CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual BI017207 – PDF DOWNLOAD

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CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual BI017207 – PDF DOWNLOAD

FILE DETAILS:

CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual BI017207 – PDF DOWNLOAD

Language : English
Pages : 336
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual BI017207 – PDF DOWNLOAD

DHJ40119, -125, 130, -132, -133, -134, -135, -137, -149, -150
DHX40126, -127, -128, -129, -136, -142

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.
• 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 ou by the CGM HMS GmbH
  after-sales service.

TABLE OF CONTENTS:

CAT 6040, 6040FS Hydraulic Shovel Operation & Maintenance Manual BI017207 – PDF DOWNLOAD

TITLEPAGE.....................................................................................................................................................................  3
1 INTRODUCTION................................................................................................................................................................ 15
	PREFACE .................................................................................................................................................................. 17
		Further machine documentation ........................................................................................................................................ 17
	WARRANTY ................................................................................................................................................................. 18
	FUNDAMENTAL SAFETY INSTRUCTIONS........................................................................................................................................... 19
		Warnings and symbols ................................................................................................................................................. 19
	DESIGNATED USE, UNAUTHORIZED USE ......................................................................................................................................... 20
		Noise emission information ........................................................................................................................................... 21
		Vibration information ................................................................................................................................................ 21
	ORGANIZATIONAL MEASURES .................................................................................................................................................. 22
		Selection and qualification of personnel; basic responsibilities ..................................................................................................... 23
		Safety instructions governing specific operational phases ............................................................................................................ 23
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 24
		Warning of special dangers ........................................................................................................................................... 25
		Gas, dust, steam and smoke ........................................................................................................................................... 25
		Hydraulic equipment .................................................................................................................................................. 26
	FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 27
	NOTES .................................................................................................................................................................... 29
2 OPERATION................................................................................................................................................................... 31
	OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 33
		Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 34
	FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 35
	DESCRIPTION OF THE HYDRAULIC SHOVEL....................................................................................................................................... 36
		Hydraulic shovel layout .............................................................................................................................................. 37
		Undercarriage ........................................................................................................................................................ 38
		Superstructure ....................................................................................................................................................... 38
		Drive ................................................................................................................................................................ 38
		Hydraulic system ..................................................................................................................................................... 38
		Control and Monitoring Platform (CAMP) ............................................................................................................................... 38
		Board-Control-System (BCS) ........................................................................................................................................... 39
		Demand control / Zero-flow regulation ................................................................................................................................ 39
		Automatic reset to idling ............................................................................................................................................ 39
		Electrical system .................................................................................................................................................... 39
		Signs ................................................................................................................................................................ 40
		Entering and leaving the machine Safety instructions ................................................................................................................. 48
		Access ladder lighting ............................................................................................................................................... 48
		Swinging ladder (optional) ........................................................................................................................................... 49
		Folding ladder ....................................................................................................................................................... 50
		Emergency exit in driver’s cab and escape ladder ..................................................................................................................... 51
		Escape ladder near engine compartment (optional) ..................................................................................................................... 52
		Switching the cab interior lighting on and off ....................................................................................................................... 53
		Switching the maintenance lights on and off .......................................................................................................................... 54
		Emergency shut-off function .......................................................................................................................................... 55
		Battery isolator switch, shutting off supply voltage ................................................................................................................. 57
		Starter isolator switch, shutting off starter voltage ................................................................................................................ 57
		Reducing the operators exposure to vibrations ........................................................................................................................ 60
		Trainer's / instructor's seat ........................................................................................................................................ 60
		Fire extinguisher .................................................................................................................................................... 61
		Automatic fire-extinguishing system (optional) ....................................................................................................................... 62
		Windscreen washer .................................................................................................................................................... 62
		Operating hours meter ................................................................................................................................................ 62
		Emergency escape device / seat (optional) ............................................................................................................................ 63
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 66
		Engine 1 (LH), control and monitoring ................................................................................................................................ 73
		Engine 2 (RH), control and monitoring ................................................................................................................................ 75
	PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 94
		Reducing the operator's exposure to noise ............................................................................................................................ 94
		Refuelling ........................................................................................................................................................... 95
		Back-up heating (option), filling in fuel ............................................................................................................................ 95
		Service station (tanklift) ........................................................................................................................................... 96
		Emergency off switch ................................................................................................................................................. 98
		Switching the electrical system on and off ...........................................................................................................................103
		Engines, emergency shut-off ..........................................................................................................................................103
		Preheating system for engine and hydraulic oil (optional) ............................................................................................................104
		Fuel preheating system (optional) ....................................................................................................................................105
	STARTING AND STOPPING THE ENGINES ........................................................................................................................................106
		Starting the engines .................................................................................................................................................106
		Starting the left-hand engine.........................................................................................................................................106
		Starting the right-hand engine........................................................................................................................................106
		Engines – adjusting the speed ........................................................................................................................................107
		Starting the engines at low temperatures .............................................................................................................................107
		Shutting off the engines .............................................................................................................................................108
		Shutting off the left-hand engine.....................................................................................................................................108
		Shutting off the right-hand engine....................................................................................................................................108
	AIR CONDITIONER (OPTIONAL) ...............................................................................................................................................109
		Back-up heating driver’s cab (optional) ..............................................................................................................................110
		Back-up heating (optional) ...........................................................................................................................................111
	MAXIMUM MACHINE INCLINATIONS, INFORMATION ................................................................................................................................112
	TRAVELLING, SAFETY INSTRUCTIONS ..........................................................................................................................................114
	TRAVELLING ...............................................................................................................................................................115
		Superstructure basic position ........................................................................................................................................115
		Travelling forwards/backwards ........................................................................................................................................115
		Superstructure holding brake .........................................................................................................................................119
		Track parking brake ..................................................................................................................................................119
	TRANSPORTING THE MACHINE .................................................................................................................................................120
		Transport - Safety instructions ......................................................................................................................................120
	WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................121
	WORKING OPERATION ........................................................................................................................................................123
		Before starting work .................................................................................................................................................123
		Activating the electronic hydraulic shovel control ...................................................................................................................123
		Swinging the superstructure ..........................................................................................................................................124
		Braking the superstructure ...........................................................................................................................................124
		Working ..............................................................................................................................................................125
		After daily operation ................................................................................................................................................126
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................127
		Securing the machine .................................................................................................................................................128
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................129
	ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................130
		Monitoring, warning and control elements .............................................................................................................................130
		On-board crane, putting into operation ...............................................................................................................................131
		On-board crane, drive unit ...........................................................................................................................................131
		On-Board crane, – blocking the boom in position of rest ..............................................................................................................132
		Checking the on-board crane ..........................................................................................................................................132
	NOTES ....................................................................................................................................................................133
3 INSPECTION AND SERVICING....................................................................................................................................................135
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................137
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................141
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................143
		Plan V ...............................................................................................................................................................145
		Plan N ...............................................................................................................................................................147
		Plan T and W .........................................................................................................................................................149
		Plan A – E ...........................................................................................................................................................151
	LUBRICATING CHART – GREASE ...............................................................................................................................................158
		Lubricating chart – Grease (legend) ..................................................................................................................................159
		Filling quantities - Grease...........................................................................................................................................159
	INSPECTION PLAN - OIL ....................................................................................................................................................160
		Inspection plan – Oil (legend) .......................................................................................................................................161
		Filling quantities - oil .............................................................................................................................................162
		Filling quantities - other............................................................................................................................................162
	LUBRICANTS / CONSUMABLES .................................................................................................................................................163
		Notes on the selection of oils and greases ...........................................................................................................................163
		Avoid mixing of different hydraulic fluids ...........................................................................................................................163
		I. Oils for combustion engines .......................................................................................................................................164
		II. Oil for hydraulic system .........................................................................................................................................165
		III.a Oils for pump distribution gearboxes and travel gearboxes ......................................................................................................166
		III.b Oil for swing gearboxes ........................................................................................................................................167
		V. Grease for bearings, slew rings and track system (Central lubrication system) .....................................................................................168
		Grease for idlers, track rollers and support rollers (Lifetime lubrication) ..........................................................................................169
		Coolant for use on all combustion engines ............................................................................................................................170
	SERVICING WORK ...........................................................................................................................................................171
		Hose line for oil and cooling liquid changes .........................................................................................................................171
	ENGINE ...................................................................................................................................................................172
		Engine - Safety instructions .........................................................................................................................................172
		Engine oil, checking the level / topping up ..........................................................................................................................173
		Engine oil reservoir (optional), checking the oil level / topping up .................................................................................................174
		Engine oil, change ...................................................................................................................................................175
		Engine oil reservoir (optional), draining the oil off ................................................................................................................177
		Engine oil filter, replace ...........................................................................................................................................179
		Engine oil reservoir (optional), replacing the oil filters ...........................................................................................................180
		Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................181
	COOLING SYSTEM ...........................................................................................................................................................182
		Temperature ..........................................................................................................................................................182
		Radiators ............................................................................................................................................................183
		Cooling-liquid level check ...........................................................................................................................................183
		Cooling liquid, change ...............................................................................................................................................186
		Testing the cooling liquid composition ...............................................................................................................................188
	AIR-INTAKE SYSTEM ........................................................................................................................................................189
		Dust trap, cleaning  .................................................................................................................................................189
		Main filter elements .................................................................................................................................................190
		Main filter elements, checking and cleaning ..........................................................................................................................191
		Safety filter element ................................................................................................................................................192
		Air-intake lines .....................................................................................................................................................192
	FUEL SYSTEM ..............................................................................................................................................................193
		Fuel system - Safety instructions ....................................................................................................................................193
		Fuel filter, replace .................................................................................................................................................193
		Primary fuel filter, drain water .....................................................................................................................................194
		Primary fuel filter, replace .........................................................................................................................................194
		Venting the fuel system ..............................................................................................................................................195
		Cleaning the fuel tanks ..............................................................................................................................................195
		Water trap (optional) ................................................................................................................................................197
	ELECTRICAL SYSTEM  .......................................................................................................................................................199
		Electrical system - Safety instructions ..............................................................................................................................199
		Alternator - Instructions ............................................................................................................................................199
		Electrical circuit diagrams ..........................................................................................................................................199
		Electrical system switch-cabinets ....................................................................................................................................199
		Replacing lamps and bulbs ............................................................................................................................................199
		Battery ..............................................................................................................................................................200
		Charging batteries inside the machine, safety instructions ...........................................................................................................201
		Removing and installing the battery ..................................................................................................................................202
		Switchgear cabinet, aeration .........................................................................................................................................203
		Xenon floodlight projector, replacing the lamp .......................................................................................................................205
		Lighting systems in LED technonogy, instructions .....................................................................................................................207
	HYDRAULIC SYSTEM .........................................................................................................................................................208
		Hydraulic system - Safety instructions ...............................................................................................................................208
		Depressurizing the hydraulic system ..................................................................................................................................208
		Checking the hydraulic oil level .....................................................................................................................................209
		Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) .............................................................................................211
		Bypass valves (hydraulic oil reservoir) ..............................................................................................................................214
		Replacing the bypass valves and sealing rings ........................................................................................................................214
		Replacing the hydraulic oil return-flow filters (filter housing cooling system) ......................................................................................215
		Bypass valves (filter housing - cooling system) ......................................................................................................................216
		Breather filter ......................................................................................................................................................217
		Filter (control circuit and auxiliary control circuit)................................................................................................................218
		High-pressure filter for working hydraulics ..........................................................................................................................219
		High-pressure filters for the servo circuit ..........................................................................................................................220
		High-pressure filters for feeding circuits and slewing pumps .........................................................................................................221
		Changing the hydraulic oil ...........................................................................................................................................222
		Avoid mixing of different hydraulic fluids ...........................................................................................................................222
		Venting the hydraulic system..........................................................................................................................................226
		Cleaning the hydraulic oil cooler.....................................................................................................................................227
		Electronic hydraulic shovel control...................................................................................................................................228
		Pressure accumulator - Emergency lowering ............................................................................................................................229
	PUMP TRANSFER GEARBOX ....................................................................................................................................................230
		Checking the pump gearbox oil level / Topping up with oil ............................................................................................................230
		Changing the pump gearbox oil ........................................................................................................................................232
		Pump gearbox venting .................................................................................................................................................234
		Pump transfer gearbox lube oil filters ...............................................................................................................................235
	SWING GEARBOX ............................................................................................................................................................236
		Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................236
		Gearbox venting ......................................................................................................................................................236
		Changing the swing gearbox oil .......................................................................................................................................237
	TRAVEL GEARBOX (PN 2763213) ..............................................................................................................................................239
		Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................239
		Pre-chamber / spur wheel section, Check the oil level / Top up with oil ..............................................................................................239
		Hydraulic motor chamber - Check the oil level / Top up with oil ......................................................................................................239
		Travel gearbox, Changing oil .........................................................................................................................................240
		Pre-chamber / spur wheel section, Changing oil .......................................................................................................................240
		Hydraulic motor chamber, Changing oil ................................................................................................................................241
		Travel gearbox breather filter, Clean / Replace ......................................................................................................................241
	TRAVEL GEARBOX (PN 3719869) ..............................................................................................................................................242
		Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................242
		Hydraulic motor chambers, Check the oil level / Top up with oil ......................................................................................................242
		Travel gearbox, Changing oil .........................................................................................................................................243
		Hydraulic motor chambers, Changing oil ...............................................................................................................................243
	CRAWLER TRACKS ...........................................................................................................................................................244
		Track roller, Support roller .........................................................................................................................................245
		Track tensioner ......................................................................................................................................................246
		Pressure-accumulator inspection regulations ..........................................................................................................................247
		Checking the gas charging pressure in the pressure accumulator........................................................................................................247
	SWING RING ...............................................................................................................................................................248
		Swing ring – Instructions ............................................................................................................................................248
		Bearing races ........................................................................................................................................................248
	CENTRAL LUBRICATING SYSTEM ...............................................................................................................................................250
		Design ...............................................................................................................................................................250
		Function .............................................................................................................................................................251
		Filling up the grease container ......................................................................................................................................252
		Breather filter grease container, check / replace ....................................................................................................................252
		Checking the greasing pressure .......................................................................................................................................253
		Unblocking a grease line .............................................................................................................................................253
		Oilfilter replace (hydraulic circuit grease pump) ....................................................................................................................254
		Grease filter replace (filling the grease container) .................................................................................................................255
		Grease filter replace (Grease lines) .................................................................................................................................255
	OTHER MAINTENANCE ........................................................................................................................................................256
		Engine ...............................................................................................................................................................256
		Heating and air conditioning .........................................................................................................................................256
		Reservoirs for used grease at the A-frame, emptying ..................................................................................................................257
		Hydraulic ladder, pressure accumulator ...............................................................................................................................257
		Pressure-accumulator inspection regulations  .........................................................................................................................258
		Extract from the German regulations...................................................................................................................................258
		Checking the gas charging pressure in the pressure accumulator .......................................................................................................258
	ON-BOARD CRANE, DRIVE UNIT ...............................................................................................................................................259
		On-board crane, greasing..............................................................................................................................................259
		On-Board crane, checking tightness of fastening bolts ................................................................................................................260
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................261
		Putting the hydraulic shovel out of operation.........................................................................................................................261
		Battery storage ......................................................................................................................................................261
		Recommissioning.......................................................................................................................................................261
	NOTES  ...................................................................................................................................................................263
4 REPAIR WORK.................................................................................................................................................................265
	REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................267
	CONFINED SPACES - SAFETY INSTRUCTIONS ....................................................................................................................................268
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................269
	REPAIR WORK, ENGINE.......................................................................................................................................................270
	HYDRAULIC SYSTEM .........................................................................................................................................................271
		Repair instructions ..................................................................................................................................................271
		Hydraulic hoses – Instructions  ......................................................................................................................................271
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................272
	WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................273
	DISPOSAL AT THE END OF THE SERVICE LIFE ..................................................................................................................................276
		Appropriate disposal of batteries ....................................................................................................................................277
	NOTES ....................................................................................................................................................................279
5 ANNEX.......................................................................................................................................................................281
	BOARD-CONTROL-SYSTEM .....................................................................................................................................................283
		BCS III, what’s that? ................................................................................................................................................283
		The keys on the front side ...........................................................................................................................................284
		Other elements on the front side .....................................................................................................................................284
		BCSIII, the start screen .............................................................................................................................................285
		Information given on the start screen, top section ...................................................................................................................286
		Information given on the start screen, central section ...............................................................................................................287
		Information given on the start screen, lower section .................................................................................................................288
		Information given on the “Service” screen ............................................................................................................................289
		Engine data screen ...................................................................................................................................................290
		Hydraulic data screen ................................................................................................................................................291
		Lubrication data screen ..............................................................................................................................................292
		Controls adjustment data screen ......................................................................................................................................293
		View documents screen ................................................................................................................................................294
		Signal table screen ..................................................................................................................................................295
		Signal table screen, location ........................................................................................................................................296
		Signal table screen, diagram .........................................................................................................................................297
		Signal table screen, diagram configuration ...........................................................................................................................298
		Code table screen ....................................................................................................................................................299
		BCS III, interfaces ..................................................................................................................................................300
		USB interface, data storage ..........................................................................................................................................300
		Saving data to a USB stick ...........................................................................................................................................301
		Saving data to a USB stick, continued ................................................................................................................................302
		Saving data to a USB stick, continued ................................................................................................................................303
		BCSIII, cleaning .....................................................................................................................................................304
		BCSIII, disposal .....................................................................................................................................................304
	TROUBLESHOOTING ..........................................................................................................................................................305
		Instructions on troubleshooting ......................................................................................................................................305
		Layout of the fault table ............................................................................................................................................305
		Possible causes ......................................................................................................................................................305
		Measures .............................................................................................................................................................305
		Section ..............................................................................................................................................................305
	FAULT TABLES .............................................................................................................................................................306
		Combustion engine - Fault table ......................................................................................................................................306
		Working hydraulics – Fault table .....................................................................................................................................307
		Track drive – Fault table ............................................................................................................................................308
		Swing mechnism – Fault table .........................................................................................................................................309
		Central lubricating system – Fault table .............................................................................................................................310
	ENGINE MONITORING, CONTROL LAMPS .........................................................................................................................................311
	HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................312
	ABBREVIATIONS ............................................................................................................................................................313
		ABBREVIATIONS.........................................................................................................................................................314
	TECHNICAL DATA ...........................................................................................................................................................315
		Product Specification Sheet...........................................................................................................................................317
	NOTES ....................................................................................................................................................................327
6 INDEX.......................................................................................................................................................................329

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