Cat 6090ACFS Hydraulic Shovel Operation and Maintenance Manual BI015810 – PDF DOWNLOAD

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Cat 6090ACFS Hydraulic Shovel Operation and Maintenance Manual BI015810 – PDF DOWNLOAD

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Cat 6090ACFS Hydraulic Shovel Operation and Maintenance Manual BI015810 – PDF DOWNLOAD

Language : English
Pages : 248
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat 6090ACFS Hydraulic Shovel Operation and Maintenance Manual BI015810 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH 400
Introduction
PREFACE

• These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency.
• Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine. The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
• The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as

In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.

• This can be acquired, for example, in several days’ instruction by a qualified mechanic or by attending an Terex O&K training course for operators or maintenance personnel. The Terex O&K after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. All Terex O&K operating manuals are issued in German and then translated.
• Even a good translation may give rise to questions which Terex O&K will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex O&K aftersales service.
• 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 operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you

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TABLE OF CONTENTS:

Cat 6090ACFS Hydraulic Shovel Operation and Maintenance Manual BI015810 – PDF DOWNLOAD

1 INTRODUCTION............................................................................................................................................................... 13
	PREFACE.................................................................................................................................................................. 15
	WARRANTY................................................................................................................................................................. 16
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17
		Warnings and symbols................................................................................................................................................. 17
	DESIGNATED USE........................................................................................................................................................... 18
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 19
		Selection and qualification of personnel; basic responsibilities..................................................................................................... 20
		Safety instructions governing specific operational phases............................................................................................................ 20
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 21
		Warning of special dangers........................................................................................................................................... 22
		Gas, dust, steam and smoke........................................................................................................................................... 23
		Hydraulic / pneumatc equipment....................................................................................................................................... 23
		Noise................................................................................................................................................................ 23
		Oil, grease and other chemical substances............................................................................................................................ 23
		Transporting and recommissioning..................................................................................................................................... 23
	ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS ..................................................................................................... 24
	SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR .................................................................................................................. 26
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 27
	NOTES.................................................................................................................................................................... 29
2 OPERATION.................................................................................................................................................................. 31
	OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 33
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 35
	DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 36
		Excavator layout..................................................................................................................................................... 37
		Undercarriage........................................................................................................................................................ 38
		Superstructure....................................................................................................................................................... 38
		Drive................................................................................................................................................................ 38
		Hydraulic system..................................................................................................................................................... 38
		Pump Managing System (PMS)........................................................................................................................................... 38
		Programmable Logic Controller (PLC) ................................................................................................................................. 38
		Control Management System (CMS) ..................................................................................................................................... 38
		Demand control / Zero-flow regulation................................................................................................................................ 39
		Board-Control-System (BCS) .......................................................................................................................................... 39
		Electrical system ................................................................................................................................................... 39
		Signs ............................................................................................................................................................... 43
		Entering and leaving the machine Safety instructions................................................................................................................. 44
		Ramp-type ladder .................................................................................................................................................... 45
		Escape ladder (Optional) ............................................................................................................................................ 46
		EMERGENCY STOP switch ............................................................................................................................................... 48
		Servicing switch .................................................................................................................................................... 49
		Windscreen washer ................................................................................................................................................... 49
		Driver's seat ....................................................................................................................................................... 50
		Fire extinguisher.................................................................................................................................................... 52
		Automatic fire-extinguishing system (optional)....................................................................................................................... 53
		Emergency escape device (optional)................................................................................................................................... 54
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 58
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 77
		Service station (tanklift) .......................................................................................................................................... 77
		Battery main switch, switching on and off ........................................................................................................................... 80
		Electrical system (24V), switching on and off ....................................................................................................................... 80
		Switching the electric motors on and off ............................................................................................................................ 81
		Time-out before restart ............................................................................................................................................. 82
		Electric motors can not be switched on .............................................................................................................................. 83
		In case of failure .................................................................................................................................................. 83
		Circuit breaker, switching on and off ............................................................................................................................... 84
		Motor protection relay, functions ................................................................................................................................... 86
		Air conditioner (option)............................................................................................................................................. 87
	DRIVING SAFETY INSTRUCTIONS ............................................................................................................................................. 88
	TRAVELLING .............................................................................................................................................................. 89
		Superstructure basic position ....................................................................................................................................... 89
		Travelling forwards/backwards ....................................................................................................................................... 89
		Locking the superstructure .......................................................................................................................................... 93
		Track parking brake ................................................................................................................................................. 93
	TRANSPORTING THE MACHINE ................................................................................................................................................ 94
		Transport - Safety instructions ..................................................................................................................................... 94
	WORKING OPERATION - SAFETY INSTRUCTIONS ................................................................................................................................. 95
	WORKING OPERATION ....................................................................................................................................................... 97
		Before starting work ................................................................................................................................................ 97
		Swinging the superstructure ......................................................................................................................................... 97
		Braking the superstructure .......................................................................................................................................... 97
		Working ............................................................................................................................................................. 98
		Emergency lowering of the working equipment ......................................................................................................................... 99
		 After daily operation .............................................................................................................................................. 99
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................100
		Securing the machine ................................................................................................................................................102
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................103
	NOTES  ..................................................................................................................................................................105
3 INSPECTION AND SERVICING...................................................................................................................................................107
	SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTORS .................................................................................................................109
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................111
	FIRE AND EXPLOSION HAZARD ...............................................................................................................................................117
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................119
		Intervals............................................................................................................................................................119
		Oils / Greases ......................................................................................................................................................119
		Cleaning jobs .......................................................................................................................................................119
		Components ..........................................................................................................................................................119
		Plan V ..............................................................................................................................................................121
		Plan N ..............................................................................................................................................................123
		Plan T and W ........................................................................................................................................................125
		Plan A – E ..........................................................................................................................................................127
	LUBRICATING CHART – GREASE ..............................................................................................................................................134
		Lubricating chart – Grease (legend) .................................................................................................................................135
		Filling quantities - Grease..........................................................................................................................................135
	INSPECTION PLAN - OIL ...................................................................................................................................................136
		Inspection plan – Oil (legend) ......................................................................................................................................137
		Filling quantities - oil ............................................................................................................................................138
		Filling quantities - other...........................................................................................................................................138
	LUBRICANTS ..............................................................................................................................................................139
		Notes on the selection of oils and greases ..........................................................................................................................139
	LUBRICANTS ..............................................................................................................................................................140
		I. Oils for combustion engines (On-Board Crane, option) .............................................................................................................140
		II. Oils for hydraulic system (selection) ...........................................................................................................................141
		III.a Oils for pump gearboxes .......................................................................................................................................142
		III.b Oils for swing gearboxes ......................................................................................................................................143
		III.c Oils for drive gearboxes ......................................................................................................................................144
		V. Greases for bearings and swing rings .............................................................................................................................145
	SERVICING WORK ..........................................................................................................................................................146
		Hose line for oil changes ...........................................................................................................................................146
	ELECTRIC MOTOR ..........................................................................................................................................................147
		Electric motor - Safety instructions ................................................................................................................................147
		Cleaning the electric motors  .......................................................................................................................................147
		Electric motors, greasing ...........................................................................................................................................148
	ELECTRICAL SYSTEM  ......................................................................................................................................................149
		Electrical system - Safety instructions .............................................................................................................................149
		Battery .............................................................................................................................................................150
		Control cabinets ....................................................................................................................................................152
		Slip ring assembly ..................................................................................................................................................154
		Floodlight projector, replacing the lamp ............................................................................................................................155
	HYDRAULIC SYSTEM ........................................................................................................................................................157
		Hydraulic system - Safety instructions ..............................................................................................................................157
		Depressurizing the hydraulic system .................................................................................................................................157
		Checking the hydraulic oil level ....................................................................................................................................158
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................160
		Bypass valves (hydraulic oil reservoir) .............................................................................................................................162
		Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................163
		Bypass valves (filter housing) ......................................................................................................................................164
		Breather filter .....................................................................................................................................................165
		Filter (control circuit).............................................................................................................................................166
		High-pressure filter for working hydraulics .........................................................................................................................167
		High-pressure filters for the servo circuit .........................................................................................................................168
		High-pressure filters for pump-flushing circuit .....................................................................................................................169
		High-pressure filters for slewing circuit ...........................................................................................................................170
		Changing the hydraulic oil ..........................................................................................................................................171
		Venting the hydraulic system.........................................................................................................................................175
		Cleaning the hydraulic oil cooler....................................................................................................................................176
		Electronic excavator control.........................................................................................................................................177
		Pressure accumulator - Emergency lowering............................................................................................................................178
	PUMP TRANSFER GEARBOX ...................................................................................................................................................179
		Checking the gearbox oil level / Topping up with oil ................................................................................................................179
		Gearbox venting .....................................................................................................................................................181
		Pre-chambers, checking oil level ....................................................................................................................................181
		Gear oil filter .....................................................................................................................................................182
	SWING GEARBOX ...........................................................................................................................................................183
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................183
		Changing the gearbox oil ............................................................................................................................................184
		Gearbox venting .....................................................................................................................................................184
	TRAVEL GEARBOX ..........................................................................................................................................................185
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................185
		Travel gearbox - Changing the oil ...................................................................................................................................185
		Preliminary gearbox - Draining off oil ..............................................................................................................................186
	CRAWLER TRACKS ..........................................................................................................................................................187
		Track tensioner .....................................................................................................................................................189
		Pressure-accumulator inspection regulations .........................................................................................................................191
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................191
	SLEWING RING ............................................................................................................................................................192
		Slewing ring - Instructions..........................................................................................................................................192
		Bearing races........................................................................................................................................................192
	CENTRAL LUBRICATING .....................................................................................................................................................194
		Design ..............................................................................................................................................................194
		Function ............................................................................................................................................................195
		Filling up the grease container .....................................................................................................................................196
		Breather filter .....................................................................................................................................................196
		Checking the greasing pressure ......................................................................................................................................197
		Unblocking a grease line ............................................................................................................................................197
		Oilfilter for hydraulic circuit grease pump replace .................................................................................................................198
		Grease filter replace (Filling the grease container) ................................................................................................................199
		Grease filter replace (Grease lines) ................................................................................................................................200
	OTHER MAINTENANCE .......................................................................................................................................................201
		Heating and air conditioning ........................................................................................................................................201
		Equipment ...........................................................................................................................................................201
	LADDER (OPTIONAL) .......................................................................................................................................................202
		Pressure-accumulator inspection regulations .........................................................................................................................203
		Extract from the German regulations..................................................................................................................................203
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................203
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................204
		Monitoring, warning and control elements ............................................................................................................................204
		Checking the on-board crane..........................................................................................................................................204
		Drive unit ..........................................................................................................................................................205
		On-board crane, servicing ...........................................................................................................................................205
		On-Board crane, checking tightness of fastening bolts ...............................................................................................................206
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................207
		Putting the excavator out of operation...............................................................................................................................207
		Battery storage......................................................................................................................................................207
		Recommissioning......................................................................................................................................................207
	NOTES  ..................................................................................................................................................................208
4 REPAIR WORK................................................................................................................................................................212
	SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ..................................................................................................................214
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................216
	FIRE AND EXPLOSION HAZARD ...............................................................................................................................................218
	HYDRAULIC SYSTEM.........................................................................................................................................................219
		Repair ..............................................................................................................................................................219
		Hydraulic hoses – Instructions  .....................................................................................................................................219
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................220
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................221
	NOTES ...................................................................................................................................................................222
5 ANNEX......................................................................................................................................................................224
	TROUBLESHOOTING .........................................................................................................................................................226
		Instructions on troubleshooting .....................................................................................................................................226
		Layout of the fault table ...........................................................................................................................................226
		Possible causes .....................................................................................................................................................226
		Measures ............................................................................................................................................................226
		Section .............................................................................................................................................................226
	FAULT TABLES ............................................................................................................................................................227
		Working hydraulics – Fault table ....................................................................................................................................227
		Track drive – Fault table ...........................................................................................................................................228
		Swing mechnism – Fault table ........................................................................................................................................229
		Central lubricating system – Fault table ............................................................................................................................230
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................231
	ABBREVIATIONS ...........................................................................................................................................................232
	TECHNICAL DATA ..........................................................................................................................................................234
	NOTES  ..................................................................................................................................................................240
6 INDEX......................................................................................................................................................................242

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