and its driving motors switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, the system must be depressurized: (do not leave the operator's seat) Stand working equipment on the ground, Shut off the engines, Move all control levers and pedals repeatedly into all ndirections.

Screwed connections, piping, hydraulic hoses Repair any leakage in the piping and hose system immediately.

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

If oil has penetrated into the skin, consult a doctor immediately.

Never repair damaged piping; always replace them.

Replace hydraulic hoses immediately on detecting any damage or moist areas.

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Non-polluting disposal

Engine exhaust gases

Dispose of oils, greases, cooling liquids, detergents, solvents and oil-containing components, such as filters, cleaning rags, replaced wearing parts and unusable machine parts, without polluting the environment and separately from other waste.

Do not dispose of these substances together with household wastes.

Fill these substances into the containers provided for such purposes.

Like any other oil, also bio-degradable, "environmental-friendly" hydraulic oil must be disposed of separately.

Do not allow oils and oily wastes to penetrate into the soil or into water. They are an environmental hazard.

Used pressure vessels for cold-starting fluid (ether) must be disposed of properly. Contact the supplier with regard to disposal / return of the vessels.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.

Do not keep them on the machine.

Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside; Do not work on the exhaust system an do not make any modifications to it.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Do not damage or open the vessels.

Do not expose the vessels to great heat or direct sunlight.

Do not dispose of in fire.

Keep the vessels in a place inaccessible to unauthorized persons.

Dispose of the vessels properly.

Seals After replacing parts or after opening housings replace seals. Always use new seals and gaskets.

Clean sealing faces prior to assembly.

Individual spares may contain asbestos. Such spares or their packaging are marked with: Never process spares containing asbestos mechanically. Inhaling asbestos dust is a health hazard.

Clean sealing faces prior to assembly.

Handling batteries Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Batteries give off explosive gases.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapors.

Wear gloves, firm protective clothing and goggles / face protection shield when handling batteries.

If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Before working on the electrical system Before performing work on the electrical system where tools, spare parts, etc. can come into contact with electrical conductors or contacts, the battery must be disconnected.

Disconnect first the negative and then the positive terminal.

After the work: Reconnect first the positive and then the negative terminal.

3-5

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Handling of cold-starting fluid (ether)

Filters

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapors of escaping cold-starting fluid.

In contact with the skin, ether can cause frostbites and irritations. Avoid skin contact.

Wear suitable protective gloves and goggles.

Even apparently empty pressure vessels can still contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.

Do not keep them on the machine.

Replace / clean all filter elements or filter cartridges within the specified periods.

All filters are coordinated carefully with the equipment. Original CGM HMS parts must be used to ensure smooth running and a long service life of the engine and the hydraulic units.

Do not damage or open the vessels.

Do not expose the vessels to great heat or direct sunlight.

Do not dispose of in fire.

Keep the vessels in a place inaccessible to unauthorized persons.

Dispose of the vessels properly.

Selecting oils and greases Use the recommended qualities only, matching viscosities with the temperature level.

3-6

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

After servicing To prevent corrosion, coat all bright metal parts with a grease film.

On completing work, re-install all protective devices.

Never start up the drive motors while work is being done on the machine.

Carry out performance tests with the machine.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Avoid parking the hydraulic shovel in places where combustible substances such as coal dust or tar are present.

Place suitable fire guarding (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

open or smoldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

3-7

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing

This page intentionally left blank.

3-8

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing INSPECTION AND SERVICING PLANS - INSTRUCTIONS Intervals The inspection and servicing plan lists all jobs which have to be done on the machine at regular intervals.

The individual inspection and servicing plans are marked with letters providing a link between the operating hours (OH) recorded by the hours-run meter of the machine and the inspection and servicing plans.

Plan V N

Do all jobs .... ...once prior to initial commissioning. ...after initial commissioning and during the running-in period (up to 100 OH).

T ...every 10 OH or every working shift 2) 2 W …every 60 OH or weekly .

A …after every 250 OH. B …after every 500 OH. C …after every 1000 OH. D …after every 5000 OH. E …after every 10000 OH. OH = Bh = Operating hours

Change of engine oil The intervals stated for changing the engine oil apply to fuels with a sulphur content of ≤ 0.5% and a permanent ambient temperature down to –10° C (14 °F).

In case of higher sulphur content and/or a permanent ambient temperature of below –10° C (14 °F), shorter intervals are required.

If the engine oil change intervals are not reached within 6 months, the oil must be changed at least after 6 months.

2

Air-intake system The air filter must be serviced only if the BCS so indicates. Replace the filter elements after one year at the latest.

Oils / Greases For the specification of oils and greases to be used refer to the „LUBRICANTS / CONSUMABLES“ section.

The numerals mentioned in the “Oil / Grease” column in the inspection and servicing plans have the following meaning: I Oils for combustion engines and compressors II Oils for hydraulic systems IIIa, b, c Oils for gearboxes V Greases for bearings and swing rings

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

Components The maintenance intervals for components, e.g. engine and gearbox, are listed in the following CGM HMS maintenance schedules.

It is possible that the manufacturer’s documentation for these components states intervals deviating from the above-mentioned intervals.

In such case, only the maintenance intervals specified by CGM HMS shall apply.

Whichever comes first.

3-9

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing

This page intentionally left blank.

3-10

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan V Plan V – Once prior to initial commissioning Location

Servicing work

Engine Engine oil reservoir Cooling system Cooling liquid level Electrical system Battery

Check oil level Check oil level

Lighting Monitoring, warning and control elements

BCS Swing system Hydraulic system

Hydraulic oil reservoir Hydraulic cylinders Pump drive gearbox - Pre-chambers expansion reservoir Swing gearbox Travel gearbox - Pre-chambers - Brake chambers Swing ring Internal gearing Undercarriage Track roller Support roller Track tensioner Idler

3

Page 1 of 2 Quantity/ No. 2 2

Check

2

Check liquid level (not applicable when maintenance-free batteries build in) Check operation Check function of monitoring, warning and control elements Check emergency OFF function Check function Perform the „Slew brake test“ (see chapter „Service – Slew brake test“) Check function of working and travelling movement Check pressure (see Service Manual) Check oil level Vent (see chapter “Venting hydraulic system“) Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level

8

Check grease filling Check for leaks and free movement 3 Check grease filling, fill with grease Check for leaks and free movement 3 Check grease filling, fill with grease Check pressure (see Service Manual) Check for leaks and free movement 3 Check grease filling, fill with grease

1 2 2 6 2 2x2 2x2 1 2x7 2x2 2 2

Machines with undercarriage greasing system

3-11

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan V – once prior to initial commissioning Location

Central lubricating system Grease container Greasing and pause cycles Level control Service – Station (tanklift) - Arm bearing grease nipple - Hydr. cylinder bearing grease nipple Air conditioner (optional) Compressor Hydraulic ladder On-board crane (optional) - Fastening bolts - Bearings - Joint (column / boom) - Cylinder bearing - Swing ring Hydraulic oil reservoir Crane drive engine

- Battery Escape ladder near operator’s cab - Locking device - Ladder Emergency escape device / seat (optional) - Harness holding device on cab roof Fall arrest static line on working equipment (optional) All lines, fittings and connections All articulated joints and hinges

3-12

Servicing work

Check filling level Check setting Check function Check operation Lubricate Lubricate Check oil level Lubricate Check for tightness Lubricate Lubricate Lubricate Grease Check oil level (see “On-Board Crane“ operating instructions) Check oil level (see “Crane drive Engine“ operating instructions) Check liquid level Check function Check function Check free movement Check completeness and condition Check for tightness Check condition Check function Inspect visually for leaks, wearing marks Grease

Page 2 of 2 Quantity/ No. 1

1 1 2

1 16 4 2 5 1 1 1

2

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan N Plan N – After initial commissioning and during the running-in period (up to 100 OH) Page 1 of 2 Location

Engine (after 100 Bh) - Bearing - Fastening bolts Cooling system Water filter Radiator - Bearing - Fastening bolts Hydraulic system Oil cooler - Bearing - Fastening bolts Return-flow filter Magnetic rod Filter housing (cooling system) - Return flow filter - Magnetic rod Pressure accumulator – emergency lowering Pressure accumulator – hydraulic ladder Pressure accumulator – track tensioner Pump drive gearbox and cooling circuit - Pre-chambers - Gearbox oil filter (cooling circuit) - Fastening bolts Swing gearbox - Fastening bolts Travel gearbox - Pre-chambers - Brake chambers - Fastening bolts

4

Servicing work

Quantity/ No.

Check for tightness (see Service Manual) Replace

2x2

Check for tightness (see Service Manual)

Check for tightness (see Service Manual) Replace Clean Replace clean Check function Check function Check function Change oil Change oil Replace Check for tightness (see Service Manual) Change oil Check for tightness (see Service Manual) Change oil Change oil Change oil Check for tightness (see Service Manual)

2x7 2 3 1 1 2 2x2 4 2 4 2x9 2x1 6

4

2 2x2 2x2

see “Refilling quantities – Oil“ table

3-13

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan N – After initial commissioning and during the running-in period (up to 100 OH) Page 2 of 2 Location

Swing ring Fastening bolts (swing ring, undercarriage and superstructure) Superstructure Fastening bolts, especially at superstructure / pedestal / operator´s cab All lines, fittings and connections

3-14

Servicing work

Check for tightness (see Service Manual)

Check for tightness Inspect visually for leaks, wearing marks

Quantity/ No.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan T and W Plan T - (Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Location

Servicing work

Quantity/ No.

Engine

Check oil level

2

Engine oil reservoir

Check oil level

2

Cooling fluid

Check level

2

Radiator

Check / clean

2

Fuel filter

Drain off water

2x3

Fuel cooling system

Check / clean

2

Fuel tanks

Drain off water and sediment

2

Air-intake system

Check BCS - indication

Intake and clean-air lines

Check for tightness and leaks

Page 1 of 2 Plan Plan T W

Cooling system

Fuel system

Electrical system Lighting

Check operation

Switchgear cabinet - Breather filter - Dust trap

Remove dust

1

- EMERGENCY OFF button

Check function

6

Monitoring, warning and control elements

Check function of monitoring, warning and control elements

BCS

Check function

Hydraulic system

Check function of working and travelling movement

1

Inspect visually for leaks Hydraulic oil reservoir

Check oil level

1

Oil cooler

Check / clean

2

Fan wheel

Check condition

2

Pump drive gearbox and cooling circuit

Check oil level

2

- Pre-chambers expansion reservoir

Check oil level

2

Oil filter (tell-tale)

Check

Swing gearbox

Check oil level

6

Reservoirs for used grease at the A-frame

Check, depollute used grease

2

Travel gearbox

Check for leaks

2

Service-station (tanklift)

Inspect visually for leaks and damages

2x1

3-15

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan T and W Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Location Undercarriage Tracks Track roller Support roller Idler Face shovel - Clam cylinder chamber

- Mechanical stops on rearwall and stick Central lubricating system Grease container Lubricating points Air conditioner 5 On-board crane Fastening bolts Crane drive engine

Hydraulic oil reservoir - Reflow filter (contamination indicator) Fire extinguisher Automatic fire-extinguishing system (optional) Escape ladder near operator’s cab - Locking device - Ladder Emergency escape device / seat (optional) - Harness holding device on cab roof Fall arrest static line on working equipment (optional) All lines, fittings and connections Hydraulic shovel Operator’s cab - Window panes - Mirrors ROPS Structure Operator’s seat belt Trainer’s seat belt

5 before each deployment

3-16

Servicing work

Quantity/ No.

Inspect track tension visually Check for leaks and free movement Check for leaks and free movement Check for leaks and free movement

2 2x7 2x2 2

Inspect, remove all accumulated debris, rocks, soil and so on.

Check for wear

2x1

Check filling level Check visually

1

(see “Air Conditioning manual“)

1

Check for tightness Check oil level (see “Crane drive Engine“ operating instructions) Check oil level Check

16 1

Check condition Check control module

2 1

Check function Check function Check for free movement Check completeness and condition Check for tightness Check condition Check function Inspect visually for leaks, wearing marks Overall cleaning Clean Clean Inspect visually for damage Check condition Check condition

1 1

Page 2 of 2 Plan Plan T W

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan A – E Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location Servicing in acc. with W or T Monitoring, warning and control elements - Joystick - Control spool - Pedal - Control spool (machine with loading shovel) - Control spool (machine with backhoe bucket) Operator’s cab - Fastening bolts to cab module

6

Servicing work

No. of

grease lightly

2x4

6

grease lightly

3x2

6

grease lightly

2x2

6

Page 1 of 7 Plan Plan Plan Plan Plan A B C D E

Check for tightness (see Service Manual for tightening torque)

apply a thin layer of low temperature grease

3-17

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

No. of

Engine

Carry out oil analysis

2

Change oil

2

7

2

7

Clean - Bearing - Fastening bolts

Check tightness

- Rubber bearing

Check condition

Engine oil reservoir

Change oil Clean

- Oil filter

Replace

V-belt

Check tension

2x2

Check condition Centrifuge

Clean

2x1

- Rotor seal

Replace

2x1

- Casing seal

Check /replace

2x1

Inspection and servicing

(see Operating and maintenance manual for engine)

7

see “Refilling quantities – Oil“ table

3-18

2

Page 2 of 7 Plan Plan Plan Plan Plan A B C D E

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

No. of

Cooling system Water filter Radiator - Check tightness - Fastening bolts - Rubber bearing Cooling liquid

Inspect visually for leaks Replace

2x2

Anti-freeze Lines Hose clamps Fuel system Fuel filter Water trap Fuel tank, breather filter Fuel tank Air-intake system Main filter element

Check tightness Check condition Check DCA4-concentration (see Engine Operating Instructions) Change Check Check for leaks Check tightness

1

Page 3 of 7 Plan Plan Plan Plan Plan A B C D E

8

Replace Clean Replace Clean

2x3 2x3 2x2 2

Check / replace

2x6

9

Secondary filter element

Replace

2x6

10

Air-intake lines and clean-air lines Hoses

Check for tightness and leaks Replace

Electrical system Battery cable connections

Check for tightness

Battery

Check fluid level

8

Clean

1

Replace

1

Switchgear cabinet - Breather filter - Filter element

8

Cooling-liquid replacement after 2 years at the latest Replacement of main filter element after one year resp. after 3 cleaning cycles.

10 Replacement of secondary filter element after one year resp. after 3 cleaning cycles of the main filter element at the latest.

9

3-19

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 4 of 7 Location

Servicing work

Hydraulic system

Check pressure (see Service Manual)

Oil cooler, bearing - Fastening bolts - Rubber bearing High-pressure filters for working hydraulics Return-flow filter - Bypass valve Filter housing cooling circuit - Return-flow filter - Bypass valve - Magnetic rod Filter (pilot control circuit)

Filter (control circuit)

Filter (swing mechanism pump feeding-circuit) Filter (swing mechanism)

Hydraulic oil reservoir - Magnetic rod - Breather filter Pressure accumulators Cylinder (seals and guide rings)

11

Check for tightness Check condition Check for contamination and damage Replace Replace Check / clean filter sieve Replace Check / clean filter sieve Check / clean Check for contamination and damage Replace Check for contamination and damage Replace Check for contamination and damage Replace Check for contamination and damage Replace Carry out oil analysis Change oil Check / clean Replace Check pressure (see Service Manual) Replace

No. of

Plan A

Plan B

Plan C

Plan D

Plan E

2x4 2x4 2x7 2x4 3 3 1 2x1 2x1 1 1 2x1 2x1 6 6 1 1

11 12

2 2

see “Refilling quantities – Oil“ table Unless it is regularly analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest 12

3-20

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

Pump drive gearbox and cooling circuit

Carry out oil analysis

- Breather filter - Pre-chamber - Breather filter Fastening bolts Oil filter

Swing gearbox

Breather filter Travel gearbox

- Magnetic plug Pre-chambers - Magnetic plug Brake chambers Breather filter Swing ring Gearing / pinion Fastening bolts (swing ring, undercarriage and superstructure)

13

Change oil Clean Replace Change oil Clean Check for tightness (see Service Manual) Check for contamination and damage Replace Carry out oil analysis Change oil Replace Carry out oil analysis Check oil level Change oil Clean Check oil level Change oil Clean Check oil level Change oil Clean / replace Check grease filling Check condition Check for tightness (see Service Manual)

No. of

Page 5 of 7 Plan Plan Plan Plan Plan A B C D E

2 13

2 2x1 2x1 13 2x9 2x1

2x1 2x1 6 13 6 6x1 2 2 13 2 2x4 2x1 13 2x1 2x1 2x2 13 2x2 2x3 1

see “Refilling quantities – Oil“ table

3-21

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

Undercarriage

Check wear (see Service Manual)

Diaphragm accumulator

Check pressure (see Service Manual)

2x2

- Diaphragm

Replace

2x2

Track roller

Check for leaks and free movement

2x7

Support roller

Check for leaks and free movement

2x2

Idler

Check for leaks and free movement

2x1

Carbody-crawler frame fastening bolts and disks

Replace after 30.000 OH (see Service Manual)

52

Central lubricating system Oil filter (hydraulic circuit grease pump)

Check function Check for contamination and damage

Grease filter (filling grease container)

Replace Check for contamination and damage

1 1

Replace Check for contamination and damage Replace

1 2x1

Grease filter (grease lines)

No. of

1

2x1

Breather filter

Check / replace

1

Air conditioner resp. heating

(see Air conditioner manual)

1

- Filter mat

Clean / replace if damaged

3

Hydraulic ladder

Lubricate

- Greasing points

Lubricate

- Air suction

3-22

Page 6 of 7 Plan Plan Plan Plan Plan A B C D E

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Location

On-board crane 14 - Bearing - Joint (column / boom) – Cylinder bearing – Swing ring Hydraulic system – Return-flow filter – Breather filter

Crane drive engine – Oil filter – Fastening bolts – Fuel filter – Air filter – Battery cable connection

Steel components

Modules – Fastening bolts Attachment - boom - stick All articulated joints and hinges

Servicing work

No. of

Lubricate Lubricate Lubricate Grease Change oil Replace Replace see “On-Board Crane“ operating instructions Clean Change oil Replace Check for tightness Replace Replace Check for tightness see “Crane Drive Engine“ operating instructions Visual inspection acc. to "Structural Inspection Report every 500 OH" 16 If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrate, magnetic powder or ultrasonic test.

4 2 5 1 1 15 1 1

Page 7 of 7 Plan Plan Plan Plan Plan A B C D E

1 1 15 1 1 1 1 2

Check for tightness Check welding seams Check welding seams Grease

14

Do all servicing jobs at least once a year and when necessary

15

see “Refilling quantities – Oil“ table

16

Structural Inspection Reports“ for inspections every 500 OH can be downloaded from the CGM HMS GmbH website www.bucyrus-HEX.de, section „Support, Warranty“.

3-23

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing LUBRICATING CHART

Fig. 3-1:

3-24

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Lubricating chart – Grease (legend) No. Greasing point

1 4 5

6

Number

Lubricant properties

Central lubricating system – grease container Hydraulic ladder On-board crane

1

V 17 V 17

- Bearing - Joint (column / boom)

4 2

V 17

- Cylinder bearing

5

- Swing ring

1

Grease every .... operating hours 10 1000 250

250 250 250

Graphite spray

250

V 17

1000 1000

Monitoring, warning and control elements - Joystick - Pedal

18

2x4 18 3x2

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities - Grease Greasing point

Central lubricating system – grease container Internal gearing – Roller-bearing swing ring Idler (connected to the undercarriage lubricating system) Track rollers (connected to the undercarriage lubricating system) Support rollers (connected to the undercarriage lubricating system)

17

see "LUBRICANTS" section.

18

apply a thin layer of low temperature grease

Lubricant properties

V 17

Filling quant. kg

lb

appr. 1000 appr. 600 2 x appr. 36

appr. 2204.6 (294 gal) appr. 1322 2 x appr. 79.4

14 x appr. 45

14 x appr. 99.2

4 x appr. 15

4 x appr. 33

V 17

3-25

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-2:

3-26

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Inspection plan – Oil (legend) No. Location

Lubricant 19 properties

I I

1

Engine

2

1

2

2

Engine with engine oil reservoir Engine oil reservoir

2

3

Hydraulic system

1

4

Pump drive gearbox

2

I II III.a

Check oil level every ... OH 10

Change oil every ... OH 250

10

5000

10

5000

10

10000

10

1000

10

1000

10

1000

500

5000

- Pre-chambers

2x1

5

Swing gearbox

6

6

Travel gearbox

2

- Pre-chambers

2x2

500

5000

- Brake chambers

2x2

500

5000

10

250

10

1000

7

19

Number

III.b III.a

20

On-board crane - Crane drive engine

1

- Hydraulic oil reservoir

1

I II

21 22

see "LUBRICANTS" section

20

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

21

Change oil at least once a year.

22

Change hydraulic oil at least once a year.

3-27

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Filling quantities - oil Location

Filling quantity

Oil

liters

gal

Engine

2 x appr. 260

2 x appr. 69

Engine oil reservoir

2 x appr. 640

2 x appr. 169

Hydraulic oil reservoir

appr. 10000

appr. 2640

Hydraulic oil total

appr. 13000

appr. 3450

Pump drive gearbox - Pre-chambers

2 x appr. 160 9 x appr. 2

2 x appr. 42.3 9 x appr. 0.53

Swing gearbox

6 x appr. 38

6 x appr. 10

Travel gearbox

2 x appr. 215

2 x appr. 56.8

- Pre-chambers On-board crane (optional) - Crane drive engine

4 x appr. 2,5

4 x appr. 0.66

appr. 5.5

appr. 1.45

- Hydraulic oil reservoir

appr. 50

appr. 13.2

I I II II III.a III.b III.a I II

Filling quantities - other Location

Filling quantity liters

gal

Cooling system - engine

2 x appr. 350

2 x appr. 92.5

Fuel tank

2 x appr. 8200

2 x appr. 2166

Fuel tank, crane drive engine (optional)

appr. 20

appr. 5.3

Screen washer

appr. 13

appr. 3.4

3-28

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing LUBRICANTS / CONSUMABLES Notes on the selection of oils and greases Original CGM HMS oils and greases Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies.

The lubricants tables in the CGM HMS Operation and Maintenance Manual contain specifications for the oils and greases that are approved for use in CGM HMS machines. These oils and greases are especially adapted to CGM HMS machines and their units and assemblies.

Other oils and greases which do not fulfill the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies.

For this reason, CGM HMS only approves the use of the specified oils and greases.

All other qualities are not approved.

Alternative oils and greases The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the CGM HMS Operation and Maintenance Manual.

In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with CGM HMS specifications, CGM HMS does not assume any responsibility and does not accept any warranty claims.

(CGM HMS = Caterpillar Global Mining Hydraulic Mining Shovels)

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfill the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-29

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing I.

Fig. 3-3:

3-30

Oil for combustion engines and compressors

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing

II.

Fluid for hydraulic system

Fig. 3-4:

3-31

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing III.a Oil for pump drive gearboxes and travel gearboxes

Fig. 3-5:

3-32

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing III.b Oils for swing gearboxes

Fig. 3-6:

3-33

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing V.

Fig. 3-7:

3-34

Greases for bearings, swing rings and track system

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Coolant for use on all combustion engines

Fig. 3-8:

3-35

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing SERVICING WORK Hose line for oil and cooling liquid changes Collect escaping oil and cooling liquid and discard without polluting the environment.

The engines, the hydraulic oil reservoir, the pump drive gearboxes, the swing gearboxes and the radiators (engine cooling liquid) are moreover equipped with automatic drain valves (1, Fig. 3-10:) These automatic drain valves permit oil- and cooling-liquid changes without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more easily.

Filling and draining is can be done by means of a hose through the service station (tanklift) (Fig. 3-9:).

For filling and draining, a flexible hose is connected to the express coupling on the service station and to the service vehicle at the other end.

The filling operations require an overpressure, whereas the draining operations require low pressure.

Fig. 3-10:

Change oil or cooling liquid as follows: Place a collecting recipient for used oil or cooling liquid under the corresponding automatic drain valve. For the recipient capacity refer to the "Re-filling quantities - Oil" table or to the "Refilling quantities - Other" table.

Unscrew protective cap from automatic drain valve.

Screw on hose line (2) to open the valve, so that the oil or the cooling liquid can flow out.

When the oil or the cooling liquid has drained away, unscrew hose line to allow the valve to close automatically.

Screw protective cap back in place.

Fig. 3-9:

3-36

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing ENGINE Engine - Safety instructions Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system and do not make any modifications to it.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Read and observe: "Inspection and Servicing – Safety Instructions" and the engine operating instructions.

Risk of injury from hot or rotating parts of the engine.

Shut off engines and allow to cool down.

Secure the machine as described in the "Securing the machine" section.

Skin contact with cooling liquid is a potential health hazard.

Protect the skin from potentially harmful contact with engine oil.

Wear protective gloves and firm working clothing.

Attention, Ether!

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Secure the machine as described in section “Securing the machine” before starting Inspection and Servicing.

“Retensioning the alternator belt”, “Checking and adjusting the valve clearance”, these and other servicing works are described in the engine manufacturer's operating instructions.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged.

Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

3-37

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Engine oil, checking the oil level / topping up The engine oil pressure and oil temperature are constantly monitored by the BCS (2, Fig. 3-11) when the machine is in operation.

The actual pressure and temperature of the engine oil can be displayed on the screen (2) and on the gauges (131, 133, 141, 143, Fig. 3-12).

The BCS warns the operator if the engine oil pressure is too low and the oil temperature too high.

Fig. 3-13:

If the oil level is at the "min" mark or below, top up with engine oil through filler tube (2, Fig. 3-14:).

Fig. 3-11

Fig. 3-14:

Engine oil can also be filled in from the service station (Fig. 3-15:) through express coupling (8) for the left-hand engine, express coupling (9) for the right-hand engine (see chapter "Changing the engine oil").

Fig. 3-12

Park the machine on a horizontal surface and secure against inadvertent movements.

Shut off engines.

Draw out oil dipstick (1, Fig. 3-13:).

Wipe oil off the dipstick with a clean, lint-free cleaning rag and re-insert. Draw out dipstick a second time. The oil level should now lie between the marks (arrows, Fig. 3-13:).

Fig. 3-15:

3-38

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Engine oil reservoir, checking the oil level The hydraulic shovel is equipped with an engine oil change interval prolonging mechanism.

The engine oil reservoirs are located in the cab module and in the oil cooling module.

If required the oil pans of the engines are automatically filled up with engine oil from the engine oil reservoirs.

That means the engine oil pans of the engines are sufficient filled up with engine oil as long as engine oil is in the engine oil reservoirs.

Check oil level in the engine oil reservoirs regularly and fill up if neccessary.

Park the machine on a horizontal surface and secure against inadvertent movements.

Shut off engines.

Unlock the oil dipstick (Fig. 3-16:) and withdraw.

Wipe oil off the dipstick with a clean, lint-free cleaning rag and re-insert.

Draw out dipstick a second time. The oil level should lie at the mark. If the oil level is below, the engine oil is filled in from the service station (Fig. 3-17:) through express coupling (6) for the left-hand engine oil reservoir,

Fig. 3-16:

express coupling (7) for the right-hand engine oil reservoir. (see chapter "Engine oil reservoir - Changing the oil").

Fig. 3-17:

3-39

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Engine oil, change Risk of scalding from hot engine oil.

The engines may also be hot.

Read and observe: "Inspection and servicing – Safety instructions".

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

A description of the service station can be found in part 2 of this manual, chapter “Service Station (tanklift)”.

Drawing off engine oil with the service station Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Bring engine oil to operating temperature.

Park the machine on a horizontal surface and secure.

Shut off the engines.

Draw off the engine oil through express coupling (8, Fig. 3-18:) for the lefthand engine express coupling (9) for the right-hand engine.

Unscrew cap of express coupling and connect hose line of the service vehicle.

Draw off engine oil.

After the engine oil has been drawn off: Remove the hose line. The express coupling closes automatically.

Screw on protective cap.

Fig. 3-18:

3-40

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Filling in engine oil Oil grade see “LUBRICANTS / CONSUMABLES” section.

Fill in engine oil through filler tube (2, Fig. 3-19:) until the oil level has reached the "max" mark (Fig. 3-20:) on dipstick (1).

Filling in engine oil through the service station Oil grade see “LUBRICANTS / CONSUMABLES” section.

Fill in engine oil through express coupling (8, Fig. 3-21:) for the lefthand engine, express coupling (9) for the right-hand engine.

Fig. 3-19:

To do so Unscrew cap of express coupling and connect filling hose of the service vehicle.

Fill in engine oil until the oil level has reached the "max." mark (Fig. 3-20:) on dipstick (1, Fig. 3-19:).

Start the engines and allow to run at idling for abt. 2 minutes.

Check oil level at dipstick (1, Fig. 3-19:) and top up with oil to the "max" mark (Fig. 3-20:) if required.

Remove the filling hose.

The express coupling closes automatically.

Screw on protective cap.

Fig. 3-20:

Fig. 3-21:

3-41

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Engine oil reservoir, filling in / draining off the oil Risk of scalding from hot engine oil.

The engines oil reservoirs may also be hot.

Read and observe: "Inspection and servicing – Safety instructions".

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Draining off the oil Park the machine on a horizontal surface and secure the machine.

Shut off the engines.

Draw off engine oil with the service station through express coupling (6, Fig. 3-22:) for the lefthand engine oil reservoir, express coupling (7) for the right-hand engine oil reservoir.

To do so Unscrew cap of express coupling and connect hose line of the service vehicle.

Drain off engine oil.

Remove the hose line.

The express coupling closes automatically.

Screw on protective cap.

After the engine oil has been drawn off: Replace the oil filters for the “Oil change interval prolongation system”.

Fig. 3-22:

3-42

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Engine oil reservoir, filling in engine oil Oil grade see “LUBRICANTS / CONSUMABLES” section.

The engine oil is filled in with the service station (Fig. 3-23:) through express coupling (6) for the left-hand engine oil reservoir, express coupling (7) for the right-hand engine oil reservoir.

To do so Switch on the display system with toggle switch (23, Fig. 3-23:), indicator lamp (22) Lightsup.

Unscrew cap of express coupling and connect hose line of the service vehicle.

Fill in engine oil until the oil reservoirs are filled. Monitoring lamp (1) for the left-hand oil reservoir, or monitoring lamp (2) for the righthand reservoir lit up when the reservoirs are filled.

Remove the hose line.

The express coupling closes automatically.

Screw on protective cap.

Switch off the display system with toggle switch (23, Fig. 3-23:), indicator lamp (22) is off.

Fig. 3-23:

3-43

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Filters for the “Oil change interval prolongation system”, replace Risk of scalding from hot engine oil.

Read and observe: "Inspection and servicing – Safety instructions".

The filter housing may also be hot. Wear protective gloves and firm working clothing.

Collect escaping oil and discard with-out polluting the environment Oil filters Carry out servicing of the full-flow oil filters (engine oil change interval prolongation) in accordance with the engine operating instructions.

The filter elements (two for each engine) are placed in the engine compartment, at the rear wall of the hydraulic tank.

Replacement: Shut off the engines.

Unscrew the filters (arrow, Fig. 3-24:).

Install new filter together with slightly oiled sealing ring and tighten by hand.

Thereafter: Allow engines to run at idling for a short while and check filters for tightness and leaks before shutting off the engines.

Check oil level after abt. 10 minutes and top up, if required.

3-44

Fig. 3-24:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Eliminator filter and centrifuge Risk of injury from rotating parts in the centrifuge. The eliminator filter may be hot.

Read and observe: "Inspection and servicing - Safety instructions" and the Moatti Lube Oil Filter Instruction Book.

Wear protective gloves and firm protective clothing.

Collect escaping oil and discard without polluting the environment.

Fig. 3-25:

Centrifuge, servicing Engine oil impurities filtered out in the eliminator filters (1, Fig. 3-25:) are transported to the centrifuge (2) where they are filtered out by centrifugal force.

To do so: Shut off engines.

Wait for 5 - 10 min. then dismantle the centrifuge.

Dismantling the centrifuge The rotor of the centrifuge must be stationary.

The pressure in the centrifuge must have been eliminated.

The rotor may be hot.

Wear protective gloves and firm protective clothing.

Slacken screws (2, Fig. 3-26:).

Slacken hollow screw (6) and remove together with cover (1).

Withdraw rotor housing (4) and set down on a timber base.

Unscrew nut (3) and remove rotor housing (4).

Remove dirt in rotor housing by tapping lightly.

Impurities in the engine oil are filtered out in the eliminator filter (1, Fig. 3-25:).

Most of the cleaned engine oil flows back to the engine after being cleaned.

A small quantity of the engine oil flows in the bypass to the centrifuge (2).

The eliminator filter is self-cleaning and maintenance-free. (see "Moatti Lube Oil Filter Instruction Book")

Fig. 3-26:

3-45

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Withdraw plate assembly (12, Fig. 3-27:) from rotor (13).

Risk of injury.

The plates may have sharp edges.

Cleaning the centrifuge Check the inside of the rotor housing.

Remove any dirt deposits without damaging the surface of the rotor housing. If necessary, clean all centrifuge parts in diesel fuel. Remove all residual dirt particles with compressed air or an air/water pistol.

Adhering dirt unbalances the rotor and may damage the bearings.

Assembling the centrifuge The plates (16, Fig. 3-28:) have 4 possible opposing positions.

Fig. 3-27:

Remove clip (14, Fig. 3-28:) and distributor plate (15).

Remove plates (16) and end plate (17) from distributor (18) .

Fig. 3-28:

3-46

Place paper filter into the rotor cap (4, Fig. 3-27:): Assembly is done in the reverse sequence to dismantling.

Run engines at idling speed for a short time and check centrifuge for leaks.

Shut off engines.

Check oil level after ca. 10 minutes; top up if necessary.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Cold-starting fluid (ether) - Replacing the pressure vessel Read and observe: "Inspection and servicing Safety instructions" Risk of injury Cold-starting fluid is composed mainly of ether.

Ether is toxic when the mists and vapors are inhaled. Ether is harmful to the eyes, the skin, the respiratory system and the central nervous system.

Prolonged inhalation of ether can be fatal.

In contact with the skin, ether can cause frostbites and irritations.

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Before replacing an empty pressure vessel: Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation of the surroundings.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapors of escaping cold-starting fluid (ether).

Avoid skin contact. Wear suitable protective gloves and goggles.

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is screwed onto an electro-mechanical metering valve. At temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Replacing the pressure vessel: Remove the clamp around the pressure vessel.

Unscrew the pressure vessel carefully from the metering valve.

Remove the used seal from the metering valve.

Insert a new seal into the valve (supplied with the new pressure vessel).

Screw the new pressure vessel onto the metering valve and tighten by hand.

Fasten the clamp round the pressure vessel.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.

Do not keep them on the machine.

Do not damage or open the vessels.

Do not expose the vessels to great heat or direct sunlight.

Do not dispose of in fire.

Keep the vessels in a place inaccessible to unauthorized persons.

Dispose of the vessels properly.

3-47

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing COOLING SYSTEM Risk of scalding from hot cooling liquid.

Read and observe: "Inspection and servicing - Safety instructions".

Temperature The cooling liquid circuit is controlled by a thermostat. The max. admissible temperature is ca. 100° C / 212°F. In case of higher temperatures, the BCS displays a warning on the screen (Fig. 3-29:).

Secure the machine as described in the "Securing the machine" section.

Shut off the engines and allow to cool down.

Collect escaping cooling liquid and discard without polluting the environment.

Protect the skin from contact with cooling liquid.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Fig. 3-29:

The temperature of the cooling liquid is also displayed by the gauges (132 and 142, Fig. 3-30:).

Gauge (132) shows the temperature of the cooling liquid in the left engine.

Gauge (142) shows the temperature of the cooling liquid in the right engine.

Fig. 3-30:

3-48

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Radiators The radiators are located on the superstructure in the counterweight module.

Weekly checks: Check radiator fins for dirt and clean carefully and accurately, if required.

The expansion reservoirs of the engine cooling system (2, Fig. 3-33:) are accessible from the superstructure.

Risk of scalding from hot cooling liquid.

Wait until cooling liquid has cooled down.

Open caps of the expansion reservoirs cautiously after releasing pressure.

Cooling-liquid level, check An insufficient cooling-liquid level is displayed on the BCS screen (Fig. 3-31:).

Fig. 3-31:

Insufficient cooling-liquid levels are also monitored by the warning lamps (136 and 146, Fig. 3-32:).

Warning lamp (136) is for the cooling system of the left-hand engine, warning lamp (146) is for the cooling system of the right-hand engine.

Check cooling-liquid level at the monitoring device (4). The cooling-liquid level must reach the markings at the monitoring device.

If required, top up cooling liquid.

First release pressure from the expansion reservoir by lifting up the red lever integrated in cap (1).

When the pressure has been released turn cap into the "open" position and remove.

Top up with cooling liquid.

The cooling-liquid level must be between the “min“ and “max” markings at the monitoring device (4).

After topping up cooling-liquid screw cap of the filler neck (1) back in place.

Fig. 3-33:

Fig. 3-32:

3-49

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Cooling-liquid, topping up Cooling liquid can be topped up through the filler tube of the expansion reservoirs or through the service station (tanklift).

Risk of scalding from hot cooling liquid.

Wait until cooling liquid has cooled down.

Open caps of the expansion reservoirs cautiously after releasing pressure.

Do not fill in cold cooling liquid when the engine is at operating temperature.

Before refilling, allow engine to cool down to below 50° C / 122°F. Fill small amounts of cooling liquid through filler tube (1, Fig. 3-34:) into the cooling system.

For topping up of the cooling system use specially prepared water only.

Specially prepared water must consist of: calcium-free water, distilled water, rain water, anti-freeze compound.

The anti-freeze compound must always be filled into the system independent of climatic conditions.

In this case, it serves as corrosion protection for the aluminum cooler.

The mixing ratio of anti-freeze / cooling water must be at least 50 % : 50 % (anti-freeze protection down to -40 °C / -40°F).

For use at lower temperatures, the amount of antifreeze must be increased accordingly (maximum is 60% : 40%).

Alternatively a “ready to use coolant” can be used (see “LUBRICANTS / CONSUMABLES”).

For further detailed information see engine manufacturers operation and maintenance manual.

After topping up cooling-liquid screw cap of the filler tube (1) back in place.

After filling in cooling liquid allow the engines to run for short period to eliminate air voids before topping up with cooling liquid until the cooling liquid level is between the “min” and “max” marking of the monitoring device (4).

In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks.

Check regularly: Fig. 3-34:

all lines for leaks and all hose clamps for tightness.

Checking the DCA4 concentration Observe the instructions of the engine manufacturer with regard to the DCA4 concentration (see engine manufacturer's operation and maintenance manual).

3-50

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Cooling liquid, topping up using the Service-Station The cooling liquid can also be filled in with the service station (Fig. 3-35:) through express coupling (2) for the left-hand engine, express coupling (3) for the right-hand engine.

Prior to topping up cooling liquid release pressure from the cooling system.

To do so move lever of the ball valves in the direction of the arrow (Fig. 3-35:).

The pressure is released then and the express couplings (2 and 3) are then accessible.

Remove cap of express coupling. Connect the filling hose of the service vehicle.

Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator at the expansion reservoirs.

Remove hose.

The express coupling closes automatically.

Push on protective cap.

Close ball valves (Fig. 3-35:).

Fig. 3-35:

3-51

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Cooling liquid change Risk of scalding from hot cooling liquid.

The radiators may also be hot.

Wait until cooling liquid and radiators have cooled down.

Open caps of the expansion reservoirs cautiously after releasing pressure.

Do not fill in cold cooling liquid when the engine is at operating temperature.

Before refilling, allow engine to cool down to below 50° C / 122°F. Read and observe: Inspection and servicing – Safety instructions.

Drawing off cooling liquid The cooling liquid can be drawn off faster with the service station (Fig. 3-36:) through express coupling (2) for the left-hand cooling circuit, express coupling (3) for the right-hand cooling circuit.

Prior to drawing off cooling liquid release pressure from the cooling system.

To do so move lever of the ball valves in the direction of the arrow (Fig. 3-36:).

The pressure is released then and the express couplings (2 and 3) are then accessible.

Remove cap of express coupling. Connect hose line of the service vehicle.

Draw off cooling liquid.

Fill in fresh cooling liquid, see “Filling in cooling liquid”.

Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

The cooling liquid must be analyzed regularly according to the engine manufacturers Operating and Maintenance Manual and changed after two years at the latest.

A description of the service station can be found in part 2 of this manual, chapter “Service Sation (tanklift)”.

Fig. 3-36:

3-52

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Filling in cooling liquid Shut off the engines.

Fill in cooling liquid with the service station (Fig. 3-37:) through: express coupling (2) for the left-hand cooling circuit, express coupling (3) for the right-hand cooling circuit.

Check ball valves (Fig. 3-37:).

They must be open. The express couplings (2 and 3) are then accessible.

Remove cap of express coupling.

Connect hose of the service vehicle.

Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator at the expansion reservoirs (4, Fig. 3-38:).

Remove hose from express coupling.

The coupling closes automatically.

Push on protective cap.

Close ball valves (Fig. 3-37:).

Fig. 3-37:

The cooling liquid can also be filled in through filler neck (1, Fig. 3-38:).

Fig. 3-38:

Testing the cooling liquid composition The engine operating instructions contain a detailed description of how to prepare and test the cooling liquid composition. In case of imminent frost check that the factory-adjusted anti-freeze concentration is sufficient for the expected temperatures.

Check the cooling liquid in the cooling system regularly to ensure that the water filter replacement interval resp. the SCA mixture is sufficiently concentrated to prevent corrosion under the corresponding operating conditions.

3-53

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Water filter, change Risk of scalding from hot cooling liquid.

Read and observe: "Inspection and servicing – Safety instructions".

For further detailed information see engine manufacturers Operation and Maintenance Manual.

The filter housings may be hot, too.

Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

Replace water filter regularly according to the maintenance plans.

The water filters (Fig. 3-39:) are mounted at the engine housing.

Close valves (2, Fig. 3-39:).

Unscrew water filters (1).

Tightening the filter element with a tool can damage or deform the filter head.

Screw on new water filter until the sealing ring contacts the filter head. Continue to tighten the filter by another ½ to ¾ turn.

Open valves (2).

3-54

Fig. 3-39:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing AIR-INTAKE SYSTEM Risk of injury when falling down from the superstructure. Put on your fall protection equipment before entering the superstructure.

Risk of injury caused by hot parts of the engine exhaust system.

Let exhaust cool down.

Read and observe the "Engine - Safety instructions" chapter.

Main filter elements Insufficient air-intake performance, caused by a contaminated main filter element, is displayed on the BCS-screen (Fig. 3-41:).

Clean or renew main filter elements only if the BCS displays a warning on the screen (Fig. 3-41:) or the vacuum-meters (8, Fig. 3-42:) show a red signal with the engines running at high speed.

Shut off the engines before working on the air-intake system.

Do not start the engine when parts of the air-intake system have been detached.

Engine damage may occur if the engine is allowed to draw in unfiltered air.

Secure the machine as described in the “Securing the machine” section.

Fig. 3-41:

Each engine is equipped with six dry-air filters (Fig. 3-40:) consisting of main and secondary filter element.

Fig. 3-42:

Fig. 3-40:

3-55

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Removal and installation Unscrew nut (1, Fig. 3-43:)) and remove cover (2).

Unscrew nut (4) and withdraw main filter element (5). Do not lose the washer under nut (4).

Replace or clean main filter element New or cleaned main filter elements should always be at hand to shorten hydraulic shovel downtimes.

Before installing the filter element, clean contact faces at cover (2, Fig. 3-43:) and at filter housing.

Put on cover (2) and tighten nut (1).

During the removal of the main filter element, the safety element (7, Fig. 3-44:) must remain in the filter housing.

Fig. 3-43:

Fig. 3-44:

3-56

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Checking and cleaning the main filter element Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 3-45:).

Any damage is then clearly visible.

Replace damaged or deformed elements immediately.

Check element seal. When the seal is damaged, the filter element must be replaced, too.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.

Blow filter element (Fig. 3-46:) clean with dry compressed air from the inside by moving the compressed-air gun up and down.

The pressure at the nozzle must not exceed 3 bars / 43psi.

Cleaning is terminated when all visible dust has been blown out of the filter element.

Fig. 3-45:

Never clean filter element by beating against hard objects.

Replace the main filter element after 1000 operating hours or 3 cleaning cycles; and, after one year of operation at the latest.

Fig. 3-46:

3-57

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Secondary filter element Removal and installation Replace the secondary filter elements (7, Fig. 3-47:) after 1000 operating hours or 3 cleaning cycles; after one year of operation at the latest.

Never clean the secondary filter element, but always renew.

Remove main filter element (5, Fig. 3-48:) as described above.

Check the vacuum indicator (6, Fig. 3-47: resp. arrow Fig. 3-49:) whether - the green spot is visible; in this case the secondary filter must not be replaced - the green spot is not visible; in this case the secondary filter must be replaced.

Unscrew vacuum indicator (6) and withdraw secondary filter element (7).

Install the new secondary filter element and a cleaned or a new main filter element.

Fig. 3-47:

Fig. 3-48:

Fig. 3-49:

3-58

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Air-intake lines, check

Dust collection, function

At regular intervals: Check all parts of intake lines for leaks and hose clamps for tightness; Replace defective rubber parts and clamps between filter housing and engine.

During all works on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engines.

Dust accumulating on the filter-housing bottom is constantly sucked away by the exhaust system during operation.

The non-return valves (1, Fig. 3-50:) in the suction lines prevent engine exhaust gases from being sucked in.

At regular intervals: check suction lines for leaks and hose clamps for tightness.

Fig. 3-50:

3-59

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing FUEL SYSTEM Fuel system - Safety instructions

Fuel filters, replace Risk of injury.

When working at the fuel filters it is necessary to keep the engine running.

Keep away from hot or rotating parts of the engine.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

When working on the fuel system: secure the machine as described in the "Securing the machine" section, keep away naked flames, do not smoke.

Collect escaping fuel and discard without polluting the environment.

Diesel fuel may cause skin injury.

Avoid skin contact with diesel fuel.

Wear firm working clothing. Wear protective gloves or use a barrier cream.

Fuel tank supply valve, function The fuel tank supply valve is mounted in the fuel line from the fuel tank to the fuel filter set. It is located on top of each fuel tank (Fig. 3-51:). This ball valve cuts the fuel flow to the engine when closed.

To close the ball valve, shift the lever in position “0”.

To open the ball valve, shift lever in position “I”.

Read and observe the "Fuel system – Safety instructions” chapter.

The machine is equipped with a triple fuel filter set (Fig. 3-53:). First replace the right or left filter element. Replace the filter element in the center position at last.

Fuel filter change is necessary after 250 OH or when the fuel level in the clear filter cover reaches the red line at the filter element.

Leave engine running.

When starting with the left filter, swing the handle (1, Fig. 3-52:) on the left filter to the "OFF" position. To change the right filter, swing the handle on the right filter to the "OFF" position.

Place a collecting vessel for escaping fuel under the filter to be replaced.

Fig. 3-52:

Fig. 3-51:

3-60

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Loosen the vent cap (1, Fig. 3-53:) on the filter to be replaced.

Open the drain valve (5) and drain the fuel.

Then close the drain valve (5).

Fig. 3-53:

Using the collar / vent cap wrench (Fig. 3-54:) remove the clear cover (2, Fig. 3-53:) by removing the collar (4).

Fig. 3-55:

Fig. 3-54:

Discard the O-ring (8, Fig. 3-55:) from the base of the cover (2).

Remove the filter element (3) by pulling upwards and twisting slightly from the filter stud.

Remove the sealing grommet (7) too.

New O-ring seals and grommet are supplied with the new filter elements.

Dispose of the filter in an environmentally responsible manner according to the state, federal, national and / or global environmental recommendations.

Install the new filter (3) and grommet (7) on the filter stud.

Place the new cover O-ring (8), cover (2) and collar (4) over the filter.

Press down filter, holding it in place, while hand tightening the collar until seated. Do not use tools to tighten.

Fill the clear cover (2) with enough fresh, clean fuel to cover the bottom half of the filter element.

Make sure the new O-ring (6) is installed on the vent cap (1), install the vent cap (1). Tighten by hand.

Swing the valve handle (1, Fig. 3-52:) into position "ON".

Raise the engine rpm for one minute to purge the air from the system.

Replace the other outer filter the same way.

Then replace the center fuel filter (see. "Replacing the center fuel filter").

After then replace the filters at the other engine.

3-61

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Replacing the center fuel filter Now replace the filter element located in the center position.

Leave the engine running.

Swing both the right and the left handles (1, Fig. 3-56:) to the "ON" position and the center unit valve handle to the "OFF" position.

Change filter as described above.

Swing the center valve to the "ON" position.

Ensure that all three handles (1) are in the "ON" position.

Check the fuel system for leaks.

Fuel filters, draining water Drain water from the triple fuel filters weekly. To do so: Turn off the engine and open the filter vent (1, Fig. 3-57:).

Place a cup under the drain valve at the base and open the drain valve (5).

Water will flow into the cup. When fuel begins to flow out of the drain, close the drain valve (5).

Close the filter vent (1).

Start the engine. Raise the engine rpm for one minute to purge the air from the system.

Drain water from the fuel filters at the other engine.

Fig. 3-56:

Fig. 3-57:

3-62

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Fuel tank breather filter, replace The fuel tanks are vented with breather valves (3, Fig. 3-58:).

Replace breather valves regularly according to the inspection plans. To do so: Unscrew the caps (3), replace filter elements and screw caps back in place.

Fuel tanks, clean Explosion hazard due to fuel vapors.

Read and observe the "Inspection and Servicing, Safety instructions" chapter.

Do not use white spirit, paraffin oil or other solvents.

For flushing and cleaning use diesel fuel.

Skin contact with diesel fuel may cause skin injury.

Avoid skin contact.

Wear firm working clothing. Wear protective gloves or use a barrier cream.

Fuel must be prevented from penetrating into the soil. Keep fuel for filtering and re-use or discard without polluting the environment.

Fig. 3-58:

Use up as much fuel as possible.

Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plugs of the tanks.

Close ball valve on top of the fuel tank (Fuel tank supply valve, see Fig. 3-51:).

Unmount cover of fuel tank.

Loosen drain plug (5, Fig. 3-59:) at the bottom of the fuel tank and drain off fuel.

Flush tank with diesel fuel.

Inspect fuel tank inside for damages.

Screw drain plug back (5) in place.

Mount cover of fuel tank, attach all connections.

Fig. 3-59:

3-63

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing After cleaning the fuel tanks fill in fresh fuel.

Open cover of filler tube on top of the fuel tanks and screw off lid of filler tube (2, Fig. 3-60:).

Fill in fuel through the strainer in filler tube Fuel can also be filled into both fuel tanks through the service station (1, Fig. 3-61:).

For more information see chapter “Refueling” in Part 2 of this manual.

Unscrew cap of express coupling.

Connect filling hose of the service vehicle.

Fill in fuel.

The filling level is displayed on the BCS screen (Fig. 3-62:).

Remove filling hose.

The express coupling closes automatically.

Screw on protective cap.

Open fuel supply ball valves on top of the fuel tanks. To do so, shift lever of the ball valve from position “0” to position “I”.

Fig. 3-60:

Fig. 3-61:

Fig. 3-62:

3-64

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing ELECTRICAL SYSTEM Electrical system - Safety instructions Risk of injury caused by battery acid and gases.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Carry out every work on the electrical / electronic systems only if you are a qualified electrician and after having received special trainings.

Wear goggles, working gloves and firm working clothing.

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the electronic modules of the PMS and the CMS.

Alternator - Instructions Never disconnect cables from the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator.

Do not interchange the cables when connecting the battery (observe polarity).

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the regulator.

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

Electrical circuit diagrams The electrical circuit diagrams and wiring diagrams are annexed to the spare-parts list. Further information can be found in the CGM HMS Service Manual "Working with circuit diagrams".

Electrical system switch-cabinets The electrical system switch-cabinets are located in the cab module, in the pump compartment and behind the hydraulic reservoir. The cabinets are described in the spare-parts list (electrical circuit diagram) together with the designation of the electrical components.

Fuses and their function are listed on a sheet inside the switch-cabinets in the cab module.

Use only original fuses with the specified current rating.

Replacing lamps and bulbs If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Xenon-working floodlights are operated with high voltage.

Read and observe the chapter: “Floodlight projector, replacing the lamp”.

Floodlights working with LED-technology do not have replaceable lamps / bulbs. The floodlight must be replaced if defective.

3-65

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Xenon floodlight projector, replacing the lamp Safety instructions The floodlight projectors use xenon technology.

The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector.

When the projector is turned on, the ballast unit generates a high-voltage pulse of more than 25000 volts to start the xenon lamp.

Warning!

This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance, if the lamp is operated improperly, if the projector housing is opened in an inappropriate way or by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp.

Allow the xenon lamp to cool off before removing it from the projector.

Wear goggles and safety gloves when replacing the lamp.

Never stick your hand into the lamp holder. The contacts may still be live with residual voltage.

Never switch on the projector when the xenon lamp has been removed.

There is a risk of voltage discharge and damage to the lamp holder.

The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters).

If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector.

If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol.

The replaced Xenon lamp must be disposed of as special waste.

Never switch on projectors when housing or electrical wiring is damaged.

Have damaged projectors be replaced by a qualified electrician as soon as possible.

3-66

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Replacing a defective Xenon-lamp Read and observe the: „Xenon floodlight projector, replacing the lamp, Safety instructions“.

Fig. 3-63

Switch off the projector, shut off the engine and cut out the battery main switch.

Wait until the housing of the floodlight projector has cooled down.

Withdraw the power supply connector from the projector.

Remove four screws (1, Fig. 3-63) and withdraw the reflector (2) from the projector housing.

Withdraw connector (Fig. 3-64) from Xenon lamp socket.

Unscrew Xenon lamp holding clamp (Fig. 3-65).

Remove the defective Xenon lamp and replace by a new one. Do not touch the glass bulb of the lamp.

Reinstall the new lamp. Screw lamp holding clamp back in place.

Plug the power supply connector onto the lamp.

Re-assemble the housing.

Fig. 3-64

Fig. 3-65

3-67

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Lighting systems in LED technology, instructions The lights of the maintenance lighting system (Fig. 3-66) as well as the working floodlights (Fig. 3-67) are equipped with lamps in LED technology (lightemitting diodes).

High-performance LEDs ensure the emission of light with high luminance. If the light is allowed to shine directly into the eyes from a short distance and over prolonged periods, there is a risk of injury to the retina.

Do not look for a prolonged period into the light cones of the LEDs. Adjust the lights in such way that they do not shine directly into the eyes and that you are not blinded by the glare.

The lights become hot in operation.

The heat is dispersed via the ribbed metal housing.

For this reason, the housings must not be covered up and cleaning rags or similar things placed over them.

Fig. 3-66

The high-performance LEDs in these lights have a very long service life and can therefore not be replaced. If one or more of these LEDs fail, the light can remain in service if the remaining luminance is still sufficient.

Fig. 3-67

3-68

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Battery, checking the state of charge Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Risk of injury caused by battery acid and gases.

Wear goggles, working gloves and firm working clothing.

Do not eat, drink or smoke when handling batteries.

Wash hands after handling.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Checking the battery fluid level (Not applicable in case of maintenance-free batteries) Unscrew caps (Fig. 3-68:).

If checking inserts are provided, the battery acid must reach up to their bottom.

If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm / 0.4".

If the fluid level is too low, top up with distilled water only.

Checking charge of batteries The acid temperature must be 20 ° C / 68°F. Unscrew caps of the battery (Fig. 3-68:).

Measure the acid density of the battery using a commercial acid tester (Fig. 3-68:).

The acid density measured is in direct correlation with the battery charge.

Acid density kg / dm3 Charge Normal Tropical condicondition tions 1,28 1,23 fully charged 1,20 1,12 half charged, recharge 1,12 1,08 discharged, recharge immediately

On closed / sealed (so called „maintenance-free“) batteries, the charging status can be checked using a charge meter. Ask your Caterpillar dealer for assistance.

Fig. 3-68:

3-69

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Battery, removing and installing Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Risk of injury caused by battery acid and gases.

Wear goggles, working gloves and firm working clothing.

Do not eat, drink or smoke when handling batteries.

Wash hands after handling.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

The batteries (Fig. 3-69:) are located above the hydraulic oil reservoir.

The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

Shut off the engines before removing the batteries to avoid damaging the alternator and the regulator.

Turn key in key-switch to position "0" and withdraw.

Switch battery-isolator-switch to position "0" (if equipped with).

Switch battery-main-switch to position "0" (if equipped with).

Detach battery holder.

Disconnect the cable lug from the negative terminal of the battery.

Disconnect the cable lug from the positive terminal of the battery.

Insulate the cable lugs.

Lift battery out of battery box.

Before installing new batteries, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.

Install the new batteries.

Connect the cable lug to the positive terminal of the battery. Tighten the clamping screws of the cable lugs. Do not use too much force to avoid deformation.

Connect the cable lug to the negative terminal of the battery.

Apply special terminal grease or acid-free petroleum jelly on the battery terminal posts and clamping lugs. Loose or corroded clamping lugs will lead to alternator or regulator overloading.

After putting the machine back to operation: Check battery cabling for tightness, retighten if necessary.

Check battery holders nuts for tight-ness, retighten if necessary.

Repeat these checks regularly.

Fig. 3-69:

3-70

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Charging batteries inside the machine, safety instructions Explosion hazard.

Battery gases are highly flammable.

Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

Risk of injury from acid splashes and battery gases.

Wear safety goggles or a face protection shield and acid proof protective gloves.

Do not lean over the batteries while charging.

The batteries of the machine can also be charged while installed in the machine.

For this purpose, the arm of the service station (Fig. 3-70:) is equipped with a socket outlet for a charging cable.

Risk of fire Do not use the socket outlet (Fig. 3-70:) for jump-starting of the engines.

The connectors and the cables are not designed for the high currents flowing during the starting phase.

Check before charging why the batteries are discharged and replace the batteries if they are defective.

Check the connecting cables of the battery set for damage, corrosion and tight fit.

Never charge the batteries while they are frozen.

Warm them up beforehand and check for proper functioning.

Do not charge the batteries when they are warmer than "warm to the touch" (45 °C / 113 °F).

Use only approved chargers for 24 volts DC. Read and observe the instructions for the charger.

The charging cable must have a conductor cross2 section of at least 70 mm .

Charging the batteries Cut out the battery main switch.

For battery ventilation unscrew the cover of the battery cabinet.

Connect the charging cable to the socket outlet (Fig. 3-70:).

Switch on the charger and watch the charging process.

Stop the charging process: if the batteries are getting hot, if acid escapes from the batteries, if the charge current is still insignificantly low even after 15 minutes of charging.

Before starting a new charging cycle, check the batteries and the connecting cable thoroughly and replace any damaged components. It may be necessary to remove the batteries and to charge them one by one.

When the batteries are full: Shut off the charger first before withdrawing the charging cable from the socket outlet.

Read the instructions of the charger in order to know when the charging cycle has ended.

The batteries are fully charged, if the charging current and voltage remain constant (for voltage-controlled chargers); the charging current does not any rise longer for two hours (current-controlled chargers); the charger shuts off or switches over to trickle charge (automatic chargers).

Fig. 3-70:

3-71

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Switchgear cabinet Breather filter In the switchgear cabinet, the air is drawn in by a ventilator via the filter (Fig. 3-71:).

Emptying dust trap Press dust trap (14, Fig. 3-71:) and hold until the dust trap is empty.

Emptying the dust collector Loosen clamps (11, Fig. 3-71:).

Remove dust collector (12) and empty.

Filter element Remove the dust collector (12, Fig. 3-71:).

Withdraw filter element (13, Fig. 3-72:).

Replace or clean filter element (13).

Refit dust collector (12, Fig. 3-71:).

Fig. 3-71:

Fig. 3-72:

3-72

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Checking and cleaning the filter element Check the filter paper of the element by inserting a lamp into the element (Fig. 3-73:). Any damage can then be seen.

Replace damaged or distorted element immediately.

Check element seal. If damaged, replace filter element too.

Cleaning with compressed air allows the filter element to be re-used immediately.

Blow filter element (Fig. 3-74:) dry with compressed air by moving the compressed-air piston up and down inside it.

The pressure at the nozzle must not exceed 3 bars / 43psi.

Cleaning is completed when no more dust is seen to leave the filter element.

Fig. 3-73:

Never clean filter element by beating it against hard objects.

Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Fig. 3-74:

3-73

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing HYDRAULIC SYSTEM Hydraulic system - Safety instructions Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Secure the machine as described in the "Securing the machine” section.

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated.

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

Wait until the hydraulic system is cooled down to moderate temperature before starting work.

Contact with hydraulic oil can cause skin injury.

Avoid skin contact with hydraulic oil.

Wear protective gloves and firm working clothing.

Hydraulic system, depressurizing Hydraulic systems may only be opened if they are completely depressurized.

Even when an hydraulic shovel is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-75:) and with its drive engines stationary, there may still be a considerable amount of residual pressure in parts of the hydraulic system, as e.g. the primary pressure resulting from the last hydraulic movements before the immobilization.

Residual pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be freed from pressure, i.e. depressurized:

Fig. 3-75:

Locate the system section to be opened.

Depressurize the section to be opened. If required, the necessary measures described must be combined Open the depressurized system section with caution.

3-74

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Examples of system sections: 1) working hydraulics 2) servo control circuit 3) pre-charged return-flow line Depressurizing Park the hydraulic shovel on a horizontal surface.

Set the working equipment on the ground.

Shut off the drive engines.

Do not switch off the electrical system Sections 1 and 2: servo control and working hydraulics Shift both control levers repeatedly into all dIrections (Fig. 3-76:).

Hydraulic oil level, check Bring hydraulic oil to operating temperature (abt. 50 °C / 122°F).

Park the machine on a horizontal surface.

Stand working equipment on the ground as shown on the sign (2, Fig. 3-77:).

The oil level must be between the “min” and “max” marks of the decals (2) beside the inspection glass (1, Fig. 3-77:).

Fig. 3-77:

The hydraulic oil level is also monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-78:) if the hydraulic oil level is too low or too high. In this case: Shut off the engines, locate cause and rectify.

Fig. 3-76:

Section 3: return-flow line After shutting down the engine, the pre-charging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

Fig. 3-78:

3-75

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of the decals (2) beside the inspection glass (1, Fig. 3-80:) (oil grade see "LUBRICANTS / CONSUMABLES").

The acoustic warning signal “Travel Alarm” sounds.

Unscrew the hose line; the express coupling closes automatically.

Screw protective cap back in place

Fig. 3-79

Stand working equipment on the ground as shown on the sign (Fig. 3-80:).

Signs (2, Fig. 3-80:) are attached beside the inspection glass (1).

Fig. 3-81:

Hydraulic oil can also be filled in through the return-flow filters. To do so: Remove cover (3, Fig. 3-82:).

Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of the decals (2, Fig. 3-80:) beside the inspection glass (1). (oil grade see "LUBRICANTS / CONSUMABLES").

Before fitting the cover (3, Fig. 3-82:), check the sealing ring and replace, if damaged.

Fit cover together with sealing ring.

Fig. 3-80:

If necessary, fill in hydraulic oil by means of the service station (Fig. 3-81:).

A description of the service station can be found in part 2 of this manual, chapter “Service Station (tanklift)”.

Unscrew cap of express coupling (10).

Connect filling hose express coupling of the service vehicle.

Fig. 3-82:

3-76

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Hydraulic oil return-flow filters (hydraulic oil reservoir), replace Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

The return-flow filters must be replaced: when servicing works in accordance with the servicing plan are carried out; when the BCS displays a warning on the screen (Fig. 3-83:). In this case, the filter elements (9, Fig. 3-84:) are heavily contaminated; after repairs on the hydraulic system; in case of damage.

Remove cover (3) together with sealing ring (5) and bracket (7).

Remove press part (8) and sealing ring (10).

Withdraw filter element (9) and sealing ring (11) from basket (12).

Insert a new filter element.

If a filter element (9) is damaged, remove basket (12) and check/clean.

Fig. 3-83:

Fig. 3-84:

3-77

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Loosen screws (13, Fig. 3-85:) and take off bracket (14) and washer (15).

Remove basket (12) and clean in paraffin oil.

Install basket (12) using screws (13) with brackets (14) and washers (15).

Insert filter element (9) together with sealing ring (11) and press part (8) with sealing ring (10).

Refit bracket (7).

Refit cover (3) together with sealing ring (5).

Clean the magnetic rod (4).

The magnetic rod is located under cover (3).

If metal filings are detected, locate cause and rectify.

Contact your Caterpillar dealer service, if required.

Replace also the three return-flow filters in the filter housing cooling-system (Fig. 3-86:).

The return-flow filters are located under the cover (30, Fig. 3-87:). (see under "Hydraulic oil return-flow filter / Filter housing cooling-system, replace").

Fig. 3-86:

Fig. 3-85:

Fig. 3-87:

3-78

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Bypass valves (hydraulic oil reservoir) Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Check sealing ring for damage and replace, if required.

Re-assemble the bypass valve.

Check sealing ring (24) for damage and replace, if required.

Insert bypass valve and fasten with screws (22).

Clean also the screen of the bypass valve in the filter housing (cooling-system).

The bypass valve is located under the cover (30, Fig. 3-90:). (see under "Bypass valves / Filter housing (cooling-system").

Cleaning the filter screens Remove cover (3, Fig. 3-88: resp. Fig. 3-89:) together with sealing ring (5).

Unscrew screws (22). Withdraw bypass valve.

Take off screen (23) together with sealing ring and clean in white spirit or paraffin oil. Replace, if required.

Fig. 3-89:

Replacing the bypass valves and sealing rings Remove bypass valve as described under "Cleaning the screens".

Re-assemble the bypass valve with a new screen (23, Fig. 3-89:) and a new sealing ring.

Insert bypass valve with new sealing ring (24) and fasten with screws (22).

Replace also the bypass valve and sealing ring in the filter housing (cooling-system).

The bypass valve is located under the cover (30, Fig. 3-90:). (see under "Bypass valves / Filter housing (cooling-system").

Fig. 3-88:

3-79

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Hydraulic oil return-flow filters (filter housing cooling system), replace

Replace the return-flow filters (35, Fig. 3-90:) together with the return-flow filters in the hydraulic oil reservoir.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-90:

Detach cover (30) together with sealing ring (36).

Remove retaining disk (33) together with sealing rings (32 and 37).

Withdraw filter element (35).

Insert a new filter element.

Clean the magnetic rod (31).

If metal filings are detected, locate cause and rectify.

Contact your Caterpillar dealer for service, if required.

Refit cover (30) with new sealing ring (36).

3-80

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Bypass valves (filter housing cooling system) Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Cleaning the screens Clean/replace the bypass valves (Fig. 3-91:) together with the bypass valves in the hydraulic oil reservoir.

Detach cover (30) together with sealing ring (36).

Unscrew screws (22) and withdraw bypass valve.

Take off screen (23) together with sealing ring (24) and clean in white spirit or paraffin oil; replace, if required.

Check sealing ring (24) for damage and replace, if required.

Re-assemble the bypass valve.

Insert bypass valve and fasten with screws (22).

Refit cover (30) with a new sealing ring (36).

Replacing the bypass valves and sealing rings Replace the bypass valves and sealing rings together with the bypass valves in the hydraulic oil reservoir.

Remove the bypass valve as described under "Cleaning the screens".

Re-assemble the bypass valve with a new screen (23) and a new sealing ring (24).

Insert bypass valve with new sealing ring (24) and fasten with screws (22).

Refit cover (30) with a new sealing ring (36).

Fig. 3-91:

3-81

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Hydraulic tank breather filter, replace Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury.

Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose of used filter elements accordding to the environmental regulations.

Replacing the filter elements The breather filters (20, Fig. 3-92:) ensure venting of the hydraulic oil reservoir at varying hydraulic oil levels.

Inspect and replace the filter elements according to the maintenance plans.

In case the machine is working in very dusty conditions or in an environment with high air humidity, the filter elements must be inspected and replaced in shorter intervals. This protects the hydraulic tank from beeing con-taminated.

Unscrew bolts (21). Remove holding brackets (22) and withdraw filter elements (20).

Attach new filter elements (20) with foam rings to their cylindrical connections.

Install holding brackets (20) using bolts (21).

Fig. 3-92:

3-82

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Filter (control circuit main pumps), replace

Replacing the filter element Change filter element regularly and when the BCS indicates a contamination.

Risk of scalding caused by hot hydraulic oil.

The filter housings may also be hot.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Fig. 3-93:

Unscrew filter housing (5, Fig. 3-93:).

Withdraw filter element (6) from filter housing (5).

Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.

Insert new filter element into filter housing (5) and refit to the filter head with new, lightly oiled sealing ring (8).

Check for leaks after putting the filter into operation.

3-83

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing High-pressure filter for working hydraulics, replace To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with eight high-pressure filters (Fig. 3-94:).

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Depressurize the hydraulic system.

Clean the filter block and the filter housings carefully.

Place a suitable collecting recipient under the filter housings (Fig. 3-94:).

Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.

Unscrew drain plug (11, Fig. 3-95:) and drain the hydraulic oil from the filter housing (9).

Unscrew filter housing (9) by counterclockwise rotation.

Disengage filter element (15) with a slight turn from its retaining catch and withdraw from filter housing (9).

Check filter housing (9) as well as used filter surface for debris.

Clean filter housing (9) and the sealing faces at the filter head with white spirit or paraffin oil.

Check sealing ring (14) and retaining ring (13) on the filter housing for position and damage.

Replace, if necessary.

Install the new filter element (15) with a new, slightly oiled seal (10) on the spigot again by slightly turning it.

Screw in the filter housing (9) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Check high-pressure filters for leaks after putting the hydraulic system back into operation.

Fig. 3-94:

Fig. 3-95:

3-84

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing High-pressure filters for the servo circuit, replace The hydraulic shovel is equipped with two highpressure filters (1, Fig. 3-96:) for the servo circuit.

Both filters are located between the pump gears.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Depressurize the hydraulic system.

Clean the filter block and the filter housings carefully.

Fig. 3-96:

Place a suitable collecting recipient under the filter housings (Fig. 3-96:).

Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.

Remove filter housing (5, Fig. 3-97:) and pour out used oil.

Withdraw filter element (6) from filter housing (5).

Check seals (7 and 8) and replace lightly oiled, if required.

Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.

Insert new filter element into filter housing (5) and refit to filter head with a new, lightly oiled retaining ring (9).

Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Check the high-pressure filter for leaks after putting it into operation.

Fig. 3-97:

3-85

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing High-pressure filters for pumpflushing circuit The hydraulic shovel has a high-pressure filter for each flushing circuit (2, Fig. 3-98:). The filters are located above the distributor gearboxes.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Depressurize the hydraulic system.

Clean the filter block and the filter housings carefully.

Fig. 3-98:

3-86

Place a suitable collecting recipient under the filter housings (Fig. 3-98:).

Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.

Remove filter housing (5, Fig. 3-99:) and pour out used oil.

Withdraw filter element (6) from filter housing (5).

Check seals (7 and 8) and replace lightly oiled, if required.

Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.

Insert new filter element into filter housing (5) and refit to filter head with a new, lightly oiled retaining ring (9).

Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Check the high-pressure filter for leaks after putting it into operation.

Fig. 3-99:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing High-pressure filters for feeding circuits and swing pumps The hydraulic shovel has four high-pressure filters (3, Fig. 3-100:) for the feeding circuits of the swing pumps. Two high-pressure filters each are installed beside the pump drive gearbox.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Depressurize the hydraulic system.

Clean the filter block and the filter housings carefully.

Place a suitable collecting recipient under the filter housings (Fig. 3-100:).

Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.

Unscrew drain plug (11, Fig. 3-101:) and drain the hydraulic oil from the filter housing (9).

Unscrew filter housing (9) by counterclockwise rotation.

Disengage filter element (15) with a slight turn from its retaining catch and withdraw from filter housing (9).

Check filter housing (9) as well as used filter surface for debris.

Clean filter housing (9) and the sealing faces at the filter head with white spirit or paraffin oil.

Check sealing ring (14) and retaining ring (13) on the filter housing for position and damage.

Replace, if necessary.

Install the new filter element (15) with a new, slightly oiled seal (10) on the spigot again by slightly turning it.

Screw in the filter housing (9) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Check high-pressure filters for leaks after putting the hydraulic system back into operation.

Fig. 3-100:

Fig. 3-101:

3-87

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing High-pressure filters for swing circuit, replace The hydraulic shovel has one high-pressure filter (Fig. 3-102:) for each of the six swing circuits.

Checking/cleaning the filter elements The filter elements are only to be cleaned/changed if necessary.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Fig. 3-103:

Shut off the engines.

Depressurize the hydraulic system.

Clean the filter block and the filter housings carefully.

Collect escaping hydraulic oil and discard without polluting the environment.

Loosen flange (6, Fig. 3-102:).

Unscrew cover (5, Fig. 3-103:).

Withdraw filter element (2) together with sealing ring (3) and retaining ring (4) from housing (1).

Clean filter element (2) with white spirit or paraffin oil.

Insert filter element into filter housing (1) and refit with new, lightly oiled sealing ring (10) and a new retaining ring (4).

Screw cover (5) into housing (1).

Refit flange (6, Fig. 3-102:) to housing (1).

Check high-pressure filter for leaks after putting it into operation.

Fig. 3-102:

3-88

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Changing the hydraulic oil Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Do not start up the drive engines when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry.

Avoid mixing of different hydraulic fluids (see chapter “Avoid mixing of different hydraulic fluids” for more information).

Oil grade see “LUBRICANTS / CONSUMABLES” section.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfill the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-89

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Drawing off hydraulic oil The hydraulic oil can also be drawn off through the service station (Fig. 3-104:).

Bring hydraulic oil to operating temperature (ca. 50° C / 122°F).

Retract hydraulic cylinders as far as possible and stand working equipment on the ground.

Shut off the engines.

Unscrew cap of express coupling (10).

Connect hose line of the service vehicle.

Remove hose line. The coupling closes automatically.

Screw on protective cap.

Drain off hydraulic oil as described under "Draining off the hydraulic oil".

Remove cap (3, Fig. 3-105:).

Detach the return-flow filter.

Fig. 3-105:

Fig. 3-104:

Cleaning the hydraulic oil reservoir Explosion hazard.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engines.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Use diesel fuel or a special flushing oil.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.

3-90

Place a collecting recipient for the flushing oil under the drain plug (1, Fig. 3-106:) of the hydraulic oil reservoir.

Unscrew drain plug (1).

Clean the inside of the hydraulic oil reservoir with diesel fuel or flushing oil.

Remove all sediments and also the residues of the cleaning agent thoroughly Refit cap (3, Fig. 3-105:).

Fig. 3-106:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Filling in hydraulic oil Hydraulic oil is filled by means of the service station (Fig. 3-107:).

The oil level is also displayed on the BCSscreen (Fig. 3-109:).

Vent the hydraulic system.

Check the oil level in the hydraulic oil reservoir.

Top up with oil, if required.

Unscrew the hose line. The express coupling closes automatically.

Screw protective cap back in place.

Fig. 3-107:

Unscrew cap of express coupling (10).

Connect filling hose express coupling of the service vehicle.

Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of the decals (2) beside the inspection glass (1, Fig. 3-108:). (oil grade cf. "LUBRICANTS / CONSUMABLES").

Fig. 3-109:

Hydraulic oil can also be filled in through the return-flow filter.

Remove cover (3, Fig. 3-110:).

Before fitting the cover (3), check the sealing ring and replace, if damaged.

Install cover.

Fig. 3-108:

Fig. 3-110:

3-91

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Venting the hydraulic system Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented after assembly on site and prior to initial commissioning, before each recommissioning of the hydraulic shovel, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes, after each hydraulic oil change, after replacement of hoses or lines.

Venting the hydraulic components Hydraulic pumps and hydraulic motors (with electric motors shut off).

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions.

Hydraulic cylinder Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-111: and Fig. 3-112:) must be either completely retracted or completely extended.

Fig. 3-112:

Always admit oil first to that side of the cylinder where the piston (2) is. This is • the piston-side port (3) when the piston rod is retracted (1, Fig. 3-111:), • the rod-side port (4) when the piston rod is extended (1, Fig. 3-112:).

If, for assembly reasons, the piston rod is in middle position, admit oil first to the piston-side port (4).

When oil is admitted for the first time to the cylinder, the oil flow must be reduced. Therefore extend or retract the piston rod as slowly as possible.

The screws/nozzles of the following components must be opened until oil emerges bubble-free from the opening: Always vent only the system section that has been opened.

the travel brake valve at the venting screw, the oil cooler manifold at the mini-measuring ports, the servo system at the venting screws of the control blocks (under the servo caps), the intake line at the venting screw (with drive motors stationary).

Fig. 3-111:

3-92

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

Shut off the engines.

Never start cleaning work until the cooler fan blades have stopped turning.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

Allow the hydraulic oil cooler to cool down.

Wear protective gloves and firm protective clothing.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan.

The speed of the fan motors (1, Fig. 3-113:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C / 140°F.

Cleaning The hydraulic oil coolers are located in the oil cooler module.

Clean the hydraulic oil coolers at regular intervals.

Shut off the engines.

Remove any accumulated dirt.

Clean the fan blades (2).

Clean the radiators with a jet of water or compressed air from outside to inside.

Leave hydraulic oil coolers to dry.

Check the hydraulic motors (1) for free movement.

In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

Fig. 3-113:

3-93

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Electronic shovel control

Pedal

Joystick

At regular intervals acc. to the maintenance plans: Remove old grease and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-115:).

Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

At regular intervals acc. to the maintenance plans: Loosen gaiter and move upwards.

Apply a thin layer of low temperature grease on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-114:) to prevent jamming of the joysticks.

Refit gaiter using a cable strap.

Fig. 3-115:

Fig. 3-114:

3-94

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Pressure accumulator - Emergency lowering To permit the working equipment to be lowered in an emergency, the machine is equipped with a pressure accumulator (1, Fig. 3-116:).

The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

Fig. 3-116:

Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Group

II p ≥ l bar and p·x l ≤ 200

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been released

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory: Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Inspections prior to commissioning at the factory at the place of use Pressure testing Inspection certificate Prototype and pressure test (Check of correctness and certified by the manufacturer correct installation) issued by an expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and fluid.

3-95

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing PUMP DRIVE GEARBOX Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the engines.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Park and secure the machine as described in the "Securing the machine" section.

Read and observe: "Inspection and servicing Safety instructions”.

Fig. 3-117:

Checking the gearbox oil level / Topping up with oil The pump drives must be in operation for at least 30 minutes prior to checking the oil level, because oil is accumulated in the pump mounting flanges for lubrication of the profile hollow shaft. Checking the oil level when the pump drives are cold give wrong results.

Observe the information decals attached to the gearbox housings near the dipsticks.

Unscrew dipstick (1, Fig. 3-117: and Fig. 2-118:) and wipe clean.

Insert dipstick (1) again until the thread lies on top of the dipsticks tube. Do not screw in (2, Fig. 2-118:).

Pull out dipstick (1) a second time. Oil level should be between the two dipstick markers “min” and “max” Top up with fresh gearbox oil if required.

(Oil grade see: “LUBRICANTS / CONSUMABLES”).

Inspect dipstick’s sealing ring and replace if damaged.

Screw in dipstick (1) back in place.

In case of significant oil losses check for leaks at the gearbox and on all components of the gearbox oil cooling system.

Too much oil in the gearbox may be a signal of defective seals at hydraulic components. Contact your Caterpillar dealer service.

3-96

Fig. 3-118:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Pump drive gearbox, Changing the gearbox oil Change the gearbox oil when the gearbox is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon and abraded matter) better.

Recommendation: if the gearbox oil is heavily soiled, the gearbox should be flushed with fresh gearbox oil. In this case contact your Caterpillar dealer.

Drawing off gearbox oil The gearbox oil is drained with the service station (Fig. 3-119:) through express coupling (4) for the left-hand pump drive gearbox, express coupling (5) for the right-hand pump drive gearbox.

Unscrew protective cap of express coupling and connect hose line of the service vehicle.

Draw off gearbox oil.

Remove hose after the oil has been drawn off.

The coupling closes automatically.

Screw on protective cap.

Filling in gearbox oil (Oil grade see “LUBRICANTS / CONSUMABLES”).

The gearbox oil is filled in with the service station (Fig. 3-119:) through express coupling (4) for the left-hand pump drive gearbox express coupling (5) for the right-hand pump drive gearbox.

Unscrew protective cap of express coupling and connect hose line of the service vehicle.

Fill in gearbox oil until the oil level reaches the”max” mark on dipstick (1, Fig. 3-120:).

Remove hose after the oil has been filled in.

The coupling closes automatically.

Screw on protective cap.

Start engine and run for a maximum of two minutes at idle speed, then stop. The pump drive oil cooling circuit has now been filled with oil.

Check gearbox oil level and top up to the correct filling level.

Check for leaks and for correct filling level after putting the machine back into operation. Top up with gearbox oil if required.

Note: The oil level is to be checked after about 30, 60 and 240 minutes running time as oil collects in the mounting flanges or is dammed there to lubricate the splined hollow shafts. The gearbox oil cooling system is also to be filled with oil. Therefore it is absolutely necessary to check the oil level and top up with oil up to the correct level.

Fig. 3-119:

Fig. 3-120:

3-97

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Pump drive gearbox breather The gearbox is vented through the breather valve (2, Fig. 3-121:), mounted on top of the gearbox housing.

Clean breather valve (2) in accordance with the servicing plan.

Unscrew breather filter (2), clean with white spirit or paraffin oil and blow dry with compressed air.

Screw breather filter (2) back in place.

Pre-chambers, expansion reservoir Check oil level The oil level in the pre-chambers expansion reservoir is visually at the inspection glass (3, Fig. 3-122:) in expansion reservoir (1).

Check the oil level in the pre-chambers regularly.

The oil level should reach up at least to the middle of the inspection glass (3). Top up with gearbox oil, if required.

The pre-chambers expansion reservoirs are vented through breather valves (2).

Clean breather valve (2) in accordance with the servicing plan.

Unscrew breather filter (2), clean with white spirit or paraffin oil and blow dry with compressed air.

Screw breather filter (2) back in place.

Fig. 3-121:

Fig. 3-122:

3-98

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Pump drive gearbox lube oil filters, clean / replace Check filter tell-tales (1, Fig. 3-123:) regularly - at operating temperature - for indication of contamination.

If the red sector is visible through transparent cap (2), the filter element must be cleaned or changed.

Remove flange (3, Fig. 3-124:).

Pour oil out of filter pot (4) and remove filter element (5).

Clean filter element in spirits or petroleum, change if damaged.

Clean filter head (6, Fig. 3-123:) and filter pot (4). Check o-ring (7, Fig. 3-124:) for damage; change if necessary.

Oil the O-ring lightly. Place filter element into filter pot and re-assemle.

Check filters for leakages after recommencing operation.

Fig. 3-123:

Filter element (5) must be changed after having been cleaned 8 - 10 times; at the latest however, after 1000 operating hours.

Fig. 3-124:

3-99

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing SWING GEARBOX The gearbox housings may be hot.

Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Swing gearbox - checking the oil level / topping up with oil Park the machine as described under "Securing the machine".

Screw out dipstick (1, Fig. 3-125:) and wipe clean.

Insert dipstick (1) fully again (do not screw in) and withdraw a second time.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required.

Screw dipstick (1) back in place.

Fig. 3-125:

3-100

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Swing gearbox, changing the gearbox oil Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Draining off oil Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Attach hose (8, Fig. 3-126:) to drain valve (7) and drain off oil completely.

The use of the oil draining hose is described in the "Draining hose for oil changes" chapter.

The drain valve (7, Fig. 3-126:) is accessible from the undercarriage.

Remove hose. The oil drain valve closes automatically.

Fig. 3-126:

Filling in new oil / Topping up (Oil grade see “LUBRICANTS / CONSUMABLES”).

Unscrew plug (4, Fig. 3-127:) and fill in new oil.

Check oil level with dipstick (1, Fig. 3-127:).

Screw in plug (4) again.

Fig. 3-127:

Swing gearbox venting The gearbox is vented through breather filter (2, Fig. 3-127:).

Clean breather filter in accordance with the servicing plan.

Unscrew breather filter (2), clean in white spirit or paraffin oil and blow dry with compressed air.

Screw breather filter (2) back in place.

3-101

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing TRAVEL GEARBOX The gearbox housings may be hot.

Read and observe: "Inspection and servicing - Safety instructions.

Travel gearbox - changing the oil Main gear, draining off oil Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Shut off the engines.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Travel gearbox - checking the oil level / topping up with oil Park the machine as described under "Securing the machine".

The oil level must be visible in the level gauge (4, Fig. 3-128:); top up with gearbox oil if necessary.

Fig. 3-129:

Park the machine as described under "Securing the machine".

Move the hydraulic shovel until the screw plugs (1, 2 and 3, Fig. 3-129:) are in the position shown in the diagram: screw plug (1) in horizontal position screw plug (2) in bottom position screw plug (3) at ca. 23° from horizontal (2 o'clock position).

Fig. 3-128:

3-102

Place a collecting recipient for used oil under the main gearbox. Choose the required capacity in accordance with the "Refilling quantities Oil" table.

Unscrew plug (2) and drain off oil completely.

Slackening plug (3) allows the oil to run out more readily.

Clean plugs (2 and 3).

Screw in plug (2).

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Preliminary gearbox - draining off oil Place a collecting recipient for used oil under the preliminary gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Unscrew plug (5, Fig. 3-130:) and drain off oil completely.

Clean plug (5) and screw back in place.

Pre-chambers - draining off oil Place a collecting recipient for used oil under the pre-chamber. Choose the required capacity in accordance with the "Refilling quantities Oil" table.

Unscrew plugs (1, Fig. 3-132:), clean, and screw back into place.

Pre-chambers - filling in oil Unscrew plugs (2, Fig. 3-132:) and overflow (3).

Fill in oil through the opening of the overflow (3) until it flows out of the opening of the plug (2).

Fig. 3-130:

Main gear and preliminary gearbox Filling in oil (Oil grade see “LUBRICANTS / CONSUMABLES”).

Move the hydraulic shovel until the screw plugs (1 and 3, Fig. 3-131:) are in the positions shown in the diagram: Unscrew plugs (1 and 3). Fill in oil through opening in plug (3) until it flows out of opening in plug (1) or the oil level is visible in the level gauge (4, Fig. 3-130:).

Fig. 3-132:

If oil emerges from the overflow (3, Fig. 3-132:), the external sealing of the driving motor must be checked.

Fig. 3-131:

3-103

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing CRAWLER TRACKS

Carbody-crawler frame fastening bolts and disks, replace

Tracks – cleaning

The fastening bolts as well as the tempered disks (1 and 2, Fig. 3-134) must be replaced any time that they are removed or after 30.000 operating hours of the machine.

Do not re-use removed bolts.

To tighten these bolts to the prescribed tightening torque, heavy hydraulically driven equipment is necessary.

For more detailed information see: - Service Manual, chapter 2.9 "Tightening Procedure for bolts" for tightening torques used, - Service Manual, chapter 3.2.1 "Torque Tools" for description of hydraulic torque tools, - Service Manual, chapter 4 “Undercarriage” for bolts replacement procedure.

Note: In the area of the bolted connections every welding work is prohibited. If welding is necessary in case of damages or cracks, the bolts have to be removed before starting welding work.

Clean tracks, track and support rollers, sprockets and idlers regularly and whenever required. Cleaning is especially important in winter to prevent the tracks from being thrown off oil from leaking out of track and support rollers, sprockets and idlers excessive wear the track from breaking.

To clean the tracks: raise one side of the hydraulic shovel with the working equipment and allow track to turn; clean the side member supporting the track; clean track and support rollers (1 and 2, Fig. 3-133:) thoroughly; clean the sliding planes on the idler guides.

Fig. 3-133:

Fig. 3-134:

3-104

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Track roller fastening Check fastening bolts (4 Fig. 3-135:) regularly for tightness: Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual")

Fig. 3-135:

Support roller fastening Check fastening bolts (3, Fig. 3-135:) regularly for tightness Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual").

Track tensioner Design The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-136: and Fig. 3-138: show parts of the tracks and the tensioner:

Fig. 3-136:

Pos. 1 2 3 4 5 6 7 8 9

Function Crawler track Support roller Drive sprocket Track roller Pressure cylinder Idler Mini - measuring port Pressure limiting valve Pressure accumulator

Fig. 3-137:

3-105

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Technical data Track tensioning pressure Pressure limiting valve Gas pressure in pressure accumulator (nitrogen filling pressure)

ca. 90 bars / 1305psi 400 bars / 5800psi 72 bars / 1044psi

Function The tensioning system is under permanent pressure of ca. 72 bars / 1044psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engines have been started. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so: Stop the engines.

Open both pressure limiting valves (8, Fig. 3-138:) to slacken the tracks.

After the work, screw down the pressure limiting valves (8) to the limit stop.

The pressure-limiting valves (8) are preset to a pressure of 400 bars / 5800psi and sealed in this position. The lead seal must not be removed and the pressure setting of 400 bars / 5800psi must not be changed.

The track tensioners are maintenance-free.

3-106

Fig. 3-138:

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating

pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner.

They are no substitute for the inspections as required by the "Pressure Vessel Regulations".

Before checking the gas charging pressure (nitrogen filling pressure) in the pressure accumulator, the track must first be slackened, i.e. the hydraulic part of the tensioning system must be depressurized. See under "Function".

Tab. 3-1

Group

IV p ≥ l bar p·x l ≥ 1000

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Internal inspection: every 10 years for noncorrosive fluids; otherwise pressure testing every 5 years: every 10 years by an expert

3-107

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing (1, Fig. 3-140:) and the pinion (2) are enclosed in a housing (3, Fig. 3-141:). The housing forms a grease-filled trough in which the pinion of the swing mechanism moves.

Shut off the engines.

Wear protective gloves and firm protective clothing.

Swing ring - Instructions The grease filling must be replaced: when repairs have been carried out on the swing ring, the swing ring seals or the swing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the swing ring.

Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

Bearing races The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing .

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-139:).

Fig. 3-140:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-139:). The amount of grease used up during operation is replenished by the central lubricating system.

The housings have a check opening which is closed with a cover (2, Fig. 3-141:For checking, the cover must be removed.

Fig. 3-141:

Fig. 3-139:

3-108

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Swing ring - Checking the grease filling Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines.

Wear protective gloves and firm protective clothing.

At regular intervals: check internal gearing and teeth of swing mechanism pinion for condition, check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm / 0.79" of grease over its whole circumference (Fig. 3-142:).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued swing movements.

Swing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Add grease when: the housing has been replaced, old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never swing the superstructure when refilling grease.

Swing ring - Checking the bolts for tightness The fastening bolts of the swing ring in the superstructure and the undercarriage are tightened with their respective torque.

Check torque, see: "Service Manual".

When these values are reached, the fastening bolts are perfectly tight.

Loosen slack bolts before tightening them with a torque wrench to the prescribed torque (see: "Service Manual").

Fig. 3-142:

3-109

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing CENTRAL LUBRICATING SYSTEM Design The hydraulic shovel is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those mentioned in the "Lubricating chart - Grease".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and at least one engine is running.

All greasing points connected to the system are greased at regular intervals.

The automatic greasing is interrupted when the engines are stopped with the idle timers.

The central lubricating system is controlled electrohydraulically by the PLC (Programmable logical controller).

The PLC is located in a switch box underneath the cab.

Fig. 3-144:

If a fault occurs, BCS gives a warning on the screen (Fig. 3-144:). This happens, for example, if the filter element in the hydraulic line is contaminated.

If one of the following faults occurs, BCS gives a warning and at the same time the grease pump is switched off: Grease container is empty, Greasing pressure in the grease lines is below 250 bars (3626psi).

In this cases, BCS switches off the hydraulic function of the shovel/backhoe cylinders after 15 minutes. This prevents damages from lack of greasing.

Inform the responsible maintenance personnel immediately.

Keep on working after the fault has been fixed.

Fig. 3-143:

3-110

After the fault has been fixed, actuate the "Reset" button in the control column (64, Fig. 3-143:) or the “Reset” button in the control box located at the grease container. The buttons must be actuated for at least one second.

For further information on the function and setting refer to the Service Manual, chapters 9 and 11.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Function The two grease pumps (1 and 2, Fig. 3-145:) pump grease through the greasing lines to the main grease distributors of the superstructure.

Pump (1) supports the greasing points on the uppercarriage and working equipment.

Pump (2) supports the undercarriage greasing system (optional).

The control elements of the lubricating system are installed on the panel (3).

Fig. 3-145:

As soon as the grease container is empty, the BCS (Fig. 3-146:) gives a warning signal.

In the event of a fault, the "dumping" function is switched off automatically after 15 min.

Work can be continued when the grease container is filled with grease.

Fig. 3-146:

3-111

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Filling up the grease container

Breather filter

Fill up the grease container through the service station (Fig. 3-147:).

The use of the hose is described in the chapter "Hose for oil and cooling liquid changes" Switch on the display system with toggle switch (23, Fig. 3-147:), lamp (22) lights up.

Unscrew the cap of the express coupling (11).

Connect the filling hose of the service vehicle.

Fill in grease.

When the grease container is full, the monitoring lamp (24) lights up.

Remove the flexible hose.

The express coupling closes automatically.

Refit the protective cap.

Switch off display system with toggle switch (23), lamp (22) is off.

Check/change the breather filter at regular intervals acc. to the maintenance plans.

Unscrew wing nut that fixes the cover (10, Fig. 3-148:).

Withdraw cover (7, Fig. 3-149:) and filter element (8).

Check filter element. Replace if necessary.

Re-install breather filter.

Fig. 3-148:

Fig. 3-147:

Fig. 3-149:

3-112

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Checking the greasing pressure Check every week, whether the hydraulic oil pressure indicated by pressure gauge (3, Fig. 3-148:) is 60 bars / 870psi (the pressure is depending on temperature and viscosity of the oil and may vary).

In the event of deviating pressure values, shut off the engines and check the central greasing system.

Lower oil pressure means that not all of the greasing points are supplied with grease.

Higher oil pressure may cause bursting of a greasing line.

Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.

Unblocking a grease line

Fig. 3-150:

The necessary greasing pressure of 320 bars for the superstructure and 180 bars for the undercarrige is generated by means of a pressure translator.

The greasing pressure for the superstructure is indicated by pressure gauge (2, Fig. 3-150:), the greasing pressure for the undercarriage by the pressure gauge (1).

Put the hydraulic shovel back into operation only after the lubricating system works properly and after having actuated the unloaded working equipment for abt. 5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

3-113

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Oil filter for hydraulic circuit grease pump, replace

Replacing the filter element Change filter element regularly and when the BCS indicates a contamination.

Risk of scalding caused by hot hydraulic oil.

The filter housings may also be hot.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

For filtering of the hydraulic oil, high pressure filter (arrow, Fig. 3-151:).is installed in the pumping line.

Fig. 3-151:

3-114

Fig. 3-152:

Unscrew filter housing (5, Fig. 3-152:).

Withdraw filter element (6) from filter housing (5).

Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.

Insert new filter element into filter housing (5) and refit to the filter head with new, lightly oiled sealing ring (8).

Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Check high-pressure filters for leaks after putting the hydraulic system back into operation.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Grease filter replace (Filling the grease container) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Shut off the engines.

Grease filter (13, Fig. 3-153:) is installed in the grease filling line to the grease container.

Checking the filter element Unscrew filter housing (5, Fig. 3-154:).

Withdraw filter element (3) from housing (5).

Remove the grease.

Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.

Check seals (4) and replace, if required.

Insert filter element into housing (5) and attach to the filter head (1) with a new, slightly oiled sealing ring (2).

Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Check high-pressure filters for leaks after putting the hydraulic system back into operation.

Fig. 3-153:

Fig. 3-154:

Replacing the filter element Remove filter element as described under "Checking the filter element".

Check seals (4) and replace, if required.

Insert new filter element and reassemble.

Check high-pressure filter for leaks after the system has been put into operation.

3-115

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Grease filter replace (Grease lines) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Shut off the engines.

Grease filters are installed in the greasing lines to superstructure and working equipment (2, Fig. 3-155:) and to undercarriage greasing system (1, optional).

Checking the filter element Unscrew filter housing (5, Fig. 3-156:).

Withdraw filter element (3) from housing (5).

Remove the grease.

Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.

Check seals (4) and replace, if required.

Insert filter element into housing (5) and attach to the filter head (1) with a new, slightly oiled sealing ring (2).

Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Check high-pressure filters for leaks after putting the hydraulic system back into operation.

Fig. 3-155:

Fig. 3-156:

Replacing the filter element Remove filter element as described under "Checking the filter element".

Check seals (4) and replace, if required.

Insert new filter element and reassemble.

Check high-pressure filter for leaks after the system has been put into operation.

3-116

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing OTHER MAINTENANCE Engine Information about maintenance can be found in the engine operating instructions.

Further servicing works not described are carried out by the CGM HMS Service or the engine manufacturer.

Cleaning Check the engines regularly.

If the engine is cleaned with a steam-jet cleaner, make sure that the jet is not directed towards electrical components.

If no steam-jet cleaner is available, the engines must be cleaned with suitable cleaning agents (cold cleaners).

Cooling system Check the radiators regularly.

Shut off the engines.

Remove any accumulated dirt.

Clean the fan blades (2, Fig. 3-157:).

Clean the radiators with a jet of water or compressed-air from the outside.

Dry up coolers.

Check free movement of hydraulic motors (1).

Do not clean radiators with a wire brush or similar hard objects.

In case of firmly adhering dirt, remove radiator and clean.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Fig. 3-157:

Means of fastening Check fastening bolts regularly for tightness.

The seating planes of the bolts must be free from paint, dirt and rust.

Exhaust system Check the fastening bolts regularly for tightness when the exhaust system is cold.

3-117

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Reservoirs for used grease at the A-frame, emptying

Heating and air conditioning, check

Remove used grease from the reservoirs (Fig. 3-158:) regularly according to the maintenance plans.

Do not re-use the grease because it is polluted.

Dispose off used grease as well as cleaning rags without polluting the environment and separately from other waste.

Clean or replace the filter mats in the air suction regularly.

The filter mats are located in the air conditioner housing (Fig. 3-159:) below the roof of the cab.

Open housing of air conditioner.

Clean or replace filter mats.

Close housing.

Fig. 3-158:

Fig. 3-159:

3-118

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Working equipment, check welding seems

Clam cylinder chamber, check for soiling

Check the welded joins of the working equipment regularly.

Inspections must be carried out acc. to the "Structural Inspection Reports" every 500 OH and every 5000 OH. "Structural Inspection Report" forms for those inspections can be downloaded from the CGM HMS website, section "Support, Warranty".

The inside located joins are accessible through the man-holes in stick (arrow, Fig. 3-160:) and boom (arrow, Fig. 3-161:).

In unfavourable circumstances during working operation loose material can reach the clam cylinders chambers in the shovel rearwall.

To avoid damage to the clam cylinders and their hydraulic lines and hoses, inspect the clam cylinder chambers before starting each working shift.

Fig. 3-162:

Fig. 3-160:

Lift up the rubber cover plate of the clam cylinder chambers (arrows, Fig. 3-162:).

Remove all accumulated material from the chamber.

Check cylinders and all hydraulic lines, hoses and connections for damage and leaks.

Fig. 3-161:

3-119

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Window panes - cleaning Clean the outside of the cab windows from the walkways (see Fig. 3-163:).

Use a clean sponge or a soft cloth.

Wash the windows with a mild soap or with a mild detergent. Also use plenty of lukewarm water.

Rinse the windows thoroughly.

Dry the windows with a moist chamois or with a moist cellulose sponge.

Fig. 3-163:

Mirror – cleaning / adjusting position Adjust all mirrors as specified in this Operation and Maintenance Manual. Failure to heed this warning can lead to personal injury or death.

Slips and falls can result in personal injury. Use the machine's access systems when adjusting the mirrors.

Mirrors provide additional visibility around your machine.

Make sure that the mirrors are in proper working condition and that the mirrors are clean.

Adjust the rearview mirrors (if equipped) for the best visibility close to the machine.

Adjust all mirrors at the beginning of each work period and adjust the mirrors when you change operators.

Park the machine on a level surface.

Lower the work tool to the ground.

Stop the engine.

Adjust rear view mirrors in order to provide maximum visibility besides and behind the machine (arrow, Fig. 3-164:).

Hand tools may be needed in order to adjust the mirrors.

Fig. 3-164:

3-120

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing HYDRAULIC LADDERS (OPTIONAL) To allow the hydraulic ladders on both sides of the superstructure (Fig. 3-165:) to be lowered in an emergency, the ladder mechanisms are equipped with pressure accumulators (1, Fig. 3-166:).

The pressure accumulators are located in the superstructure.

Pressure accumulators must be checked regularly.

Observe the relevant regulations in your own country.

Fig. 3-165:

Fig. 3-166:

3-121

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Group

III p ≥ l bar and p·x l ≥ 200 bars p·x l ≤ 1000 bars

3-122

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and operating fluids.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing ON-BOARD CRANE, DRIVE UNIT The drive unit supplies the crane with hydraulic power. The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

Crane engine More and detailed information about the diesel engine can be found in the Operating and Maintenance Manual for the crane engine.

Before each shift check engine oil level. If necessary top up with engine oil through opening of dipstick (3, Fig. 3-167:).

After each shift fill up fuel tank (1).

Regularly check batteries (4) and cable connections.

Regularly, at least once a year: - change engine oil, - replace engine oil filter, - check / replace air filter (2), - replace fuel filter.

Do not start engine with air filter (2) removed.

Fig. 3-167:

Hydraulic system For more and detailed information, see crane operating instructions.

Prior to each deployment, check the hydraulic oil level at the inspection glass (1, Fig. 3-168:); top up with hydraulic oil if necessary.

Check contamination of hydraulic oil filter regularly at contamination indicator (4).

Regularly, but at least once a year replace the hydraulic oil filter (3) and the breather filter (2).

Fig. 3-168:

3-123

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing On-board crane, lubricating Servicing work Lubricate all bearings regularly and as required, and spray swing ring with a graphite spray (Fig. 3-169:) 1 - bearing 4 lube points 2 - joint (column/boom) 2 lube points 3 - cylinder bearing 5 lube points 4 - swing ring Graphite spray

On-Board crane, checking tightness of fastening bolts The hydraulic driven on-board crane (Optional) is fixed on the uppercarriage of the machine by means of 16 fastening bolts. The upper and lower fastening bolts (Fig. 3-170:) are important and safety relevant components, they carry all loads and forces of the crane.

Check tightness of all fastening bolts: in regular intervals according to the maintenance plans and before every start of the on-board crane.

Check tightness of the fastening bolts by means of a torque wrench. The tightening torque for fastening bolts M20, quality 10.9, lightly oiled is: 557 Nm.

Fig. 3-169:

Fig. 3-170:

3-124

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING Putting the hydraulic shovel out of operation Park the hydraulic shovel on firm and level ground.

Set the working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.

Set all control elements to "0".

Clean the machine.

Carry out a visual inspection of the hydraulic shovel.

Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.

Carry out engines preservation.

Protect all bright metal parts (e.g. piston rods) from rust and dirt.

Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.

Fill up the fuel tanks.

Remove the batteries; see: "Battery storage".

Secure the machine against unauthorized starting by: - withdrawing the key from the key-switch, - locking the cab door, - securing all lockable hatches.

Cover up all openings.

Battery storage During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C / 68°F. Observe the following points with regard to maintenance: Clean the batteries.

Check the acid density and the electrolyte level of the battery every two weeks.

Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.

Keep the batteries clean and dry on the outside.

Recommissioning Remove the covers.

Degrease / clean all protected components.

Remove engines preservation in acc. with the engine operationg anstructions.

Check the fuel level in tanks.

Check track tension (visual inspection).

Check level and condition of the cooling liquid in the cooling system.

Check grease filling in grease container.

Oil level - drive engines, - swing gearboxes, - pump drive gearboxes, - travel gearboxes.

Check oil level in hydraulic oil reservoir.

Check battery acid density and level.

Install batteries and reconnect.

Function checks: - superstructure holding brake, - track brake, - lighting system, - signalling equipment.

Vent the hydraulic system.

3-125

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing

This page intentionally left blank.

3-126

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

3-127

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Inspection and servicing

This page intentionally left blank.

3-128

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work 4 REPAIR WORK Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

4-1

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work

This page intentionally left blank.

4-2

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work REPAIR WORK - SAFETY INSTRUCTIONS Operation and Maintenance Manual Never carry out repair work without having read and understood the Operation and Maintenance Manual.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Repair personnel Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from CGM HMS.

Working in greater heights Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Prestressed units Never open defective prestressed units but replace them as an entirety.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

The operating manual contains no information on this point.

Dismantling components Never do dismantling while the machine is at operating temperature.

Oils, greases, or coolants may have a high temperature and result in burning or scalding.

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of CGM HMS. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the drive engines while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

4-3

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work CONFINED SPACES - SAFETY INSTRUCTIONS Work in confined spaces can lead to unexpected dangerous situations, such as the formation of flammable vapors exploding during welding operations or the lack of oxygen and harmful gases causing loss of consciousness.

What are "confined spaces"?

Confined spaces on this machine are, for instance, components of the working equipment such as the monoblock boom, the lower part of the boom, the stick or the hydraulic reservoir (Fig. 4-1: - Fig. 4-3:).

These components are provided with manholes.

Manholes offer access to the inside of these components in order to carry out inspections or repairs such as welding work.

Dangerous situations can also exist in other spaces which are not very often visited or which are badly ventilated. In these spaces, harmful or flammable gases can accumulate unnoticed.

Fig. 4-1:

Work in such spaces may only be carried out by specially qualified persons who have been instructed as to the situational risks.

Before visiting these spaces, the following safety precautions must be taken: The narrow space must be ventilated for a prolonged time, e.g. with a blower. Do not blow oxygen into the space. Oxygen increases the risk of fire.

Use your personal protective equipment, e.g. respiratory mask.

Use a safety harness and have a second person stand by with a rescue rope attached to the harness.

Evacuate the gases produced during welding.

Fig. 4-2:

Fig. 4-3:

4-4

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work REPAIR WORK, FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substances can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Avoid parking the hydraulic shovel in places where combustible substances such as coal dust or tar are present.

Place suitable fire guarding (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

open or smoldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

4-5

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work REPAIR WORK, ENGINE Read and observe the "Repair - Safety instructions" chapter and the engine operating instructions before working on the engine.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine and allow to cool down.

Carry out repair work only if the machine has been secured as described in the "Securing the machine" section of these Operation and Maintenance Manual.

Check and replace V-belts only when the engine is stationary.

4-6

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged.

Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work HYDRAULIC SYSTEM Repair instructions Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair Safety instructions".

Replace damaged and leaking hydraulic hoses and pipes as soon as possible by new ones.

Use original spare parts from CGM HMS. They are adapted to the respective function.

Do not re-use old hoses.

Never repair damaged hoses.

Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

Hydraulic hoses – Instructions Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years).

Check the date of manufacture on the hose or on the hose fitting regularly.

The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading.

The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multi-shift operation and round-the-clock work).

Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection: Damage to the outer fiber reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks).

Embrittlement of the outer fiber reinforcement layer (cracks in the hose material).

Changes in the usual shape of the hose under pressure or in pressure less condition in bends or curves such as detachment of fiber layers, formation of bubbles or bulges.

Leaks.

Non-observance of fitting requirements.

Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.

Detachment of the hose from the fitting.

Corrosion in fittings reducing the strength of the function of the fitting.

4-7

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So: Never handle accumulators mechanically, never weld or solder.

Testing and servicing work must be carried out by experts only.

Prior to any testing and servicing work, depressurize the hydraulic part of the system.

To dismantle the accumulator, always wear goggles and working gloves.

Fill accumulator with nitrogen only, never with compressed air or oxygen.

Report any defects or damage to the machine owner without delay.

Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately.

4-8

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work".

Read these safety instructions before starting any welding or flame-cutting operations.

Welding work by qualified personnel only Carry out welding work only if you have received special training and if you have been ordered to perform such work.

Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country.

Observe all warning and instruction signs attached to the machine.

Wear the prescribed personal protective equipment such as: protective clothing,

Increased risk of fire during welding work Always bear in mind that the heat, the sparks or dripping red-hot metal or slag produced in the process constitute a considerable risk of fire.

The present safety instructions provide information on how to minimize the risk of fire.

Remove all combustible materials close to the welding location or cover them up with noncombustible materials.

If works in the vicinity of combustible materials cannot be avoided, further persons with firefighting equipment must be present on site as fireguards.

Observe the instructions of the machine owner and of the mine.

Health hazards Welding operations produce harmful gases. Do not inhale the fumes and gases and make sure the surroundings of the welding location are well ventilated or equipped with an exhaust system.

Remove all kinds of paint and all coatings as well as all residues of oils and greases from the weld area.

Do not wind the welding cables round your body or parts of your body. The electromagnetic fields produced may damage your health.

protective gloves, protective mask and, a fall-arrest system for persons working at height.

4-9

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work Tanks, pressure vessels and pressure accumulators Any work on vessels containing or having contained combustible or combustion-accelerating substances, potentially explosive substances or substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work.

This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease.

Welding work on pressure vessels and pressure accumulators is forbidden.

Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the vessels against damage and high temperatures.

Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured.

Inform yourself about the locations in the machine where the pressure accumulators of the hydraulic system are installed. Do not perform welding work in the vicinity of these pressure accumulators before they have been covered up safely against accidental contact or flying sparks. Have the pressure accumulators removed from the machine, if safe protection cannot be ensured.

4-10

Slewing rings and articulated joints The welding current must not flow through ballbearing or roller-bearing slewing rings, through bolted connections or articulated joints or through hydraulic cylinders.

An electric current flowing through an air gap (e.g. in the bearing or in the articulation) produces a spark which damages the metallic surface.

The welding clamps must therefore always be connected very close to the weld area (max. 2 - 3 m away (6.6-9.8 ft)).

Information relating to the electrical system and to electronic modules Electric arc welding produces electromagnetic fields, electrostatic charges and voltage spikes which can cause damage to electronic modules.

Although the electronic modules of the machine are carefully protected against these influences, it is nevertheless necessary to take additional precautions in order to prevent such damage to the greatest possible extent.

Switch off the electrical system ("ignition OFF").

Open the battery main switch (or disconnect the starter batteries from the machine).

Lay the welding cables as far away from electric lines as possible.

If it is not possible to implement all of the abovementioned precautions, all connectors must be removed from the electronic modules before beginning any welding work.

Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.

Never touch the enclosures of electrical and electronic modules with the welding electrode.

Protect electric lines against the heat emanating from the weld area.

Restore all electrical connections when the welding operations are terminated.

Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work Welding on the counterweight

Welding on the cab

Counterweights may contain a build-up of flammable gases. In case these flammable gases were ignited, deflagrations may occur.

Therefore any work listed below must not be carried out on conterweights: Welding, Flame cutting, Grinding, Drilling, milling and All other mechanical work that generates heat.

For more information please contact your local Caterpillar dealer

The operator's cab is designed in such a way that it meets the FOPS (Falling Objects Protective Structure) requirements in accordance with DIN EN ISO 3449.

Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

Welding on components of the working equipment and on other fully or partly closed steel structures Components may be equipped with pipelines routed inside. These lines can contain combustible substances such as hydraulic oil or lubricating grease which may be set on fire by welding operations.

Check whether pipes or hosepipes are connected to the steel component.

Depressurize these lines.

Open the screwed connections and empty the lines routed inside the component.

Start welding only after these operations have been carried out.

Electric lines may also be be laid inside partly open steel structures in order to protect them against damage. They are not always visible from each viewing direction. Electric lines may catch fire as a result of the heat produced during welding.

Therefore check carefully whether electric lines are laid in the vicinity of the weld area.

Protect electric lines against the heat produced at the weld area or have them removed before starting the welding operations.

Further information More detailed information concerning the state-ofthe-art execution of welding operations can be found in the Service Manual "Welding for maintenance and repair".

For problems or queries please contact the competent service personnel.

If parts of the machine have to be removed or dismantled, please read and observe the chapters: "Assembly of working equipment, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

4-11

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work DISPOSAL AT THE END OF THE SERVICE LIFE Dismantling and removal instructions Before beginning work, think about the risks involved, e.g.: Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity.

Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

Read the following text attentively and observe the instructions given. Respecting the instructions will help you to protect yourself against health hazards and injuries and to prevent avoidable environment pollution.

4-12

Risk of deflagrations In the course of time, flammable gases may have formed or accumulated in the hollow spaces of welded constructions, e.g. the counterweight. To remove these flammable gases, the hollow spaces must be purged carefully with compressed air before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Risk of fire Remainders of fuel or oils may lead to the formation of flammable gases in tanks or other hollow spaces. When these tanks or hollow bodies are cut into pieces, the gases may ignite or even explode.

For this reason, remove all fuel or oil remainders from these components and purge them carefully with compressed air in order to eliminate flammable gases (other efficient methods of removing flammable gases can also be applied) before work with hand grinders, flame cutters or other sparking tools is being undertaken.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work Disposing of the machine without polluting the environment Before stripping down the machine at the end of its service life observe the following instructions: The assemblies of the machine contain various operating fluids or lubricants. These substances may pollute the environment (so-called hazardous substances) and must therefore be disposed of properly.

Observe the national laws and regulations governing the non-polluting disposal of these substances.

Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly.

Fuel system: fuel tanks, fuel filters, fuel lines, filling station.

Auxiliary attachment and units, such as an onboard crane or an auxiliary heater have their own fuel tanks with the corresponding line systems.

Hydraulic oil: hydraulic oil reservoir, hydraulic cylinders, hydraulic motors, hosepipes, piping, hydraulic pumps, hydraulic valves, hydraulic oil filter, filling station.

Further hazardous substances Batteries contain lead and acid.

Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.

Pressure accumulators contain nitrogen under high pressure and possibly remainders of hydraulic oil.

Lamps of Xenon working lights contain mercury.

The required electronic control circuits are integrated in the housings of the working lights.

The fluorescent lamps of the maintenance lighting (discharge types) contain mercury.

Insulating material of cables can contain PVC. The fire extinguishing system (if installed) contains trigger charges (ATTENTION, explosion risk) on the extinguishing agent containers.

Pressure accumulators, extinguishing gas and extinguishing powder.

For more detailed information please refer to the manufacturer's safety datasheets.

Engine coolant: engine, radiator, expansion reservoir, piping and hosepipes, filling station.

Gearbox oil in swing, travelling and transfer gearbox systems, expansion tanks, piping and hosepipes, filling station; idlers, support and track rollers.

Have the refrigerant (R134A) sucked out of the air conditioner system.

Grease from the central lubricating system, grease drum, piping and hosepipes, distributors, filling station; grease accumulations in bearings of the working equipment, grease filling in the swing ring, grease filling in track and support rollers as well as in idlers.

4-13

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work Appropriate disposal of batteries The machine is equipped with batteries containing lead and other harmful and polluting substances.

Damaged or used batteries must therefore not be disposed of in the environment. They must be disposed of properly and separately from other waste.

The batteries are marked with the corresponding symbols (Fig. 4-4:).

Since batteries contain also reusable materials, they are taken back free of charge by the manufacturer, dealer or by other specialized companies.

In the European Community, the final consumer is obliged by law to to dispose of used batteries in designated waste collections centers.

Observe the current regulations and laws of your country with regard to the handling of damaged or used batteries.

Fig. 4-4:

The symbols in Fig. 4-4: have the following meaning: Crossed-out waste bin= Do not dispose of batteries with normal household waste.

Pb……= Chemical symbol for lead.

Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

4-14

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

4-15

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Repair work

This page intentionally left blank.

4-16

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex 5 ANNEX Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

5-1

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex

This page intentionally left blank.

5-2

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex BOARD-CONTROL-SYSTEM, OPERATOR LEVEL BCS III, what’s that?

What it is The BCSIII is the third generation of the Board Control System. This generation represents the current stage of development of this reliable monitoring and control system for Caterpillar Global Mining Hydraulic Mining Hydraulic Mining Shovels (CGM HMS) GmbH. The BCSIII communicates with other electronic units in the shovel and makes up the CAMP system, the Control And Monitoring Platform.

Controllers actuate and monitor functions such as the motor management, drive and control of the hydraulic pumps, the servo control and others. The controllers are basically computers that have been configured for their special application.

Other electronic units of the CAMP system that communicate with the BCSIII are located in cabinets in the module below the operator’s cab, the pump compartment and the engine compartment.

The exchange of data between sensors, controllers, the BCSIII and other involved components takes place via the CAN bus.

What it does The Board Control System, abbreviated to BCS, monitors all the essential functions of the shovel and its components.

It releases an appropriate signal if any maximum value is exceeded and also sends a report to be archived in the memory bank.

If a normal operating status can be reached by temporarily reducing the shovel's output, then this is monitored by BCS and done by the CAMP system.

If it is necessary for the operator to take certain action, e.g. to stop one of the engines a relevant command is sent to the BCS display screen.

BCS also gives information on servicing and trouble-shooting.

Sensors installed at various points on the shovel constantly transmit their readings to the controllers of the CAMP system.

All essential pieces of operating data are displayed on the BCSIII screen in the form of simulated instruments as well as they are archived and can be called up as and when required.

Fig. 5-1:

Benefits for the operator Because BCS automatically warns of any abnormal conditions that require a corrective action, the operator can concentrate fully on the work in hand, and is not distracted by constantly having to keep an eye on many instruments or by having to decide upon appropriate actions to be taken in case of limit values being exceeded.

The operator and the servicing crew also have the means of calling up particular background information from the BCS archive.

The housing – installed in the control column inside the operator’s cab (Fig. 5-1:) – integrates the computer, the monitor, the control elements and the interfaces.

SIL2 functionality Safety related functions on the machine have been checked to minimize the risk of faults in their own function. Tests were performed according to the standards of functional safety (ISO 61508).

To fulfilll the requirements for reaching the Safety Integrated Level 2 (SIL2) new components and electronic units had to be used on the machine.

These components and units are servo-controllers, sensors, switches, hand levers (joysticks), foot pedals and valves.

Want more information?

More detailed and more technical information for service personnel could be found in the “Service Manual”, chapter 9.

There is more extensive information given about the communicating units and about troubleshooting.

5-3

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex The keys on the front side

Other elements on the front side

A membrane keypad is located on the front side of the housing (Fig. 5-2:). The keys can be used to navigate through the screen pages.

The keys in the row below the screen (1 – 0) will perform the same task as the active area on the screen above.

Example: In (Fig. 5-2:) the key (1) lies directly below the active area "Service". Touching the "Service" area or pressing key "1", will take you to the same screen page.

They can also be used for numerical inputs.

The keys provided with arrows on the right side of the screen are used to navigate in a screen page.

Pressing the key with the "door symbol" gives access to the previous screen page.

Pressing the bottom key in the row confirms an input (like “Enter”).

(located on top of the column of keys on the right side) The green LED lights up when the electrical system of the machine is switched on, operating voltage is available. The green LED flashes with each key press and when the background lighting of the screen is turned off.

The yellow LED flashes if the temperature inside the device lies outside the permissible range. The automatic heating system is then active.

The brightness sensor measures the ambient brightness. The BCS automatically controls the background illumination of the screen and the illumination of the keypad.

Fig. 5-2:

5-4

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex BCSIII, the start screen The screen displays the graphical user interface of the Board Control System. The basic screen (Fig. 5-3:) appears when all electronic units of the CAMP system have started and when their selftests have been completed.

Note: At low outside temperatures it is possible that the basic screen appears a few minutes after switching on the electrical system (warming up phase).

Starting from this basic screen, the user can access a number of other screens. This does not require an input device such as a keyboard, mouse or similar.

The BCS screen is designed as a touch-screen. By slightly touching the active areas, the user can perform activities such as changing to another screen page.

Active areas are shown on the screen as threedimensional graphics. In the basic configuration – not activated - they seem to project out of the user interface. When touched, they appear to be lowered.

Never use pointed objects such as a ball pen, screw operator, nail or similar.

This could damage the active surface of the touch-screen.

Do not press on the sensitive areas, just slightly touch them!

Fig. 5-3:

5-5

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Information given on the start screen, top section The symbols shown in the top row of the start screen (Fig. 5-4:) appear in grey color if function is not activated, in green color if everything is OK or in red if a warning is given. In this case more information is displayed in the red “failure row” below.

6

Operating hours meter.

7

Right engine monitoring.

8

Service station, turns to red color if lowered.

Swinging superstructure or travelling the machine not possible then.

1

Left engine monitoring.

2

Central lubrication system monitoring.

9

3

The number of dumpers you loaded is displayed here (if counted with the key in the right joystick).

Hydraulic ladder, turns to red color if lowered. Swinging superstructure or travelling the machine not possible then.

10

Track parking brakes monitoring.

4

Connection to Remote Service System (optional).

11

Superstructure holding brakes monitoring.

12

Servo-switch inside seat monitoring.

5

Hydraulic system monitoring.

Fig. 5-4:

5-6

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Information given on the start screen, central section 1

Left engine data during operation: bar = engine oil pressure, Rpm = revolutions per minute, Ltr = fuel in fuel reservoir, red means: top up with fuel soon.

Water = temperature of cooling fluid in degrees Celsius, left arrowhead-shaped symbol slides up and down displaying the current temperature. The symbol showing a halfed arrowhead is a trailing pointer displaying the maximum temperature. Slide to “0” with your fingertip.

2

Hydr. Oil = Hydraulic oil temperature in degrees Celsius, displayed graphically and numerically.

V = on-board voltage, displayed graphically and numerically.

Spanner symbol = operating time until next service is to be due, symbols are red then.

3

Right engine data during operation: bar = engine oil pressure, Rpm = revolutions per minute, Ltr = fuel in fuel reservoir, red means: top up with fuel soon.

Water = temperature of cooling fluid in degrees Celsius, left arrowhead-shaped symbol slides up and down displaying the current temperature. The symbol showing a halfed arrowhead is a trailing pointer displaying the maximum temperature. Slide to “0” with your fingertip.

Fig. 5-5:

5-7

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Information given on the start screen, lower section 1

2

Button “Service”.

Tapping with your fingertip opens a gate to much more information about the hydraulic shovel’s current behavior.

A menu will appear where you can select the section you want information about (see chapter “Service screen”).

Button “Setup”.

Tapping with your fingertip opens a login window that permits access to the BCS section that is exclusively for service personnel.

A password is needed to get access.

Fig. 5-6:

5-8

3

Button “Fault”.

Tapping this button opens a list of failures stored in the failure memory.

A detailed description can be found in the “Service Manual”, chapter 9.

4

The red “failure row”.

Here the system displays detailed information about the failure occurred and gives instructions about what to do.

5

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

6

Clock.

Can be adjusted in the “Setup” section by service personnel.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Emergency Stop, reset function In case the Emergency Stop function has been activated by one or more of the Emergency Stop switches or by operating the battery circuit breaker, the main screen changes and displays the reset button (1, Fig. 5-7:). The machine is inactivated then, engines cannot be started.

Call the responsible service personnel immediately. The fault has to be located and eliminated.

Before being able to restart the engines the reset button, located in the front door of the 24 Voltswitch cabinet (X1) must be pressed. The switch cabinet is located in the cab module.

After pushing the reset button, the green LED inside the push switch lights up. This signalizes that the Emergency Stop function is back in function again.

1

This symbol appears on the main screen when the Emergency Stop function has been activated.

Fig. 5-7:

5-9

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Swing circuit lock-out function If the system detects an error with the swing function the swing circuit lock-out screen pops up on the main page displaying the faulty component(s).

Call the responsible service personnel immediately. The fault has to be located and eliminated.

The pop-up window disappears after touching anywhere in the window. It will stay in the background until another fault happens or the operator navigates to a different screen and goes back to the main screen.

The fault can be reviewed on the “Servo Controller Menu”, available after logging in to the Setup-Level I-Menu (password required).

Fig. 5-8:

5-10

Squared symbols meanings: Green color = OK Yellow color = Minor fault detected, 48 hours to solve the problem before status changes to red and safe stop sequence is initiated.

Red color = Major fault detected, safe stop sequence is initiated.

The all-over status (green, yellow, red) of the swing circuit is displayed at the end of the chain and correlates with the three conditions mentioned above.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Information given on the “Service” screen 1

2

3

Tapping on the photo of the engine opens a screen displaying current engine data (see “Engine data screen”).

Same result when tapping on button “Engine” or pressing key “1” on the housing.

Tapping on the photo of the hydraulic pumps opens a screen displaying current hydraulic data (see “Hydraulic data screen”).

Same result when tapping on button “Hydraulic” or pressing key “3” on the housing.

Tapping on the photo of the lubrication control opens a screen displaying current lubrication data (see “Lubrication data screen”).

Same result when tapping on button “Lubrication” or pressing key “5” on the housing.

4

Tapping on the photo of the control lever (joystick) opens a screen displaying control elements adjusting data (see “Controls adjustment data screen”).

Same result when tapping on button “Servosystem” or pressing key “7” on the housing.

5

Tapping on this button opens the “View documents” screen (see: “View documents screen”).

6

Adjusting screen brightness. Sliding the green button sets screen brighter / darker.

Tapping on button “Autom.” sets brightness to automatic mode.

7

Tapping on this button opens the “Signal Table” screen (see: “Signal Table screen”).

8

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-9:

5-11

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Engine data screen This screen displays data of the left engine. Same data for the right engine are available after tapping on the button “right engine”.

1

This section of the screen displays current engine data.

2

Here the oil change interval is displayed as well as the remaining operating hours (h) until the next oil change.

After carrying out oil change tap on button “done”, this resets the graphical oil change bar and the (h) counter.

Fig. 5-10:

5-12

3

In this section information about faults and malfunctions are displayed. Fault description follows the SAE J1939 standard.

SPN Number = Suspect Parameter Number, FMI = Failure Mode Identifier.

The “failure row” below displays a failure description.

4

All data displayed can be saved to an USBstick after tapping this button (see: “Saving data to an USB-stick”).

5

Tapping on this button opens a window displaying all the faults / malfunctions the system is able to display (see: “Code Table screen”).

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Hydraulic data screen 1

This screen displays data related to the hydraulic system.

2

All data displayed can be saved to an USBstick after tapping this button (see: “Saving data to an USB-stick”).

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-11:

5-13

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Lubrication data screen 1

2

This screen displays data related to the central lubrication system.

Here is information about the status of the lubricating system of the upper carriage.

If the system detects faults or malfunctions in the lubrication system of the upper carriage they are marked here with a red dot.

Call the responsible service personnel.

Fig. 5-12:

5-14

3

Here you get information about the status of the lubricating system of the under carriage.

4

If the system detects faults or malfunctions in the lubrication system of the under carriage they are marked here with a red dot.

Call the responsible service personnel.

5

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Controls adjustment data screen The characteristic curves of control levers (1, Fig. 5-13:) and control pedals (2) are adjustable by service personnel. The adjusted values are shown here graphically and numerically.

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

If adjustment is needed, call the responsible service personnel.

Adjustment is to be done in the “Setup” section of BCSIII. Access to this area is for service personnel only (password required).

Fig. 5-13:

5-15

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex View documents screen Technical documentation for the machine is stored in memory.

Tapping on the buttons opens the appropriate pdf file and displays it on the screen by means of the build in viewer.

You can navigate inside the documents using the navigation elements known from other computer usage, like buttons, sliders, links from the contents page and so on.

Fig. 5-14:

5-16

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Signal table screen 1

To identify and localize sensors and units on the machine, some photos were attached. If you tap on a “Name” and then the button “Location” became readable, a photo is available. Otherwise the button is grayed.

In Fig. 5-15: ID 110 “Main Pump 1/3 Pressure” is marked and button “Location” (1) is readable. When tapping on it, a photo appears and shows where the sensor is located (see Fig. 5-16:).

2

Tapping on button “Diagram” opens a screen showing the data coming from four sensors in a diagram (see Fig. 5-17:).

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

This is a listing of all the signal sources that are connected to the BCS- and CAMP-system.

In the “Status” column small icons visualize the signal status: green=ok; red=malfunction.

In column “Code” you can find the identifier for the sensor or unit that helps the maintenance personnel to localize the sensor in the electric schematics (in this example the identifier for the sensor is “3B22”) .

Fig. 5-15:

5-17

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Signal table screen, location Button “Location” has been tapped, a photo appears showing where the sensor “3B22” is located at the machine.

Fig. 5-16:

5-18

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Signal table screen, diagram This is a diagram showing the data coming from four signal sources (sensors) for a longer period of time.

The signal sources (channel 1-4) can be selected from a listing after tapping the “Config” button (see: “Signal table screen, diagram configuration”).

1

Tapping on button “Config.” opens a window listing all the signal sources available for BCS and CAMP (Fig. 5-18:).

2

Listing of the four signal sources selected: ID, Name, actual value and value at cursor in the diagram.

3

Rec = starts recording the data from the selected sources; Stop = stops recording data; Rev = scrolls the diagram in reverse; Fwd = scrolls the diagram forwards.

4

Diagram window, displays the data from four sources as four lines in different colors.

5

Save = save data to memory; Load = load older data from memory; Delete = delete data displayed.

6

Buttons to scroll, scale up, scale down and reset to base setting the diagram window.

7

Select signal source to be displayed (channel 1-4)

8

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-17:

5-19

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Signal table screen, diagram configuration Button “Config.” has been tapped, a window appears displaying all the signal sources available.

In column “Channel” you can mark four signal sources whose data you want to display in the diagram (Fig. 5-17:).

Mark the line with the signal source you want and press the appropriate numeric key on the BCS housing: “1” for channel 1; “2”, “3” and “4” for the other channels.

Fig. 5-18:

5-20

1

For example: This signal source is selected and marked to be displayed on channel 3.

2

For example: This signal source is selected and marked to be displayed on channel 2.

3

Tapping the button will confirm your selection.

4

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Code table screen Coming from the “Engine data screen” (Fig. 5-10:) after tapping the “Code Table” button.

This screen displays a listing of all available trouble codes according to the SAE J1939 standard.

Active faults or malfunctions are displayed on the “Engine data screen” with their “SPN Number” and their “FMI Number”. To get the description for the fault or malfunction, key in both numbers at (1) and tap on the button left aside.

The appropriate description will be displayed (2).

1

SPN = Suspect Parameter Number, according to SAE J1939 standard, For example: 94

2

FMI = Failure Mode Identifier, according to SAE J1939 standard, For example: 18

3

Tapping these buttons will scroll the listing: forward, reverse, to beginning, to end.

4

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-19:

5-21

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Slew brake test screen The slew brake test screen (Fig. 5-20:) is available after logging in to the Setup-Level I-Menu (password required).

A slew brake test must be performed during commissioning of the machine and after repair work or maintenance work carried out on the slewing system.

The slew brake test should be performed at every maintenance scheduled by the customer.

This is to ensure proper functioning of the slew brake system. Proper functioning of the slew brake system has influence to machine safety.

Before performing the slew brake test, ensure the machine is in a safe workplace where the machine can rotate 360° without hitting an obstacle. Check that all persons have left the area around the machine. Activate the horn.

To perform the slew brake test, follow the instructions (4) given on the screen.

Fig. 5-20:

5-22

1

Preconditions to be fulfillled before performing the slew brake test, from left to right: - swing brake applied, - servo control switch in control column must be in position OFF, - operator sitting on his seat.

Symbols change to green with precondition fulfillled.

Time limit to fulfilll preconditions is 60 sec.

2

Button to start the test.

3

Hydraulic pressures in the units of the slewing systems, left-hand and right-hand.

4

Instructions to perform the slew brake test.

5

Instruments displaying hydraulic pressure in left-hand / right-hand slewing system.

6

Indicators showing the progress during testing: -“pending”, color red after starting the test, -“in progress”, color yellow ehen 300 bar, - “passed”, color green when test OK.

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex BCS III, interfaces The BCS system comes with different data interfaces. This feature allows the communication with external electronic devices.

Three connectors are located on the right-hand side-wall of the control column (Fig. 5-21:): 1

USB 2.0, jack type A. This jack accepts, for example, a USB stick used to save operating data for evaluation on an external computer.

2

Jack D sub, 9 pins.

Used to connect a computer with a diagnosis software with access to the CAN bus.

This connection is reserved for service personnel.

3

Fig. 5-21:

Ethernet, jack type RJ45.

For the connection of future extensions, for example, the CMDI system (i.e. Caterpillar Mining Data Interface).

USB interface, data storage A USB stick can be connected to the USB plug-in connection of type A (1, Fig. 5-21:).

Suitable are such USB sticks that would also work ® on computers with WINDOWS operating systems; they may be formatted with the NTFS or the FAT32 file system.

If a screen page displays the symbol of a USB stick, the operating data of this screen page can be saved. The BCS will create a text file.

For a detailed description see: “Saving data to a USB stick”.

5-23

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Saving data to a USB stick All screens which have the “USB-stick-button” (1, Fig. 5-22:) offer the functionality to store data for external use.

All data related to the current screen will be stored to a USB stick. In this example all data from the “Service, left engine” screen will be saved to a file.

File format is RTF (Rich Text Format).

The file name will be automatically created following this pattern: “Shovel type+serial number+screen name.rtf”.

For example: “RH120172_Engine_LH.rtf”.

If this file already exists, an extension with increment numbers will be added to the file name: “RH120172_Engine_LH_(1).rtf”.

“RH120172_Engine_LH_(2).rtf”. ……

Fig. 5-22:

5-24

Save data: Plug a USB stick into the USB jack (see: “BCSIII, interfaces”).

To save the data, tap on button (1, Fig. 5-22:).

The BCS system checks the USB interface before saving the data. If no USB stick is detected, a new window appears showing the folder structure on the CF-card as well as the message “Please plug a USB stick”..

If a USB stick is found, a new window appears, see next page (Fig. 5-23:).

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Saving data to a USB stick, continued This window shows the current data you want to save in a file and asks for confirmation.

If you want to save the data tap on the “Yes” button (1, Fig. 5-23:). The file will be written on the USB stick.

Otherwise tap on the “No” button and return to the screen you want.

If you want to see the files stored on the USB stick, tap on the “Open” button (2).

A new window appears showing the folder / file structure on the USB stick, see next page (Fig. 5-24:).

Fig. 5-23:

5-25

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Saving data to a USB stick, continued This window (Fig. 5-24:) displays the folder / file structure on the USB stick plugged into the USB jack.

Mark the file you want to see by tapping on the filename (2).

Tapping a button “show” (1) opens another window which shows the file.

Tapping the button with the door icon (3) leaves the current screen and opens the previous screen.

Fig. 5-24:

5-26

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex BCSIII, cleaning

BCSIII, disposal

Clean dirty screens with a soft, slightly moist cloth.

In order to remove persistent dirt, you can use in addition a conventional cleaning agent for LCD monitors.

This electronic device contains substances that might be harmful to the environment.

The electronic components and the tubes of the background illumination contain, for example, lead (Pb) and mercury (Hg).

The background illumination lamps are CCFL-typelamps (Cold Cathode Fluorescent Lamps).

The battery for backing up the memory contains lithium.

Therefore, this device must not be disposed of with your regular household waste. It must be disposed of properly as electronic scrap.

Never use solving or scouring cleaning agents.

This could damage the surface of the screen.

Do not use compressed air or water under pressure (high pressure cleaner or steam cleaner).

This could damage the electronic components.

The escaping liquid from a damaged LCD screen may be harmful.

Do not come in contact with escaping liquids. In case of skin contact, wash immediately with water and soap.

5-27

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex TROUBLESHOOTING Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

For this reason, it is vital to read through the relevant section of the Operation and Maintenance Manual once again before rectifying any faults.

If you are unable to detect the cause of the fault or to rectify it, apply to the CGM HMS after-sales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM HMS after-sales service. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified.

The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

Fault The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

Study the problem carefully. First think, then act.

Ask yourself the following questions: Which warning signals preceded the fault?

What repair and servicing work was carried out previously?

Has this defect already occurred?

Is it one or several simultaneously occurring faults?

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the Operation and Maintenance Manual. If there is no entry, the CGM HMS after-sales service should be consulted

5-28

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex FAULT TABLES Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts, but runs unevenly or intermittently Engine gets too hot, temperature warning activated Engine not working at full power Engine not working on full cylinder capacity Engine without oil pressure or oil pressure too low Engine oil consumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly Cause Oil level too low •

• • •

• • • • •

• •

•

•

•

•

•

A

Oil level too high

Engine oil level

S

Engine inclination too big

Engine Op. P Instr.

W Lubricants

•

• •

Air filter contaminated / turbo-charger defective

Engine Op. W Instr.

Air intake syst. P

Fuel filter contaminated

Fuel filter

Fuel quality not corresponding to specification •

• •

1) Contact the CGM HMS Service

Chapter ref.

Engine oil level

Engine oil of wrong SAE-class

•

Remedial action P Check E Adjust W Replace A Top up S Reduce R Clean

P/W P

Charge-air line leaking

•

Radiator / cooling fins contaminated

•

Cooling fan or water pump defective or loose

•

Cooling air gets too hot / heat build-up

Cooler cleaning R Engine Op. P/W Instr.

P

•

Battery defective or discharged

Battery

•

Cable connections in starter circuit loose or corroded

P

Starter defective or pinion not in mesh

P

• •

•

•

• • • •

•

•

•

• • • •

•

• • • •

Injection valve defective Combustion engine blocked on output side

•

•

Engine Instr.

• •

• PMS malfunction • Celect coding lamp flashing/lit Celect defective (software error)

Op. E P

Injection line leaking

• •

1)

Shut-off relay jamming Incorrect valve setting

P

Engine Instr.

Op. P/W 1) 1) 1) 1)

5-29

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Working hydraulics – Fault table Fault

Remedial action

Working and swing functions not operational No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics Uncontrolled working movements Cause Electronic shovel control not activated/defective

•

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS Service Chapter ref.

Working

P

•••••

•

Malfunction of pressure-relief valve

1)

•

•

Servo system pump defective

1)

••••• • •

ECO-power switch in 80%-position

•

Fuel filter contaminated

• • •

• •

5-30

• Malfunction of primary / secondary pressure-relief valves Engine speed too low

1) P P Fuel filter

P/W

Engine mal- 1) function Hydraulic oil temperature too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R lamp lit) oil cooler contaminated cooler cleaning 1) Engine coolant temperature too high (warning lamp lit and PMS fault indicator lamp flashing) 1) • Malfunction of solenoid valves Insufficient engine power

• Malfunction of control spool Engine coupling defective

1)

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Track drive – Fault table Fault

Remedial action

No forward travel and no reversing travel Maximum travel speed cannot be reached Insufficient traction power

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS Service Chapter ref.

•

•

•

Cause Malfunction of pressure-relief valves

•

•

•

Servo system pump defective

1)

•

•

•

• •

•

Malfunction of travel valve (pedal)

1)

Engine nominal speed too low

1)

Malfunction of control spool

1)

•

ECO-power switch in 80%-position

•

Insufficient engine power

• •

1)

Travelling

P

Engine mal- 1) function Hydraulic oil temperature too high (warning lamp lit, PMS fault Hydraulic oil P/R indicator lamp lit) oil cooler contaminated cooler cleaning 1) Engine coolant temperature too high (warning lamp lit and PMS fault indicator lamp flashing)

5-31

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Swing mechanism – Fault table Fault

Remedial action

No swing possible P E W A S R

•

Cause Electronic shovel control not activated / defective

Check Adjust Replace Top up Reduce Clean 1) Contact the CGM HMS Service Chapter ref.

Working

•

Limiting switch optional, hydraulic ladder not complete retracted

Operation

P

•

Superstructure holding brake applied

P

Pressure-relief valve adjusted too low level / defective

1)

Servo system pump defective

1)

No right-hand or left-hand swinging Swing performance insufficient Uncontrolled swinging movement

•

•

• • •

•

Malfunction in feed-pressure circuit of swing pump

1)

•

Malfunction in high-pressure circuit of swing system

1)

•

Malfunction of moment-regulating valve

1)

Malfunction in swing pump displacement cylinder

1)

Excessive leakage in swing motor

1)

•

• •

5-32

P

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Central lubricating system – Fault table Fault

Remedial action

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

•

Cause Timer defective

•

• •

•

•

•

Check Adjust Replace Top up Reduce Clean Vent 1) Contact the CGM HMS Service Chapter ref.

P E W A S R L

P/W

Lines between timer and hydraulic motor defective

P/W

Hydraulic motor defektive

P/W

•

Grease pump defective

P/W

•

Grease sieve clogged

P/R

•

Distributor defective

P/W

•

Grease container empty

P/A

•

Grease pump does not suck grease

P/L

•

Leaky lines

P/L

•

Non-return valve defective Pressure switch defective

P/W E

•

•

5-33

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Engine control module, displaying stored fault codes Engine electronics, displaying faults The engines electronic control modules (ECM) can display and record detectable fault conditions within the ECM system and circuits.

The fault lamps are located in the front panel of the control cabinet in the cab module (Fig. 5-25:).

The fault lamps (1, 2 and 3, Fig. 5-26:) for the left engine (LH) and (4, 5 and 6) for the right engine (RH) will light up for approx. two seconds after switching on the electrical system of the machine using key switch (32, Fig. 5-27:). They will go out one after the other when no faults are being detected.

Fig. 5-25:

While a fault condition is being detected, the fault lamps will turn “ON“: Engine stop lamp (1 = LH and 4 = RH) Level 1 faults, includes engine protection and critical sensor in-range faults.

Indicates that continued operation will likely damage the engine.

Operator must stop the engine as soon as safety permits.

Warning lamp (2 = LH and 5 = RH) Level 2 faults, includes critical sensor out of range faults.

Indicates that critical sensors are not functional.

Operator must schedule engine service and have the fault corrected that same day.

Fig. 5-26:

Engine monitoring lamp (3 = LH and 6 = RH) Level 3 faults, includes engine information and non-critical sensor out of range faults.

Indicates that service is required within the next preventative maintenance interval.

The fault must be corrected at the next preventative maintenance operation.

Fig. 5-27:

5-34

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex Engine electronic, displaying faults in memory To determine an active fault code, the system must be switched into diagnostic mode. To do so: Shut off engine.

Turn key switch electrical system (32) in position „ON“, don’t start the engine.

Turn momentary switch „ACTIVATION FAILURE MEMORY“ (7 or 9, Fig. 5-28:) for one or two seconds to the right.

If there are no active faults in the memory, fault lamps (1 – 6, Fig. 5-26:) will light up only while momentary switch (7 or 9, Fig. 5-28:) is turned.

However, if an active fault does exist, the warning lamp will begin flashing out the three digit diagnostic code.

Example: One single flash; Two flashes with short pause between = 2; Short pause; Three flashes with short pause between = 3; Short pause; Four flashes with short pause between = 4; One single flash; Longer pause, then repeating the same code.

The fault code is = 234.

Fig. 5-28:

Increment / Decrement switch (8 and 10, Fig. 5-28:) is used to sequence forward or backwards through the active faults in memory.

In the engine manufacturers manual for the ECMSystem you can find a table listing all the fault codes with information about reason and effect.

Contact the responsible person or your dealer service.

To quit the diagnostic mode, turn key switch electrical system (32) in position “OFF” or start the engine.

5-35

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex HYDRAULIC CIRCUIT DIAGRAM

Vibration data

Detailed information can be found in the „Service Manual“ chapter 8 or contact CGM HMS Service.

On the condition that the shovel is used within the limits of its designated use, the installation of seats for operators in conformity with ISO 7096 ensures that the weighted vibration accelerations awz (measured in compliance with ISO 2631 Part I) fulfilll the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG. The vibrations transferred are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. the "Lärm - und Vibrations-Arbeitsschutzverordnung" of 18.12.2008, Section 4.

The effective value of the weighted acceleration to which the whole-body is exposed, does not exceed 2 0.5 m/s .

The measurement uncertainty is ±3% (tolerance of the measuring instruments).

5-36

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex ABBREVIATIONS A abt. acc.

Ah API approx.

Ampere (SI base unit of electric current) about according to Ampere hours (SI base unit of quantity of electricity) American Petroleum Institute approximately

BA bar Bh

= OI = Operation and Maintenance Manual unit of pressure, 1 bar = 14.5 psi = OH = Operating hour

CAMP CE

Control and Monitoring Platform Communauté Européenne = European community Committee for European Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee 1 centimeter (= /100 m) Cubic centimeters per revolution counterclockwise Caterpillar Global Mining clockwise

CECE

CEN cm 3 cm /rev CCW CGM CW dB(A) dia.

DIN

Decibel (sound intensity according measuring method A) Diameter German Industrial Standard

ECM eff. e.g.

EN etc.

Electronic Control Module on engines Effective For example European Standard Et cetera

Fig. FMI FOPS FS ft

Figure, serial number of illustration Failure Mode Identifier, description malfunctions according to SAE J1939 Falling objects protective structures Rock shovel (working equipment) foot (unit of distance), 1 ft = 0.30 meter

gal GET

gallon (unit of volume), 1 gal = 3.78 liters Ground Engaging Tool

HD HMS Hydr.

Heavy duty Hydraulic Mining Shovel Hydraulic, Hydraulics

i i.e.

Transmission ratio id est = that is

to

of

IFN

ISO service rating, blocked

Incl.

ISO

Including, inclusive of International Standardization Organization

kg 3 kg/dm

Kilogram (unit of weight), 1 kg = 2.2 lb Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

km/h kNm kW l lb Lb/in² LED l/min LpA LwA

Liter (unit of volume), 1 liter = 0.26 gal pound (unit of mass), 1 lb = 0.45 kg Pounds per square inch (= psi) Light-emitting diode Liters per minute Sound pressure at workplace Sound power level of the machine in stationary operation

m MA mA max. min.

-1 min mm

Meter (unit of distance), 1 m = 3.28 ft Tightening torque 1 Milliampere (= /1000 A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (=1/1000 m)

N N, kN NLGI NLGI– Klasse Nm No.

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency – lubricant classification acc. to DIN 51 818 Newtonmeter (unit of torque) Number

OH op.inst.

OW

Operating hour Operation and Maintenance Manual Superstructure

oz

ounce (unit of volume) 1 oz = 0.03 liter

PMS P/No. PPE PS psi PLC

Pump Managing System Part number Personal Protection Equipment Metric horsepower (1 PS = 0.74 kW) pound per square inch (unit of pressure), 1 psi = 0.069 bar Programmable logic controller

Qty.

Quantity

5-37

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex ABBREVIATIONS R, r resp.

RTF ROPS rpm

Radius Respectively Rich Text Format, text based file format Roll-over protective structures -1 Revolutions per minute (= min )

SAE sec./s.

SM SN SPN

Society of Automotive Engineers (USA) Second Service Manual CGM HMS part number Suspect Parameter Number, description of malfunctions according to SAE J1939 Width across flats

SW t TBG THB TL tm typ.

U/min USB UW V VDMA

Metric ton (= 1000 kg) Civil Engineering Employer’s Liability Insurance Association Technical Handbook i.e. Service Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of swing torque) Typical Revolutions per minute Universal Serial Bus, interface for fast data exchange Undercarriage Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W

Watt (unit of electric power)

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

5-38

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex PRODUCT SPECIFICATION SHEET

5-39

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex

This page intentionally left blank.

5-40

BI015760

6090 FS Hydraulic Shovel We understand the challenges you face, the importance of reliability, and the relationship between uptime and productivity. That’s why we continually strive to produce the safest, most reliable and productive hydraulic mining shovels possible. Offering the widest payload range of any manufacturer in the industry, the ability to optimally pair with our popular line of mining trucks, and the support of our world-class Cat® dealer network, we are uniquely positioned to partner with you to help achieve your productivity targets. We understand what matters to you.

Our hydraulic mining shovels are built with you in mind.

Because in mining, every day matters and every load counts.

Substantially larger than any other available hydraulic mining shovel, the 6090 FS offers a versatile and selective digging capable alternative to electric rope shovels.

Having garnered more than a decade of field experience in varying applications and climates, we have refined the design for improved reliability and productivity, substantiated by a greater than 100% increase in 6090 FS orders over the past two years. When paired with our ultra-class line of Cat mining trucks, you can load up to 9000 tonnes (9,900 tons) of material per hour.

General Data

Operating Weight

Operating weight Face Shovel Engine output SAE J1995 Standard bucket capacity Face Shovel (SAE 2:1)

Shovel Standard track pads Operating weight Ground pressure

980 tonnes

1,080 tons

3360 kW

4,500 hp

52.0 m3

68.0 yd3

2000 mm 980 000 kg 25.8 N/cm2

• Additional track pads available on request

Features • TriPower shovel attachment • Independent oil-cooling system • Spacious walk-through machine house • 5-circuit hydraulic system • Electronic-hydraulic servo control • Board Control System (BCS) • Torque control in closed-loop swing circuit • Automatic central lubrication system • LED working lights

6 ft 7 in 2,160,510 lb 37.4 psi

6090 FS Hydraulic Shovel Specifications Diesel Engines Cummins QSK60 Make and model Total rated net power ISO 3046/1 Total rated net power SAE J1349 Total rated net power SAE J1995 Number of cylinders (each engine) Bore Stroke Displacement Aspiration

Maximum altitude without deration – above sea level Emission certification Fuel tank capacity

Electrical System (diesel drive) System voltage Batteries in series/parallel installation

2 × QSK60 2-stage 4,500 hp 3360 kW 1,800 min-1 1,800 min-1 3360 kW 4,500 hp 1,800 min-1 1,800 min-1 3360 kW 4,500 hp 1,800 min-1 1,800 min-1 16 159 mm 6.25 in 190 mm 7.48 in 60.2 L 3,674 in3 2-stage turbocharged; aftercooled and intercooled 4880 m 16,000 ft

Alternators Working spot lights

Hydraulic System with Pump Managing System Main pumps Maximum oil flow Diesel version AC version

U.S. EPA Tier 4 Interim 15 100 L 4,000 gal

Maximum pressure, attachment Maximum pressure, travel Swing pumps Maximum oil flow Diesel version AC version Maximum pressure, swing pumps Total volume of hydraulic oil – approximately Hydraulic tank capacity – approximately

Electric Motors – 6090 AC FS

Total Output Voltage Total Rated Current IN Frequency Revolutions Maximum starting current

24V 6 × 210 Ah – 12V each 630 Ah – 24V in total 2 × 175A each 12 × high brightness LED lights

• Battery isolation relays • Emergency stop switches accessible from ground level, in engine module and in operator’s cab

• Hydraulically driven radiator fan with electronically controlled fan speed • Micro processed engine control • Heavy-duty air fi lters with automatic dust evacuation • Two-stage fuel fi lter includes water separator • Additional high-capacity water separator • Pre-lube starting system • Eliminator with centrifuge for engine oil fi ltration • Engine-oil-change interval of 1,000 hours

Type

BI015760

2 × Squirrel cage induction motors 3200 kW 6.6 kV ± 10% (other on request) 332A 50 Hz (60 Hz on request) 1,500 min-1 (1,800 min-1 at 60 Hz) 780A

8 × variable flow axial piston pumps 8 × 936 8 × 247 L/min gal/min 8 × 943 8 × 249 L/min gal/min 310 bar 4,495 psi 360 bar 5,220 psi 6 × reversible swash plate pumps 6 × 488 L/min 6 × 496 L/min 350 bar 13 000 L

6 × 129 gal/min 6 × 131 gal/min 5,080 psi 3,450 gal

10 000 L

2,640 gal

• Pump Managing System contains: – Electronic load limit control – Flow on demand from main pumps depending on joystick position – Automatic regulation of main pumps to zero flow without demand – Automatic RPM reduction of engine speed during working breaks – Reduced oil flow of main pumps at high hydraulic oil temperature or engine temperature • Pressure cut-off for main pumps • Cooling of pump transmission gear oil • Filters: – Full-flow high-pressure fi lters (100 μm) for the main pumps, installed directly behind each pump – High pressure fi lters (100 μm) for the closed swing circuit – Full-flow fi lters (10 μm) for the complete return circuit – Full-flow fi lters (10 μm) for the cooling return circuit – Pressure fi lters (40 μm and 6 μm) for servo circuit – Transmission oil fi lters (40 μm)

• Custom-made electric motors with increased gap between rotor and stator to withstand severe mining conditions • Power limit control by Pump Management System

2

6090 FS Hydraulic Shovel SpecifiBI015760 cations Hydraulic Oil Cooling Oil flow of cooling pumps Diesel version AC version Diameter of fans

Operator’s Cab Operator’s eye level – approximately Internal dimensions of cab Length Width Height Internal dimensions of amenity cab Length Width Height

4 × 975 4 × 258 L/min gal/min 4 × 1000 4 × 264 L/min gal/min 4 × 1524 mm 4 × 60 in

• Cooling system is fully independent of all main circuits, i.e. controlled cooling capacity is available whenever engine is running • Gear-type cooling pumps supplying high-volume, low-pressure oil to aluminum coolers • Fan speed is thermostatically controlled • Extremely high cooling efficiency to ensure optimum oil temperature

Parking brakes

Maximum swing speed Diesel version AC version Swing ring

28 ft 10 in

2200 mm 1600 mm 2150 mm

7 ft 3 in 5 ft 3 in 7 ft 1 in

1600 mm 1600 mm 2150 mm

5 ft 3 in 5 ft 3 in 7 ft 1 in

• Pneumatically cushioned and multi-adjustable comfort seat with lumbar support, seat heating, safety belt, head and armrests • Safety switch in seat cushion to automatically neutralize the hydraulic controls when operator leaves the seat • Joystick controls integrated in independently adjustable seat consoles • Fold-away auxiliary seat with safety belt • FOPS (rock guard; approved according to DIN ISO 3449) integrated into cab structure • All-round safety glass, armored windshield and sliding side window • Windshield with parallel intermittent wiper/washer • Roller blind at windshield • Robust instrument panel includes large colored BCS screen with transflective technology • Board Control System (BCS); electronic monitoring and data logging system for vital signs and service data of engines, hydraulic system and lubrication system • Machine access via retractable boarding ladder, hydraulically operated

Swing System Swing drives

8.8 m

6 compact planetary transmissions with axial piston motors Wet multiple disc brake, spring-loaded/hydraulically released 3.9 rpm 4.1 rpm Triple race roller bearing with sealed internal gearing

• Closed-loop swing circuit with torque control • Hydraulic braking of the swing motion by counteracting control • All race ways of swing ring as well as grease bath for internal gearing supplied by automatic central lubrication system

Retractable Service Station Retractable service station installed underneath the engine module and easily accessible from ground Equipped with: • Quick couplings for: – Diesel fuel – Engine coolant – left/right – Pump transmission gear oil – left/right – Engine oil (oil pan) – left/right – Engine oil (additional tank – optional) – left/right – Hydraulic oil tank – Grease container • Cat® jump-start socket • Indicator lights for fuel tanks left/right full and grease container full

3

6090 FS Hydraulic Shovel Specifications Undercarriage Travel speed (2 stages) 1st stage – maximum 2nd stage – maximum Maximum tractive force Gradeability of travel drives – maximum Track pads (each side) Bottom rollers (each side) Support rollers (each side) Travel drives (each side)

Parking brake

BI015760

Automatic Lubrication System Capacity of grease container 1.6 km/h 1.4 2.2 km/h 1.9 4338 kN 44%

0,87 mph 0.99 1.37 1.18 mph 974,880 lbf

1000 L

264 gal

• Dual-circuit system with hydraulically driven heavy-duty pump and electronic time relay control to adjust the pause/lube times • Connected to the lubrication system are the swing roller bearing with internal gearing, and all pivot points of attachment, bucket and cylinders • System failures displayed by Board Control System • Grease fi lters (200 μm) between service station and container as well as directly behind grease pump

48 7 2 plus a skid plate in between 1 planetary transmission with 2 two-stage axial piston motors Wet multiple disc brake, spring applied/ hydraulically released

Attachment • Boom and stick are torsion-resistant, welded box design of high-tensile steel with massive steel castings at pivot areas • Welding procedures allow for internal counter-welding (double prep weld) wherever possible • Boom and stick are stress-relieved after welding • Inspection hole in boom and stick • Catwalks with rails at boom • Pressure-free lowering of boom and stick by means of a float valve • Shovel attachment with unique TriPower kinematics ensuring the following main features: – Horizontal automatic constant-angle bucket guidance – Vertical automatic constant-angle bucket guidance – Automatic roll-back limiter to prevent material spillage – Kinematic assistance to hydraulic forces – Constant boom momentum throughout the entire lift arc – Crowd force assistance • All buckets are equipped with a wear package consisting of: – Special liner material covering main wear areas inside and outside of bucket – Lip shrouds between teeth – Wing shrouds on side walls – Heel shrouds at bottom edges • Special wear packages for highly abrasive materials on request

• Cast double-grouser combined pad-links with bushings connected by hardened full floating pins • All running surfaces of sprockets, idlers, rollers and pad links, as well as teeth contact areas of sprocket and pad links, are hardened • Fully hydraulic, self-adjusting track tensioning system with membrane accumulator • Automatic hydraulic retarder valve to prevent over-speed on downhill travel • Acoustic travel alarm • Idlers, bottom rollers and support rollers are connected to the automatic lubrication system

4

6090 FS Hydraulic Shovel SpecifiBI015760 cations Dimensions All dimensions are approximate.

8 9

10 11

14

1

4

2

3 5

6

12

7

13

1

8800 mm

28 ft 10 in

8

8050 mm

26 ft 5 in

2

2945 mm

9 ft 8 in

9

7800 mm

25 ft 7 in

3

3150 mm

10 ft 4 in

10

9720 mm

31 ft 11 in

4

7470 mm

24 ft 6 in

11

7600 mm

24 ft 11 in

5

1135 mm

3 ft 9 in

12

2000 mm

6 ft 7 in

6

8445 mm

27 ft 8 in

13

8600 mm

28 ft 3 in

7

10 980 mm

36 ft 0 in

14

9990 mm

32 ft 9 in

5

6090 FS Hydraulic Shovel Specifications

BI015760

Working Range – TriPower Face Shovel Attachment (FS) All dimensions are approximate. ft 70

m 22

65

20

60

18

55 50

16

45

14

40

12

35

10

30 25

8

20

6

15

4

10 5 0 5

2 0 2

10 22 70

20

18

65

60

16 55

50

14

12

45

40

10 35

30

8

6

25

20

4 15

2

0 m

5

0 ft

10

Boom

9.5 m

31 ft 2 in

Boom

9.5 m

31 ft 2 in

Stick

5.8 m

19 ft

Stick

5.8 m

19 ft

3300 kN 3200 kN 2400 kN

741,610 lbf 719,140 lbf 539,350 lbf

Working Range Maximum digging height Maximum digging reach Maximum digging depth Maximum dumping height

20.2 m 19.0 m 2.3 m 14.5 m

66 ft 3 in 62 ft 4 in 7 ft 7 in 47 ft 7 in

Crowd distance on level

6.2 m

20 ft 4 in

Face Shovels Type Tooth system Capacity SAE/PCSA 1:1 Capacity SAE/CECE 2:1 Total width Inner width Opening width Number of teeth Weight including universal wear kit Maximum material density (loose)

Iron Ore Shovel on request 56.9 yd3 43.5 m3 3 37.0 m 48.4 yd3 5600 mm 18 ft 4 in 5100 mm 16 ft 9 in 2700 mm 8 ft 10 in 6 77 000 kg 169,750 lb 2.6 t/m3 4,380 lb/yd3

Digging Forces Maximum crowd force Maximum crowd force at ground level Maximum breakout force

Heavy Rock Shovel on request 48.4 m3 63.3 yd3 3 42.0 m 54.9 yd3 5600 mm 18 ft 4 in 5100 mm 16 ft 9 in 2700 mm 8 ft 10 in 6 79 500 kg 175,270 lb 2.2 t/m3 3,710 lb/yd3

6

Heavy Rock Bucket Shovel on request 54.0 m3 70.6 yd3 3 47.0 m 61.5 yd3 6170 mm 20 ft 3 in 5600 mm 18 ft 4 in 2650 mm 8 ft 8 in 6 84 300 kg 185,850 lb 2.0 t/m3 3,370 lb/yd3

Standard Rock Shovel on request 59.8 m3 78.2 yd3 3 52.0 m 68.0 yd3 6170 mm 20 ft 3 in 5600 mm 18 ft 4 in 2650 mm 8 ft 8 in 6 86 000 kg 189,600 lb 1.8 t/m3 3,030 lb/yd3

BI015760 6090 FS Hydraulic Shovel Optional Equipment

Optional Equipment Optional equipment may vary. Consult your Cat dealer for details.

GENERAL • Export crating • Finishing as per end user’s corporate colors • Customizing of logos as per customer’s specification

SUPERSTRUCTURE • Hydraulic service crane on superstructure with auxiliary engine • Mesabi radiators instead of standard radiators • 2nd retractable boarding ladder on righthand side of engine module • Various cold-weather packages • Additional lighting

Additional optional equipment available on request.

7

CAB • Various heating and air conditioning systems • Outside-mounted sun shields • Additional instrumentation UNDERCARRIAGE • Track pad width 1800 mm (5 ft 11 in)

BI015760

6090 FS Hydraulic Shovel

Materials and specifications are subject to change without notice.

Featured machines in photos may include additional equipment.

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.cat.com © 2013 Caterpillar Inc. All Rights Reserved.

CAT, CATERPILLAR, SAFETY.CAT.COM, their respective logos, “Caterpillar Yellow” and the “Power Edge” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Product ID: 6090 FS

AEHQ7170 November 2013

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

5-41

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Annex

This page intentionally left blank.

5-42

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Index 6 INDEX Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

6-1

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Index

This page intentionally left blank.

6-2

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Index

A ABBREVIATIONS ........................................ 5-4 About this Operation and Maintenance Manual1-1 Access ladder lighting ................................ 2-18 Activating the electronic shovel control ..... 2-91 After daily operation ................................... 2-95 Air conditioner (optional) ............................ 2-77 Air-intake lines, check ................................ 3-59 AIR-INTAKE SYSTEM ............................... 3-55 Alternator - Instructions.............................. 3-65 Appropriate disposal of batteries ................. 4-8 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .................................... 2-96 Automatic fire-extinguishing system (optional)2-31 Automatic reset to idling .............................. 2-9 Avoid mixing of different hydraulic fluids3-29, 3-89

B Back-up heating (option), filling in Diesel fuel2-65 Back-up heating (optional) ......................... 2-79 Back-up heating operator’s cab (optional) . 2-78 Battery isolator switch, shutting off supply voltage2-25 Battery storage ........................................ 3-125 Battery, checking the state of charge ........ 3-69 Battery, removing and installing ................ 3-70 BCS III, interfaces ...................................... 5-23 BCS III, what’s that? .................................... 5-3 BCSIII, cleaning ......................................... 5-27 BCSIII, disposal ......................................... 5-27 BCSIII, the start screen................................ 5-5 Bearing races ........................................... 3-108 Before starting work ................................... 2-91 Board-Control-System (BCS) ...................... 2-9 Board-control-system, operator level ........... 5-3 Braking the superstructure......................... 2-92 Breather filter ........................................... 3-112 Bypass valves (filter housing - cooling system)3-81 Bypass valves (hydraulic oil reservoir) ...... 3-79

C Carbody-crawler frame fastening bolts and disks, replace.................................................. 3-104 CENTRAL LUBRICATING System .......... 3-110 Central lubricating system – Fault table .... 5-33 Changing the hydraulic oil ......................... 3-89 Charging batteries inside the machine, safety instructions ............................................. 3-71 Checking the gas charging pressure in the pressure accumulator................ 3-107, 3-122 Checking the gearbox oil level / Topping up with oil3-96 Checking the greasing pressure .............. 3-113 Clam cylinder chamber, check for soiling 3-119 Cleaning the hydraulic oil cooler ................ 3-93 Code table screen ...................................... 5-21

Cold-starting fluid (ether) – Replacing the pressure vessel ...................................................... 3-47 Combustion engine - Fault table ................ 5-29 confined spaces - Safety instructions........... 4-4 Control and Monitoring Platform (CAMP)..... 2-8 Controls adjustment data screen ............... 5-15 Coolant for use on all combustion engines 3-35 Cooling liquid change ................................. 3-52 COOLING SYSTEM ................................... 3-48 Cooling-liquid level, check .......................... 3-49 Cooling-liquid, topping up ........................... 3-50 Corrosion protection for pins and bearings (bushings and hubs) ............................... 2-98 CRAWLER TRACKS ................................ 3-104

D Demand control / Zero-flow regulation ......... 2-9 DESCRIPTION OF THE hydraulic shovel.... 2-6 Design ...................................................... 3-110 Designated use ............................................ 1-3 Designated use, unauthorized use............... 1-4 Dismantling and removal instructions .......... 4-6 Disposal at the end of the service life .......... 4-6 Disposing of the machine without polluting the environment .............................................. 4-7 Drive unit ...................................................... 2-8 Dust collection, function ............................. 3-59

E Electrical circuit diagrams .......................... 3-65 Electrical Storm Injury Prevention .............. 2-64 Electrical system .......................................... 2-9 ELECTRICAL SYSTEM ............................. 3-65 Electrical system - Safety instructions........ 3-65 Electrical system switch-cabinets............... 3-65 Electronic shovel control ............................ 3-94 Eliminator filter and centrifuge .................... 3-45 Emergency exit in operator’s cab and escape ladder ...................................................... 2-20 Emergency lowering of the equipment ....... 2-94 Emergency off switch ................................. 2-67 Emergency shut-off function ...................... 2-23 Emergency Stop, reset function ................... 5-9 Engine ...................................................... 3-117 ENGINE ...................................................... 3-37 Engine - Safety instructions ....................... 3-37 Engine 1 (LH), control and monitoring ....... 2-43 Engine 2 (RH), control and monitoring ....... 2-45 Engine control module, displaying stored fault codes ...................................................... 5-34 Engine data screen .................................... 5-12 Engine oil reservoir, checking the oil level . 3-39 Engine oil reservoir, filling in /draining off the oil3-42 Engine oil, change ...................................... 3-40 Engine oil, checking the oil level / topping up3-38 Engines – adjusting the speed ................... 2-75 Engines, emergency shut-off ..................... 2-72

6-3

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Index Entering and leaving the machine, Safety instructions ............................................. 2-18 Extract from the German regulations....... 3-122

Hydraulic system - Safety instructions ....... 3-74 Hydraulic system, depressurizing .............. 3-74 Hydraulic tank breather filter, replace ........ 3-82

F

I

FAULT TABLES ......................................... 5-29 Filling........................................................ 3-112 Filling quantities - Grease .......................... 3-25 Filling quantities - oil .................................. 3-28 Filling quantities - other.............................. 3-28 Filter (control circuit main pumps), replace 3-83 Fire and explosion hazard .................. 1-11, 2-5 Fire extinguisher ........................................ 2-30 Fluid for hydraulic system .......................... 3-31 Folding ladder ............................................ 2-19 Fuel filters, draining water.......................... 3-62 Fuel filters, replace .................................... 3-60 FUEL SYSTEM .......................................... 3-60 Fuel system - Safety instructions ............... 3-60 Fuel tank breather filter, replace ................ 3-63 Fuel tank supply valve, function ................ 3-60 Fuel tanks, clean ........................................ 3-63 Function ................................................... 3-111 Further hazardous substances .................... 4-7 Further machine documentation .................. 1-1

Information given on the ............................. 5-11 Information given on the start screen, central section ...................................................... 5-7 Information given on the start screen, lower section5-8 Information given on the start screen, top section5-6 Inspection and servicing - Safety instructions3-3 Inspection and Servicing plans - Instructions3-9 inspection and servicing work, Fire and Explosion Hazard ...................................................... 3-7 INSPECTION PLAN - OIL .......................... 3-26 Inspection plan – Oil (legend) .................... 3-27 Instructions on troubleshooting .................. 5-28

G Gas, dust, steam and smoke ....................... 1-9 Grease filter replace (Filling the grease container)3-115 Grease filter replace (Grease lines)......... 3-116 Greases for bearings, swing rings and track system .................................................... 3-34

H Harness (optional) ..................................... 2-32 Heating and air conditioning, check......... 3-118 High-pressure filter for working hydraulics, replace3-84 High-pressure filters for feeding circuits and swing pumps..................................................... 3-87 High-pressure filters for pump-flushing circuit3-86 High-pressure filters for swing circuit, replace3-88 High-pressure filters for the servo circuit, replace3-85 Hose line for oil and cooling liquid changes3-36 HYDRAULIC CIRCUIT DIAGRAM .............. 5-3 Hydraulic data screen ................................ 5-13 Hydraulic equipment .................................. 1-10 Hydraulic hoses – Instructions ..................... 4-1 Hydraulic LADDERS ................................ 3-121 Hydraulic oil level, check ........................... 3-75 Hydraulic oil return-flow filters (filter housing cooling system), replace ........................ 3-80 Hydraulic oil return-flow filters (hydraulic oil reservoir), replace .................................. 3-77 Hydraulic shovel layout ................................ 2-7 Hydraulic system ......................................... 2-8 HYDRAULIC SYSTEM .............................. 3-74 HYDRAULIC SYSTEM ................................ 4-1

6-4

L Layout of the fault table .............................. 5-28 Lighting systems in LED technology, instructions3-68 LUBRICANTS / consumables .................... 3-29 LUBRICATING CHART – GREASE ........... 3-24 Lubricating chart – Grease (legend)........... 3-25 Lubrication data screen .............................. 5-14

M Main control valves – attach/remove the handrail2-97 Main filter elements .................................... 3-55 Maximum machine inclinations, information2-80 Measures .................................................... 5-28 Mirror – cleaning / adjusting position........ 3-120 Monitoring cameras .................................. 2-102 MONITORING, WARNING AND CONTROL ELEMENTS ............................................ 2-36

N Noise emission information .......................... 1-5 Notes ............................ 1-13, 2-103, 3-127, 5-8 NOTES ......................................................... 4-9 Notes on the selection of oils and greases 3-29

O Oil filter for hydraulic circuit grease pump, replace3-114 Oil for combustion engines and compressors3-30 Oil for pump drive gearboxes and travel gearboxes3-32 Oils for swing gearboxes ............................ 3-33 ON-BOARD CRANE (OPTIONAL) ............. 2-99 On-Board crane, – blocking the boom in position of rest ........................................................ 2-101 On-board crane, checking ........................ 2-101 On-Board crane, checking tightness of fastening bolts ...................................................... 3-124 On-board crane, drive unit ....................... 3-123 On-board crane, drive unit ....................... 2-100 On-board crane, lubricating ...................... 3-124

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Index On-board crane, monitoring, warning and control elements ................................................. 2-99 On-board crane, putting into operation .... 2-100 Operating hours meter ............................... 2-29 Operation - Safety instructions .................... 2-3 Operation and Maintenance Manual, where to store it in the operator’s cab ..................... 2-4 Operator’s seat .......................................... 2-26 Organizational measures ............................. 1-6 Other elements on the front side ................. 5-4 OTHER MAINTENANCE ......................... 3-117

P Plan A - E ................................................... 3-17 Plan N ........................................................ 3-13 Plan T and W ............................................. 3-15 Plan V ........................................................ 3-11 Possible causes ......................................... 5-28 Pre-chambers, expansion reservoir........... 3-98 Preface......................................................... 1-1 Pressure accumulator - Emergency lowering3-95 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ...................................... 4-2 Pressure-accumulator inspection regulations3-107 Pressure-accumulator inspection regulations3-122 product specification sheet .......................... 5-6 PUMP DRIVE GEARBOX.......................... 3-96 Pump drive gearbox breather .................... 3-98 Pump drive gearbox lube oil filters, clean / replace3-99 Pump drive gearbox, Changing the gearbox oil3-97 Putting the hydraulic shovel out of operation3-125 PUTTING THE hydraulic shovel OUT OF OPERATION AND RECOMMISSIONING3-125 Putting the machine back into operation, reset of emergency shut off function ................... 2-24 PUTTING THE MACHINE INTO OPERATION2-64

R Radiators ................................................... 3-49 Recommissioning .................................... 3-125 Reducing operators exposure to vibrations 2-28 Reducing the operator's exposure to noise 2-64 Refueling .................................................... 2-65 Repair instructions ....................................... 4-1 Repair work - Safety instructions ................. 4-3 repair work, ENGINE ................................... 4-6 repair work, Fire and Explosion Hazard ...... 4-5 Replacing lamps and bulbs ....................... 3-65 Reservoirs for used grease at the A-frame, emptying ............................................... 3-118 Risk of deflagrations .................................... 4-6 Risk of fire .................................................... 4-6

S Safety instructions governing specific operational phases ...................................................... 1-7 Safety line on boom ................................ 2-96

Saving data to a USB stick ......................... 5-24 Saving data to a USB stick, continued5-25, 5-26 Secondary filter element ............................ 3-58 Section ....................................................... 5-28 Securing the machine................................. 2-97 Selection and qualification of personnel; basic responsibilities .......................................... 1-7 Service station (tanklift) .............................. 2-66 SERVICING WORK ................................... 3-36 Shutting off the engines ............................. 2-76 Signal table screen ..................................... 5-17 Signal table screen, diagram ...................... 5-19 Signal table screen, diagram configuration 5-20 Signal table screen, location ...................... 5-18 Signs........................................................... 2-10 Slew brake test screen ............................... 5-22 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables...................................... 1-8 Starter isolator switch, shutting off starter voltage2-25 Starting and stopping the engines.............. 2-74 Starting the engines ................................... 2-74 Starting the engines at low temperatures... 2-75 Superstructure .............................................. 2-8 Superstructure basic position ..................... 2-83 Superstructure holding brake ..................... 2-87 Swing circuit lock-out function .................... 5-10 SWING GEARBOX .................................. 3-100 Swing gearbox - checking the oil level / topping up with oil ................................................... 3-100 Swing gearbox venting ............................. 3-101 Swing gearbox, changing the gearbox oil 3-101 Swing mechanism – Fault table ................. 5-32 SWING RING ........................................... 3-108 Swing ring - Instructions ........................... 3-108 Swinging the superstructure ....................... 2-92 Switchgear cabinet ..................................... 3-72 Switching the cab interior lighting on and off2-21 Switching the electrical system on and off . 2-72 Switching the maintenance lights on and off2-22

T The keys on the front side ............................ 5-4 Track drive – Fault table ............................. 5-31 Track parking brake.................................... 2-87 Track tensioner......................................... 3-105 Tracks – cleaning ..................................... 3-104 Trainer's / instructor's seat ......................... 2-28 Transport - Safety instructions ................... 2-88 Transporting the machine .......................... 2-88 TRAVEL GEARBOX................................. 3-102 Travel gearbox - changing the oil ............. 3-102 Travel gearbox - checking the oil level / topping up with oil ................................................... 3-102 TRAVELLING ............................................. 2-83 Travelling forwards/backwards................... 2-83 TRAVELLING, SAFETY INSTRUCTIONS . 2-82 TROUBLESHOOTING ............................... 5-28

6-5

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Index

Venting the hydraulic system ..................... 3-92 Vibration data ............................................... 5-3 Vibration information .................................... 1-5 View documents screen............................. 5-16

Warnings and symbols ................................. 1-3 Warranty ....................................................... 1-2 Water filter, change .................................... 3-54 Welding and flame cutting works - Safety instructions ................................................ 4-3 Window panes - cleaning ......................... 3-120 Windscreen washer .................................... 2-29 Working equipment, check welding seems3-119 Working hydraulics – Fault table ................ 5-30 WORKING OPERATION............................ 2-91 Working operation - Safety instructions ..... 2-89 Working operations .................................... 2-93

W

X

Warning of special dangers ......................... 1-9

Xenon floodlight projector, replacing the lamp3-66

U Unblocking a grease line ......................... 3-113 Undercarriage .............................................. 2-8 USB interface, data storage....................... 5-23

V

6-6

BI015760

OMM 6090, 6090FS(3 847 002.04)-EN

Index

This page intentionally left blank.

6-2

BI015760

© Copyright Caterpillar Global Mining HMS GmbH 2014

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Printed in Germany