CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90005 – PDF DOWNLOAD

Description

CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90005 – PDF DOWNLOAD

FILE DETAILS:

CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90005 – PDF DOWNLOAD

Language : English
Pages : 228
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90005 – PDF DOWNLOAD

Preface:
These operating instructions are designed to fa- miliarize the operator with the machine
and its designated use.

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

• In addition to the operating instructions and the mandatory rules and regulations for
  accident pre- vention and environmental protection in the user’s country and at the place
  where the machine is to be used, the generally recognized technical rules for safe and
  proper working must be observed [1].
• The operating instructions are directed to the con- struction-machine specialist. They cannot
  provide basic know-how. This can be acquired, for exam- ple, in several days’ instruction by
  a qualified O&K Mining mechanic or by attending an O&K Mining training course for
  operators or maintenance per- sonnel.
• The O&K-Mining after-sales service will be pleased to deal with any queries you
  may have after reading through the operating instructions.
• All O&K Mining operating manuals are issued in German and then translated. Even a good
  transla- tion may give rise to questions which O&K Mining 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 O&K Mining after-sales serv- ice.

• 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 oper- ating 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.

IMAGES PREVIEW OF THE MANUAL:

Need help? Contact: [email protected]

TABLE OF CONTENTS:

CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90005 – PDF DOWNLOAD

PART 1 – INTRODUCTION 1
Preface 3
Warranty 3
FUNDAMENTAL SAFETY INSTRUCTIONS 4
Warnings and symbols 4
Designated use 4
Organizational measures 5
Selection and qualification of personnel; basic responsibilities 6
Safety instructions governing specific operational phases 6
Standard operation 6
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 7
Warning of special dangers 8
Electric energy 8
Gas, dust, steam and smoke 8
Hydraulic and pneumatic equipment 9
Noise 9
Oil, grease and other chemical substances 9
Transporting and recommissioning 9
ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED
EXCAVATORS 10
Fire and explosion hazard 12
NOTES 13
PART 2 – OPERATION 15
Operation – Safety instructions 17
Fire and explosion hazard 19
DESCRIPTION OF THE EXCAVATOR 20
Excavator layout 21
Undercarriage 21
Superstructure 21
Loading bucket 21
Undercarriage 22
Superstructure 22
Drive 22
Hydraulic system 22
Pump Managing System (PMS) 22
Stored Program Control (SPC) 22
Demand control / Zero-flow regulation 23
Board Control System (BCS) 23
Electrical system 23
Power supply 23
Signs 25
Warning and instruction signs 25
Machine number 25
Electric motor number 25
Component numbers 25
Entering and leaving the machine Safety instructions 26
Ramp-type ladder 26
Access 27
Escape ladder 27
Ramp lighting 27
Cab interior lamp 28
Servicing lighting 29
110 V socket 29
EMERGENCY STOP pushbuttons 30
Unlocking the EMERGENCY STOP button 30
Windscreen washer 31
Driver’s seat 32
Adjusting the backrest 32
Adjusting the lumbar support 32
Adjusting the seat cushion 32
Adjusting the armrests 32
Fore-and-aft adjustment 32
Adjusting the seat suspension 32
Fore-and-aft adjustment of the seat plate 32
Passenger seat 33
Adjusting the backrest 33
Adjusting the seat cushion 33
Adjusting the armrests 33
Fore-and-aft adjustment 33
Adjusting the seat suspension 33
Fire extinguisher 34
Extinguishing agent 34
Inspection 34
Automatic fire-extinguishing system 35
Inspection 35
MONITORING, WARNING AND CONTROL ELEMENTS 36
PUTTING THE MACHINE INTO OPERATION 60
Refilling of consumables 60
Refilling – Safety instructions 60
Service station (tanklift) 60
Lowering the service station 60
Raising the service station 60
Refilling / draining 60
Electrical system on / off 63
Battery main switch 63
Switch-disconnector 64
Switching on 64
Shutting off 64
Off-load disconnector 64
Switching on 64
Shutting off 64
Motor protective relay 65
Switching the electric motor on and off 66
Before switching on the electric motor 66
Switching on 67
Shutting off 68
EMERGENCY STOP 68
TRAVELLING – SAFETY INSTRUCTIONS 69
TRAVELLING 70
Superstructure basic position 70
Travelling forwards/backwards 70
Regulating the travelling speed 71
Travelling on level ground 71
Cornering 71
Turning 71
Travelling over longer distances 73
Locking the superstructure 74
Track parking brake 74
Transporting the machine 75
Transport – Safety instructions 75
Transport 75
WORKING OPERATIONS – SAFETY INSTRUCTIONS 76
WORKING OPERATION 78
Before starting work 78
Warming up 78
Switching on the electronic excavator control 78
Slewing and braking the superstructure 78
Braking the superstructure 78
Working 79
Raising and lowering the boom 79
Extending and retracting the bucket or backhoe bucket stick 79
Filling and emptying the bucket 79
Opening and closing the bucket 79
Lowering the equipment in an emergency 79
After daily operation 80
Parking the machine 80
ASSEMBLY OF WORKING EQUIPMENT – SAFETY INSTRUCTIONS 81
Securing the machine 83
Corrosion protection for pins and bearings (bushings and hubs) 84
Voler A C : 84
Application of Voler A C 84
NOTES 85
PART 3 – INSPECTION AND SERVICING 87
Inspection and servicing – Safety instructions 89
Fire and Explosion Hazard 93
Inspection and servicing plans – Instructions 95
Intervals 95
Oils / Greases 95
Cleaning jobs 95
Oil-check service 95
Contact the O&K Mining After-Sales Service 95
Plan V – Once prior to initial commissioning 97
Plan V – Once prior to initial commissioning 98
Plan N – After initial commissioning and during the running-in period 99
Plan T – Every 10 OH or every working shift 101
Plan W – Every 60 OH or once a week 101
Plan A – after every 250 OH 103
Plan C – after every 1000 OH 103
Plan B – after every 500 OH 103
Plan D – after every 5000 OH 103
Plan E – after every 10000 OH 103
LUBRICATING CHART – GREASE / LOADING BUCKET 108
Lubricating chart – Grease / Loading bucket (legend) 109
Refilling quantities – Grease 109
INSPECTION PLAN – OIL 110
Inspection plan – Oil (legend) 111
Refilling quantities – Oil 112
Refilling quantities – Others 112
LUBRICANTS 113
I Oils for combustion engines and compressors (selection) 113
II Oils for hydraulic systems (selection) 114
III Oils for gearboxes (selection) 115
V Greases for bearings and slewing rings 116
SERVICING WORK 117
Hosepipe for oil and coolant changes 117
ELECTRIC MOTOR 118
Electric motor – Safety instructions 118
Greasing the electric motors 118
Cleaning the electric motor 118
ELECTRICAL SYSTEM 119
Electrical System – Safety Instructions 119
Battery main switch 119
Battery 120
Checking the battery fluid level 120
Checking the battery charge 120
Removing and installing the battery 120
Charging the batteries 121
Control cabinet 122
Venting filter 122
Cleaning the pre-filter 122
Emptying the dust collector 122
Filter element 122
Checking and cleaning the filter element 123
Control cabinet 124
Venting filter 124
Replacing the filter element 124
Checking the filter element 124
Slip ring unit 125
HYDRAULIC SYSTEM 126
Hydraulic system – Safety instructions 126
Depressurizing the hydraulic system 126
Checking the hydraulic oil level / Topping up 127
Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) 129
Bypass valves (hydraulic oil reservoir) 131
Cleaning the filter sieves 131
Replacing the hydraulic oil return-flow filters (filter housing – cooling system) 132
Bypass valves (filter housing – cooling system) 133
Cleaning the filter sieves 133
Breather filters 134
Replacing the filter elements 134
High-pressure filter for working hydraulics 134
Checking / cleaning the filter elements 135
Replacing the filter elements 135
High-pressure filter for the servo circuits 136
Checking / cleaning the filter elements 136
Replacing the filter elements 136
High-pressure filters for pump-flushing circuit 137
Checking / cleaning the filter elements 137
Replacing the filter elements 137
High-pressure filters for feeding circuits/slewing gear pumps 138
Checking / cleaning the filter elements 138
Replacing the filter elements 138
High-pressure filters for slewing circuit 139
Changing the hydraulic oil 140
Drawing off the hydraulic oil 140
Cleaning the hydraulic oil reservoir 141
Filling in hydraulic oil 142
Venting the hydraulic system 143
Venting the hydraulic components 143
Cleaning the hydraulic oil cooler 144
Cleaning 144
Pressure accumulator – Emergency lowering 145
Pressure-accumulator inspection regulations 145
Extract from the German regulations 145
Extract from the German acceptance regulations 145
Checking the gas charging pressure in the pressure accumulator 145
PUMP TRANSFER GEARBOX 146
Checking the gearbox oil level / Topping up 146
Drawing off oil 146
Filling in oil 147
Gearbox venting 148
Pre-chamber 148
Checking the oil level 148
SLEWING GEARBOX 149
Gearbox – Checking the oil level / Topping up 149
Changing the gearbox oil 149
Draining off oil 149
Filling in new oil / Topping up 150
Gearbox venting 150
Venting bore 150
Slewing gear neck 150
TRAVEL GEARBOXES 151
Travel gearbox – Checking the oil level / Topping up 151
Travel gearbox – Changing the oil 151
Main gearbox – Draining off oil 151
Preliminary gearbox – Draining off oil 151
Main and preliminary gearbox – Filling in oil 152
Pre-chamber – Draining off oil 152
Pre-chamber – Filling in oil 152
CRAWLER TRACKS 153
Cleaning 153
Track rollers 153
Topping up oil 153
Cleaning 153
Track roller fastening 154
Support rollers 154
Support roller fastening 154
Track tensioner 154
Design 154
Technical data 155
Function 155
Pressure-accumulator inspection regulations 155
Extract from the German regulations 155
Extract from the German acceptance regulations 155
Checking the gas charging pressure in the pressure accumulator 156
Idlers 157
Checking the oil level 157
Filling in oil 157
Greasing the idler guides 157
SLEWING RING 158
Slewing ring – Instructions 158
Bearing races 158
Internal gearing 158
Slewing ring – Checking the grease filling 159
Slewing ring – Filling in grease 159
Slewing ring – Checking the screws for tightness 159
CENTRAL LUBRICATING SYSTEM 160
Design and function 160
Filling the grease container 161
Breather filter 161
Checking the greasing pressure 162
Unblocking a grease line 162
Cleaning the grease sieve 162
Cleaning 162
AIR CONDITIONER 163
Venting filter 163
Cleaning the pre-filter 163
Emptying the dust collector 163
Filter element 163
Checking and cleaning the filter element 164
OTHER MAINTENANCE WORK 165
Cooling system 165
RAMP-TYPE LADDER 166
Guide pulleys and locking bolt 166
Pressure-accumulator inspection regulations 167
Extract from the German regulations 167
Extract from the German acceptance regulations 167
Checking the gas charging pressure in the pressure accumulator 167
ON-BOARD CRANE 168
Monitoring, warning and control elements 168
Checking the on-board crane 168
Extract from the inspection and testing regulations 168
Drive unit 169
Crane engine 169
Air-intake system 169
Hydraulic system 169
On-board crane 169
Servicing 169
PUTTING OUT OF OPERATION AND RECOMMISSIONING 170
Putting the excavator out of operation 170
Battery storage 170
Recommissioning 170
Immobilization for more than 3 months 170
NOTES 171
PART 4 – REPAIR WORK 173
Repair work – Safety instructions 175
HYDRAULIC SYSTEM 178
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 178
WELDING OPERATIONS 179
Welding operations – Safety instructions 179
NOTES 181
PART 5 – ANNEX 183
TROUBLESHOOTING 185
Instructions on troubleshooting 185
Layout of the fault table 185
Fault 185
Possible causes 185
Measures 185
Section 185
FAULT TABLES 187
Working hydraulics, Fault table 187
Track drive, Fault table 188
Slewing mechanism, Fault table 189
Central lubricating system, Fault table 190
Tightening torques and angles, Table 191
ABBREVIATIONS 193
TECHNICAL DATA 195
Update to version 01, see pages 107 and 153a
BI015806
OPERATING INSTRUCTIONS RH 400 E
PART 6 – INDEX 198

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V