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CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90011 – PDF DOWNLOAD
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Description
CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90011 – PDF DOWNLOAD
FILE DETAILS:
CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90011 – PDF DOWNLOAD
Language : English
Pages : 246
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90011 – 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 protec- tion. - The operating instructions must always be avail- able in the driver’s cab of the machine.
The operating instructions must be read and put into practice by any person in charge of
carrying out work with or on the machine, such as
▪ operation, including setting-up, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
▪ maintenance (inspection, servicing, repair) and / or
▪ transport.
- In addition to the operating instructions and the mandatory rules and regulations for
accident pre- vention and environmental protection in the user’s country and at the place where the
machine is to be used, the generally recognized technical rules for safe and proper working must be
observed ¹ - The operating instructions are directed to the con- struction-machine specialist. They cannot
provide basic know-how. This can be acquired, for exam- ple, in several days’ instruction by a
qualified me- chanic 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
transla- tion may give rise to questions which Terex O&K will be pleased to answer. - The operating instructions are not work instruc- tions for carrying out major repairs. Such
work is willingly done for you by the Terex O&K after- sales 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 cov- ering 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 i complete and
in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
Customer Support: [email protected]
TABLE OF CONTENTS:
CAT 6090ACFS Hydraulic Shovel Operation & Maintenance Manual DHS90011 – 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 .....................................................................................................................................................188 Pressure-accumulator inspection regulations .........................................................................................................................190 Checking the gas charging pressure in the pressure accumulator.......................................................................................................190 SLEWING RING ............................................................................................................................................................191 Slewing ring - Instructions..........................................................................................................................................191 Bearing races........................................................................................................................................................191 CENTRAL LUBRICATING .....................................................................................................................................................193 Design ..............................................................................................................................................................193 Function ............................................................................................................................................................194 Filling up the grease container .....................................................................................................................................195 Breather filter .....................................................................................................................................................195 Checking the greasing pressure ......................................................................................................................................196 Unblocking a grease line ............................................................................................................................................196 Oilfilter for hydraulic circuit grease pump replace .................................................................................................................197 Grease filter replace (Filling the grease container) ................................................................................................................198 Grease filter replace (Grease lines) ................................................................................................................................199 OTHER MAINTENANCE .......................................................................................................................................................200 Heating and air conditioning ........................................................................................................................................200 Equipment ...........................................................................................................................................................200 LADDER (OPTIONAL) .......................................................................................................................................................201 Pressure-accumulator inspection regulations .........................................................................................................................202 Extract from the German regulations..................................................................................................................................202 Checking the gas charging pressure in the pressure accumulator.......................................................................................................202 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................203 Monitoring, warning and control elements ............................................................................................................................203 Checking the on-board crane..........................................................................................................................................203 Drive unit ..........................................................................................................................................................204 On-board crane, servicing ...........................................................................................................................................204 On-Board crane, checking tightness of fastening bolts ...............................................................................................................205 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................206 Putting the excavator out of operation...............................................................................................................................206 Battery storage......................................................................................................................................................206 Recommissioning......................................................................................................................................................206 NOTES ..................................................................................................................................................................207 4 REPAIR WORK................................................................................................................................................................211 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ..................................................................................................................213 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................215 FIRE AND EXPLOSION HAZARD ...............................................................................................................................................217 HYDRAULIC SYSTEM.........................................................................................................................................................218 Repair ..............................................................................................................................................................218 Hydraulic hoses – Instructions .....................................................................................................................................218 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................219 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................220 NOTES ...................................................................................................................................................................221 5 ANNEX......................................................................................................................................................................223 TROUBLESHOOTING .........................................................................................................................................................225 Instructions on troubleshooting .....................................................................................................................................225 Layout of the fault table ...........................................................................................................................................225 Possible causes .....................................................................................................................................................225 Measures ............................................................................................................................................................225 Section .............................................................................................................................................................225 FAULT TABLES ............................................................................................................................................................226 Working hydraulics – Fault table ....................................................................................................................................226 Track drive – Fault table ...........................................................................................................................................227 Swing mechnism – Fault table ........................................................................................................................................228 Central lubricating system – Fault table ............................................................................................................................229 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................230 ABBREVIATIONS ...........................................................................................................................................................231 TECHNICAL DATA ..........................................................................................................................................................233 NOTES ..................................................................................................................................................................239 6 INDEX......................................................................................................................................................................241
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