CAT 6040 AC 6040 ACFS Hydraulic Shovel Operation & Maintenance Manual 3847027 – PDF DOWNLOAD

Description

CAT 6040 AC 6040 ACFS Hydraulic Shovel Operation & Maintenance Manual 3847027 – PDF DOWNLOAD

FILE DETAILS:

CAT 6040 AC 6040 ACFS Hydraulic Shovel Operation & Maintenance Manual 3847027 – PDF DOWNLOAD

Language : English
Pages : 270
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6040 AC 6040 ACFS Hydraulic Shovel Operation & Maintenance Manual 3847027 – PDF DOWNLOAD

PREFACE:

• This Operation and Maintenance Manual is de- signed to familiarize the operator with the
  machine and its designated use.
• The Operation and Maintenance Manual contain important information on how to operate the
  ma- chine safely, properly and with maximum efficiency. Observing these instructions helps to
  prevent haz- ardous situations, to reduce repair costs and down- times and to increase the
  reliability and service life of the machine.
• The Operation and Maintenance Manual must be supplemented by the respective national rules
  and regulations for accident prevention and environ- mental protection.
• The Operation and Maintenance Manual must al- ways be available in the operator’s cab of the
  machine.

The Operation and Maintenance 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, troubleshooting in the course of work, care,
evacuation of pro- duction waste and disposal of fuels and con- sumables,
▪ maintenance (inspection, servicing, repair) and
/ or
▪ transport.

• In addition to the Operation and Maintenance 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 ma- chine is to be used, the generally recognized tech- nical rules for safe and proper
  working must be observed ¹
• The Operation and Maintenance 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 (Caterpillar Global Mining Hydraulic Mining Shovels 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 Maintenance Manual.
• All CGM HMS GmbH Operation and Maintenance Manuals are issued 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 Maintenance Manual are not work instructions for carrying out major
  repairs. Such work is willingly done fo you by the CGM
  HMS GmbH after-sales service.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT 6040 AC 6040 ACFS Hydraulic Shovel Operation & Maintenance Manual 3847027 – 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 1-6
ORGANIZATIONAL MEASURES 1-7
Selection and qualification of personnel; basic responsibilities 1-8
Safety instructions governing specific operational phases 1-8
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-9
Warning of special dangers 1-10
Gas, dust, steam and smoke 1-11
Hydraulic / pneumatc equipment 1-11
Noise 1-11
Oil, grease and other chemical substances 1-11
Transporting and recommissioning 1-11
ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS 1-12
Safety instructions for excavators with electric motor 1-13
FIRE AND EXPLOSION HAZARD 1-14
NOTES 1-1
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operation and Maintenance Manual, where to store it in the operator’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE SHOVEL 2-6
Shovel layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Control and Monitoring Platform (CAMP) 2-8
Demand control / Zero-flow regulation 2-9
Automatic reset to idling 2-9
Board-Control-System (BCS) 2-9
Electrical system 2-9
Power supply 2-10
Operation with cable reel (optional) 2-11
Signs 2-12
Entering and leaving the machine Safety instructions 2-24
Access ladder lighting 2-24
BA 6040(3 847 027.00)-EN
TABLE OF CONTENTS
vi
Swinging ladder 2-25
Folding ladder (optional) 2-26
Emergency exit in operator’s cab and escape ladder 2-27
Switching the cab interior lighting on and off 2-28
Switching the maintenance lights on and off 2-29
EMERGENCY STOP switch 2-30
Servicing switch 2-31
Windscreen washer 2-31
Operator’s seat 2-32
Fire extinguisher 2-34
Automatic fire-extinguishing system (optional) 2-35
Trainer’s / instructor’s seat 2-35
Emergency escape device (optional) 2-36
MONITORING, WARNING AND CONTROL ELEMENTS 2-40
PUTTING THE MACHINE INTO OPERATION 2-58
Service station (tanklift) 2-58
Battery main switch, switching on and off 2-61
Electrical system (24V), switching on and off 2-61
Switching the electric motor on and off 2-62
Time-out before restart 2-63
Electric motor can not be switched on 2-64
In case of failure 2-64
Circuit breaker, switching on and off 2-65
Motor protection relay, functions 2-66
Air conditioner (optional) 2-68
Back-up heating operator’s cab (optional) 2-68
TRAVELLING, SAFETY INSTRUCTIONS 2-69
TRAVELLING 2-70
Superstructure basic position 2-70
Travelling forwards/backwards 2-70
Superstructure holding brake 2-74
Track parking brake 2-74
TRANSPORTING THE MACHINE 2-75
Transport – Safety instructions 2-75
WORKING OPERATION – SAFETY INSTRUCTIONS 2-76
WORKING OPERATION 2-78
Before starting work 2-78
Activating the electronic servo control 2-78
Swinging the superstructure 2-79
Braking the superstructure 2-79
Working 2-80
Emergency lowering of the working equipment 2-81
After daily operation 2-82
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-83
Securing the machine 2-84
BA 6040(3 847 027.00)-EN
TABLE OF CONTENTS
vii
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-85
ON-BOARD CRANE (OPTIONAL) 2-86
On-board crane, monitoring, warning and control elements 2-86
On-board crane, putting into operation 2-87
On-board crane, drive unit 2-87
On-Board crane, – blocking the boom in position of rest 2-88
On-board crane, checking 2-88
Monitoring cameras 2-89
NOTES 2-91
3 INSPECTION AND SERVICING 3-1
SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR 3-3
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-4
FIRE AND EXPLOSION HAZARD 3-8
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Servicing Intervals 3-9
Oils / Greases 3-9
Cleaning jobs 3-9
Components 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 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids 3-29
LUBRICANTS / CONSUMABLES 3-30
I. Oil for combustion engines (On-Board Crane, option) 3-30
II. Oil for hydraulic system (selection) 3-31
III.a Oil for pump gearboxes and travel gearboxes 3-32
III.b Oil for swing gearboxes 3-33
V. Grease for bearings, swing rings and track system (Central lubrication system) 3-34
Greases for idlers, track rollers and support rollers (Lifetime lubrication) 3-35
SERVICING WORK 3-36
Hose line for oil changes 3-36
ELECTRIC MOTOR 3-37
Electric motor – Safety instructions 3-37
Electric motor, cleaning 3-37
BA 6040(3 847 027.00)-EN
TABLE OF CONTENTS
viii
Electric motor, greasing 3-38
ELECTRICAL SYSTEM 3-39
Electrical system – Safety instructions 3-39
Battery, checking state of charge 3-40
Electrical system, control cabinets 3-42
Slip ring assembly, servicing work 3-44
Electrical circuit diagrams 3-44
Replacing fuses 3-44
Replacing lamps and bulbs 3-44
Xenon floodlight projector (optional), replacing the lamp 3-45
Lighting systems in LED technonogy, instructions 3-47
HYDRAULIC SYSTEM 3-48
Hydraulic system – Safety instructions 3-48
Depressurizing the hydraulic system 3-48
Checking the hydraulic oil level 3-49
Hydraulic oil return-flow filters, replace 3-51
Hydraulic oil return-flow filters, replace (from machine no. 170138) 3-53
Bypass valves, clean / replace 3-55
Hydraulic oil tank breather filters, replace 3-56
Filter (servo control circuit), replace 3-57
High-pressure filter for working hydraulics, replace 3-58
Filters for swing charge pump, replace 3-59
High-pressure filters for the servo circuit, replace 3-60
Changing the hydraulic oil 3-61
Avoid mixing of different hydraulic fluids 3-61
Venting the hydraulic system 3-65
Cleaning the hydraulic oil cooler 3-66
Electronic excavator control 3-67
Pressure accumulator – Emergency lowering 3-68
PUMP DRIVE GEARBOX 3-69
Pump drive gearbox, checking oil level / Topping up with oil 3-69
Pump drive gearbox, changing oil 3-71
Pump drive gearbox, pre-chamber 3-72
Pump drive gearbox, venting 3-72
Pre-chambers working pumps, draining oil, changing oil 3-73
Pre-chambers swing pumps, draining oil, changing oil 3-73
Pump gearbox cooling circuit, replace oil filter 3-74
SWING GEARBOX 3-75
Swing gearbox – Checking the oil level / Topping up with oil 3-75
Swing gearbox – Changing the gearbox oil 3-75
Swing gearbox, venting , 3-76
SWING GEARBOX 3-77
Swing gearbox – Gearbox – Checking the oil level / Topping up with oil 3-77
Swing gearbox – Changing the gearbox oil 3-78
Swing gearbox – venting 3-79
TRAVEL GEARBOX 3-80
Travel gearbox – Checking the oil level / Topping up with oil 3-80
Travel gearbox – Changing oil 3-81
BA 6040(3 847 027.00)-EN
TABLE OF CONTENTS
ix
Travel gearbox – Breather filter 3-82
CRAWLER TRACKS 3-83
Track rollers 3-84
Track tensioner 3-85
Pressure-accumulator inspection regulations 3-86
Checking the gas charging pressure in the pressure accumulator 3-86
SWING RING 3-87
Swing ring – Instructions 3-87
Bearing races 3-87
CENTRAL LUBRICATING 3-89
Design and function 3-89
Function 3-90
Filling up the grease container 3-91
Breather filter 3-91
Checking the greasing pressure 3-92
Checking the greasing pressure 3-93
Unblocking a grease line. 3-94
Unblocking a grease line. 3-94
Oilfilter (hydraulic circuit grease pump) ) 3-95
Grease filter (Filling the grease container) 3-96
Grease filter (Grease lines) 3-97
OTHER MAINTENANCE 3-98
Heating and air conditioning 3-98
Equipment, check for cracks 3-98
Reservoirs for used grease at the A-frame, emptying 3-99
Hydraulic ladder, pressure accumulator 3-99
Pressure-accumulator inspection regulations 3-100
Extract from the regulations 3-100
Checking the gas charging pressure in the pressure accumulator 3-100
ON-BOARD CRANE, DRIVE UNIT 3-101
On-board crane, lubricating 3-102
On-Board crane, checking tightness of fastening bolts 3-102
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-103
Putting the excavator out of operation 3-103
Battery storage 3-103
Recommissioning 3-103
NOTES 3-1
4 REPAIR WORK 4-1
SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR 4-3
REPAIR WORK – SAFETY INSTRUCTIONS 4-4
FIRE AND EXPLOSION HAZARD 4-5
HYDRAULIC SYSTEM 4-6
Repair 4-6
Hydraulic hoses – Instructions 4-6
BA 6040(3 847 027.00)-EN
TABLE OF CONTENTS
x
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-7
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-8
DISPOSAL AT THE END OF THE SERVICE LIFE 4-11
Appropriate disposal of batteries 4-12
NOTES 4-13
5 ANNEX 5-1
TROUBLESHOOTING 5-3
Instructions on troubleshooting 5-3
Layout of the fault table 5-3
Possible causes 5-3
Measures 5-3
Section 5-3
FAULT TABLES 5-4
Working hydraulics – Fault table 5-4
Track drive – Fault table 5-5
Swing mechnism – Fault table 5-6
Central lubricating system – Fault table 5-7
HYDRAULIC CIRCUIT DIAGRAM 5-8
ABBREVIATIONS 5-9
NOISE AND VIBRATION INFORMATION 5-11
Noise emission information 5-11
Vibration information 5-11
PRODUCT SPECIFICATION SHEET 5-13
NOTES 5-15
6 INDEX 6-1

Questions? Email us: [email protected]

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V