CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90009, DHS90010 – PDF DOWNLOAD

Description

CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90009, DHS90010 – PDF DOWNLOAD

FILE DETAILS:

CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90009, DHS90010 – PDF DOWNLOAD

Language : English
Pages : 275
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90009, DHS90010 – PDF DOWNLOAD

PREFACE:

• These operating instructions are designed to famil- iarize the operator with the machine and its
  desig- nated 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 Bu- cyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or
  maintenance personnel.
• The Bucyrus HEX after-sales service will be pleased to deal with any queries you may
  have after reading through the operating instructions.
• All Bucyrus HEX operating manuals are issued in German and then translated. Even a good transla-
  tion may give rise to questions which Bucyrus HEX 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 Bucyrus HEX 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 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 is
  complete and in the language requested by you.

IMAGES PREVIEW OF THE MANUAL:

Customer Support: [email protected]

TABLE OF CONTENTS:

CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90009, DHS90010 – 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........................................................................................................................................... 22
		Hydraulic equipment.................................................................................................................................................. 23
		Noise................................................................................................................................................................ 23
		Oil, grease and other chemical substances............................................................................................................................ 23
		Ether ............................................................................................................................................................... 23
		Transporting and recommissioning..................................................................................................................................... 23
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 24
	NOTES ................................................................................................................................................................... 25
2 OPERATION.................................................................................................................................................................. 27
	OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 29
	OPERATION, 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
		Programmable Logic Controller (PLC) ................................................................................................................................. 34
		Control Management System (CMS) ..................................................................................................................................... 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
		Escape ladder ....................................................................................................................................................... 38
		Ramp type ladders ................................................................................................................................................... 39
		Windscreen washer ................................................................................................................................................... 42
		EMERGENCY STOP pushbuttons .......................................................................................................................................... 43
		Driver's seat ....................................................................................................................................................... 44
		Fire extinguisher ................................................................................................................................................... 46
		Automatic fire-extinguishing system ................................................................................................................................. 46
		Harness (optional) .................................................................................................................................................. 47
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 50
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 79
		Refuelling .......................................................................................................................................................... 79
		Service station (tanklift) .......................................................................................................................................... 79
		Switching the electrical system on and off .......................................................................................................................... 85
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 87
	AIR CONDITIONER (OPTION)................................................................................................................................................. 90
	TRAVELLING .............................................................................................................................................................. 91
		SAFETY INSTRUCTIONS ................................................................................................................................................. 91
		Superstructure basic position ....................................................................................................................................... 92
		Locking the superstructure .......................................................................................................................................... 96
		Track parking brake ................................................................................................................................................. 96
	TRANSPORTING THE MACHINE ................................................................................................................................................ 97
		Safety instructions ................................................................................................................................................. 97
	WORKING OPERATION ....................................................................................................................................................... 98
		Safety instructions ................................................................................................................................................. 98
		Before starting work ................................................................................................................................................ 99
		Swinging the superstructure ......................................................................................................................................... 99
		Braking the superstructure .......................................................................................................................................... 99
		Working .............................................................................................................................................................100
		Emergency lowering of the equipment .................................................................................................................................101
		After daily operation ...............................................................................................................................................102
	ASSEMBLING WORKING EQUIPMENT ............................................................................................................................................103
		SAFETY INSTRUCTIONS .................................................................................................................................................103
		Securing the machine ................................................................................................................................................105
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................106
	NOTES ...................................................................................................................................................................107
3 INSPECTION AND SERVICING...................................................................................................................................................109
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................111
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................117
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................119
		Intervals ...........................................................................................................................................................119
		Change of engine oil ................................................................................................................................................119
		Air-intake system ...................................................................................................................................................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 .......................................................................................................................................................135
		Lubricating chart – Grease (legend) .................................................................................................................................136
		Filling quantities - Grease..........................................................................................................................................136
	INSPECTION PLAN - OIL ...................................................................................................................................................137
		Inspection plan – Oil (legend) ......................................................................................................................................138
		Filling quantities - oil ............................................................................................................................................139
		Filling quantities - other...........................................................................................................................................139
	LUBRICANTS ..............................................................................................................................................................140
		Notes on the selection of oils and greases ..........................................................................................................................140
		Avoid mixing of different hydraulic fluids ..........................................................................................................................140
		I. Oils for combustion engines and compressors ......................................................................................................................141
		II. Oils for hydraulic system (selection) ...........................................................................................................................142
		III.a Oils for pump distribution gearboxes ..........................................................................................................................143
		III.b Oils for swing gearboxes ......................................................................................................................................144
		III.c Oils for travel gearboxes .....................................................................................................................................145
		V. Greases for bearings and swing rings .............................................................................................................................146
	SERVICING WORK ..........................................................................................................................................................147
		Hose line for oil and cooling liquid changes ........................................................................................................................147
	ENGINE ..................................................................................................................................................................148
		Engine - Safety instructions ........................................................................................................................................148
		Engine oil, checking the oil level / topping up  ....................................................................................................................149
		Engine oil reservoir, checking the oil level ........................................................................................................................150
		Changing the engine oil .............................................................................................................................................151
		Engine oil reservoir, changing the oil ..............................................................................................................................153
		Replacing the oil filters ...........................................................................................................................................155
		Eliminator filter and centrifuge ....................................................................................................................................156
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................158
	COOLING SYSTEM ..........................................................................................................................................................159
		Radiators ...........................................................................................................................................................160
		Checking cooling-liquid level .......................................................................................................................................160
		Topping up cooling-liquid ...........................................................................................................................................161
		Cooling liquid change ...............................................................................................................................................162
		Water filter change..................................................................................................................................................164
	AIR-INTAKE SYSTEM .......................................................................................................................................................165
		Main filter elements ................................................................................................................................................165
		Safety filter element ...............................................................................................................................................168
		Air-intake lines ....................................................................................................................................................169
		Dust collection .....................................................................................................................................................169
	FUEL SYSTEM .............................................................................................................................................................170
		Fuel system - Safety instructions ...................................................................................................................................170
		Replacing the fuel filters ..........................................................................................................................................170
		Fuel filters, draining water ........................................................................................................................................172
		Fuel tank, replace breather filter ..................................................................................................................................173
		Cleaning the fuel tanks .............................................................................................................................................173
	ELECTRICAL SYSTEM  ......................................................................................................................................................175
		Electrical system - Safety instructions .............................................................................................................................175
		Alternator - Instructions ...........................................................................................................................................175
		Floodlight projector, replacing the lamp ............................................................................................................................176
		Battery .............................................................................................................................................................178
		Switchgear cabinet ..................................................................................................................................................180
	HYDRAULIC SYSTEM ........................................................................................................................................................182
		Hydraulic system - Safety instructions ..............................................................................................................................182
		Depressurizing the hydraulic system .................................................................................................................................182
		Checking the hydraulic oil level ....................................................................................................................................183
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................185
		Bypass valves (hydraulic oil reservoir) .............................................................................................................................187
		Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................188
		Bypass valves (filter housing - cooling system) .....................................................................................................................189
		Breather filter .....................................................................................................................................................190
		Filter (control circuit).............................................................................................................................................191
		High-pressure filter for working hydraulics .........................................................................................................................192
		High-pressure filters for the servo circuit .........................................................................................................................193
		High-pressure filters for pump-flushing circuit .....................................................................................................................194
		High-pressure filters for feeding circuits and swing pumps ..........................................................................................................195
		High-pressure filters for swing circuit .............................................................................................................................196
		Changing the hydraulic oil ..........................................................................................................................................197
		Venting the hydraulic system.........................................................................................................................................200
		Cleaning the hydraulic oil cooler....................................................................................................................................201
		Electronic excavator control ........................................................................................................................................202
		Pressure accumulator - Emergency lowering............................................................................................................................203
	PUMP TRANSFER GEARBOX ...................................................................................................................................................204
		Checking the gearbox oil level / Topping up with oil ................................................................................................................204
		Changing the gearbox oil ............................................................................................................................................204
		Gearbox venting .....................................................................................................................................................206
		Pre-chambers ........................................................................................................................................................206
		Pump transfer gearbox lube oil filters ..............................................................................................................................207
	SWING GEARBOX ...........................................................................................................................................................208
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................208
		Changing the gearbox oil ............................................................................................................................................208
		Gearbox venting .....................................................................................................................................................209
	TRAVEL GAERBOX ..........................................................................................................................................................210
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................210
		Travel gearbox - Changing the oil ...................................................................................................................................210
		Preliminary gearbox - Draining off oil ..............................................................................................................................211
	CRAWLER TRACKS ..........................................................................................................................................................212
		Track tensioner .....................................................................................................................................................214
		Pressure-accumulator inspection regulations .........................................................................................................................216
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................216
	SWING RING ..............................................................................................................................................................217
		Swing ring - Instructions............................................................................................................................................217
		Bearing races........................................................................................................................................................217
	CENTRAL LUBRICATING .....................................................................................................................................................219
		Design ..............................................................................................................................................................219
		Function ............................................................................................................................................................220
		Filling up the grease container .....................................................................................................................................221
		Breather filter .....................................................................................................................................................221
		Checking the greasing pressure ......................................................................................................................................222
		Unblocking a grease line ............................................................................................................................................222
		Oilfilter for hydraulic circuit grease pump replace .................................................................................................................223
		Grease filter replace (Filling the grease container) ................................................................................................................224
		Grease filter replace (Grease lines) ................................................................................................................................225
	 OTHER MAINTENANCE ......................................................................................................................................................226
		Engine ..............................................................................................................................................................226
		Equipment ...........................................................................................................................................................227
	LADDERS (OPTIONAL) ......................................................................................................................................................228
		Pressure-accumulator inspection regulations .........................................................................................................................229
		Extract from the German regulations..................................................................................................................................229
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................229
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................230
		Monitoring, warning and control elements ............................................................................................................................230
		Checking the on-board crane..........................................................................................................................................230
		Drive unit...........................................................................................................................................................231
		On-board crane.......................................................................................................................................................231
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................232
		Putting the excavator out of operation...............................................................................................................................232
		Battery storage......................................................................................................................................................232
		Recommissioning......................................................................................................................................................232
	NOTES ...................................................................................................................................................................234
4 REPAIR WORK................................................................................................................................................................237
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................239
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................241
	ENGINE...................................................................................................................................................................242
	ELECTRICAL SYSTEM .......................................................................................................................................................243
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................243
		Assisted starting (with jumper cables)...............................................................................................................................243
		Starting the engine with jumper cables (external batteries ..........................................................................................................243
	HYDRAULIC SYSTEM.........................................................................................................................................................245
		Repair instructions .................................................................................................................................................245
		Hydraulic hoses – Instructions  .....................................................................................................................................245
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................246
	WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................247
	NOTES ...................................................................................................................................................................251
5 ANNEX......................................................................................................................................................................253
	TROUBLESHOOTING .........................................................................................................................................................255
		Instructions on troubleshooting .....................................................................................................................................255
		Layout of the fault table ...........................................................................................................................................255
		Possible causes .....................................................................................................................................................255
		Measures ............................................................................................................................................................255
		Section .............................................................................................................................................................255
	FAULT TABLES ............................................................................................................................................................256
		Combustion engine - Fault table .....................................................................................................................................256
		Working hydraulics – Fault table ....................................................................................................................................257
		Track drive – Fault table ...........................................................................................................................................258
		Swing mechnism – Fault table ........................................................................................................................................259
		Central lubricating system – Fault table ............................................................................................................................260
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................261
	TECHNICAL DATA  .........................................................................................................................................................263
	ABBREVIATIONS ...........................................................................................................................................................265
	ABBREVIATIONS ...........................................................................................................................................................266
	NOTES ...................................................................................................................................................................267
6 INDEX......................................................................................................................................................................269

PLEASE NOTE:

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

S.V