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

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

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

Language : English
Pages : 428
Downloadable : Yes
File Type : PDF

DESCRIPTION:

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

ELZ00101 – Up (Machine)
CC900401 – Up (Machine)

PREFACE:

• 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 qualified CGM-HMS GmbH mechanic or by attending an CGM-HMS GmbH training course for operators or maintenance personnel.
• The CGM-HMS GmbH after-sales service will be pleased to deal with any queries you may have after reading through the Operation and Mainte- nance Manual.
  CGM-HMS GmbH =
• Caterpillar Global Mining Hydraulic mining Shovels GmbH.
• Operation and Maintenance Manuals does not contain work instructions for carrying out major repairs. Such work is willingly done for you by your Caterpillar dealer.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

TABLE OF CONTENTS
Important Safety Information ii
1 INTRODUCTION 1-1
ALL PRODUCTS FOREWORD 1-3
Literature Information 1-3
Safety 1-3
Operation 1-3
Maintenance 1-3
Certified Engine Maintenance 1-3
Machine Capacity 1-4
Product Identification Number 1-4
California Proposition 65 Warning 1-4
PREFACE 1-5
Further machine documentation 1-5
WARRANTY 1-6
FUNDAMENTAL SAFETY INSTRUCTIONS 1-7
Warnings and symbols 1-7
Declaration of Conformity 1-7
Visibility Information 1-8
Noise Emission Information 1-8
Vibration Information 1-8
Sound Level Information for Machines in Eurasian Economic Union Countries 1-8
Restricted Visibility 1-9
DESIGNATED USE, UNAUTHORIZED USE 1-10
Specified Useful Life or Expected Life 1-10
ORGANIZATIONAL MEASURES 1-11
Selection and qualification of personnel; basic responsibilities 1-12
Safety instructions governing specific operational phases 1-12
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-13
Warning of special dangers 1-14
Gas, dust, steam and smoke 1-14
Hydraulic equipment 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
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE HYDRAULIC SHOVEL 2-6
Hydraulic shovel layout – upper structure 2-7
Hydraulic shovel layout – undercarriage and attachment 2-9
OMM 6040 (3 847 042.00)-EN
TABLE OF CONTENTS
vi
Undercarriage 2-10
Upper structure 2-10
Drive unit 2-10
Hydraulic system 2-10
Control and Monitoring Platform (CAMP) 2-10
Board-Control-System (BCS) 2-11
Demand control / Zero-flow regulation 2-11
Automatic reset to idling 2-11
Electrical system 2-11
Safety films and warning messages 2-12
ANSI – compliant safety messages set 2-13
Safety messages (ANSI) – Description 2-19
Additional messages (ANSI) – Description 2-25
Product Identification Number (18) 2-30
CE-Plate, European Union (11) 2-30
Eurasian Economic Union 2-32
Fire Extinguisher Location (If equipped) 2-32
Mounting and Dismounting the machine – Safety instructions 2-33
Access ladder – Lighting 2-33
Access ladder – Function 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
Putting the machine back into operation – Reset of emergency shut off function 2-39
Battery isolator switch – Shut off supply voltage 2-40
Starter isolator switch – Shut off starter voltage 2-40
Operator’s seat 2-41
Reducing operator’s exposure to vibrations 2-43
Trainer’s / instructor’s seat 2-43
Windscreen washer – Fill 2-43
MONITORING, WARNING AND CONTROL ELEMENTS 2-44
Engine 1 (LH), control and monitoring 2-51
Engine 2 (RH), control and monitoring 2-53
PUTTING THE MACHINE INTO OPERATION 2-66
Electrical Storm Injury Prevention 2-66
Reducing the operator’s exposure to noise 2-66
Refuelling 2-67
Diesel fuel – recommendations 2-67
Fuel Additives 2-68
Biodiesel 2-68
Coolant Information 2-68
Service Station (fast fill arm) – Function 2-69
Emergency off switch 2-70
Back-up heating (if equipped) – Fill fuel 2-76
Electrical system – Switch on and off 2-76
Engines – Emergency shut-off 2-76
Preheating system for engine and hydraulic oil (if equipped) 2-77
Level indicator in operator’s cab – Function 2-78
Hydrocarbon Mitigation (TIER4 engines only) 2-78
OMM 6040 (3 847 042.00)-EN
TABLE OF CONTENTS
vii
STARTING AND STOPPING THE ENGINES 2-79
Engines – Start 2-79
Starting the left-hand engine 2-79
Starting the right-hand engine 2-79
Engines – Adjust speed 2-80
Engines – Start at low temperatures 2-80
Engines – Shutdown 2-81
Engines – Idle Shutdown 2-81
Engines – Hard Shutdown 2-81
Shutdown the left-hand engine 2-81
Shutdown the right-hand engine 2-81
AIR CONDITIONER (IF EQUIPPED) 2-82
Back-up heating operator’s cab (if equipped) 2-83
Back-up heating (if equipped) 2-84
OPERATIONAL PRACTICES 2-85
Working operation – Safety instructions 2-85
Before starting work 2-86
Machine Operating Temperature Range 2-86
Warming up the hydraulic system 2-86
Running-in instructions for hydraulic cylinders 2-87
Electronic hydraulic shovel control (pilot control) – activate 2-87
Working operation – basics 2-88
OPERATION TECHNIQUES 2-94
Machine operation with backhoe attachment, Best Practices 94
Backhoe Operation – Restricted Operation 2-104
Machine operation with face shovel attachment – Best Practices 2-115
Face Shovel Operation – Restricted Operation 2-129
TRAVELING 2-144
Traveling – Safety Instructions 2-144
Before starting traveling 2-145
Traveling – Basic Movements 2-147
Counter-rotation turns / Turning on the spot 2-150
Track Parking Brake – set/release 2-151
Traveling speed – adjust 2-151
Traveling uphill and downhill on ramps and steep slopes 2-152
Traveling over long distances 2-154
Traveling – Best Practices 2-156
Traveling – Restricted Operation 2-157
Maximum Machine Inclinations 2-160
TRANSPORTING THE MACHINE 2-161
Transport – Safety instructions 2-161
Engine-off lowering of the attachment 2-162
After daily operation 2-163
ASSEMBLING ATTACHMENT – SAFETY INSTRUCTIONS 2-164
Securing the machine 2-165
Corrosion protection for pins and bearings (bushings and hubs) 2-166
OMM 6040 (3 847 042.00)-EN
TABLE OF CONTENTS
viii
MONITORING CAMERAS – FUNCTION 2-167
ENTERTAINMENT RADIO (IF EQUIPPED) – OPERATE 2-168
Entertainment Radio – Panel Controls 2-169
Entertainment Radio – General Operation 2-170
USB/MP3 Playback 2-171
Tuner Operation 2-171
NOTES 2-175
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-7
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Refer to chapter “Engine oil service interval table” for more information. 3-9
Also refer to Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”. This
publication is available from your Cat dealer. 3-9
C32 Engine Maintenance Interval Schedule – Notes 3-10
Plan V 3-11
Plan N 3-13
Plan T and W 3-15
Plan A – E 3-17
LUBRICATING CHART 3-24
Lubricating chart (legend) 3-25
INSPECTION PLAN – OIL 3-26
Inspection plan – Oil (legend) 3-27
Engine oil service interval table 3-28
Engine oil service interval table with Reserve™ Oil Tank (if equipped) 3-29
LUBRICANT VISCOSITIES AND REFILL CAPACITIES 3-30
Lubricant Viscosities (Fluid Recommendations) 30
Engine Oil 31
Hydraulic Fluids 3-32
Other Fluid Applications 3-33
Diesel Fuel Recommendations 3-34
Fuel Additives 3-34
Biodiesel 3-34
S·O·S Information 3-35
Coolant Information 3-35
Refill quantities – Oil 3-37
Refill quantities – Grease 3-38
Refill quantities – Other 3-38
SERVICING WORK 3-39
Hose line for oil and cooling liquid changes 3-39
ENGINE 3-40
Engine – Safety instructions 3-40
Walk-Around Inspection 3-41
Belt – Inspect/Replace 3-42
Fuel Injector – Inspect/Adjust 3-43
OMM 6040 (3 847 042.00)-EN
TABLE OF CONTENTS
ix
Engine Mounts – Inspect 3-43
Engine Oil Sample – Obtain 3-44
Engine Valve Lash – Check 3-45
Engine Valve Rotators – Inspect 3-45
Engine Hoses and Clamps – Inspect/Replace 3-46
Engine oil level – Check / Top up 3-49
Engine oil tank oil level (if equipped) – Check / Top up 3-50
Engine oil – Change 3-51
Engine oil tank, Drain oil 3-53
Engine oil filter – Replace 3-55
Engine oil tank (if equipped) oil filters – Replace 3-55
Engine crankcase breathers – Clean 3-56
Cold-starting fluid (ether) pressure vessel – Replace 3-57
COOLING SYSTEM 3-58
Temperature 3-58
Radiators 3-59
Cooling-liquid level – Check 3-59
Cooling liquid – Change 3-62
Coolant Extender (ELC) – Add 3-65
Coolant Sample (Level 1) – Obtain 3-66
Coolant Sample (Level 2) – Obtain 3-67
Cooling System Supplemental Coolant Additive (SCA) – Test/ Add 3-68
AIR-INTAKE SYSTEM 3-70
Engine Air Filter Primary Elements – Replace 3-71
Engine Air Filter Secondary Element – Replace 3-72
Engine Air Precleaner – Clean 3-73
Air-intake lines – Inspect 3-73
FUEL SYSTEM 3-74
Fuel system – Safety instructions 3-74
Fuel filter – System 3-74
Primary fuel filter – Drain water 3-75
Primary fuel filter – Replace 3-75
Secondary / Tertiary fuel filter – Replace 3-76
Fuel tanks – Drain / Clean 3-76
Fuel System – Prime 3-78
ELECTRICAL SYSTEM 3-79
Electrical system – Safety instructions 3-79
Alternator – Instructions 3-79
Electrical circuit diagrams 3-79
Electrical system switch-cabinets 3-79
Lamps and bulbs – Replace 3-79
Battery – Clean 3-79
Battery – Remove / Install 3-80
Switchgear cabinet filter – Clean 3-81
Lighting systems in LED technonogy – Instructions 3-83
Can-Bus Wiring Connections – Inspect 3-84
HYDRAULIC SYSTEM 3-85
Hydraulic system – Safety instructions 3-85
Hydraulic system – Depressurize 3-85
OMM 6040 (3 847 042.00)-EN
TABLE OF CONTENTS
x
Attachment circuits – Depressurize 3-86
Hydraulic system sections – Depressurize 3-87
Hydraulic oil level – Check 3-87
Hydraulic oil return-flow filter (hydraulic oil tank) – Replace 3-89
Bypass valves (hydraulic oil tank) – Check / Clean 3-91
Hydraulic oil return-flow filters (filter housing cooling system) – Replace 3-92
Hydraulic Oil Tank Breather filter – Replace 3-93
Filter (pilot circuit) – Check / Replace 3-94
High-pressure filter for working hydraulics – Check for contamination and damage 3-95
High-pressure filter for working hydraulics – Replace 3-96
Filter pump control – Clean 3-97
Hydraulic system oil sample – Obtain 3-98
Hydraulic oil – Change 3-98
Hydraulic system – Vent 3-102
Hydraulic oil cooler – Clean 3-103
Electronic hydraulic shovel control – Clean / Lubricate 3-104
Pressure accumulator – Emergency lowering 3-105
PUMP DRIVE GEARBOX 3-106
Pump drive gearbox oil level – Check / Top up 3-106
Pump drive gearbox oil sample – Obtain 3-107
Pre-chambers – Check oil level / Top up 3-107
Pump drive gearbox oil – Change 3-108
Pre-chambers oil – Change 3-109
Pre-chamber breather valve – Replace 3-109
Pump drive gearbox oil filters – Check / Replace 3-110
SWING GEARBOX 3-111
Swing gearbox oil sample – Obtain 3-111
Swing gearbox oil level – Check / Top up 3-111
Swing gearbox oil – Change 3-112
Swing gearbox – Vent 3-112
TRAVEL GEARBOX 3-113
Travel gearbox oil level – Check / Top up 3-113
Travel gearbox oil – Change 3-114
Pre-chamber / spur gear section oil – Change 3-114
Brake chamber oil – Change 3-115
Travel Gearbox Oil Sample – Obtain 3-115
Breather filter – Replace 3-115
CRAWLER TRACKS 3-116
Undercarriage – Clean 3-116
Load roller fastening – Check 3-117
Upper roller fastening – Check 3-117
Undercarriage leaks and free movement – Check 3-117
Track tensioning system 3-118
Track tension – Release 3-119
SWING RING 3-120
Swing ring – Instructions 3-120
Swing ring grease filling – Check 3-121
Swing ring – Fill grease 3-121
Swing ring – Checking the bolts for tightness 3-121
OMM 6040 (3 847 042.00)-EN
TABLE OF CONTENTS
xi
CENTRAL LUBRICATING SYSTEM 3-122
Central Lubrication System – Design 3-122
Central Lubrication System – Function 3-123
Grease container – Fill 3-124
Grease container breather filter – Check / Replace 3-124
Greasing pressure – Check 3-125
Grease line – unblock 3-125
Grease filter (Fill the grease container) – Check / Replace 3-126
Grease filter (Grease lines) – Check / Replace 3-127
OTHER MAINTENANCE 3-128
Engine – Clean 3-128
Travel Alarm – Test 3-128
Film (Product Identification) – Clean 3-129
Radiators – Clean 3-130
Air conditioning filter – Clean 3-131
Reservoirs for used grease at the A-frame – Empty 3-131
Hydraulic ladder pressure accumulator – Check 3-132
Steel structure – Check for cracks 3-133
Clam cylinder chamber – Check for soiling 3-133
Window panes – Clean 3-134
Mirror – Check/Clean/Adjust 3-134
Cameras – Check/Clean/Adjust (If equipped) 3-135
Horn – Inspect / Replace 3-136
Seat belt – Inspect 3-137
Seat belt – Replace 3-137
Entertainment Radio (If equipped) – Installation / Troubleshooting 3-138
Electrical Connections 3-138
Installation Procedures 3-139
Specifications 3-139
Troubleshooting 3-140
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-141
Hydraulic shovel – Put out of operation 3-141
Battery – Storage 3-141
Hydraulic shovel – Recommissioning 3-141
NOTES 3-143
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
CONFINED SPACES – SAFETY INSTRUCTIONS 4-4
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
Overhaul Considerations 4-6
Overhaul Recommendation 4-7
HALF LIFE 4-9
FULL LIFE 4-10
Cleaning of Components 4-11
OMM 6040 (3 847 042.00)-EN
TABLE OF CONTENTS
xii
HYDRAULIC SYSTEM 4-12
Repair instructions 4-12
Hydraulic hoses – Instructions 4-12
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-13
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-14
DISPOSAL AT THE END OF THE SERVICE LIFE 4-17
Decommissioning and Disposal 4-17
Appropriate disposal of batteries 4-18
NOTES 4-19
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
SIL2 functionality 5-3
The keys on the front side 5-4
Other elements on the front side 5-4
BCSIII – The start screen 5-5
Information given on the start screen – Top section 5-6
Information given on the start screen – TIER4 Engine related (if equipped) 1 of 2 5-7
Information given on the start screen – TIER4 Engine related (if equipped) 2 of 2 5-8
Information given on the start screen – Central section 5-9
Information given on the start screen – Lower section 5-10
Emergency Stop – reset function 5-11
Swing circuit lock-out function 5-12
Information given on the “Service” screen 5-13
Engine data screen 5-14
Inclination values/sensors state screen 5-15
Hydraulic data screen 5-16
Lubrication data screen 5-17
Controls adjustment data screen 5-18
View documents screen 5-19
Signal table screen 5-20
Signal table screen – Location 5-21
Signal table screen – Diagram 5-22
Signal table screen – Diagram configuration 5-23
Code table screen 5-24
Slew brake test screen 5-25
BCS III – High Altitude Mode 5-26
USB interface – Data storage 5-26
BCS III – Interfaces 5-26
Saving data to a USB stick 5-27
Saving data to a USB stick, continued 5-28
Saving data to a USB stick, continued 5-29
BCSIII – Cleaning 5-30
BCSIII – Disposal 5-30
TROUBLESHOOTING 5-31
Instructions on troubleshooting 5-31
Layout of the fault table 5-31
Possible causes 5-31
Measures 5-31
Section 5-31
FAULT TABLES 5-32
Combustion engine – Fault table 5-32
Working hydraulics – Fault table 5-33
Track drive – Fault table 5-34
Swing mechanism – Fault table 5-35
Central lubricating system – Fault table 5-36
ENGINE MONITORING – CONTROL LAMPS 5-37
HYDRAULIC CIRCUIT DIAGRAM 5-38
ABBREVIATIONS 5-39
ABBREVIATIONS 5-40
PRODUCT SPECIFICATION DATA 5-41
Dimensions 5-41
Working Ranges 5-42
Working Ranges (continued) 5-43
NOTES 5-45
6 INDEX _ 6-1

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