CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual 3725089 – PDF DOWNLOAD

Description

CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual 3725089 – PDF DOWNLOAD

FILE DETAILS:

CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual 3725089 – PDF DOWNLOAD

Language : English
Pages : 334
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual 3725089 – PDF DOWNLOAD

PREFACE:

• These operation and maintenance manual is de- signed to familiarize 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 min- ing-machine specialist. They cannot provide
  basic know-how. This can be acquired, for example, in several days’ instruction by a
  qualified CGM HMS GmbH mechanic or by attending an CGM HMS GmbH training course for
  operators or mainten- ance personnel.
• The CGM HMS GmbH after-sales service will be pleased to deal with any queries you may
  have after reading through the operating instructions.CGM HMS GmbH =
  Caterpillar Global Mining Hydraulic mining Shovels GmbH.
• All CGM HMS GmbH operating manuals are is- sued in German and then translated. Even a good
  translation may give rise to questions which CGM HMS GmbH 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 CGM HMS GmbH
  after-sales service.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual 3725089 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-3
Further machine documentation 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE, UNAUTHORIZED USE 1-6
Noise emission information 1-7
Vibration information 1-7
ORGANIZATIONAL MEASURES 1-8
Selection and qualification of personnel; basic responsibilities 1-9
Safety instructions governing specific operational phases 1-9
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-10
Warning of special dangers 1-11
Gas, dust, steam and smoke 1-11
Hydraulic equipment 1-12
FIRE AND EXPLOSION HAZARD 1-13
NOTES 1-15
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE HYDRAULIC SHOVEL 2-6
Hydraulic shovel layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Control and Monitoring Platform (CAMP) 2-8
Board-Control-System (BCS) 2-9
Demand control / Zero-flow regulation 2-9
Automatic reset to idling 2-9
Electrical system 2-9
Signs 2-10
Entering and leaving the machine Safety instructions 2-18
Access ladder lighting 2-18
Swinging ladder (optional) 2-19
Folding ladder 2-20
Emergency exit in driver’s cab and escape ladder 2-21
Escape ladder near engine compartment (optional) 2-22
Switching the cab interior lighting on and off 2-23
Switching the maintenance lights on and off 2-24
BA RH170B(3 725 089.00)-EN
TABLE OF CONTENTS
vi
Emergency shut-off function 2-25
Battery isolator switch, shutting off supply voltage 2-27
Starter isolator switch, shutting off starter voltage 2-27
Operator’s seat 2-28
Reducing the operators exposure to vibrations 2-30
Trainer’s / instructor’s seat 2-30
Fire extinguisher 2-31
Automatic fire-extinguishing system (optional) 2-32
Windscreen washer 2-32
Operating hours meter 2-32
Emergency escape device / seat (optional) 2-33
MONITORING, WARNING AND CONTROL ELEMENTS 2-36
Engine 1 (LH), control and monitoring 2-43
Engine 2 (RH), control and monitoring 2-45
PUTTING THE MACHINE INTO OPERATION 2-64
Reducing the operator’s exposure to noise 2-64
Refuelling 2-65
Back-up heating (option), filling in fuel 2-65
Service station (tanklift) 2-66
Emergency off switch 2-68
Switching the electrical system on and off 2-73
Engines, emergency shut-off 2-73
Preheating system for engine and hydraulic oil (optional) 2-74
Fuel preheating system (optional) 2-75
STARTING AND STOPPING THE ENGINES 2-76
Starting the engines 2-76
Starting the left-hand engine 2-76
Starting the right-hand engine 2-76
Engines – adjusting the speed 2-77
Starting the engines at low temperatures 2-77
Shutting off the engines 2-78
Shutting off the left-hand engine 2-78
Shutting off the right-hand engine 2-78
AIR CONDITIONER (OPTIONAL) 2-79
Back-up heating driver’s cab (optional) 2-80
Back-up heating (optional) 2-81
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-82
TRAVELLING, SAFETY INSTRUCTIONS 2-84
TRAVELLING 2-85
Superstructure basic position 2-85
Travelling forwards/backwards 2-85
Superstructure holding brake 2-89
Track parking brake 2-89
TRANSPORTING THE MACHINE 2-90
Transport – Safety instructions 2-90
BA RH170B(3 725 089.00)-EN
TABLE OF CONTENTS
vii
WORKING OPERATION – SAFETY INSTRUCTIONS 2-91
WORKING OPERATION 2-93
Before starting work 2-93
Activating the electronic hydraulic shovel control 2-93
Swinging the superstructure 2-94
Braking the superstructure 2-94
Working 2-95
After daily operation 2-96
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-97
Securing the machine 2-98
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-99
ON-BOARD CRANE (OPTIONAL) 2-100
Monitoring, warning and control elements 2-100
On-board crane, putting into operation 2-101
On-board crane, drive unit 2-101
On-Board crane, – blocking the boom in position of rest 2-102
Checking the on-board crane 2-102
NOTES 2-103
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-7
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Plan V 3-11
Plan N 3-13
Plan T and W 3-15
Plan A – E 3-17
LUBRICATING CHART – GREASE 3-24
Lubricating chart – Grease (legend) 3-25
Filling quantities – Grease 3-25
INSPECTION PLAN – OIL 3-26
Inspection plan – Oil (legend) 3-27
Filling quantities – oil 3-28
Filling quantities – other 3-28
LUBRICANTS / CONSUMABLES 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids 3-29
I. Oils for combustion engines 3-30
II. Oil for hydraulic system 3-31
III.a Oils for pump distribution gearboxes and travel gearboxes 3-32
III.b Oil for swing gearboxes 3-33
V. Grease for bearings, slew rings and track system (Central lubrication system) 3-34
Grease for idlers, track rollers and support rollers (Lifetime lubrication) 3-35
Coolant for use on all combustion engines 3-36
BA RH170B(3 725 089.00)-EN
TABLE OF CONTENTS
viii
SERVICING WORK 3-37
Hose line for oil and cooling liquid changes 3-37
ENGINE 3-38
Engine – Safety instructions 3-38
Engine oil, checking the level / topping up 3-39
Engine oil reservoir (optional), checking the oil level / topping up 3-40
Engine oil, change 3-41
Engine oil reservoir (optional), draining the oil off 3-43
Engine oil filter, replace 3-45
Engine oil reservoir (optional), replacing the oil filters 3-46
Cold-starting fluid (ether) – Replacing the pressure vessel 3-47
COOLING SYSTEM 3-48
Temperature 3-48
Radiators 3-49
Cooling-liquid level check 3-49
Cooling liquid, change 3-52
Testing the cooling liquid composition 3-54
AIR-INTAKE SYSTEM 3-55
Dust trap, cleaning 3-55
Main filter elements 3-56
Main filter elements, checking and cleaning 3-57
Safety filter element 3-58
Air-intake lines 3-58
FUEL SYSTEM 3-59
Fuel system – Safety instructions 3-59
Fuel filter, replace 3-59
Primary fuel filter, drain water 3-60
Primary fuel filter, replace 3-60
Venting the fuel system 3-61
Cleaning the fuel tanks 3-61
Water trap (optional) 3-63
ELECTRICAL SYSTEM 3-65
Electrical system – Safety instructions 3-65
Alternator – Instructions 3-65
Electrical circuit diagrams 3-65
Electrical system switch-cabinets 3-65
Replacing lamps and bulbs 3-65
Battery 3-66
Charging batteries inside the machine, safety instructions 3-67
Removing and installing the battery 3-68
Switchgear cabinet, aeration 3-69
Xenon floodlight projector, replacing the lamp 3-71
Lighting systems in LED technonogy, instructions 3-73
HYDRAULIC SYSTEM 3-74
Hydraulic system – Safety instructions 3-74
Depressurizing the hydraulic system 3-74
Checking the hydraulic oil level 3-75
Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) 3-77
BA RH170B(3 725 089.00)-EN
TABLE OF CONTENTS
ix
Bypass valves (hydraulic oil reservoir) 3-80
Replacing the bypass valves and sealing rings 3-80
Replacing the hydraulic oil return-flow filters (filter housing cooling system) 3-81
Bypass valves (filter housing – cooling system) 3-82
Breather filter 3-83
Filter (control circuit and auxiliary control circuit) 3-84
High-pressure filter for working hydraulics 3-85
High-pressure filters for the servo circuit 3-86
High-pressure filters for feeding circuits and slewing pumps 3-87
Changing the hydraulic oil 3-88
Avoid mixing of different hydraulic fluids 3-88
Venting the hydraulic system 3-92
Cleaning the hydraulic oil cooler 3-93
Electronic hydraulic shovel control 3-94
Pressure accumulator – Emergency lowering 3-95
PUMP TRANSFER GEARBOX 3-96
Checking the pump gearbox oil level / Topping up with oil 3-96
Changing the pump gearbox oil 3-98
Pump gearbox venting 3-100
Pump transfer gearbox lube oil filters 3-101
SWING GEARBOX 3-102
Swing gearbox – Checking the oil level / Topping up with oil 3-102
Gearbox venting 3-102
Changing the swing gearbox oil 3-103
TRAVEL GEARBOX (PN 2763213) 3-105
Travel gearbox – Checking the oil level / Topping up with oil 3-105
Pre-chamber / spur wheel section, Check the oil level / Top up with oil 3-105
Hydraulic motor chamber – Check the oil level / Top up with oil 3-105
Travel gearbox, Changing oil 3-106
Pre-chamber / spur wheel section, Changing oil 3-106
Hydraulic motor chamber, Changing oil 3-107
Travel gearbox breather filter, Clean / Replace 3-107
TRAVEL GEARBOX (PN 3719869) 3-108
Travel gearbox – Checking the oil level / Topping up with oil 3-108
Hydraulic motor chambers, Check the oil level / Top up with oil 3-108
Travel gearbox, Changing oil 3-109
Hydraulic motor chambers, Changing oil 3-109
CRAWLER TRACKS 3-110
Track roller, Support roller 3-111
Track tensioner 3-112
Pressure-accumulator inspection regulations 3-113
Checking the gas charging pressure in the pressure accumulator 3-113
SWING RING 3-114
Swing ring – Instructions 3-114
Bearing races 3-114
CENTRAL LUBRICATING SYSTEM 3-116
Design 3-116
BA RH170B(3 725 089.00)-EN
TABLE OF CONTENTS
x
Function 3-117
Filling up the grease container 3-118
Breather filter grease container, check / replace 3-118
Checking the greasing pressure 3-119
Unblocking a grease line 3-119
Oilfilter replace (hydraulic circuit grease pump) 3-120
Grease filter replace (filling the grease container) 3-121
Grease filter replace (Grease lines) 3-121
OTHER MAINTENANCE 3-122
Engine 3-122
Heating and air conditioning 3-122
Reservoirs for used grease at the A-frame, emptying 3-123
Hydraulic ladder, pressure accumulator 3-123
Pressure-accumulator inspection regulations 3-124
Extract from the German regulations 3-124
Checking the gas charging pressure in the pressure accumulator 3-124
ON-BOARD CRANE, DRIVE UNIT 3-125
On-board crane, greasing 3-125
On-Board crane, checking tightness of fastening bolts 3-126
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-127
Putting the hydraulic shovel out of operation 3-127
Battery storage 3-127
Recommissioning 3-127
NOTES 3-129
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
CONFINED SPACES – SAFETY INSTRUCTIONS 4-4
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
HYDRAULIC SYSTEM 4-7
Repair instructions 4-7
Hydraulic hoses – Instructions 4-7
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-8
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-9
DISPOSAL AT THE END OF THE SERVICE LIFE 4-12
Appropriate disposal of batteries 4-13
NOTES 4-15
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
The keys on the front side 5-4
Other elements on the front side 5-4
BA RH170B(3 725 089.00)-EN
TABLE OF CONTENTS
xi
BCSIII, the start screen 5-5
Information given on the start screen, top section 5-6
Information given on the start screen, central section 5-7
Information given on the start screen, lower section 5-8
Information given on the “Service” screen 5-9
Engine data screen 5-10
Hydraulic data screen 5-11
Lubrication data screen 5-12
Controls adjustment data screen 5-13
View documents screen 5-14
Signal table screen 5-15
Signal table screen, location 5-16
Signal table screen, diagram 5-17
Signal table screen, diagram configuration 5-18
Code table screen 5-19
BCS III, interfaces 5-20
USB interface, data storage 5-20
Saving data to a USB stick 5-21
Saving data to a USB stick, continued 5-22
Saving data to a USB stick, continued 5-23
BCSIII, cleaning 5-24
BCSIII, disposal 5-24
TROUBLESHOOTING 5-25
Instructions on troubleshooting 5-25
Layout of the fault table 5-25
Possible causes 5-25
Measures 5-25
Section 5-25
FAULT TABLES 5-26
Combustion engine – Fault table 5-26
Working hydraulics – Fault table 5-27
Track drive – Fault table 5-28
Swing mechnism – Fault table 5-29
Central lubricating system – Fault table 5-30
ENGINE MONITORING, CONTROL LAMPS 5-31
HYDRAULIC CIRCUIT DIAGRAM 5-32
ABBREVIATIONS 5-33
ABBREVIATIONS 5-34
TECHNICAL DATA 5-35
NOTES 5-37
6 INDEX 6-1

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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]

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