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Cat 6040AC, 6040ACFS Hydraulic Excavator Operation and Maintenance Manual BI651376 – PDF DOWNLOAD
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Description
Cat 6040AC, 6040ACFS Hydraulic Excavator Operation and Maintenance Manual BI651376 – PDF DOWNLOAD
FILE DETAILS:
Cat 6040AC 6040ACFS Hydraulic Excavator Operation and Maintenance Manual BI651376 – PDF DOWNLOAD
Language : English
Pages : 270
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6040AC 6040ACFS Hydraulic Excavator Operation and Maintenance Manual BI651376 – PDF DOWNLOAD
PREFACE
About this Operating Instructions
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency.
- Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine. The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
operation, including setting-up, troubleshooting 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 Maintenance Manual 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
- The Operation and Maintenance Manual are directed to the mining-machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified 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 for you by the CGM HMS GmbH after-sales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat 6040AC 6040ACFS Hydraulic Excavator Operation and Maintenance Manual BI651376 – PDF DOWNLOAD
TITLEPAGE..................................................................................................................................................................... 1 1 INTRODUCTION................................................................................................................................................................ 11 PREFACE .................................................................................................................................................................. 13 Further machine documentation ........................................................................................................................................ 13 WARRANTY ................................................................................................................................................................. 14 FUNDAMENTAL SAFETY INSTRUCTIONS........................................................................................................................................... 15 Warnings and symbols.................................................................................................................................................. 15 DESIGNATED USE............................................................................................................................................................ 16 ORGANIZATIONAL MEASURES .................................................................................................................................................. 17 Personal protective equipment and the working clothing................................................................................................................ 17 Selection and qualification of personnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases............................................................................................................. 18 Standard operation................................................................................................................................................ 18 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 19 Warning of special dangers ........................................................................................................................................... 20 Electric energy................................................................................................................................................... 20 High-voltage system............................................................................................................................................... 20 Battery .......................................................................................................................................................... 20 Gas, dust, steam and smoke ........................................................................................................................................... 21 Hydraulic / pneumatc equipment ....................................................................................................................................... 21 Noise ................................................................................................................................................................ 21 Oil, grease and other chemical substances ............................................................................................................................ 21 Transporting and recommissioning ..................................................................................................................................... 21 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS ...................................................................................................... 22 Safety instructions for excavators with electric motor ............................................................................................................... 23 In the transformer station........................................................................................................................................ 23 On the excavator.................................................................................................................................................. 23 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 24 NOTES .................................................................................................................................................................... 25 2 OPERATION................................................................................................................................................................... 27 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 29 Operation and Maintenance Manual...................................................................................................................................... 29 Operating personnel................................................................................................................................................... 29 Personal protective gear and working clothing......................................................................................................................... 29 Safety belt........................................................................................................................................................... 29 State of the machine.................................................................................................................................................. 29 Entering and leaving the machine...................................................................................................................................... 29 Hazard range.......................................................................................................................................................... 29 Persons within the hazard zone........................................................................................................................................ 30 Marshallers........................................................................................................................................................... 30 Securing the machine.................................................................................................................................................. 30 Operation and Maintenance Manual, where to store it in the operator’s cab ............................................................................................ 30 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 31 DESCRIPTION OF THE SHOVEL ................................................................................................................................................ 32 Shovel layout ........................................................................................................................................................ 33 Undercarriage..................................................................................................................................................... 33 Superstructure.................................................................................................................................................... 33 Loading bucket.................................................................................................................................................... 33 Undercarriage ........................................................................................................................................................ 34 Superstructure ....................................................................................................................................................... 34 Drive ................................................................................................................................................................ 34 Hydraulic system ..................................................................................................................................................... 34 Control and Monitoring Platform (CAMP) ............................................................................................................................... 34 Demand control / Zero-flow regulation ................................................................................................................................ 35 Automatic reset to idling............................................................................................................................................. 35 Board-Control-System (BCS) ........................................................................................................................................... 35 Electrical system .................................................................................................................................................... 35 Power supply ......................................................................................................................................................... 36 Operation with cable reel (optional) ................................................................................................................................. 37 Automatic operation............................................................................................................................................... 37 Manual operation.................................................................................................................................................. 37 Signs ................................................................................................................................................................ 38 Warning and instruction signs..................................................................................................................................... 38 Machine number.................................................................................................................................................... 49 Motor number...................................................................................................................................................... 49 Component numbers................................................................................................................................................. 49 Entering and leaving the machine Safety instructions ................................................................................................................. 50 Access ladder lighting ............................................................................................................................................... 50 Swinging ladder ...................................................................................................................................................... 51 Folding ladder (optional) ........................................................................................................................................... 52 Emergency exit in operator’s cab and escape ladder ................................................................................................................... 53 Switching the cab interior lighting on and off ....................................................................................................................... 54 Switching the maintenance lights on and off .......................................................................................................................... 55 EMERGENCY STOP switch ................................................................................................................................................ 56 Servicing switch ..................................................................................................................................................... 57 Windscreen washer .................................................................................................................................................... 57 Operator's seat ..................................................................................................................................................... 58 Fire extinguisher .................................................................................................................................................... 60 Extinguishing agent .............................................................................................................................................. 60 Handling.......................................................................................................................................................... 60 Inspection........................................................................................................................................................ 60 Automatic fire-extinguishing system (optional) ....................................................................................................................... 61 Inspection........................................................................................................................................................ 61 Trainer's / instructor's seat ........................................................................................................................................ 61 Emergency escape device (optional) ................................................................................................................................... 62 Elements of the harness........................................................................................................................................... 62 Important hints................................................................................................................................................... 62 Taking on harness................................................................................................................................................. 63 This page intentionally left blank................................................................................................................................ 65 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 66 Optional equipment: Air conditioning.................................................................................................................................. 83 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 84 Service station (tanklift) ........................................................................................................................................... 84 Lowering the service station ..................................................................................................................................... 84 Raising the service station ...................................................................................................................................... 84 Refilling and draining ........................................................................................................................................... 84 Battery main switch, switching on and off ............................................................................................................................ 87 Switching the battery main switch on.............................................................................................................................. 87 Switching the battery main switch off............................................................................................................................. 87 Electrical system (24V), switching on and off ........................................................................................................................ 87 Switching the electrical system (24V) on.......................................................................................................................... 87 Switching the electrical system (24V) off......................................................................................................................... 87 Switching the electric motor on and off .............................................................................................................................. 88 Before switching on the electric motor............................................................................................................................ 88 Switching the electric motor on................................................................................................................................... 88 Switching the electric motor off.................................................................................................................................. 89 Time-out before restart .............................................................................................................................................. 89 Electric motor can not be switched on ................................................................................................................................ 90 In case of failure ................................................................................................................................................... 90 Circuit breaker, switching on and off ................................................................................................................................ 91 Motor protection relay, functions .................................................................................................................................... 92 Front panel control and monitoring elements ...................................................................................................................... 93 Air conditioner (optional) ........................................................................................................................................... 94 Ventilation / Heating ............................................................................................................................................ 94 Control panel (SIGMA) ............................................................................................................................................ 94 Back-up heating operator’s cab (optional) ............................................................................................................................ 94 TRAVELLING, SAFETY INSTRUCTIONS .......................................................................................................................................... 95 Trailing cable........................................................................................................................................................ 95 TRAVELLING ............................................................................................................................................................... 96 Superstructure basic position ........................................................................................................................................ 96 Travelling forwards/backwards ........................................................................................................................................ 96 Regulating the travelling speed .................................................................................................................................. 97 Travelling uphill and downhill ................................................................................................................................... 97 Cornering ........................................................................................................................................................ 98 Turning .......................................................................................................................................................... 98 Note.............................................................................................................................................................. 98 Travelling over long distances ................................................................................................................................... 99 Superstructure holding brake .........................................................................................................................................100 Track parking brake ..................................................................................................................................................100 TRANSPORTING THE MACHINE .................................................................................................................................................101 Transport - Safety instructions ......................................................................................................................................101 Transport ........................................................................................................................................................101 WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................102 Running-in instructions for hydraulic cylinders.......................................................................................................................102 Avoid extreme positions of the attachment.............................................................................................................................103 WORKING OPERATION ........................................................................................................................................................104 Before starting work .................................................................................................................................................104 Warming up........................................................................................................................................................104 Activating the electronic servo control ..............................................................................................................................104 Swinging the superstructure ..........................................................................................................................................105 Braking the superstructure ...........................................................................................................................................105 Working ..............................................................................................................................................................106 Extending and retracting the bucket or backhoe bucket stick ......................................................................................................106 Opening and closing the bottom-dump bucket .......................................................................................................................106 Raising and lowering the boom ....................................................................................................................................106 Filling and emptying the bucket or the backhoe ...................................................................................................................106 Emergency lowering of the working equipment ..........................................................................................................................107 After daily operation ................................................................................................................................................108 Parking the machine ..............................................................................................................................................108 ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS .......................................................................................................................109 Personel..............................................................................................................................................................109 Personal protective gear and working clothes..........................................................................................................................109 Tools and auxiliaries.................................................................................................................................................109 Securing the working equipment........................................................................................................................................109 Securing the machine..................................................................................................................................................109 Selecting the attachments.............................................................................................................................................109 Protective roof against falling objects...............................................................................................................................109 Securing the machine .................................................................................................................................................110 Risk of injury....................................................................................................................................................110 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................111 Application of GLEITMO 815............................................................................................................................................111 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................112 Personel..............................................................................................................................................................112 On-board crane, monitoring, warning and control elements .............................................................................................................112 On-board crane, putting into operation ...............................................................................................................................113 On-board crane, drive unit ...........................................................................................................................................113 On-Board crane, – blocking the boom in position of rest ..............................................................................................................114 On-board crane, checking .............................................................................................................................................114 Extract from the inspection and testing regulations...............................................................................................................114 Monitoring cameras ...................................................................................................................................................115 NOTES ...................................................................................................................................................................117 3 INSPECTION AND SERVICING....................................................................................................................................................119 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ...................................................................................................................121 In the transformer station............................................................................................................................................121 On the excavator......................................................................................................................................................121 In the transformer station............................................................................................................................................121 On the hydraulic excavator............................................................................................................................................121 On the hydraulic excavator............................................................................................................................................121 INSPECTION AND SERVICING – SAFETY INSTRUCTIONS ...........................................................................................................................122 Operating manual......................................................................................................................................................122 Inspection and servicing personnel....................................................................................................................................122 Personal protective equipment and working clothing....................................................................................................................122 Securing the working equipment........................................................................................................................................122 Securing the machine..................................................................................................................................................122 Climbing onto and off the machine.....................................................................................................................................122 Checking the state of tools...........................................................................................................................................122 Cleaning jobs.........................................................................................................................................................122 Handling flammable liquids............................................................................................................................................123 Fastening and securing elements.......................................................................................................................................123 Spare parts...........................................................................................................................................................123 Handling oils and greases.............................................................................................................................................123 Visisble oil losses...................................................................................................................................................123 Relieving residual pressure in the hydraulic system...................................................................................................................123 Screwed connections, piping, hydraulic hoses..........................................................................................................................123 Non-polluting disposal................................................................................................................................................124 Seals.................................................................................................................................................................124 Handling batteries....................................................................................................................................................124 Before working on the electrical system...............................................................................................................................124 Selecting oils and greases............................................................................................................................................125 Filters...............................................................................................................................................................125 Sealing elements......................................................................................................................................................125 Oil-level check and oil change........................................................................................................................................125 Lubricating...........................................................................................................................................................125 After servicing.......................................................................................................................................................125 FIRE AND EXPLOSION HAZARD ................................................................................................................................................126 INSPECTION AND SERVICING PLANS – INSTRUCTIONS ............................................................................................................................127 Servicing Intervals ..................................................................................................................................................127 Oils / Greases .......................................................................................................................................................127 Cleaning jobs ........................................................................................................................................................127 Components ...........................................................................................................................................................127 Plan V ...............................................................................................................................................................129 Plan N ...............................................................................................................................................................131 Plan T and W .........................................................................................................................................................133 Plan A – E ...........................................................................................................................................................135 LUBRICATING CHART – GREASE ...............................................................................................................................................142 Lubricating chart – Grease (legend) ..................................................................................................................................143 Filling quantities – Grease ..........................................................................................................................................143 INSPECTION PLAN - OIL ....................................................................................................................................................144 Inspection plan – Oil (legend) .......................................................................................................................................145 Filling quantities - oil .............................................................................................................................................146 Filling quantities - other............................................................................................................................................146 LUBRICANTS ...............................................................................................................................................................147 Notes on the selection of oils and greases ...........................................................................................................................147 Original CGM HMS GmbH oils and greases............................................................................................................................147 Alternative oils and greases......................................................................................................................................147 Avoid mixing of different hydraulic fluids ...........................................................................................................................147 LUBRICANTS / CONSUMABLES .................................................................................................................................................148 I. Oil for combustion engines (On-Board Crane, option) ...............................................................................................................148 II. Oil for hydraulic system (selection) .............................................................................................................................149 III.a Oil for pump gearboxes and travel gearboxes ....................................................................................................................150 III.b Oil for swing gearboxes ........................................................................................................................................151 V. Grease for bearings, swing rings and track system (Central lubrication system) ....................................................................................152 Greases for idlers, track rollers and support rollers (Lifetime lubrication) .........................................................................................153 SERVICING WORK ...........................................................................................................................................................154 Hose line for oil changes ............................................................................................................................................154 ELECTRIC MOTOR ...........................................................................................................................................................155 Electric motor - Safety instructions .................................................................................................................................155 Electric motor, cleaning ............................................................................................................................................155 Electric motor, greasing .............................................................................................................................................156 Additional servicing work.........................................................................................................................................156 ELECTRICAL SYSTEM .......................................................................................................................................................157 Electrical system - Safety instructions ..............................................................................................................................157 Battery, checking state of charge ....................................................................................................................................158 Checking the battery fluid level .................................................................................................................................158 Checking charge of the battery ...................................................................................................................................158 Charging the batteries............................................................................................................................................158 Removing and installing the battery ..............................................................................................................................159 Electrical system, control cabinets ..................................................................................................................................160 Breather filter ..................................................................................................................................................160 Emptying the dust trap ...........................................................................................................................................160 Emptying the dust collector.......................................................................................................................................160 Filter element, clean / replace...................................................................................................................................160 Checking and cleaning the filter element .........................................................................................................................161 Draining water from the switchgear cabinet........................................................................................................................161 Replacing filter mats.............................................................................................................................................161 Slip ring assembly, servicing work ...................................................................................................................................162 Electrical circuit diagrams ..........................................................................................................................................162 Replacing fuses ......................................................................................................................................................162 Replacing lamps and bulbs ............................................................................................................................................162 Xenon floodlight projector (optional), replacing the lamp ............................................................................................................163 Safety instructions...............................................................................................................................................163 Further instructions..............................................................................................................................................163 Replacing a defective Xenon-lamp..................................................................................................................................164 Lighting systems in LED technonogy, instructions .....................................................................................................................165 HYDRAULIC SYSTEM .........................................................................................................................................................166 Hydraulic system - Safety instructions ...............................................................................................................................166 Depressurizing the hydraulic system ..................................................................................................................................166 Checking the hydraulic oil level .....................................................................................................................................167 Hydraulic oil return-flow filters, replace ...........................................................................................................................169 Remove return flow filter elements................................................................................................................................169 Install return flow filter elements...............................................................................................................................170 Remove filter-basket, inspect / clean.............................................................................................................................170 Hydraulic oil return-flow filters, replace (from machine no. 170138) .................................................................................................171 Remove return flow filter elements................................................................................................................................171 Install return flow filter elements...............................................................................................................................172 Remove filter-basket, inspect / clean.............................................................................................................................172 Bypass valves, clean / replace .......................................................................................................................................173 Cleaning the filter screens.......................................................................................................................................173 Replacing the bypass valves and sealing rings ....................................................................................................................173 Hydraulic oil tank breather filters, replace .........................................................................................................................174 Replacing the filter elements ....................................................................................................................................174 Filter (servo control circuit), replace ..............................................................................................................................175 Replacing the filter element......................................................................................................................................175 High-pressure filter for working hydraulics, replace .................................................................................................................176 Replacing the filter elements ....................................................................................................................................176 Filters for swing charge pump, replace ...............................................................................................................................177 Replacing the filter elements.....................................................................................................................................177 High-pressure filters for the servo circuit, replace .................................................................................................................178 Replacing the filter element......................................................................................................................................178 Changing the hydraulic oil ...........................................................................................................................................179 Avoid mixing of different hydraulic fluids ...........................................................................................................................179 Draining off hydaulic oil using the Service Station (tanklift)....................................................................................................180 Cleaning the hydraulic oil reservoir .............................................................................................................................180 Filling in hydraulic oil using the service station................................................................................................................181 Filling in hydraulic oil through the return-flow filters..........................................................................................................182 Venting the hydraulic system..........................................................................................................................................183 Venting the hydraulic components..................................................................................................................................183 Cleaning the hydraulic oil cooler.....................................................................................................................................184 Cleaning..........................................................................................................................................................184 Electronic excavator control..........................................................................................................................................185 Joystick .........................................................................................................................................................185 Pedal.............................................................................................................................................................185 Pressure accumulator - Emergency lowering.............................................................................................................................186 Pressure-accumulator inspection regulations ......................................................................................................................186 Extract from the German regulations...............................................................................................................................186 Extract from the German acceptance regulations....................................................................................................................186 PUMP DRIVE GEARBOX .......................................................................................................................................................187 Pump drive gearbox, checking oil level / Topping up with oil .........................................................................................................187 Topping up with oil...............................................................................................................................................188 Pump drive gearbox, changing oil .....................................................................................................................................189 Drawing off gearbox oil...........................................................................................................................................189 Filling in gearbox oil ...........................................................................................................................................189 Pump drive gearbox, pre-chamber ......................................................................................................................................190 Checking oil level, topping up with oil...........................................................................................................................190 Pump drive gearbox, venting ..........................................................................................................................................190 Pre-chambers working pumps, draining oil, changing oil ...............................................................................................................191 Draining oil:.....................................................................................................................................................191 Changing oil:.....................................................................................................................................................191 Pre-chambers swing pumps, draining oil, changing oil .................................................................................................................191 Draining oil:.....................................................................................................................................................191 Changing oil:.....................................................................................................................................................191 Pump gearbox cooling circuit, replace oil filter .....................................................................................................................192 Checking for contamination........................................................................................................................................192 Replacing the filter element......................................................................................................................................192 SWING GEARBOX ............................................................................................................................................................193 (For swing gearboxes P/N 3692960).....................................................................................................................................193 Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................193 Swing gearbox - Changing the gearbox oil .............................................................................................................................193 Draining off oil .................................................................................................................................................193 Filling in new oil / Topping up ..................................................................................................................................194 Swing gearbox, venting ,..............................................................................................................................................194 SWING GEARBOX ............................................................................................................................................................195 (For swing gearbox P/N 3676892).......................................................................................................................................195 Swing gearbox - Gearbox - Checking the oil level / Topping up with oil ...............................................................................................195 Swing gearbox - Changing the gearbox oil .............................................................................................................................196 Gearbox housing, draining off oil ................................................................................................................................196 Gearbox housing, filling in new oil / topping up .................................................................................................................196 Brake chamber, draining off oil ..................................................................................................................................197 Brake chamber, filling in new oil / topping up ...................................................................................................................197 Swing gearbox - venting ..............................................................................................................................................197 TRAVEL GEARBOX ...........................................................................................................................................................198 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................198 Pre-chamber / Spur gear section - Checking the oil level / Topping up with oil ...................................................................................198 Hydraulic motor chamber - Checking the oil level / Topping up with oil ...........................................................................................198 Travel gearbox - Changing oil ........................................................................................................................................199 Draining off oil..................................................................................................................................................199 Filling in oil ...................................................................................................................................................199 Pre chamber / Spur gear section - Changing the oil / Draining off oil.............................................................................................199 Filling in oil ...................................................................................................................................................199 Hydraulic motor chamber - Changing oil ...........................................................................................................................200 Draining off oil..................................................................................................................................................200 Filling in oil ...................................................................................................................................................200 Travel gearbox - Breather filter .....................................................................................................................................200 CRAWLER TRACKS ...........................................................................................................................................................201 Cleaning .............................................................................................................................................................201 Track rollers ........................................................................................................................................................202 Track roller fastening ...........................................................................................................................................202 Support roller fastening .........................................................................................................................................202 Track tensioner ......................................................................................................................................................203 Function .........................................................................................................................................................203 Pressure-accumulator inspection regulations ..........................................................................................................................204 Extract from the German regulations...............................................................................................................................204 Extract from the German acceptance regulations....................................................................................................................204 Checking the gas charging pressure in the pressure accumulator........................................................................................................204 SWING RING ...............................................................................................................................................................205 Swing ring - Instructions.............................................................................................................................................205 Bearing races.........................................................................................................................................................205 Internal gearing..................................................................................................................................................205 Swing ring - Checking the grease filling..........................................................................................................................206 Swing ring - Filling in grease....................................................................................................................................206 Swing ring - Checking the bolts for tightness.....................................................................................................................206 CENTRAL LUBRICATING ......................................................................................................................................................207 Design and function ..................................................................................................................................................207 Function .............................................................................................................................................................208 Filling up the grease container ......................................................................................................................................209 Breather filter ......................................................................................................................................................209 Checking the greasing pressure .......................................................................................................................................210 Checking the greasing pressure .......................................................................................................................................211 Unblocking a grease line..............................................................................................................................................212 Cleaning .........................................................................................................................................................212 Unblocking a grease line..............................................................................................................................................212 Cleaning .........................................................................................................................................................212 Oilfilter (hydraulic circuit grease pump) )...........................................................................................................................213 Replacing the filter element......................................................................................................................................213 Grease filter (Filling the grease container) .........................................................................................................................214 Checking the filter element.......................................................................................................................................214 Replacing the filter element......................................................................................................................................214 Grease filter (Grease lines) .........................................................................................................................................215 Checking the filter element.......................................................................................................................................215 Replacing the filter element......................................................................................................................................215 OTHER MAINTENANCE ........................................................................................................................................................216 Heating and air conditioning .........................................................................................................................................216 Equipment, check for cracks ..........................................................................................................................................216 Reservoirs for used grease at the A-frame, emptying ..................................................................................................................217 Hydraulic ladder, pressure accumulator ...............................................................................................................................217 Pressure-accumulator inspection regulations ..........................................................................................................................218 Extract from the regulations..........................................................................................................................................218 Extract from the German acceptance regulations....................................................................................................................218 Checking the gas charging pressure in the pressure accumulator........................................................................................................218 ON-BOARD CRANE, DRIVE UNIT ...............................................................................................................................................219 Crane engine..........................................................................................................................................................219 Hydraulic system......................................................................................................................................................219 On-board crane, lubricating ..........................................................................................................................................220 Servicing work....................................................................................................................................................220 On-Board crane, checking tightness of fastening bolts ................................................................................................................220 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................221 Putting the excavator out of operation................................................................................................................................221 Battery storage.......................................................................................................................................................221 Recommissioning ......................................................................................................................................................221 NOTES ....................................................................................................................................................................222 4 REPAIR WORK.................................................................................................................................................................223 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ...................................................................................................................225 In the transformer station............................................................................................................................................225 On the excavator......................................................................................................................................................225 In the transformer station............................................................................................................................................225 On the hydraulic excavator............................................................................................................................................225 REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................226 Operation and Maintenance Manual......................................................................................................................................226 Repair personnel......................................................................................................................................................226 Working in greater heights............................................................................................................................................226 Prestressed units.....................................................................................................................................................226 Dismantling components................................................................................................................................................226 Never remove lead seals...............................................................................................................................................226 After the repair work.................................................................................................................................................226 FIRE AND EXPLOSION HAZARD ................................................................................................................................................227 HYDRAULIC SYSTEM..........................................................................................................................................................228 Repair ...............................................................................................................................................................228 Hydraulic hoses – Instructions ......................................................................................................................................228 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................229 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................230 Welding work by qualified personnel only..............................................................................................................................230 Increased risk of fire during welding work............................................................................................................................230 Health hazards........................................................................................................................................................230 Tanks, pressure vessels and pressure accumulators.....................................................................................................................231 Slewing rings and articulated joints..................................................................................................................................231 Information relating to the electrical system and to electronic modules...............................................................................................231 Welding on the counterweight..........................................................................................................................................232 Welding on components of the working equipment and on other fully or partly closed steel structures...................................................................232 Welding on the cab....................................................................................................................................................232 Further information...................................................................................................................................................232 DISPOSAL AT THE END OF THE SERVICE LIFE ..................................................................................................................................233 Dismantling and removal instructions .................................................................................................................................233 Risk of deflagrations ................................................................................................................................................233 Risk of fire .........................................................................................................................................................233 Disposing of the machine without polluting the environment ...........................................................................................................233 Further hazardous substances .........................................................................................................................................234 Appropriate disposal of batteries ....................................................................................................................................234 NOTES ....................................................................................................................................................................235 5 ANNEX.......................................................................................................................................................................237 TROUBLESHOOTING ..........................................................................................................................................................239 Instructions on troubleshooting ......................................................................................................................................239 Layout of the fault table ............................................................................................................................................239 Fault.............................................................................................................................................................239 Possible causes ......................................................................................................................................................239 Measures .............................................................................................................................................................239 Section ..............................................................................................................................................................239 FAULT TABLES .............................................................................................................................................................240 Working hydraulics – Fault table .....................................................................................................................................240 Track drive – Fault table ............................................................................................................................................241 Swing mechnism – Fault table .........................................................................................................................................242 Central lubricating system – Fault table .............................................................................................................................243 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................244 ABBREVIATIONS ............................................................................................................................................................245 ABBREVIATIONS.........................................................................................................................................................246 NOISE AND VIBRATION INFORMATION .........................................................................................................................................247 Noise emission information ...........................................................................................................................................247 Vibration information ................................................................................................................................................247 PRODUCT SPECIFICATION SHEET ..............................................................................................................................................249 6040-6040FS-MediumSpecalog_AEHQ6524-02.pdf............................................................................................................................251 6040/6040 FS Hydraulic Shovel.....................................................................................................................................251 Specifications................................................................................................................................................251 General Data..............................................................................................................................................251 Features..................................................................................................................................................251 Operating Weight..........................................................................................................................................251 Dimensions................................................................................................................................................252 Diesel Engines............................................................................................................................................252 Electric Motor – 6040 AC/6040 AC FS.......................................................................................................................252 Electrical System (diesel drive)..........................................................................................................................252 Hydraulic System with Pump Managing System................................................................................................................253 Hydraulic Oil Cooling.....................................................................................................................................253 Swing System..............................................................................................................................................253 Retractable Service Station...............................................................................................................................253 Operator’s Cab............................................................................................................................................254 Undercarriage.............................................................................................................................................254 Automatic Lubrication System..............................................................................................................................254 Attachments...............................................................................................................................................254 Working Range – TriPower Face Shovel Attachment (FS)......................................................................................................255 Working Range – Backhoe Attachment (BH)...................................................................................................................256 General Packing List......................................................................................................................................257 TriPower Shovel Attachment................................................................................................................................259 Backhoe Attachment........................................................................................................................................260 Component Accessibility on Superstructure.................................................................................................................261 Optional Equipment............................................................................................................................................261 NOTES ...................................................................................................................................................................263 6 INDEX.......................................................................................................................................................................265
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