CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90003, DHS90004 – PDF DOWNLOAD

Description

CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90003, DHS90004 – PDF DOWNLOAD

FILE DETAILS:

CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90003, DHS90004 – PDF DOWNLOAD

Language : English
Pages : 242
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90003, DHS90004 – PDF DOWNLOAD

Preface

• These operating instructions are designed to fa- miliarize the operator with the machine
  and its designated use.
• The instruction manual contains important infor- mation 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 instruction manual 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 operator’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, troubleshooting in the course of work, care,
evacuation of pro- duction waste and disposal of fuels and con- sumables.
– 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 O&K mechanic or by attending an O&K training course for operators or
  maintenance personnel.
• The O&K after-sales service will be pleased to deal with any queries you may have after
  reading through the operating instructions.
• All O&K operating manuals are issued in German and then translated. Even a good translation may
  give rise to questions which 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 O&K after-sales service.
• The documentation relating to the machine is list- ed according to scope, quantity and
  language in the shipping note of the machine or in the cover- ing 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.

IMAGES PREVIEW OF THE MANUAL:

Questions? Email us: [email protected]

TABLE OF CONTENTS:

CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90003, DHS90004 – PDF DOWNLOAD

PART 1 – INTRODUCTION
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
Standard operation 6
Special work in conjunction with utilization of the machine – maintenance and repairs during operation –
disposal of parts and consumables 7
Warning of special dangers
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
Fire and Explosion Hazard 10
NOTES 11
BI015805
Update to version 01, see pages 103 and 163a
PART 2 – OPERATION
Operation – Safety instructions 15
Fire and Explosion Hazard 17
DESCRIPTION OF THE EXCAVATOR
Excavator layout 19
Undercarriage 19
Superstructure 19
Loading bucket 19
Undercarriage 20
Superstructure 20
Drive 20
Hydraulic system 20
Pump Managing System (PMS) 20
Stored Program Control (SPC) 20
Electronic Hydraulic Servo-Control (EHSC) 20
Demand control / Zero-flow regulation 21
Automatic engine speed reduction 21
Board Control System (BCS) 21
Electrical system 21
Signs 23
Warning and instruction signs 23
Machine number 23
Engine number 23
Component numbers 23
Entering and leaving the machine – Safety instructions 24
Ramp-type ladder 24
Access 25
Escape ladder 25
Ramp lighting 25
Cab interior lamp 26
Servicing lighting 27
110 V socket 27
EMERGENCY STOP pushbuttons 28
Windscreen washer 28
Driver’s seat 29
Adjusting the backrest 29
Adjusting the lumbar support 29
Adjusting the seat cushion 29
Adjusting the armrests 29
Fore-and-aft adjustment 29
Adjusting the seat suspension 29
Fore-and-aft adjustment of the seat plate 29
BI015805
Update to version 01, see pages 103 and 163a
Passenger seat 30
Adjusting the backrest 30
Adjusting the seat cushion 30
Adjusting the armrests 30
Fore-and-aft adjustment 30
Adjusting the seat suspension 30
Automatic fire-extinguishing system 31
Inspection 31
MONITORING, WARNING AND CONTROL ELEMENTS 32
MASCHINE IN BETRIEB NEHMEN 56
Betanken
Betanken, Sicherheitshinweise 56
Service-Station (Tanklift) 56
Service-Station absenken 57
Service-Station anheben 57
Fu¨ llen bzw Absaugen 57
Meßstellen fu¨ r Flu¨ssigkeiten 58
Elektrische Anlage ein- und ausschalten 62
Batteriehauptschalter 62
Starting and stopping the engines 63
Starting the engines 63
Shutting off the engines 64
Emergency stop 64
Driving 65
TRAVELLING
Superstructure basic position 66
Travelling forwards/in reverse 66
Regulating the travelling speed 67
Travelling uphill and downhill 67
Cornering 67
Turning 67
Note 68
Travelling over longer distances 69
Locking the superstructure 70
Track parking brake 70
Transporting the machine
Transport – Safety instructions 71
Transport 71
WORKING OPERATION, SAFETY INSTRUCTIONS 72
BI015805
Update to version 01, see pages 103 and 163a
WORKING OPERATION
Before starting work 74
Switching on the electronic excavator control 74
Slewing and braking the superstructure 74
Braking the superstructure 74
Working 75
Raising and lowering the boom 75
Extending and retracting the bucket or backhoe bucket stick 75
Filling and emptying the bucket 75
Opening and closing the bucket 75
Lowering the equipment in an emergency 75
After daily operation 76
Parking the machine 76
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS
Securing the machine 79
Corrosion protection for pins and bearings (bushings and hubs)
Part nos for Voler A C 80
Application of Voler A C 80
NOTES 81
BI015805
Update to version 01, see pages 103 and 163a
PART 3 – INSPECTION AND SERVICING
Inspection and servicing – Safety instructions 85
Fire and Explosion Hazard 89
Inspection and servicing plans – Instructions
Intervals 91
Change of engine oil 91
Air-intake system 91
Oils / Greases 91
Cleaning jobs 91
Plan V 93
Plan N 95
Plan T 97
Plan W 97
Plan T 98
Plan W 98
Plan A 99
Plan B 99
Plan C 99
Plan D 99
Plan E 99
Plan A 100
Plan B 100
Plan C 100
Plan D 100
Plan E 100
Plan A 101
Plan B 101
Plan C 101
Plan D 101
Plan E 101
Plan A 102
Plan B 102
Plan C 102
Plan D 102
Plan E 102
LUBRICATING CHART – GREASE (Loading bucket)
Lubricating chart – Grease / Loading bucket 105
Filling quantities – Grease 105
INSPECTION PLAN – OIL
Inspection plan – Oil 107
Filling quantities – Oil 108
BI015805
Update to version 01, see pages 103 and 163a
Filling quantities – other 108
LUBRICANTS 109
Oils for combustion engines and compressors (selection) 109
Oils for hydraulic systems (selection) 110
Oils for gearboxes (selection) 111
Greases for bearings and slewing rings 112
SERVICING WORK
Hose line for oil and coolant changes 113
ENGINE
Engine – Safety instructions 114
Checking/adjusting the V-belt tension 114
Checking/adjusting the valve clearance 114
Checking the engine oil level / Topping up 114
Checking the oil level in the engine oil reservoir / Topping up 115
Changing the engine oil 116
Drawing off engine oil with the service station 116
Filling in engine oil through the service station 117
Replacing the engine oil filter 118
Change engine oil filter 118
Changing the oil of the engine oil reservoir 119
Drawing off engine oil 119
Drain off engine oil 119
Filling in engine oil 120
COOLING SYSTEM
Temperature 121
Radiators 121
Coolant level 121
Topping up coolant 122
Coolant 123
Drawing off coolant 123
Filling in coolant 124
AIR-INTAKE SYSTEM
Main filter elements 125
Removal and installation 125
Checking and cleaning the main filter element 126
Safety filter element 127
Replacement 127
Air-intake lines 128
BI015805
Update to version 01, see pages 103 and 163a
Dust collection 128
FUEL SYSTEM
Fuel system – Safety instructions 129
Draining fuel system 129
Replacing the fuel filter 130
Fuel filter with water separator 130
Replacing the filter element 130
Venting the fuel system 131
Cleaning the fuel tanks 131
ELECTRICAL SYSTEM
Electrical system – Safety instructions 133
Alternator – Instructions 133
Battery main switches§/§Main fuse 134
Batteries 134
Removing and installing the batteries 134
Battery box 135
Removing and installing the battery box 135
HYDRAULIC SYSTEM
Hydraulic system – Safety instructions 136
Depressurizing the hydraulic system 136
Checking the hydraulic oil level / Topping up 137
Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) 139
Bypass valves (hydraulic oil reservoir) 141
Cleaning the filter screens 141
Replacing the hydraulic oil return-flow filters (filter housing – cooling system) 142
Bypass valves (filter housing – cooling system) 143
Cleaning the filter screens 143
Breather filters 144
Replacing the filter elements 144
High-pressure filter for working hydraulics 144
Checking/cleaning the filter elements 145
Replacing the filter elements 145
High-pressure filter for the servo circuits 146
Checking/cleaning the filter elements 146
Replacing the filter elements 146
High-pressure filters for pump-flushing circuit 147
Checking/cleaning the filter elements 147
Replacing the filter elements 147
High-pressure filters for feeding circuits/slewing gear pumps 148
Checking/cleaning the filter elements 148
Replacing the filter elements 148
High-pressure filters for slewing circuit 149
BI015805
Update to version 01, see pages 103 and 163a
Changing the hydraulic oil 150
Drawing off the hydraulic oil 150
Cleaning the hydraulic oil reservoir 151
Filling in hydraulic oil 152
Venting the hydraulic system 153
Venting the hydraulic components 153
Cleaning the hydraulic oil cooler 154
Cleaning 154
Pressure accumulator – Emergency lowering
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 155
PUMP TRANSFER GEARBOX
Checking the gearbox oil level / Topping up 156
Drawing off oil 156
Filling in oil 157
Gearbox venting 158
Pre-chamber 158
Checking the oil level 158
SLEWING GEARBOX
Gearbox – Checking the oil level / Topping up 159
Changing the gearbox oil 159
Draining off oil 159
Filling in new oil / Topping up 160
Gearbox venting 160
Venting bore 160
Slewing gear neck 160
TRAVEL GEARBOXES
Travel gearbox – Checking the oil level / Topping up 161
Travel gearbox – Changing the oil 161
Main gearbox – Draining off oil 161
Preliminary gearbox – Draining off oil 161
Main and preliminary gearbox – Filling in oil 162
Pre-chamber – Draining off oil 162
Pre-chamber – Filling in oil 162
CRAWLER TRACKS
Cleaning 163
Track roller fastening 163
Track tensioner 164
Design 164
BI015805
Update to version 01, see pages 103 and 163a
Technical data 164
Function 164
Pressure-accumulator inspection regulations 165
Extract from the German regulations 165
Extract from the German acceptance regulations 165
Checking the gas charging pressure in the pressure accumulator 165
Idlers 166
Checking the oil level 166
Filling in oil 166
Greasing the idler guides 166
SLEWING RING
Slewing ring – Instructions 167
Bearing races 167
Internal gearing 167
Slewing ring – Checking the grease filling 168
Slewing ring – Filling in grease 168
Slewing ring – Checking the screws for tightness 168
CENTRAL LUBRICATING SYSTEM
Design and function 169
Filling the grease container 170
Breather filter 170
Checking the grease pressure 171
Unblocking a grease line 171
Cleaning the grease sieve 171
Cleaning 171
OTHER MAINTENANCE WORK
Engine 172
Cleaning 172
Fastenings 172
Cooling system 172
Exhaust system 172
RAMP-TYPE LADDER
Guide pulleys and locking bolt 173
Pressure-accumulator inspection regulations 174
Extract from the German regulations 174
Extract from the German acceptance regulations 174
Checking the gas charging pressure in the pressure accumulator 174
ON-BOARD CRANE
Monitoring, warning and control elements 175
Checking the on-board crane 175
Extract from the inspection and testing regulations 175
BI015805
Update to version 01, see pages 103 and 163a
Drive unit 176
Crane engine 176
Air-intake system 176
Hydraulic system 176
On-board crane 176
Servicing 176
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING
Putting the excavator out of operation 177
Battery storage 177
Recommissioning 177
NOTES 179
BI015805
Update to version 01, see pages 103 and 163a
PART 4 – REPAIR WORK
Repair work – Safety instructions 183
Fire and Explosion Hazard 185
ENGINE 186
ELECTRICAL SYSTEM
Assisted starting (with jumper cables) – Safety instructions 186
Assisted starting (with jumper cables) 187
Prior to assisted starting 187
Starting the engine with jumper cables (external batteries) 187
Connecting the jumper cables 187
Starting up the engines 187
Disconnecting the jumper cables 187
HYDRAULIC SYSTEM
Repair 188
Accumulators, safety instructions 188
WELDING OPERATIONS 189
Welding operations – Safety instructions 189
NOTES 191
BI015805
Update to version 01, see pages 103 and 163a
PART 5 – ANNEX
TROUBLESHOOTING 195
Instructions on troubleshooting 195
Layout of the fault table
Fault 195
Causes 195
Remedial action 195
Section 195
FAULT TABLES
Combustion engine – Fault table 196
Working hydraulics – Fault table 197
Fahrantrieb – Fault table 198
Slewing mechanism, Fault table 199
Central lubricating system – Fault table 200
Hydraulic circuit diagram
Legend (loading bucket) 202
Tightening torques and angles – Table 203
ABBREVIATIONS 205
TECHNICAL DATA 207
NOTES 209
BI015805
Update to version 01, see pages 103 and 163a
PART 6 – INDEX
INDEX 213
BI015805
Update to

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