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

Description

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

FILE DETAILS:

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

Language : English
Pages : 358
Downloadable : Yes
File Type : PDF

DESCRIPTION:

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

• These operating instructions are designed to fa- miliarize the operator with the machine
  and its designated use.
• The operating instructions contain important in- formation on how to operate the machine
  safely, properly and with maximum efficiency. Observing these instructions helps to
  prevent hazardous situations, to reduce repair costs and downtimes and to increase the
  reliability and service life of the machine.
• The operating instructions must be supplemented by the respective national rules and regulations
  for accident prevention and environmental protection.
• The operating instructions must always be avail- able in the driver’s cab of the machine.
• The operating instructions must be read and put into practice by any person in charge
  of carrying out work with or on the machine, such as

■ operation, including setting-up, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
■ maintenance (inspection, servicing, repair) and / or
■ transport.

In addition to the operating instructions and the mandatory rules and regulations for
accident pre- vention and environmental protection in the user’s country and at the place where the
machine is to be used, the generally recognized technical rules for safe and proper working must
be observed .

• The operating instructions are directed to the con- struction-machine specialist. They cannot
  provide basic know-how. This can be acquired, for exam- ple, in several days’ instruction by
  a qualified GERMANY Germany mechanic or by attending an Terex-Germany training course for
  operators or maintenance personnel.
• 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.
• The Operation and Maintenance Manual does not contain work instructions for carrying out
  major re- pairs. Such work is willingly done for you by the
  CGM-HMS GmbH after-sales service.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

1 INTRODUCTION 1-1
ALL PRODUCTS FOREWORD 1-2
Literature Information 1-2
Safety 1-2
Operation 1-2
Product Information 1-2
Maintenance 1-2
Maintenance Intervals 1-2
Product Capacity 1-2
CALIFORNIA PROPOSITION 65 WARNING 1-3
PREFACE 1-4
About this Operation and Maintenance Manual 1-4
Further machine documentation 1-4
WARRANTY 1-5
FUNDAMENTAL SAFETY INSTRUCTIONS 1-6
Warnings and symbols 1-6
Sound Level Information for Machines in Eurasian Economic Union Countries 1-6
Visibility Information 1-6
Restricted Visibility 1-7
DESIGNATED USE 1-8
Useful Life 1-8
ORGANIZATIONAL MEASURES 1-9
Restricted Visibility 1-9
Selection and qualification of personnel; basic responsibilities 1-10
Safety instructions governing specific operational phases 1-10
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-11
Warning of special dangers 1-12
Gas, dust, steam and smoke 1-13
Hydraulic equipment 1-13
Noise 1-13
Oil, grease and other chemical substances 1-13
Transporting and recommissioning 1-13
ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED HYDRAULIC SHOVELS1-14
Safety instructions for hydraulic shovels with electric motor 1-15
FIRE AND EXPLOSION HAZARD 1-16
NOTES 1-17
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Visibility aids 2-4
Operation and Maintenance Manual, where to store it in the operator’s cab 2-4
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FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE HYDRAULIC SHOVEL 2-6
Hydraulic shovel layout 2-7
Undercarriage 2-8
Upper structure 2-8
Drive unit 2-8
Hydraulic system 2-8
Control and Monitoring Platform (CAMP) 2-8
Demand control / Zero-flow regulation 2-9
Board-Control-System (BCS) 2-9
Electrical system 2-9
Power supply 2-10
Operation with cable reel (if equipped) 2-11
Safety films and warning messages – Overview and Description 2-12
Safety messages (ANSI) – Description 2-23
Additional messages (ANSI) – Description 2-27
Machine identification plate 2-30
Motor number plate 2-30
Eurasian Economic Union 2-31
CE-Plate, European Union 2-31
Entering and leaving the machine – Safety instructions 2-32
Access ladder – Lighting 2-32
Folding ladder – Function (if equipped) 2-33
Swinging ladder – Function (if equipped) 2-34
Emergency exit in operator’s cab and escape ladder 2-35
Cab interior lighting – Switch on and off 2-36
Maintenance lights – Switch on and off 2-37
Emergency shut off – Function 2-38
Servicing switch – Function 2-39
Windscreen washer – Reservoir 2-39
Reducing operators exposure to vibrations 2-39
Trainer’s / instructor’s seat 2-39
Operator’s seat 2-40
Fire extinguisher 2-42
Automatic fire-extinguishing system 2-42
MONITORING, WARNING AND CONTROL ELEMENTS 2-44
PUTTING THE MACHINE INTO OPERATION 2-62
Electrical Storm Injury Prevention 2-62
Reducing the operator’s exposure to noise 2-62
Service station 2-62
Battery main switch – Switch on and off 2-65
Electrical system (24V) – Switch on and off 2-65
Electric motor – Switch on and off 2-66
Time-out before restart 2-67
Electric motor can not be switched on 2-68
Circuit breaker – Switch on and off 2-69
Motor protection relay – Function 2-70
Active-power transducer – Function 2-72
Preheating system for hydraulic oil reservoir and pump gearbox, switching on and off (if equipped) 2-73
Air conditioner (if equipped) 2-74
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Back-up heating operator’s cab (if equipped) 2-74
OPERATIONAL PRACTICES 2-75
Working operation – Safety instructions 2-75
Before starting work 2-76
Machine Operating Temperature Range 2-76
Warm-up procedure for electric driven shovel 2-77
Electronic hydraulic shovel control (pilot control) – activate 2-78
Working operation – basics 2-79
OPERATION TECHNIQUES 2-85
Machine operation with backhoe attachment, Best Practices 85
Loading setups 2-89
Machine operation with face shovel attachment – Best Practices 2-95
Face Shovel Operation – Restricted Operation 2-109
TRAVELING 2-124
Traveling – Safety Instructions 2-124
Before starting traveling 2-126
Traveling – Basic Movements 2-128
Counter-rotation turns / Turning on the spot 2-131
Track Parking Brake – set/release 2-132
Traveling speed – adjust 2-132
Traveling uphill and downhill on ramps and steep slopes 2-133
Traveling over long distances 2-135
Traveling – Best Practices 2-137
Traveling – Restricted Operation 2-138
Maximum Machine Inclinations 2-141
TRANSPORTING THE MACHINE 2-142
Transport – Safety instructions 2-142
RUNNING-IN INSTRUCTIONS FOR HYDRAULIC CYLINDERS 2-143
EMERGENCY LOWERING OF THE WORKING EQUIPMENT 2-144
AFTER DAILY OPERATION 2-145
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-146
Securing the machine 2-147
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-148
ON-BOARD CRANE (IF EQUIPPED) 2-149
On-board crane, monitoring, warning and control elements 2-149
On-board crane, putting into operation 2-150
On-board crane, drive unit 2-150
On-Board crane, – blocking the boom in position of rest 2-151
On-board crane, checking 2-151
Monitoring cameras (if equipped) 2-152
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NOTES 2-153
3 INSPECTION AND SERVICING 3-1
SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS 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 / Lubricants 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 – LUBRICANT 3-24
Lubricating chart – Lubricant (legend) 3-25
Filling quantities – Lubricant 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 lubricants 3-29
LUBRICANTS / CONSUMABLES 3-30
I. Oil for combustion engines (On-Board Crane, if equipped) 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. Lubricant for bearings, swing rings and track system (Central lubrication system) 3-34
Lubricants for idlers, track rollers and upper 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 – Clean 3-37
Electric motor – Lubricate 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
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Xenon floodlight projector (if equipped), 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 hydraulic shovel 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, oil filter 3-74
SWING GEARBOX 3-75
Swing gearbox – Checking the oil level / Topping up with oil 3-75
Changing the gearbox oil 3-75
Swing gearbox, venting 3-76
TRAVEL GEARBOX 3-77
Travel gearbox – Checking the oil level / Topping up with oil 3-77
Travel gearbox – Changing oil 3-78
Travel gearbox – Breather filter 3-79
Track rollers 3-81
Track tensioner 3-82
Pressure-accumulator inspection regulations 3-83
Checking the gas charging pressure in the pressure accumulator 3-83
SWING RING 3-84
Swing ring – Instructions 3-84
Bearing races 3-84
CENTRAL LUBRICATING SYSTEM 3-86
Design and function 3-86
Function 3-87
Filling up the lubricant container 3-88
Breather filter 3-88
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Checking the greasing pressure 3-89
Checking the greasing pressure 3-90
Unblocking a lubricating line 3-91
Unblocking a lubricant line 3-91
Oilfilter (hydraulic circuit lubricant pump) ) 3-92
Lubricant filter (Filling the lubricant container) 3-93
Lubricant filter (Lubricating lines) 3-94
OTHER MAINTENANCE 3-95
Heating and air conditioning 3-95
Attachment – Check for cracks 3-95
Reservoirs for used lubricant at the A-frame – Empty 3-96
Hydraulic ladder – Pressure accumulator 3-96
Pressure-accumulator inspection regulations 3-97
Extract from the regulations 3-97
Checking the gas charging pressure in the pressure accumulator 3-97
ON-BOARD CRANE – DRIVE UNIT 3-98
On-board crane – Lubricate 3-99
On-Board crane – Check tightness of fastening bolts 3-99
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-100
Putting the hydraulic shovel out of operation 3-100
Battery storage 3-100
Recommissioning 3-100
NOTES 3-101
4 REPAIR WORK 4-1
SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS 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
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
BOARD-CONTROL-SYSTEM 5-3
BCS3e, what’s that? 5-3
What it is 5-3
What it does 5-3
Benefits for the operator 5-3
Want more information? 5-3
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xi
The keys on the front side 5-4
Other Elements on the Front Side 5-4
BCS3e, the Start Screen 5-5
Information Given on the Start Screen – Top Section 5-6
Information Given on the Start Screen – Central Section 5-7
Information Given on the Start Screen – Lower Section 5-8
Emergency Stop – Reset Function 5-9
Swing Circuit Lock-Out Function 5-10
Information Given on the “Service” Screen 5-11
Information Given on the “Service” Screen – continued 5-12
Electric Motor Data Screen 5-13
Electric Motor Data Screen – continued 5-14
Hydraulic Data Screen 5-15
Lubrication Data Screen 5-16
Controls Adjustment Data Screen 5-17
Slew Brake Test Data Screen 5-18
Signal Table Screen 5-19
Signal Table Screen – Diagram 5-20
Signal Table Screen – Diagram Configuration 5-21
Fault Storage / Fault Table – Screen 5-22
Fault Storage – Save to USB-Stick 5-23
Fault Storage – Fault Detail 5-24
BCS files – Copy to USB-Stick 5-25
BCS3e – Interfaces 5-26
USB Interface – Data Storage 5-26
Store Screenshot Screen 5-27
BCS3e – Cleaning 5-28
BCS3e – Disposal 5-28
TROUBLESHOOTING 5-29
Instructions on troubleshooting 5-29
Layout of the fault table 5-29
Possible causes 5-29
Measures 5-29
Section 5-29
FAULT TABLES 5-30
Working hydraulics – Fault table 5-30
Track drive – Fault table 5-31
Swing mechnism – Fault table 5-32
Central lubricating system – Fault table 5-33
HYDRAULIC CIRCUIT DIAGRAM 5-34
ABBREVIATIONS 5-35
NOISE AND VIBRATION INFORMATION 5-37
Noise emission information 5-37
Vibration information 5-37
PRODUCT SPECIFICATION SHEET 5-38
NOTES 5-40
6 INDEX 6-1

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