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

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

FILE DETAILS:

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

Language : English
Pages : 348
Downloadable : Yes
File Type : PDF

DESCRIPTION:

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

PREFACE:

• These operation and maintenance manual is de- signed to familiarize the operator with the
  machine and its designated use.
• The Operation and Maintenence Manual contain important information on how to operate the
  ma- chine safely, properly and with maximum effi- ciency. Observing these instructions
  helps to pre- vent hazardous situations, to reduce repair costs and downtimes and to
  increase the reliability and service life of the machine.
• The Operation and Maintenence Manual must be supplemented by the respective national rules
  and regulations for accident prevention and environ- mental protection.
• The Operation and Maintenence Manual must always be available in the operator’s cab
  of the machine.

The Operation and Maintenence Manual 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 Operation and Maintenence Man- ual 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 Operation and Maintenence Manual are di- rected to the mining-machine specialist. They
  can- not provide basic know-how. This can be acquired, for example, in several days’ instruction by
  a quali- fied CGM HMS GmbH mechanic or by attending an CGM HMS GmbH training course for
  operators or maintenance personnel.
• The CGM HMS GmbH after-sales service will be pleased to deal with any queries you may
  have after reading through the Operation and Main- tenence Manual.
  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 Operation and Maintenence Manual are not work instructions 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 – PDF DOWNLOAD

TABLE OF CONTENTS
1 INTRODUCTION 1-1
PREFACE 1-1
Further machine documentation 1-1
WARRANTY 1-2
FUNDAMENTAL SAFETY INSTRUCTIONS 1-3
Warnings and symbols 1-3
DESIGNATED USE, UNAUTHORIZED USE 1-4
Noise emission information 1-5
Vibration information 1-5
ORGANIZATIONAL MEASURES 1-6
Selection and qualification of personnel; basic responsibilities 1-7
Safety instructions governing specific operational phases 1-7
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-8
Warning of special dangers 1-9
Gas, dust, steam and smoke 1-9
Hydraulic equipment 1-10
FIRE AND EXPLOSION HAZARD 1-11
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operation and Maintenence Manual, where to store it in the operator’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
Upperstructure 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 operator’s cab and escape ladder 2-21
Switching the cab interior lighting on and off 2-22
Switching the maintenance lights on and off 2-23
Emergency shut-off function 2-24
BA 6040(3 847 024.00)-EN
TABLE OF CONTENTS
vi
Putting the machine back into operation, reset of emergency shut off function 2-25
Battery isolator switch, shutting off supply voltage 2-26
Starter isolator switch, shutting off starter voltage 2-26
Operator’s seat 2-27
Reducing the operators exposure to vibrations 2-29
Trainer’s / instructor’s seat 2-29
Fire extinguisher 2-30
Automatic fire-extinguishing system (optional) 2-31
Windscreen washer 2-31
Operating hours meter 2-31
Emergency escape device / seat (optional) 2-32
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 2-67
Switching the electrical system on and off 2-72
Engines, emergency shut-off 2-72
Preheating system for engine and hydraulic oil (optional) 2-73
Fuel preheating system (optional) 2-74
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 operator’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
Upperstructure basic position 2-85
Travelling forwards/backwards 2-85
Upperstructure holding brake 2-89
Track parking brake 2-89
TRANSPORTING THE MACHINE 2-90
Transport – Safety instructions 2-90
BA 6040(3 847 024.00)-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 upperstructure 2-94
Braking the upperstructure 2-94
Working 2-95
Emergency lowering of the working equipment 2-96
After daily operation 2-97
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-98
Securing the machine 2-99
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-100
ON-BOARD CRANE (OPTIONAL) 2-101
Monitoring, warning and control elements 2-101
On-board crane, putting into operation 2-102
On-board crane, drive unit 2-102
On-Board crane, – blocking the boom in position of rest 2-103
Checking the on-board crane 2-103
MONITORING CAMERAS (OPTIONAL) 2-104
Monitoring cameras – function 2-104
NOTES 2-105
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 3-26
Lubricating chart – Grease (legend) 3-27
Filling quantities – Grease 3-27
INSPECTION PLAN – OIL 3-28
Inspection plan – Oil (legend) 3-29
Filling quantities – oil 3-30
Filling quantities – other 3-30
LUBRICANTS / CONSUMABLES 3-31
Notes on the selection of oils and greases 3-31
Avoid mixing of different hydraulic fluids 3-31
I. Oils for combustion engines 3-32
II. Fluid for hydraulic system 3-33
III.a Oils for pump drive gearboxes and travel gearboxes 3-34
III.b Oil for swing gearboxes 3-35
V. Grease for bearings, swing rings and track system (Central lubrication system) 3-36
BA 6040(3 847 024.00)-EN
TABLE OF CONTENTS
viii
Grease for idlers, track rollers and support rollers (Lifetime lubrication) 3-37
Coolant for use on all combustion engines 3-38
SERVICING WORK 3-39
Hose line for oil and cooling liquid changes 3-39
ENGINE 3-40
Engine – Safety instructions 3-40
Engine oil, checking the level / topping up 3-41
Engine oil reservoir (optional), checking the oil level / topping up 3-42
Engine oil, change 3-43
Engine oil reservoir (optional), draining the oil off 3-45
Engine oil filter, replace 3-47
Engine oil reservoir (optional), replacing the oil filters 3-48
Centrifuge (optional) 3-49
Eliminator filter and centrifuge (optional) 3-50
Cold-starting fluid (ether) – Replacing the pressure vessel 3-52
COOLING SYSTEM 3-53
Temperature 3-53
Radiators 3-53
Cooling-liquid level check 3-54
Cooling-liquid, select 3-54
Cooling liquid, topping up 3-55
Cooling liquid, change 3-57
Testing the cooling liquid composition 3-59
Water filter, replace 3-60
AIR-INTAKE SYSTEM 3-61
Main filter elements, removal and installation 3-62
Main filter elements, checking and cleaning 3-63
Secondary filter element, replace 3-64
Air-intake lines 3-65
Dust collection 3-65
FUEL SYSTEM 3-66
Fuel system – Safety instructions 3-66
Fuel filter, replace 3-66
Breather filter fuel tank, replace 3-67
Fuel tanks, cleaning 3-67
Water trap (optional) 3-69
ELECTRICAL SYSTEM 3-71
Electrical system – Safety instructions 3-71
Alternator – Instructions 3-71
Electrical circuit diagrams 3-71
Electrical system switch-cabinets 3-71
Replacing lamps and bulbs 3-71
Battery 3-72
Charging batteries inside the machine, safety instructions 3-73
Removing and installing the battery 3-74
Switchgear cabinet, aeration 3-75
Xenon floodlight projector, replacing the lamp 3-77
Lighting systems in LED technonogy, instructions 3-79
BA 6040(3 847 024.00)-EN
TABLE OF CONTENTS
ix
HYDRAULIC SYSTEM 3-80
Hydraulic system – Safety instructions 3-80
Depressurizing the hydraulic system 3-80
Checking the hydraulic oil level 3-81
Hydraulic oil return-flow filters (hydraulic oil reservoir), replace 3-83
Hydraulic oil return-flow filters (hydraulic oil reservoir), replace (from machine no. 170130) 3-86
Bypass valves (hydraulic oil reservoir), checking / cleaning 3-88
Replacing the bypass valves and sealing rings 3-88
Replacing the hydraulic oil return-flow filters (filter housing cooling system) 3-89
Bypass valves (filter housing – cooling system), checking / replacing 3-90
Breather filter, replace 3-91
Filter (servo control circuit and auxiliary control circuit) 3-92
High-pressure filter for working hydraulics, replace 3-93
High-pressure filters for the servo circuit, replace 3-94
High-pressure filters for feeding circuits and swing pumps, replace 3-95
Filter pump control, clean 3-96
Changing the hydraulic oil 3-97
Avoid mixing of different hydraulic fluids 3-97
Venting the hydraulic system 3-101
Cleaning the hydraulic oil cooler 3-102
Electronic hydraulic shovel control, clean / lubricate 3-103
Pressure accumulator – Emergency lowering 3-104
PUMP TRANSFER GEARBOX 3-105
Pump gearbox, checking the oil level / Topping up with oil 3-105
Pump gearbox, change oil 3-106
Pump gearbox, change oil 3-106
Pump gearbox, venting 3-107
Pump transfer gearbox lube oil filters 3-108
SWING GEARBOX 3-109
Swing gearbox, checking the oil level / Topping up with oil 3-109
Swing gearbox venting 3-109
Changing the swing gearbox oil 3-110
TRAVEL GEARBOX (PN 2763213) 3-112
Travel gearbox – Checking the oil level / Topping up with oil 3-112
Pre-chamber / spur wheel section, Check the oil level / Top up with oil 3-112
Hydraulic motor chamber – Check the oil level / Top up with oil 3-112
Travel gearbox, Changing oil 3-113
Pre-chamber / spur wheel section, Changing oil 3-113
Hydraulic motor chamber, Changing oil 3-114
Travel gearbox breather filter, Clean / Replace 3-114
TRAVEL GEARBOX (PN 3719869) 3-115
Travel gearbox – Checking the oil level / Topping up with oil 3-115
Hydraulic motor chambers, Check the oil level / Top up with oil 3-115
Travel gearbox, Changing oil 3-116
Hydraulic motor chambers, Changing oil 3-116
CRAWLER TRACKS 3-117
Undercarriage, lubricating system 3-117
Track roller, Support roller 3-118
Track tensioner 3-119
BA 6040(3 847 024.00)-EN
TABLE OF CONTENTS
x
Pressure-accumulator inspection regulations 3-120
Checking the gas charging pressure in the pressure accumulator 3-120
SWING RING 3-121
Swing ring – Instructions 3-121
Bearing races 3-121
CENTRAL LUBRICATING SYSTEM 3-123
Design 3-123
Function 3-124
Filling up the grease container 3-125
Breather filter grease container, check / replace 3-125
Checking the greasing pressure 3-126
Unblocking a grease line 3-126
Oilfilter replace (hydraulic circuit grease pump) 3-127
Grease filter replace (filling the grease container) 3-128
Grease filter replace (Grease lines) 3-128
OTHER MAINTENANCE 3-129
Engine 3-129
Heating and air conditioning 3-129
Reservoirs for used grease at the A-frame, emptying 3-130
Hydraulic ladder, pressure accumulator 3-130
Pressure-accumulator inspection regulations 3-131
Extract from the German regulations 3-131
Checking the gas charging pressure in the pressure accumulator 3-131
ON-BOARD CRANE, DRIVE UNIT 3-132
On-board crane, greasing 3-132
On-Board crane, checking tightness of fastening bolts 3-133
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-134
Putting the hydraulic shovel out of operation 3-134
Battery storage 3-134
Recommissioning 3-134
NOTES 3-135
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
BA 6040(3 847 024.00)-EN
TABLE OF CONTENTS
xi
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
SIL2 functionality 5-3
The keys on the front side 5-4
Other elements on the front side 5-4
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
EMERGENCY STOP, RESET FUNCTION 5-9
SWING CIRCUIT LOCK-OUT FUNCTION 5-10
Information given on the “Service” screen 5-11
Engine data screen 5-12
Hydraulic data screen 5-13
Lubrication data screen 5-14
Controls adjustment data screen 5-15
View documents screen 5-16
Signal table screen 5-17
Signal table screen, location 5-18
Signal table screen, diagram 5-19
Signal table screen, diagram configuration 5-20
Code table screen 5-21
SLEW BRAKE TEST SCREEN 5-22
BCS III, interfaces 5-23
USB interface, data storage 5-23
Saving data to a USB stick 5-24
Saving data to a USB stick, continued 5-25
Saving data to a USB stick, continued 5-26
BCSIII, cleaning 5-27
BCSIII, disposal 5-27
TROUBLESHOOTING 5-28
Instructions on troubleshooting 5-28
Layout of the fault table 5-28
Possible causes 5-28
Measures 5-28
Section 5-28
FAULT TABLES 5-29
Combustion engine – Fault table 5-29
Working hydraulics – Fault table 5-30
BA 6040(3 847 024.00)-EN
TABLE OF CONTENTS
xii
Track drive – Fault table 5-31
Swing mechnism – Fault table 5-32
Central lubricating system – Fault table 5-33
ENGINE ELECTRONIC UNIT, DISPLAYING STORED FAULT CODES 5-34
Engine electronics, displaying faults 5-34
Engine electronic, displaying faults in memory 5-34
HYDRAULIC CIRCUIT DIAGRAM 5-35
ABBREVIATIONS 5-36
ABBREVIATIONS 5-37
PRODUCT SPECIFICATION SHEET 5-2
NOTES 5-3
6 INDEX 6-1

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