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CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90006 – PDF DOWNLOAD
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Description
CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90006 – PDF DOWNLOAD
FILE DETAILS:
CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90006 – PDF DOWNLOAD
Language : English
Pages : 258
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90006 – 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
■ 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 GERMANY Germany mechanic or by attending an Terex-Germany training course for
operators or maintenance personnel. - The Terex-Germany after-sales service will be pleased to deal with any queries you may
have after reading through the operating instructions. - All Terex Germany operating manuals are issued in German and then translated. Even a good
translation may give rise to questions which Terex Germany 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 Germany af- ter-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 covering letter if supplied separately. The operating
instruc- tions and spare-parts list are marked with the se- rial number of the machine. - On taking receipt of the consignment, please check that the documentation i
and in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
Contact us: [email protected]
TABLE OF CONTENTS:
CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90006 – PDF DOWNLOAD
TABLE OF CONTENTS.............................................................................................................................................................. 7 INTRODUCTION................................................................................................................................................................... 13 PREFACE.................................................................................................................................................................... 15 WARRANTY................................................................................................................................................................... 16 FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 17 Warnings and symbols................................................................................................................................................... 17 DESIGNATED USE............................................................................................................................................................. 18 ORGANIZATIONAL MEASURES.................................................................................................................................................... 19 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 20 Safety instructions governing specific operational phases.............................................................................................................. 20 Special work in conjunction with utilization of the machine and mainten ance and repairs as well as trouble shooting during work; disposal of parts and consumables.... 21 Warning of special dangers............................................................................................................................................. 22 Gas, dust, steam and smoke............................................................................................................................................. 23 Hydraulic equipment.................................................................................................................................................... 23 Noise.................................................................................................................................................................. 23 Oil, grease and other chemical sub stances............................................................................................................................. 23 Transporting and recommission ing...................................................................................................................................... 23 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 24 N.......................................................................................................................................................................... 25 NOTES...................................................................................................................................................................... 25 OPERATION...................................................................................................................................................................... 27 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 29 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 31 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 32 Excavator layout....................................................................................................................................................... 33 Undercarriage.......................................................................................................................................................... 34 Superstructure......................................................................................................................................................... 34 Drive.................................................................................................................................................................. 34 Hydraulic system....................................................................................................................................................... 34 Pump Managing System (PMS)............................................................................................................................................. 34 Stored Program Control (SPC)........................................................................................................................................... 34 Electronic Hydraulic Servo-Control (EHSC).............................................................................................................................. 34 Demand control / Zero-flow regulation.................................................................................................................................. 35 Automatic engine speed reduction....................................................................................................................................... 35 Board-Control-System (BCS)............................................................................................................................................. 35 Electrical system...................................................................................................................................................... 35 Sign................................................................................................................................................................... 37 Entering and leaving the machine Safety instructions................................................................................................................... 38 Windscreen washer...................................................................................................................................................... 42 EMERGENCY STOP pushbuttons............................................................................................................................................. 43 Driver's seat.......................................................................................................................................................... 44 Passenger seat......................................................................................................................................................... 45 Fire extinguisher...................................................................................................................................................... 46 Automatic fire-extinguishing system.................................................................................................................................... 46 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 48 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 75 Refuelling............................................................................................................................................................. 75 Service station (tanklift)............................................................................................................................................. 75 Switching the electrical system on and off............................................................................................................................. 81 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 83 DRIVING SAFETY INSTRUCTIONS................................................................................................................................................ 86 TRAVELLING................................................................................................................................................................. 87 Superstructure basic position.......................................................................................................................................... 87 Travelling forwards/backwards.......................................................................................................................................... 87 Locking the superstructure............................................................................................................................................. 91 Track parking brake.................................................................................................................................................... 91 TRANSPORTING THE MACHINE................................................................................................................................................... 92 Transport - Safety instructions........................................................................................................................................ 92 WORKING OPERATION - SAFETY INSTRUCTIONS.................................................................................................................................... 93 WORKING OPERATION.......................................................................................................................................................... 95 Before starting work................................................................................................................................................... 95 Slewing and braking the superstructure................................................................................................................................. 95 Braking the superstructure............................................................................................................................................. 95 Working................................................................................................................................................................ 96 After daily operation.................................................................................................................................................. 97 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 98 Securing the machine...................................................................................................................................................100 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................101 NOTES......................................................................................................................................................................103 INSPECTION AND SERVICING.......................................................................................................................................................105 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................107 FIRE AND EXPLOSION HAZARD..................................................................................................................................................113 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................115 Intervals..............................................................................................................................................................115 Change of engine oil l.................................................................................................................................................115 Air-intake system......................................................................................................................................................115 Oils / Greases.........................................................................................................................................................115 Cleaning jobs..........................................................................................................................................................115 Plan V.................................................................................................................................................................117 Plan N.................................................................................................................................................................119 Plan T.................................................................................................................................................................121 Plan A – E.............................................................................................................................................................123 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................130 Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................131 Filling quantities - Grease............................................................................................................................................131 INSPECTION PLAN - OIL......................................................................................................................................................132 Inspection plan – Oil (legend) ).......................................................................................................................................133 Filling quantities - oil...............................................................................................................................................134 Filling quantities - other.............................................................................................................................................134 LUBRICANTS.................................................................................................................................................................135 I. Oils for combustion engines and compressors (selection).............................................................................................................135 II. Oils for hydraulic system (selection)..............................................................................................................................136 III. Oils for gearboxes (selection)....................................................................................................................................137 V. Greases for bearings and slewing rings..............................................................................................................................138 SERVICING WORK.............................................................................................................................................................139 Hose line for oil and cooling liquid changes...........................................................................................................................139 ENGINE.....................................................................................................................................................................140 Engine - Safety instructions...........................................................................................................................................140 Retensioning the alternator/fan belt...................................................................................................................................140 Checking and adjusting the valve clearance.............................................................................................................................140 Checking the engine oil level / Topping up.............................................................................................................................141 Checking the oil level in the engine oil reservoir /topping up.........................................................................................................142 Changing the engine oil................................................................................................................................................143 Draining the oil off the engine oil reservoir..........................................................................................................................145 Replacing the oil filter...............................................................................................................................................147 Eliminator filter and centrifuge.......................................................................................................................................148 COOLING SYSTEM.............................................................................................................................................................150 Radiators..............................................................................................................................................................150 Water filter...........................................................................................................................................................154 AIR-INTAKE SYSTEM..........................................................................................................................................................155 Main filter elements...................................................................................................................................................155 Safety filter element..................................................................................................................................................158 Air-intake lines.......................................................................................................................................................159 Dust collection........................................................................................................................................................159 FUEL SYSTEM................................................................................................................................................................160 Fuel system - Safety instructions......................................................................................................................................160 Replacing the fuel filter..............................................................................................................................................160 Venting the fuel system................................................................................................................................................161 Cleaning the fuel tanks................................................................................................................................................161 ELECTRICAL SYSTEM..........................................................................................................................................................163 Electrical system - Safety instructions................................................................................................................................163 Alternator - Instructions..............................................................................................................................................163 Battery................................................................................................................................................................164 Switchgear cabinet.....................................................................................................................................................166 HYDRAULIC SYSTEM...........................................................................................................................................................168 Hydraulic system - Safety instructions.................................................................................................................................168 Depressurizing the hydraulic system....................................................................................................................................168 Checking the hydraulic oil level.......................................................................................................................................169 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................171 Bypass valves (hydraulic oil reservoir)................................................................................................................................173 Replacing the hydraulic oil return-flow filters (filter housing).......................................................................................................174 Bypass valves (filter housing - cooling system)........................................................................................................................175 Breather filter........................................................................................................................................................176 Filter (control circuit)...............................................................................................................................................177 High-pressure filter for working hydraulics............................................................................................................................178 High-pressure filters for the servo circuit............................................................................................................................179 High-pressure filters for pump-flushing circuit........................................................................................................................180 High-pressure filters for feeding circuits and slewing pumps...........................................................................................................181 High-pressure filters for slewing circuit..............................................................................................................................182 Changing the hydraulic oil.............................................................................................................................................183 Venting the hydraulic system...........................................................................................................................................186 Cleaning the hydraulic oil cooler......................................................................................................................................187 Electronic excavator control...........................................................................................................................................188 Pressure accumulator - Emergency lowering..............................................................................................................................189 PUMP TRANSFER GEARBOX......................................................................................................................................................190 Checking the gearbox oil level / Topping up with oil...................................................................................................................190 Changing the gearbox oil...............................................................................................................................................190 Gearbox venting........................................................................................................................................................192 Pre-chamber............................................................................................................................................................192 SLEWING GEARBOX............................................................................................................................................................193 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................193 Changing the gearbox oil...............................................................................................................................................193 Gearbox venting........................................................................................................................................................194 Slewing gear neck......................................................................................................................................................194 TRAVEL GAERBOX.............................................................................................................................................................195 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................195 Travel gearbox - Changing the oil......................................................................................................................................195 Preliminary gearbox - Draining off oil.................................................................................................................................196 CRAWLER TRACKS.............................................................................................................................................................197 Track tensioner........................................................................................................................................................199 Pressure-accumulator inspection regulations............................................................................................................................200 Checking the gas charging pressure in the pressure accumulator.........................................................................................................201 SLEWING RING...............................................................................................................................................................202 Slewing ring - Instructions............................................................................................................................................202 Bearing races..........................................................................................................................................................202 CENTRAL LUBRICATING........................................................................................................................................................204 Design and function....................................................................................................................................................204 Lube cycle / Pause period..............................................................................................................................................204 Lube cycle manual lubricating (optional)...............................................................................................................................204 Filling up the grease container........................................................................................................................................206 Breather filter........................................................................................................................................................206 Checking the greasing pressure.........................................................................................................................................207 Unblocking a grease line...............................................................................................................................................208 OTHER MAINTENANCE..........................................................................................................................................................209 Engine.................................................................................................................................................................209 RAMP-TYPE LADDER...........................................................................................................................................................211 Guide pulleys and locking bolt.........................................................................................................................................211 Pressure-accumulator inspection regulations............................................................................................................................212 Extract from the German regulations....................................................................................................................................212 Checking the gas charging pressure in the pressure accumulator.........................................................................................................212 ON-BOARD CRANE.............................................................................................................................................................213 Monitoring, warning and control elements...............................................................................................................................213 Checking the on-board crane............................................................................................................................................213 Drive unit.............................................................................................................................................................214 On-board crane.........................................................................................................................................................214 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................215 Putting the excavator out of operation.................................................................................................................................215 Battery storage........................................................................................................................................................215 Recommissioning........................................................................................................................................................216 REPAIR WORK....................................................................................................................................................................220 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................222 FIRE AND EXPLOSION HAZARD..................................................................................................................................................224 ENGINE.....................................................................................................................................................................225 ELECTRICAL SYSTEM..........................................................................................................................................................226 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................226 Assisted starting (with jumper cables).................................................................................................................................226 Starting the engine with jumper cables (external batteries.............................................................................................................226 HYDRAULIC SYSTEM...........................................................................................................................................................228 Repair.................................................................................................................................................................228 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................229 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................230 NOTES......................................................................................................................................................................232 ANNEX..........................................................................................................................................................................234 TROUBLESHOOTING............................................................................................................................................................236 Instructions on troubleshooting........................................................................................................................................236 Layout of the fault table..............................................................................................................................................236 Possible causes........................................................................................................................................................236 Measures...............................................................................................................................................................236 Section................................................................................................................................................................236 FAULT TABLES...............................................................................................................................................................237 Combustion engine - Fault table........................................................................................................................................237 Working hydraulics – Fault table.......................................................................................................................................238 Track drive – Fault table..............................................................................................................................................239 Slewing mechnism – Fault table.........................................................................................................................................240 Central lubricating system – Fault table...............................................................................................................................241 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................243 TIGHTENING TORQUES AND ANGLES – TABLE......................................................................................................................................244 ABBREVIATIONS..............................................................................................................................................................246 TECHNICAL DATA.............................................................................................................................................................248 INDEX..........................................................................................................................................................................252
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