Cat Bucyrus 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015807 – PDF DOWNLOAD

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Cat Bucyrus 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015807 – PDF DOWNLOAD

Language : English
Pages : 258
Downloadable : Yes
File Type : PDF

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Cat Bucyrus 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015807 – PDF DOWNLOAD

PREFACE

• These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information 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 available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as

• In addition to the operating instructions and the mandatory rules and regulations for accident prevention 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 construction- machine specialist. They cannot provide basic know-how. This can be acquired, for example, 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 instructions for carrying out major repairs. Such work is willingly done for you by the Terex Germany 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 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.

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TABLE OF CONTENTS:

Cat Bucyrus 6090FS Hydraulic Shovel Operation and Maintenance Manual BI015807 – 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 personnel; basic responsibilities...................................................................................................... 20
		Safety instructions governing specific operational phases.............................................................................................................. 20
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 21
		Warning of special dangers............................................................................................................................................. 22
		Gas, dust, steam and smoke............................................................................................................................................. 23
		Hydraulic equipment.................................................................................................................................................... 23
		Noise.................................................................................................................................................................. 23
		Oil, grease and other chemical substances............................................................................................................................. 23
		Transporting and recommissioning...................................................................................................................................... 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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