Cat 6040, 6040 FS Hydraulic Shovel Operation and Maintenance Manual EM030935

EM030935-01 (en-us) 01 / 2022

Operation and Maintenance Manual 6040, 6040 FS Hydraulic Shovel DHJ40119, DHJ40125, DHJ40130, DHJ40132-DHJ40135, DHJ40137, DHJ40149-DHJ40150, DHJ40157-DHJ40158, DHJ40164-DHJ40172, DHJ40174, DHJ40176-DHJ40180, DHJ40186, DHJ40188-DHJ40190, DHJ40192-DHJ40193, DHJ40195-DHJ40197, DHJ40199-DHJ40201, DHJ40203-up DHX40126, DHX40128-DHX40129, DHX40136, DHX40142, DHX40151, DHX40153-DHX40156, DHX40159-DHX40163, DHX40173, DHX40175, DHX40181-DHX40183 Replaces media numbers: BI017207, BI651394, and EM026774

Language: Original Instructions

EM030935-01 (en-us)

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN 01 / 2022

Operation and Maintenance Manual 6040, 6040 FS Hydraulic Shovel DHJ40119, DHJ40125, DHJ40130, DHJ40132-DHJ40135, DHJ40137, DHJ40149-DHJ40150, DHJ40157-DHJ40158, DHJ40164-DHJ40172, DHJ40174, DHJ40176-DHJ40180, DHJ40186, DHJ40188-DHJ40190, DHJ40192-DHJ40193, DHJ40195-DHJ40197, DHJ40199-DHJ40201, DHJ40203-up DHX40126, DHX40128-DHX40129, DHX40136, DHX40142, DHX40151, DHX40153-DHX40156, DHX40159-DHX40163, DHX40173, DHX40175, DHX40181-DHX40183

Language: Original Instructions

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known in the State of California to cause cancer, birth defects, and other reproductive harm. This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Published by:

Caterpillar Global Mining HMS GmbH

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2022. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express au-thorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

Printed in Germany

ii

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

The Operation and Maintenance Manual is in 6 sections; the sections are designed for different target groups: Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

iii

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

iv

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS TABLE OF CONTENTS 1 INTRODUCTION __________________________________________________________________ 1-1 ALL PRODUCTS FOREWORD _______________________________________________________ 1-3 Literature Information ______________________________________________________________ 1-3 Safety _________________________________________________________________________ 1-3 Operation_______________________________________________________________________ 1-3 Product Information _______________________________________________________________ 1-3 Maintenance ____________________________________________________________________ 1-3 Maintenance Intervals _____________________________________________________________ 1-3 Product Capacity _________________________________________________________________ 1-3 PREFACE _______________________________________________________________________ 1-4 Further machine documentation _____________________________________________________ 1-4 WARRANTY______________________________________________________________________ 1-5 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-6 Warnings and symbols ____________________________________________________________ 1-6 European Union, Declaration of Conformity ____________________________________________ 1-6 Visibility Information ______________________________________________________________ 1-7 Noise emission information _________________________________________________________ 1-7 Vibration information ______________________________________________________________ 1-7 Sound Level Information for Machines in Eurasian Economic Union Countries _________________ 1-7 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 _______________________________________________________ 1-12 Hydraulic equipment _____________________________________________________________ 1-13 FIRE AND EXPLOSION HAZARD ____________________________________________________ 1-14 NOTES _________________________________________________________________________ 1-15 2 OPERATION _____________________________________________________________________ 2-1 OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3 Visibility aids ____________________________________________________________________ 2-4 Operation and Maintenance Manuals, 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 Undercarriage __________________________________________________________________ 2-10 Upper structure _________________________________________________________________ 2-10 Drive unit ______________________________________________________________________ 2-10 Hydraulic system ________________________________________________________________ 2-10

v

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS 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 – overview and description ___________________________ 2-12 ISO – compliant safety messages set ________________________________________________ 2-13 Safety messages (ISO) – Description ________________________________________________ 2-18 Additional messages (ISO) – Description _____________________________________________ 2-22 ANSI – compliant safety messages set _______________________________________________ 2-27 Safety messages (ANSI) – Description _______________________________________________ 2-32 Additional messages (ANSI) – Description ____________________________________________ 2-36 Machine number ________________________________________________________________ 2-39 Component numbers _____________________________________________________________ 2-39 Engine number _________________________________________________________________ 2-39 Engine information decal __________________________________________________________ 2-39 Eurasian Economic Union _________________________________________________________ 2-40 CE-Plate, European Union ________________________________________________________ 2-40 Entering and leaving the machine Safety instructions ____________________________________ 2-41 Access ladder lighting ____________________________________________________________ 2-41 Swinging ladder (optional) _________________________________________________________ 2-42 Folding ladder __________________________________________________________________ 2-43 Emergency exit in operator’s cab and escape ladder ____________________________________ 2-44 Escape ladder near engine compartment (optional) _____________________________________ 2-45 Switching the cab interior lighting on and off ___________________________________________ 2-46 Switching the maintenance lights on and off ___________________________________________ 2-47 Emergency shut-off function _______________________________________________________ 2-48 Putting the machine back into operation, reset of emergency shut off function ________________ 2-49 Battery isolator switch, shutting off supply voltage ______________________________________ 2-50 Starter isolator switch, shutting off starter voltage _______________________________________ 2-50 Operator’s seat _________________________________________________________________ 2-51 Reducing the operators exposure to vibrations _________________________________________ 2-53 Trainer's / instructor's seat ________________________________________________________ 2-53 Fire extinguisher ________________________________________________________________ 2-54 Automatic fire-extinguishing system _________________________________________________ 2-54 Windscreen washer ______________________________________________________________ 2-55 Operating hours meter (if equipped) _________________________________________________ 2-55 Emergency escape device / seat (optional)____________________________________________ 2-56 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-60 Engine 1 (LH), control and monitoring ________________________________________________ 2-67 Engine 2 (RH), control and monitoring _______________________________________________ 2-69 PUTTING THE MACHINE INTO OPERATION __________________________________________ 2-89 Electrical Storm Injury Prevention ___________________________________________________ 2-89 Reducing the operator's exposure to noise ____________________________________________ 2-89 Refuelling _____________________________________________________________________ 2-90 Diesel fuel – recommendations _____________________________________________________ 2-90 Back-up heating (option), filling in fuel________________________________________________ 2-90 Service station (tanklift) ___________________________________________________________ 2-91 Emergency off switch ____________________________________________________________ 2-92 Switching the electrical system on and off_____________________________________________ 2-97

vi

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS Engines, emergency shut-off _______________________________________________________ 2-97 Preheating system for engine and hydraulic oil (optional) _________________________________ 2-98 Fuel preheating system (optional) ___________________________________________________ 2-99 STARTING AND STOPPING THE ENGINES __________________________________________ 2-100 Starting the engines ____________________________________________________________ 2-100 Starting the left-hand engine ______________________________________________________ 2-100 Starting the right-hand engine _____________________________________________________ 2-100 Engines – adjusting the speed ____________________________________________________ 2-101 Starting the engines at low temperatures ____________________________________________ 2-101 Shutting off the engines __________________________________________________________ 2-102 Shutting off the left-hand engine ___________________________________________________ 2-102 Shutting off the right-hand engine __________________________________________________ 2-102 AIR CONDITIONER (OPTIONAL) ___________________________________________________ 2-103 Back-up heating operator’s cab (optional) ____________________________________________ 2-104 Back-up heating (optional) _______________________________________________________ 2-105 MAXIMUM MACHINE INCLINATIONS, INFORMATION __________________________________ 2-106 TRAVELING, SAFETY INSTRUCTIONS ______________________________________________ 2-108 TRAVELING ____________________________________________________________________ 2-109 Upper structure basic position _____________________________________________________ 2-109 Traveling forwards/backwards _____________________________________________________ 2-109 Upper structure holding brake _____________________________________________________ 2-113 Track parking brake_____________________________________________________________ 2-113 TRANSPORTING THE MACHINE ___________________________________________________ 2-114 Transport - Safety instructions ____________________________________________________ 2-114 WORKING OPERATION - SAFETY INSTRUCTIONS ___________________________________ 2-115 WORKING OPERATION __________________________________________________________ 2-117 Before starting work ____________________________________________________________ 2-117 Activating the electronic hydraulic shovel control (pilot control) ___________________________ 2-117 Swinging the upperstructure ______________________________________________________ 2-118 Braking the upper structure _______________________________________________________ 2-118 Working operation ______________________________________________________________ 2-119 After daily operation ____________________________________________________________ 2-120 ASSEMBLING ATTACHMENT - SAFETY INSTRUCTIONS _______________________________ 2-121 Securing the machine ___________________________________________________________ 2-122 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___________ 2-123 ON-BOARD CRANE (OPTIONAL) ___________________________________________________ 2-124 On-board crane - monitoring, warning and control elements _____________________________ 2-124 On-board crane - putting into operation______________________________________________ 2-125 On-board crane - drive unit _______________________________________________________ 2-125 On-Board crane – blocking the boom in position of rest _________________________________ 2-126 On-board crane - checking _______________________________________________________ 2-126 MONITORING CAMERAS (OPTIONAL) ______________________________________________ 2-127 Monitoring cameras – function ____________________________________________________ 2-127

vii

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS NOTES ________________________________________________________________________ 2-128 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 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 _____________________________________________________________________ 3-19 LUBRICATING CHART – GREASE ___________________________________________________ 3-26 Lubricating chart – Grease (legend) _________________________________________________ 3-27 Filling quantities - Grease _________________________________________________________ 3-27 INSPECTION PLAN - OIL __________________________________________________________ 3-28 Inspection plan – Oil (legend) ______________________________________________________ 3-29 Engine oil service interval table _____________________________________________________ 3-30 Engine oil service interval table with ReserveTM Oil Tank (if equipped)_______________________ 3-31 Filling quantities - oil _____________________________________________________________ 3-32 Filling quantities – other __________________________________________________________ 3-32 LUBRICANTS / CONSUMABLES ____________________________________________________ 3-33 Notes on the selection of oils and greases ____________________________________________ 3-33 Avoid mixing of different hydraulic fluids ______________________________________________ 3-33 I. Oils for combustion engines ____________________________________________________ 3-34 II. Fluids for hydraulic system ___________________________________________________ 3-35 III.a Oils for pump drive gearboxes and travel gearboxes _______________________________ 3-36 III.b Oil for swing gearboxes ______________________________________________________ 3-37 V. Grease for bearings, slew rings and track system (Central lubrication system) ___________ 3-38 Grease for idlers, track rollers and upper rollers (Lifetime lubrication) _______________________ 3-39 Coolant for use on all combustion engines ____________________________________________ 3-40 SERVICING WORK _______________________________________________________________ 3-41 Hose line for oil and cooling liquid changes ___________________________________________ 3-41 ENGINE ________________________________________________________________________ 3-42 Engine - Safety instructions ________________________________________________________ 3-42 Walk-Around Inspection __________________________________________________________ 3-43 Belts - Inspect/Replace ___________________________________________________________ 3-44 Fuel Injector - Inspect/Adjust _______________________________________________________ 3-44 Engine Mounts - Inspect __________________________________________________________ 3-44 Engine Oil Sample – Obtain _______________________________________________________ 3-45 Engine Valve Lash – Check _______________________________________________________ 3-46 Engine Valve Rotators – Inspect ____________________________________________________ 3-46 Coolant Temperature Regulator – Replace ____________________________________________ 3-47 Engine Hoses and Clamps - Inspect/Replace __________________________________________ 3-48 Engine oil - check level / top up _____________________________________________________ 3-51 Engine oil reservoir (if equipped) – check oil level / top up ________________________________ 3-52 Engine oil - change ______________________________________________________________ 3-53 Engine oil reservoir (if equipped) - drain the oil off ______________________________________ 3-55

viii

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS Engine oil filter - replace __________________________________________________________ 3-57 Engine oil reservoir (if equipped) - replace the oil filters __________________________________ 3-57 Engine crankcase breather ________________________________________________________ 3-58 Engine crankcase breather – clean __________________________________________________ 3-58 Engine crankcase breathers – clean _________________________________________________ 3-58 Cold-starting fluid (ether) - Replacing the pressure vessel ________________________________ 3-59 COOLING SYSTEM _______________________________________________________________ 3-60 Temperature ___________________________________________________________________ 3-60 Radiators ______________________________________________________________________ 3-61 Cooling liquid level - check ________________________________________________________ 3-61 Cooling liquid - change ___________________________________________________________ 3-64 Coolant Extender (ELC) – Add _____________________________________________________ 3-66 Coolant Sample (Level 1) - Obtain __________________________________________________ 3-67 Coolant Sample (Level 2) - Obtain __________________________________________________ 3-68 Cooling System Supplemental Coolant Additive (SCA) - Test/ Add _________________________ 3-69 AIR-INTAKE SYSTEM _____________________________________________________________ 3-71 Dust trap - clean ________________________________________________________________ 3-71 Main filter elements ______________________________________________________________ 3-72 Main filter element – check / clean __________________________________________________ 3-73 Secondary filter element – replace __________________________________________________ 3-74 Air-intake lines – inspect __________________________________________________________ 3-74 FUEL SYSTEM __________________________________________________________________ 3-75 Fuel system - Safety instructions ___________________________________________________ 3-75 Fuel filter - replace_______________________________________________________________ 3-75 Primary fuel filter - drain water _____________________________________________________ 3-76 Primary fuel filter - replace ________________________________________________________ 3-76 Fuel system – vent ______________________________________________________________ 3-77 Breather filter fuel tanks - replace ___________________________________________________ 3-77 Fuel tanks – clean _______________________________________________________________ 3-77 Water trap (optional) – clean / replace _______________________________________________ 3-79 Fuel System – Prime _____________________________________________________________ 3-80 ELECTRICAL SYSTEM ____________________________________________________________ 3-81 Electrical system - Safety instructions ________________________________________________ 3-81 Alternator - Instructions ___________________________________________________________ 3-81 Electrical circuit diagrams _________________________________________________________ 3-81 Electrical system switch-cabinets ___________________________________________________ 3-81 Replacing lamps and bulbs ________________________________________________________ 3-81 Battery – check the state of charge __________________________________________________ 3-82 Battery charging inside the machine - safety instructions _________________________________ 3-83 Battery - Removing and installing ___________________________________________________ 3-84 Switchgear cabinet - aeration ______________________________________________________ 3-85 Xenon floodlight projector - replacing the lamp _________________________________________ 3-87 Lighting systems in LED technonogy - instructions ______________________________________ 3-89 CAN-Bus wiring connections – inspect _______________________________________________ 3-90 HYDRAULIC SYSTEM _____________________________________________________________ 3-91 Hydraulic system - Safety instructions________________________________________________ 3-91 Hydraulic system – depressurize ___________________________________________________ 3-91 Hydraulic oil level – check _________________________________________________________ 3-92 Hydraulic oil return-flow filter (hydraulic oil reservoir) – replace (up to machine no. 170129 / DHX40129)3-94 ix

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS Hydraulic oil return-flow filters - replace (from machine no. 170130 / DHJ40130) ______________ 3-97 Bypass valves (hydraulic oil reservoir) – clean / replace __________________________________ 3-99 Hydraulic oil return-flow filters (filter housing cooling system) – replace _____________________ 3-100 Bypass valves (filter housing - cooling system) – clean / replace __________________________ 3-101 Hydraulic oil tank breather filters - replace ___________________________________________ 3-102 Filter (control circuit and auxiliary control circuit) – check / replace ________________________ 3-103 High-pressure filter for working hydraulics – check / replace _____________________________ 3-104 High-pressure filters for the servo circuit – check / replace _______________________________ 3-105 High-pressure filters for feeding circuits and slewing pumps – check / replace _______________ 3-106 Hydraulic oil – change ___________________________________________________________ 3-107 Avoid mixing of different hydraulic fluids _____________________________________________ 3-107 Hydraulic system – vent _________________________________________________________ 3-111 Hydraulic oil cooler – Clean _______________________________________________________ 3-112 Electronic hydraulic shovel control – clean / lubricate ___________________________________ 3-113 Pressure accumulator - Emergency lowering _________________________________________ 3-114 PUMP DRIVE GEARBOX _________________________________________________________ 3-115 Pump drive gearbox oil level - check / top up with oil ___________________________________ 3-115 Pump drive gearbox oil sample – obtain _____________________________________________ 3-116 Pre-chambers oil level – check / top up with oil________________________________________ 3-116 Pump drive gearbox oil - change ___________________________________________________ 3-117 Pump drive gearbox pre-chambers - change the gearbox oil _____________________________ 3-119 Pump drive gearbox breather - replace ______________________________________________ 3-119 Pre-chamber breather - replace ___________________________________________________ 3-120 Pump drive gearbox lube oil filters - replace __________________________________________ 3-121 SWING GEARBOX ______________________________________________________________ 3-122 Swing gearbox oil sample – obtain _________________________________________________ 3-122 Swing gearbox oil level - check the oil level / top up with oil ______________________________ 3-122 Swing gearbox - vent ____________________________________________________________ 3-122 Swing gearbox oil - change _______________________________________________________ 3-123 TRAVEL GEARBOX (PN 2763213) __________________________________________________ 3-125 Travel gearbox oil level - check / top up with oil _______________________________________ 3-125 Pre-chamber / spur wheel section oil level - check / top up with oil ________________________ 3-125 Hydraulic motor chamber oil level - check / top up with oil _______________________________ 3-125 Travel gearbox oil - change _______________________________________________________ 3-126 Pre-chamber / spur wheel section oil - change ________________________________________ 3-126 Hydraulic motor chamber oil -change _______________________________________________ 3-127 Travel gearbox oil sample – obtain _________________________________________________ 3-127 Travel gearbox breather filter - clean / replace ________________________________________ 3-127 TRAVEL GEARBOX (PN 3719869) __________________________________________________ 3-128 Travel gearbox oil level - check / top up with oil _______________________________________ 3-128 Hydraulic motor chambers oil level - check / top up with oil ______________________________ 3-128 Travel gearbox oil sample – obtain _________________________________________________ 3-128 Travel gearbox oil - change _______________________________________________________ 3-129 Hydraulic motor chambers oil - change ______________________________________________ 3-129 CRAWLER TRACKS _____________________________________________________________ 3-130 Track roller fastening – check _____________________________________________________ 3-130 Upper roller fastening – check _____________________________________________________ 3-130 Undercarriage – check for leaks and free movement ___________________________________ 3-130 Track roller - lubricate ___________________________________________________________ 3-131 x

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS Track tensioning system _________________________________________________________ 3-132 Pressure-accumulator inspection regulations _________________________________________ 3-133 Checking the gas charging pressure in the pressure accumulator _________________________ 3-133 SWING RING ___________________________________________________________________ 3-134 Swing ring – Instructions _________________________________________________________ 3-134 Bearing races _________________________________________________________________ 3-134 Swing ring grease filling – check ___________________________________________________ 3-135 Swing ring bolts - check for tightness _______________________________________________ 3-135 CENTRAL LUBRICATING SYSTEM _________________________________________________ 3-136 Central lubricating system - Design _________________________________________________ 3-136 Central lubricating system - Function _______________________________________________ 3-137 Grease container – fill up ________________________________________________________ 3-138 Grease container breather filter - check / replace ______________________________________ 3-138 Checking the greasing pressure ___________________________________________________ 3-139 Grease line – unblock ___________________________________________________________ 3-139 Grease filter (filling the grease container) – check / replace ______________________________ 3-140 Grease filter (grease lines) - replace ________________________________________________ 3-141 OTHER MAINTENANCE __________________________________________________________ 3-142 Engine – Clean ________________________________________________________________ 3-142 Travel Alarm – Test _____________________________________________________________ 3-142 Radiator – Clean _______________________________________________________________ 3-143 Aftercooler Core - Clean/Test _____________________________________________________ 3-144 Air conditioning filter - clean ______________________________________________________ 3-144 Attachment - check for cracks _____________________________________________________ 3-145 Clam cylinder chamber - check for soiling ____________________________________________ 3-145 Window panes - clean ___________________________________________________________ 3-146 Mirror – check / clean / adjust _____________________________________________________ 3-146 Cameras – check / clean / adjust (If equipped) ________________________________________ 3-147 Horn – inspect / replace _________________________________________________________ 3-148 Seat belt – inspect ______________________________________________________________ 3-149 Seat belt – replace _____________________________________________________________ 3-149 Hydraulic ladder, pressure accumulator _____________________________________________ 3-150 Pressure-accumulator inspection regulations _________________________________________ 3-151 Extract from the German regulations _______________________________________________ 3-151 Checking the gas charging pressure in the pressure accumulator _________________________ 3-151 ON-BOARD CRANE, DRIVE UNIT (OPTIONAL) _______________________________________ 3-152 On-board crane – lubricate _______________________________________________________ 3-152 On-Board crane – check tightness of fastening bolts ___________________________________ 3-153 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING _______ 3-154 Hydraulic shovel – putting out of operation ___________________________________________ 3-154 Battery - storage _______________________________________________________________ 3-154 Hydraulic shovel – recommissioning ________________________________________________ 3-154

xi

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS NOTES ________________________________________________________________________ 3-156 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 HYDRAULIC SYSTEM _____________________________________________________________ 4-12 Hydraulic system - 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 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 The keys on the front side __________________________________________________________ 5-4 Other elements on the front side _____________________________________________________ 5-4 BCSIII - the start screen ___________________________________________________________ 5-5 Information given on the start screen, top section ________________________________________ 5-6 Information given on the start screen, central section _____________________________________ 5-7 Information given on the start screen, lower section ______________________________________ 5-8 Emergency Stop, reset function _____________________________________________________ 5-9 Swing circuit lock-out function ______________________________________________________ 5-10 Information given on the “Service” screen _____________________________________________ 5-11 Engine data screen ______________________________________________________________ 5-12 Hydraulic data screen ____________________________________________________________ 5-13 Lubrication data screen ___________________________________________________________ 5-14 Controls adjustment data screen ____________________________________________________ 5-15 View documents screen __________________________________________________________ 5-16 Signal table screen ______________________________________________________________ 5-17 Signal table screen, location _______________________________________________________ 5-18 Signal table screen, diagram _______________________________________________________ 5-19 Signal table screen, diagram configuration ____________________________________________ 5-20 Code table screen _______________________________________________________________ 5-21 Slew brake test screen ___________________________________________________________ 5-22 BCS III, interfaces _______________________________________________________________ 5-23

xii

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS USB interface, data storage _______________________________________________________ 5-23 Saving data to a USB stick ________________________________________________________ 5-24 Saving data to a USB stick, continued _______________________________________________ 5-25 Saving data to a USB stick, continued _______________________________________________ 5-26 BCSIII, cleaning_________________________________________________________________ 5-27 BCSIII, disposal _________________________________________________________________ 5-27 TROUBLESHOOTING _____________________________________________________________ 5-28 Instructions on troubleshooting _____________________________________________________ 5-28 Layout of the fault table ___________________________________________________________ 5-28 Possible causes ________________________________________________________________ 5-28 Measures______________________________________________________________________ 5-28 Section _______________________________________________________________________ 5-28 FAULT TABLES __________________________________________________________________ 5-29 Combustion engine - Fault table ____________________________________________________ 5-29 Working hydraulics – Fault table ____________________________________________________ 5-30 Track drive – Fault table __________________________________________________________ 5-31 Swing mechnism – Fault table _____________________________________________________ 5-32 Central lubricating system – Fault table ______________________________________________ 5-33 ENGINE MONITORING, CONTROL LAMPS ___________________________________________ 5-34 HYDRAULIC CIRCUIT DIAGRAM ____________________________________________________ 5-35 ABBREVIATIONS ________________________________________________________________ 5-36 ABBREVIATIONS _______________________________________________________________ 5-37 PRODUCT SPECIFICATION SHEET _________________________________________________ 5-38 NOTES _________________________________________________________________________ 5-39 6 INDEX __________________________________________________________________________ 6-1

xiii

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

TABLE OF CONTENTS

xiv

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction 1 INTRODUCTION Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

1-1

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction

1-2

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction ALL PRODUCTS FOREWORD Literature Information This manual should be read carefully before using this product for the first time and before performing maintenance. This manual should be stored in the product literature holder or in the product literature storage area. Immediately replace this manual if lost, damaged, or unreadable. This manual may contain safety information, operation instructions, transportation information, lubrication information, and maintenance information. Some photographs or illustrations in this publication show details or attachments that can be different from your product.

Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your product, which are not included in this publication.

Whenever a question arises regarding your product, or this publication, consult your dealer for the latest available information.

Safety The safety section, if present, lists basic safety precautions. In addition, this section identifies the text and locations of safety messages used on the product. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance, and repair on this product.

Operation The operation section, if present, is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, controls, attachment controls, transportation, and towing information (if applicable). Photographs and illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the product. Operating techniques outlined in this publication are basic.

Skill and techniques develop as the operator gains knowledge of the product and its capabilities.

Maintenance The maintenance section, if present, is a guide to equipment care. Proper maintenance and repair are essential to keep the equipment and systems operating correctly. As the owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual. The Maintenance Interval Schedule lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the "When Required" service interval.

The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or "one safe source" for all maintenance procedures.

Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty, or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily.

Product Capacity Additional attachments or modifications may exceed product design capacity, which can adversely affect product performance characteristics, safety, reliability, and applicable certifications. Contact your dealer for further information.

Product Information The product information section, if present, may pro- vide specification data, product intended use, product identification plate locations, and certification information.

1-3

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction PREFACE The Operation and Maintenance Manual is designed to familiarize the operator with the machine and its designated use.

The Operation and Maintenance Manual 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 Operation and Maintenance Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

The Operation and Maintenance Manual must always be available in the driver's cab of the machine.

The Operation and Maintenance Manual must be read and put into practice by any person in charge of carrying out work with or on the machine, such as  operation, including setting-up, troubleshooting in the course of work, care, evacuation of 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 1.

The Operation and Maintenance Manual is 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 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.

CGM HMS GmbH = Caterpillar Global Mining Hydraulic mining Shovels GmbH.

1

Complies with VDMA recommendation "Operating instructions"

1-4

The Operation and Maintenance Manual is not a work instruction for carrying out major repairs.

Such work is willingly done for you by your Catdealer.

Further machine documentation The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The Operation and Maintenance Manual, the spare-parts list and the Technical Handbooks are marked with the serial number of the machine.

The documentation supplied with your machine is rather comprehensive. Therefore, it has been split up in several volumes: Volume 1: the present Operation and Maintenance Manual, Volume 2: Parts Manual of the machine, Volume 3: electrical circuit diagram and key, Volume 4: documentation of machine components, Volume 5: Service Manual Part 1 Volume 6: Service Manual Part 2 Depending on the size of your machine, the documentation can also consist of more volumes.

If you cannot find the information you are looking for in the present Operation and Maintenance Manual please check also the other volumes of the documentation.

The Service Manual Part 1 also provides information on how to assemble the machine, on functions of the hydraulic system, on hydraulic circuit diagrams etc.

On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction WARRANTY The warranty of CGM HMS GmbH presupposes among other things that the servicing works as described in the Operation and Maintenance Manual have been performed: 

Do not operate the machine  when components / assemblies are defective or missing, 

by your Cat-dealer

or 

in a workshop authorized in writing by CGM HMS GmbH or by your Cat dealer,

and 

by using the original spare parts of CGM HMS GmbH.

The proper execution of the servicing works must be documented on the CGM HMS GmbH Service checklists.

if one or several of such components of which more than one are installed in the machine have been removed.

In cases of doubt seek advice from the CGM HMS GmbH Service.

CGM HMS GmbH refuses to assume the guaranteee for damage and consequential damage caused by an abusive utilization of the machine.

Therefore: Do not operate the machine,  when several track rollers or support rollers have been removed; 

when one or several slewing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by CGM HMS GmbH as "abusive utilization".

Why? The machines have been designed and built on the basis of detailed calculations and so that all of the components installed absorb the occurring forces and are thus loaded to an equal extent.

Example: If the machine is used for working with, for instance, one or even several track rollers removed, the forces must be absorbed by the remaining track rollers. These are then overloaded or loaded to a greater extent than calculated.

The consequences are higher wear and consequential damage to the track rollers, but also to other components of the machine: chassis, travel gearbox and crawler track.

1-5

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction FUNDAMENTAL SAFETY INSTRUCTIONS

European Union, Declaration of Conformity

Complies with VDMA recommendation "Operation and Maintenance Manual"

An EC or EU Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements for the European Union.

In order to determine the details of the applicable Directives, review the complete EC or EU Declaration of Conformity provided with the machine.

The extract shown below from an EC or EU Declaration of Conformity for machines that are declared compliant to "2006/42/EC" applies only to those machines originally "CE" marked by the manufacturer listed and which have not since been modified.

Warnings and symbols The following signs are used in the Operation and Maintenance Manual to designate instructions of particular importance: Precautionary rules and measures designed to protect the machine operator and other persons from lifethreatening danger or injuries and to prevent extensive damage.

Information and precautionary measures designed to prevent damage to the machine or other property.

Content of the Original EC or EU Declaration of Conformity Manufacturer: Caterpillar Global Mining Hydraulic Mining Shovels GmbH (CGM HMS GmbH) Karl-Funke-Straße 36 D-44149 Dortmund Germany The manufacturer certifies that the machine Category: Hydraulic excavator Type : 6040 / 6040 FS fulfills the relevant provisions of the following EC Directives: 2006/42/EC, 2000/14/EC amended by 2005/88/EC, 2002/44/EC. Harmonised standards taken into consideration: EN 474-1, EN 474-5.

Authorised person for documents: Design Department Date: 14.03.2012 Signed by: Engineering Manager Factory Manager

1-6

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction Visibility Information

Noise emission information

Before you start the machine, perform a walkaround inspection in order to ensure that there are no hazards around the machine.

While the machine is in operation, constantly survey the area around the machine in order to identify potential hazards as hazards become visible around the machine.

Your machine may be equipped with visual aids.

Some examples of visual aids are Closed Circuit Television (CCTV) and mirrors.

Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean.

Adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual.

If equipped, the Work Area Vision System shall be adjusted according to Operation and Maintenance Manual, SEBU8157, "Work Area Vision System".

If equipped, the Cat Detect Object Detection shall be adjusted according to the Operation and Maintenance Manual, "Cat Detect Object Detection" for your machine.

It may not be possible to provide direct visibility on large machines to all areas around the machine.

Appropriate job site organization is required in order to minimize hazards that are caused by restricted visibility.

Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area.

Examples of job site organization include the following:  Safety instructions

Noise emission data are specified in acc. with ISO 6394.

Time-averaged A-weighted emission sound pressure level at operator’s position with the machine running at high idle: LAeq = 72 dB.



Controlled patterns of machine movement and vehicle movement



Workers that direct safe movement of traffic



Restricted areas



Operator training



Warning symbols or warning signs on machines or on vehicles



A system of communication



Communication between workers and operators prior to approaching the machine

Modifications of the machine configuration by the user that result in a restriction of visibility shall be evaluated.

Vibration information On the condition that the excavator is used within the limits of its designated use, the installation of seats for drivers in conformity with ISO 7096 ensures that the weighted vibration accelerations awz (measured in compliance with ISO 2631 Part I) fulfil the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG. The vibrations transferred are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. with the "Regulations for noise and vibration at the place of work", Section 4, as of 18.12.2008.

The effective value of the weighted acceleration to which the whole body is exposed, does not exceed 0.5 m/s2.

The measurement uncertainty is ±3% (tolerance of the measuring instruments).

Sound Level Information for Machines in Eurasian Economic Union Countries The declared dynamic operator sound pressure level is 76 dB(A) when “ISO 6396:2008” is used to measure the value for an enclosed cab. The measurement was conducted at 70 % of the max-imum engine cooling fan speed. The sound level may vary at different engine cooling fan speeds. The measurement was conducted with the cab doors and the cab windows closed.

The declared exterior sound power level LWA is 120 dB(A) when the value is measured according to the dynamic test procedures and the conditions that are specified in “ISO 6395:2008”.

The meas-urement was conducted at 70 % of the maximum engine cooling fan speed. The sound level may vary at different engine cooling fan speeds.

1-7

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction DESIGNATED USE, UNAUTHORIZED USE The machine has been built in accordance with state-of-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property (acceptable risk) An acceptable risk is present, e.g.: loose material or material to be loaded may drop out of the bucket or backhoe while the working equipment is being swivelled.

The machine must be used only in technically perfect condition in accordance with its designated use and the instructions set out in the Operation and Maintenance Manual, and only by safetyconscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

With attached shovel attachment, the machine is to be used solely for loosening and loading of:  sand, oil sand,  gravel,  blasted rock,  ore,

Using the hydraulic shovel or its attachments for purposes other than or extending beyond those stated above, e.g.:  for lifting or transporting persons,  as a working platform,  for lifting crane loads without the attachment being approved for this purpose,  for driving in posts, sheetpiles supports, etc. without the attachment being approved for this purpose,  for moving material to the side (sweeping),  for breaking down rocks by beating with the shovel or the backhoe,  for fitting or reparing of other machines is contrary to its designated use and considered as "unauthorized use".

Lifting eyes on the under carriage - are settled for transporting with a crane only.

- must not be used for towing a machine.

 coal, and other raw materials.

With attached backhoe attachment, the machine can additionally also be used for excavating and loading of excavatable soils and other raw materials.

Operating the machine within the limits of the desigated use also involves observing the instructions set out in the Operation and Maintenance Manual and complying with the inspection and maintenance directives.

Improper use may involve a life-threatening risk for operators or other personnel or may cause injury or extensive damage.

The manufacturer/supplier cannot be held liable for any damage resulting from other than the designated use. The risk involved in such misuse lies with the user.

1-8

Useful Life The useful life of this machine is dependent upon many factors including the machine owner’s desire to rebuild the machine back to factory specifications. Consult your Cat dealer for assistance in calculating overall owning and operating costs required to determine the machines useful life. The following items are required to obtain an economical useful life of this machine:  Perform regular preventive maintenance procedures as described in the Operation and Maintenance Manual.  Perform machine inspections as described in the Operation and Maintenance Manual and correct any problems discovered.  Perform system testing as described in the Operation and Maintenance Manual and correct any problems discovered.  Ensure that machine application conditions comply with Caterpillar’s recommendations.  Ensure that the operating weight does not exceed limits set by manufacturer.  Ensure that all frame cracks are identified, inspected, and repaired to prevent further development.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction ORGANIZATIONAL MEASURES The Operation and Maintenance Manual must always be at hand at the place of use of the machine, e.g. by stowing them in the place provided for such purpose.

In addition to the Operation and Maintenance Manual, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment or traffic regulations.

The Operation and Maintenance Manual must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the Operation and Maintenance Manual and in particular the chapter on safety before beginning work. Reading the Operation and Maintenance Manual after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance.

Check - at least from time to time - whether the personnel is carrying out the work in compliance with the Operation and Maintenance Manual and paying attention to risks and safety factors.

For reasons of security, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewellery, such as rings, may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts.

Use protective equipment wherever required by the circumstances or by law.

Restricted Visibility The size and the configuration of this machine may result in areas that cannot be seen when the operator is seated. For restricted visibility areas, an appropriate job site organization must be utilized to minimize hazards of this restricted visibility. For more information regarding job site organization refer to Operation and Maintenance Manual, “Visibility Information.”

Personal protective equipment and the working clothing Depending on the cleaning, servicing and/or repair activities to be performed, the personal protective equipment and the working clothing may consist of the following items: 

fall arresters



protective suit



helmet



goggles - e. g. for cleaning work - or for welding work



protective gloves - e.g. for work on hot units - for grinding and welding work



protective working gloves - e.g. for fitting work - for grinding and welding work



ear protectors

Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine immediately and report the malfunction to the competent authority/person.

Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Use only the original spare parts of CGM HMS GmbH. They are the only ones to fulfill the technical specifications of the machine.

Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the Operation and Maintenance Manual for routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

1-9

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction Selection and qualification of personnel; basic responsibilities Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorized personnel works on or with the machine.

Define the machine operator's responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

Work on chassis and brake systems must be performed by skilled personnel only, which has been specially trained for such work.

Work on hydraulic systems must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Safety instructions governing specific operational phases Standard operation Avoid any operational mode that might be prejudicial to safety.

Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working area and the bearing capacity of the soil.

Take the necessary precautions to ensure that the machine is in a safe and reliable state.

Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional.

Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine's working behaviour) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it.

In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified immediately.

1-10

Start the machine from the driver's seat only.

During start-up and shut-down procedures always watch the indicators in accordance with the Operation and Maintenance Manual.

Before setting the machine in motion, make sure that nobody is at risk.

Before starting work or travelling with the machine, check that braking, signalling and lighting systems are fully functional.

Before setting the machine in motion always check that the accessories have been safely stowed away.

Shut the machine down until damaged or nonfunctioning visibility aid(s) is repaired (if applicable) or until appropriate job site organization is used to minimize hazards that are caused by any resulting restricted visibility.

In conditions of poor visibility and after dark always switch on the lighting system.

Persons accompanying the driver must be seated on the passenger seat provided for this purpose.

When crossing underpasses and bridges or when passing under overhead lines always make sure that there is sufficient clearance.

Always keep a distance from the working face and from slopes.

Avoid any operation that might be a risk to machine stability.

Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

On sloping terrain always adapt your travelling speed to the prevailing ground conditions.

Before leaving the driver's seat always secure the machine against inadvertent movement and unauthorized use. Shut off the engines.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation and Maintenance Manual, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shutdown procedures set out in the Operation and Maintenance Manual and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by:  removing the ignition key and 

attaching a warning sign.

Fig. 1-1:

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movements.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Never use machine parts as a climbing aid Wear a safety harness when carrying out maintenance work at heights above 1 m.

Wear an approved harness equipped with fall arresters and safety lines.

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use aggressive detergents. Use lint-free cleaning rags.

Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switch-gear cabinets.

Ensure during cleaning of the machine that the temperature sensors of the fire-warning and fire-fighting systems do not come into contact with hot cleaning agents as this might activate the fire-fighting system.

Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material. This material must not be spray-washed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

After cleaning remove all covers and tapes applied for that purpose.

After cleaning, examine all fuel, lubricant, brake and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defect found must be rectified without delay.

Always tighten any screwed connections that have been loosened during maintenance and repair.

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of maintenance and repair work.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

1-11

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction Warning of special dangers

Electrical Storm Injury Prevention

Electric energy

When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures:  Mount the machine.

Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

If your machine comes into contact with a live wire  do not leave the machine  drive the machine out of the hazard zone; warn others against approaching and touching the machine  have the live wire de-energized  do not leave the machine until the damaged or contacted line has been safely de-energized.

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

High-voltage system Floodlamps equipped with gaz discharge lamps (Xenon) require a high-voltage supply (ca. 25 kV).

The high voltage is generated by a ballast unit.

Switch off the electrical system of the hydraulic shovel before touching the lamp or the ballast unit.

Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.

1-12



Dismount the machine.

If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

Gas, dust, steam and smoke Always start and operate the engine in a wellvented area; If in an enclosed area, vent the exhaust to the outside; Do not modify or tamper with the exhaust system Diesel engine exhaust and some of its constituents are known to cause cancer, birth defects, and other reproductive harm Operate fuel-operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.

Observe the regulations in force at the respective site.

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction Hydraulic equipment

Ether

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

Depressurize all system sections and pressure pipes (hydraulic system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Hydraulic lines must be laid and fitted properly.

Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

The machine can be equipped with pressure vessels for cold-starting fluid (ether) installed in the engine compartment. Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the vessels against damage and high temperatures.

Do not store pressure vessels with cold-starting fluid (ether) on the hydraulic shovel.

Do not eat, drink or smoke when replacing pressure vessels with cold-starting fluid (ether). Observe the instructions on the pressure vessels.

Provide for sufficient ventilation (see also Part 3 "Inspection and servicing").

Do not open empty cold-starting fluid pressure vessels (ether). Have the vessels disposed of properly.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Noise During operation, all sound baffles of the machine must be closed.

Always wear the prescribed ear protectors.

Oil, grease and other chemical substances When handling oil, grease or other chemical substances, observe the product-related safety regulations (see safety specifications).

Be careful when handling hot consumables (risk of burning or scalding).

Transporting and recommissioning The machine must be loaded and transported only in accordance with the Operation and Maintenance Manual.

Use only appropriate means of transport and lifting gear of adequate capacity.

The recommisioning procedure must be strictly in accordance with the Operation and Maintenance Manual.

1-13

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard.

Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Even battery gases can ignite in open flames or fire.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

1-14

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

If necessary, also cover the ground with fireprotective blankets.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Clean the hydraulic shovel before starting a job.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, 

carbon-dioxide or



foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

1-15

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Introduction

1-16

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation 2 OPERATION Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

2-1

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

2-2

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation OPERATION - SAFETY INSTRUCTIONS Operation and Maintenance Manuals Never operate the machine before having read and understood the Operation and Maintenance Manuals.

Pay special attention to the "Fundamental Safety Instructions" and to all warning and instruction signs attached to the machine.

Familiarize yourself with the layout, the functioning and the sense of actuation of the control elements prior to starting up the machine.

Activate the control elements from the operator's seat only.

Keep the Operation and Maintenance Manuals with the machine at all times.

Operating personnel The operating personnel must be fully informed of the operation and application of this or comparable machines.

The necessary know-how can be acquired in several days' instruction, e.g. by an CGM HMS GmbH mechanic or by attending an CGM HMS GmbH operator's training course.

Personal protective gear and working clothing Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation.

Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in control levers being inadvertently activated.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the attachment and component combinations approved by CGM HMS GmbH. Clear-cut data are given in the technical specification.

Never install and commission other attachment and component combinations without CGM HMS GmbH having first inspected and approved the project.

Before starting work or traveling with the machine, check that the braking, signalling and lighting systems are fully functional.

Poor visibility may result in accidents. Always clean the windows and the glass covers of all lamps before starting the machine.

Check that all warning and instruction signs attached to the machine are present and legible.

Entering and leaving the machine Always face the machine when entering or leaving it.

Use only the ladders, steps, platforms and grab handles provided when entering and leaving the machine.

Always maintain a three point contact with the steps and grab handles.

Always keep ladders, steps and platforms in a non-slip, safe state and remove any oil, grease, soil, snow, ice and other foreign matter immediately.

Safety belts For machines with safety belts for operating personnel: Check the safety belts attached to the operator's seat as well as at the trainer’s seat. In the event of damage or after an accident, have them replaced immediately.

Apply the safety belts before starting work.

Fig. 2-1:

2-3

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Hazard range

Visibility aids

The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its attachment and attachments or of swinging loads.

Your machine may be equipped with visual aids.

Some examples of visual aids are cameras and mirrors. Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean.

For the best visibility of the area that is close to the machine adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual.

Shut the machine down until damaged or nonfunctioning visibility aid is repaired (if applicable) or until appropriate job site organization is used to minimize hazards that are caused by any resulting restricted visibility.

Shut the machine down until damaged or nonfunctioning visibility aid(s) is repaired (if applicable) or until appropriate job site organization is used to minimize hazards that are caused by any resulting restricted visibility.

Persons within the hazard zone Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

Marshallers The marshaller must keep outside the hazard zone.

Have a marshaller to assist you:  when you have no clear overview over the hazard zone of the machine, 

when reversing,



when shunting.

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie/camera).

Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller.

Stop the machine immediately if you lose contact with the marshaller.

Operation and Maintenance Manuals, where to store it in the operator’s cab One copy of the Operation and Maintenance Manuals for the machine must be available in the operator’s cab during operation.

Replace the Operation and Maintenance Manual if lost, damaged or unreadable.

The binder with the Operation and Maintenance Manual can be stored in the tray (Fig. 2-2:).

Securing the machine Secure the machine as described under "Securing the machine" before:  mounting or dismantling the attachment, 

parking the machine after daily operation,



carrying out any servicing or repair work.

Fig. 2-2:

2-4

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Clean rubber or electrical with compressed air only.

Ensure sufficient ventilation.

Even battery gases can ignite in open flames or fire.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

Clean the hydraulic shovel before starting work.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved before starting work.

open or smouldering fire may occur.

2-5

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation DESCRIPTION OF THE HYDRAULIC SHOVEL

Fig. 2-3:

2-6

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Hydraulic shovel layout – upper structure Fig. 2-3:

Upper structure 11 – Engine 12 - Radiator (engine cooling liquid)

35 - Fire-extinguisher

13 - Air-intake system

36 - Control-cabinet

14 - Exhaust system

37 – Batteries

15 - Fuel Tank

38 - Service-station (tank lift)

16 - Engine oil reservoir (if equipped)

39 – On-board crane (optional)

17 - Hydraulic oil reservoir

40 – Drive unit for on-board crane (optional)

18 – Hydraulic oil cooler

41 – Control cabinet with battery main switch and

19 – Filter housing (cooling system) 20 – Pump drive gearbox 21 - Working pump 22 – Slewing pump 23 - Servo system pump 24 - Gearbox oil circulating pump 25 - Filling pump (slewing circuit) 26 - Fan drive pump (engine radiator) 27 – Pump for fan drive and hydraulic oil cooling 28 – Cooling oil pump

starter isolator 42 – Emergency ladder near operator’s cab 43 – Emergency ladder engine compartment (opt.)

44 – Grease container of central lubricating system 45 – Tool cabinet (optional) 46 – Ladder 47 – Hydraulic ladder 48 – Counterweight 49 – Compressor drive (air conditioning) 50 – Condenser (air conditioning system)

29 - Slewing gear 31 - Operator's cab 32 - Control stand with BCS 33 - Control-cabinet 34 - Air conditioner

2-7

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-4:

2-8

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Hydraulic shovel layout – undercarriage and attachment Fig. 2-3:

Undercarriage 1 - Track drive 2 – Idler 3 - Track roller 4 - Upper roller 5 - Crawler track 6 - Track tensioner 7 - Swing ring 30 – Travel block and rotor

Face shovel attachment 51 – Boom 52 - TriPower linkage 53 – Stick 54 - Bottom-dump bucket 55 - Boom cylinder 56 - Stick cylinder 57 - Tipping cylinder 58 - Bottom-dump cylinder 64 - Control valves 65 - Quick-action valve

Backhoe bucket attachment 53 - Stick 55 - Boom cylinder 56 - Stick cylinder 59 - Monoblock boom 60 - Backhoe bucket 61 - Backhoe cylinder 62 - Toggle link 63 - Toggle lever 64 - Control valves 65 - Quick-action valve

2-9

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Undercarriage The undercarriage of the hydraulic shovel serves as a stable base and for traveling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and upper structure are connected by means of a swing ring.

Upper structure The upper structure accommodates the drive and part of the hydraulic and electrical equipment.

Drive unit The drive unit comprises diesel engines, pump drive gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Hydraulic system All working and traveling movements are performed hydraulically. The movements are controlled by servovalves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the upper structure to the undercarriage is ensured by the rotor.

The hydraulic system is overload-protected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

2-10

Control and Monitoring Platform (CAMP) The electronic CAMP system ensures the control and monitoring of all electrical and hydraulical functions of the shovel.

Four interconnected electronic units ensure optimal use of the installed engine power. Microprocessors are used to adapt the power output of the hydraulic pumps optimally to actual operating conditions.

The machine is thus prevented from demanding more hydraulic power than the diesel engines can provide.

The desired working movements are detected by microcontrollers which permanently sense the position of hand levers and pedals.

As soon as movement is detected, the corresponding signals are transmitted to the electronic units. These units activate the drive control in order to provide the hydraulic energy needed for working. Only then do they activate the electrohydraulic valves which control the execution of the working movements.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Board-Control-System (BCS) The BCS is a micro-processor-controlled system for the acquisition and processing of measuring data. It's function consists in collecting data of the hydraulic shovel operating conditions and to evaluate, store and display these data to the hydraulic shovel operator. For this purpose, the BCS is connected via a bus system to the Control and Monitoring Platform (CAMP). An interface with the outside world ensures the transfer of stored data and software updating.

The measured values (actual values) from the sensors and transducers installed in the hydraulic shovel are compared to the predefined reference values. Inadmissible deviations are indicated as fault messages on a display screen. Sensor or transducer defects or defective connecting cables are detected and indicated by plain-text messages.

The data from the engine electronics are acquired, processed and displayed in the same way.

Critical states of operation are brought to the operator's attention by means of optical and acoustic warning signals.

The display screen of the BCS is a touch-screen with a surface sensitive to the touch. This feature supports the hydraulic shovel operator or the service technician in navigating through the menus of the BCS sorftware.

For further information in this respect, please refer to section 5 in this Operation and Maintenance Manuals or to the brochure "Board-Control-System – Operation and Maintenance Manuals"

Demand control / Zero-flow regulation In the fine-control range, swivelling of the hydraulic pumps, and thus the variation of oil flow, are proportional to control lever and pedal valve travel. This means that during the work, the pumps supply only as much hydraulic oil as required to perform the working movement. In the neutral position of the control levers, the pumps are automatically swivelled to zeroflow.

These special features offer the following advantages:  reduced fuel consumption 

minimum power losses



reduced temperature of the hydraulic oil



greater service life of hydraulic pumps and diesel engines.

Automatic reset to idling If no servovalves are actuated by the control pedals or levers for more than 8 seconds (factory-set value, adjustable), the engine is automatically set back to idling speed (factory setting ca. 1000 rpm, adjustable). This feature, too, contributes to reducing the fuel consumption.

Electrical system The electrical system operates on 24 volts.

2-11

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Safety films and warning messages – overview and description Warning and additional messages Observe the warning and instruction signs attached to the machine.

There are several specific safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages.

Make sure that all of the safety messages are legible.

Keep all the safety films and warning messages legible and clean.

Clean the safety messages if you cannot read the words.

When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages.

Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message.

Loose adhesive will allow the safety message to fall.

Replace warning messages and films immediately if they have become illegible or have been lost.

New warning messages and films can be ordered from the CGM HMS Spare Parts Service. The ordering part numbers are set out in the spare-parts list of the machine.

Fig. 2-5: - Fig. 2-9: and Fig. 2-37: – Fig. 2-41: show the location of warning messages and films on the machine.

Note: There could be two different sets of safety messages on the hydraulic shovel. Depending on the national regulations in the country the hydraulic shovel is working the safety messages set could be: - ISO – compliant safety messages or - ANSI – compliant safety messages.

2-12

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation ISO – compliant safety messages set

Fig. 2-5:

2-13

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-6:

2-14

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-7:

2-15

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-8:

2-16

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-9:

2-17

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Safety messages (ISO) – Description In this section you can find a description of all safety messages and additional messages fitted to the machine (ISO compliant messages set).

The number in brackets, f.ex. (27), corresponds with the number of the film shown in the safety messages overview graphics.

The number corresponds also with the films item number in the spare parts manual.

Do Not Operate (27) This safety message is located in the cab on the left side window.

WARNING Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Fig. 2-10:

Hot Fluid Under Pressure (4)

Fig. 2-11:

This safety message is located on the cooling system expansion reservoir pressure cap.

WARNING Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.

Refer to Operation and Maintenance Manual, “Cooling System Coolant Level - Check” for further information.

Batteries, Flammable Gas (3) This safety message is positioned on the battery cabinet.

WARNING Explosion hazard-Improper jumper cable connections can cause explosions. Could cause serious injury or death. See Operation and Maintenance Manual for proper procedure for jumper cable connection.

Fig. 2-12:

2-18

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Crushing Hazard (9) This safety message is located on the rear of each side of the machine.

WARNING Machine swings. Crushing hazard could cause serious injury or death.

Stay back.

Fig. 2-13:

Falling Hazard (13) This safety message is located on the upper structure of the machine at the handrail gates.

WARNING Falling hazard. Could cause serious injury or death when falling down from great height. Use caution when performing service work on the attachment. Always wear your fall protection equipment. Read Operation and Maintenance Manual.

Refer to Operation and Maintenance Manual, “Working on the attachment- Safety Instructions” for further information.

Fig. 2-14:

Fire Hazard (2) This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the cab module.

WARNING Fire hazard. No open fire near area while lighting burners. Could cause serious injury or death. Read Operation and Maintenance Manual.

Refer to Operation and Maintenance Manual, “Fire and Explosion Hazard – Safety Instructions” for further information.

Fig. 2-15:

2-19

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Head Bump Hazard (7) This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments.

WARNING Head bump hazard because of low clearance.

Could cause serious injury or death. Stay back and wear a hard hat.

Fig. 2-16:

Trip Hazard (8) This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments.

WARNING Trip hazard because of obstacles on the floor.

Could cause serious injury or death. Be careful and pay extra attention on your steps. Read Operation and Maintenance Manual.

Refer to Operation and Maintenance Manual, “Fundamental Safety Instructions” for further information.

Fig. 2-17:

Hot Surface (11)

Fig. 2-18:

2-20

This safety message is located in two locations.

This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the oil cooler module.

WARNING Components and assemblies of the hydraulic system and components in the engine compartments can be hot while engines are running or immediately after engine shutdown. Hot parts or hot components can cause burns or serious injury or death. Do not allow these parts to contact your skin, when engines are running or immediately after engine shutdown.

Use protective clothing or protective equipment to protect your skin. Wait until hot components have cooled down.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Cutting Hazard (32) This safety message is located in two locations.

This message is located outside the oil cooler module and outside the counterweight near the cooling fan wheels.

WARNING Severe hazard caused by self starting fan wheels. Could cause serious injury or death.

Keep hands away from fan. Shut off engines and wait until hydraulic system and engine cooling system has cooled down before starting work.

Read Operation and Maintenance Manual.

Fig. 2-19:

Refer to Operation and Maintenance Manual, “Other Maintenance Work” for further information.

Belt Entanglement Hazard (12) This safety message is located in two locations.

This safety message is located on the belt cover assembly on each engine.

WARNING Entanglement hazard. Could cause serious injury or death. Do not touch while engine is running. Keep hands away.

Do not operate engine with guard removed.

Shut off engines before starting work.

Fig. 2-20:

2-21

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Additional messages (ISO) – Description

Lashing point (6) This message is located in two locations.  On the right-hand side of the carbody in the near of each of the lashing points,  On the left-hand side of the carbody in the near of each of the lashing points.

Fig. 2-21:

Battery Disconnect Switch (19) This message is located in the control cabinet on the deck of the engine module next to the battery disconnect switch.

Fig. 2-22:

Starter Disconnect Switch (21) This message is located in the control cabinet on the deck of the engine module next to the starter disconnect switch.

Fig. 2-23:

2-22

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Personal Protection Equipment (PPE) Required (10) This message is located on the upper structure of the machine at the entrance to the pump bay.

Eye, ear and foot protection are mandatory beyond this place.

Fig. 2-24:

High Pressure Water Jet Prohibited (5) This message is located on electrical components in six locations. This message is located on the upper structure of the machine  at the entrance to the pump bay,  on the control cabinets in the cab module,  on the control cabinets near the doors to the engine compartments,  on the control cabinet behind the hydraulic fluid reservoir.

Washing with high pressure water jet is prohibited.

Read Operation and Maintenance Manual.

Fig. 2-25:

Refer to Operation and Maintenance Manual, “Electrical System” and “Inspection and Servicing Safety Instructions” for further information.

Maintenance Lights Switch (24) This message is located near the maintenance light switches in three locations  inside the operator’s cab next to the door,  inside the cab module next to the door,  in the engine compartment.

Fig. 2-26:

2-23

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Emergency Stop Reset Switch (20) This message is located inside the cab module on the front side of the 24 volt control cabinet next to the emergency stop reset switch.

Fig. 2-27:

Hydraulic fluid level (14 and 15) This message is located at the hydraulic fluid reservoir near the inspection glass.

Refer to Operation and Maintenance Manual, “Hydraulic System” for further information.

Fig. 2-28:

Fan rotation (35) This message is located in two locations. This message is located inside the oil cooler module and inside the counterweight near the cooling fan wheels.

The message shows the direction of rotation.

Fig. 2-29:

2-24

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Engine Shut Off Switch (18) This message is located in six locations. This message is located near the engine shut off switches  on the control box at the fast fill arm,  on the left side of the upper structure near the location of the pulling rope switch,  inside the operator’s cab at the control column,  on both control cabinets near the doors to the engine compartments  on the control cabinet behind the hydraulic fluid reservoir.

Fig. 2-30:

Refer to Operation and Maintenance Manual, “Emergency shut-off function” for further information.

Alternate exit (33) This message is located in the cab on the left, slidable window pane.

Refer to Operation and Maintenance Manual, “Alternate exit in operator’s cab and escape ladder” for further information.

Fig. 2-31:

Seat Belt (34) This message is located in the cab on the right side of the operator’s seat.

WARNING A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

Fig. 2-32:

2-25

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

CE – Sign (25) This message is located inside the cab on the left window pane (in Europe only).

This message indicates that the machine has been built in compliance with European directives.

Fig. 2-33:

Ladder up switch

Fig. 2-34:

Ladder down switch

Fig. 2-35:

Machine Operation (28,29) This message is located inside the cab on the left window pane.

The message shows the function of the operator controls, one message is for machines with backhoe attachment, one is for machines with shovel attachment.

Refer to Operation and Maintenance Manual, “Monitoring, Warning and Control Elements” for further information.

Fig. 2-36:

2-26

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation ANSI – compliant safety messages set

Fig. 2-37:

2-27

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-38:

2-28

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-39:

2-29

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-40:

2-30

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-41:

2-31

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Safety messages (ANSI) – Description In this section you can find a description of all safety messages and additional messages fitted to the machine (ANSI compliant messages set).

The number in brackets, f.ex. (27), corresponds with the number of the film shown in the safety messages overview graphics.

The number corresponds also with the films item number in the spare parts manual.

Fig. 2-42:

Do Not Operate (18) This safety message is located in the cab on the left side window.

WARNING Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Hot Fluid Under Pressure (16)

Fig. 2-43:

This safety message is located on the cooling system expansion reservoir pressure cap.

WARNING Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.

Refer to Operation and Maintenance Manual, “Cooling System Coolant Level - Check” for further information.

Batteries, Flammable Gas (10) Fig. 2-44:

This safety message is positioned on the battery cabinet.

CAUTION Explosion hazard. Battery gases can cause explosions. Could cause serious injury or death. Do not smoke. No open flames.

Crushing Hazard (2)

Fig. 2-45:

2-32

This safety message is located on all four corners of the machine.

DANGER Machine swings. Crushing hazard could cause serious injury or death.

Stay back.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Falling Hazard (23) This safety message is located on the upper structure of the machine at the handrail gates.

CAUTION Falling hazard. Could cause serious injury or death when falling down from great height. Use caution when performing service work on the attachment. Always wear your fall protection equipment.

Refer to Operation and Maintenance Manual, “Working on the attachment- Safety Instructions” for further information.

Fig. 2-46:

Fire Hazard (9) This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the cab module.

CAUTION Fire hazard. Oil or fuel escaping in the event of damage can produce flammable vapours.

Could cause serious injury. No open flames. Do not smoke.

Refer to Operation and Maintenance Manual, “Fire and Explosion Hazard – Safety Instructions” for further information.

Fig. 2-47:

Head Bump Hazard (8) This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments.

CAUTION Head bump hazard because of low clearance.

Could cause serious injury. Stay back and wear a hard hat.

Fig. 2-48:

Trip Hazard (7) This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments.

CAUTION Trip hazard because of obstacles on the floor.

Could cause serious injury. Be careful and pay extra attention on your steps.

Fig. 2-49:

Refer to Operation and Maintenance Manual, “Fundamental Safety Instructions” for further information.

2-33

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Hot Surface (6)

Fig. 2-50:

This safety message is located in two locations.

This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the oil cooler module.

CAUTION Components and assemblies of the hydraulic system and components in the engine compartments can be hot while engines are running or immediately after engine shutdown. Hot parts or hot components can cause burns or serious injury. Do not allow these parts to contact your skin, when engines are running or immediately after engine shutdown. Use protective clothing or protective equipment to protect your skin. Wait until hot components have cooled down.

Cutting Hazard (14) This message is located outside the oil cooler module.

WARNING Self-starting, rotating fan blades. Can cause serious injury or cut. Keep hands away from fan. Turn off and lock-out electrical system before servicing.

Fig. 2-51:

Refer to Operation and Maintenance Manual, “Other Maintenance Work” for further information.

Cutting Hazard (15) This message is located outside the counterweight near the cooling fan wheels.

WARNING Rotating fan blades. Can cause serious injury or cut. Keep hands clear. Lock-out / tag out engine before servicing.

Refer to Operation and Maintenance Manual, “Other Maintenance Work” for further information.

Fig. 2-52:

Belt Entanglement Hazard (28) This safety message is located in two locations.

This safety message is located on the belt cover assembly on each engine.

WARNING Entanglement hazard. Could cause serious injury or death. Do not touch while engine is running. Keep hands away.

Do not operate engine with guard removed.

Shut off engines before starting maintenance work.

Fig. 2-53:

2-34

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Head Bump Hazard (17) This safety message is located under the upper structure near to the fast fill arm / servicestation.

CAUTION Head bump hazard when the servicestation is moving downwards. Could cause serious injury. Stay back and wear a hard hat.

Fig. 2-54:

Injury hazard, Personal Protection Equipment (PPE) Required (3) This message is located on the upper structure of the machine at the entrance to the pump bay.

Eye, ear, head, hand and foot protection are mandatory beyond this place.

Fig. 2-55:

WARNING Serious injury can result from failure to use personal protective equipment. Wear appropriate personal protective equipment required for tasks being performed.

Hazardous noise level (5) This message is located on the upper structure of the machine at the entrance to the pump bay.

Ear protection is mandatory beyond this place.

CAUTION Hazardous noise level when engine running.

May cause loss or degration of hearing over a period of time. Wear proper personal protective equipment / ear protection beyond this point.

Fig. 2-56:

Always Use Seat Belt (22) This message is located in the cab on the right side of the operator’s seat.

CAUTION A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury.

Fig. 2-57:

2-35

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Additional messages (ANSI) – Description

Lashing point (6) This message is located in two locations.  On the right-hand side of the carbody in the near of each of the lashing points,  On the left-hand side of the carbody in the near of each of the lashing points.

Fig. 2-58:

Notes on welding (4) This message is located on the upper structure of the machine at the entrance to the pump bay.

Electric components may be damaged when electric welding work is performed near to them.

Refer to Operation and Maintenance Manual, “Welding and flame cutting works - Safety Instructions” for further information.

Fig. 2-59:

Notes on cleaning electric assemblies (12)

Fig. 2-60:

2-36

This message is located on electrical components in six locations. This message is located on the upper structure of the machine  at the entrance to the pump bay,  on the control cabinets in the cab module,  on the control cabinets near the doors to the engine compartments,  on the control cabinet behind the hydraulic fluid reservoir.

Washing with high pressure water jet is prohibited.

Refer to Operation and Maintenance Manual, “Electrical System” and “Inspection and Servicing Safety Instructions” for further information.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Emergency exit (19) This message is located in the cab on the left, slidable window pane.

Refer to Operation and Maintenance Manual, “Emergency exit in operator’s cab and escape ladder” for further information.

Fig. 2-61:

Location of fire extinguisher (13) This message is located on the deck of the upper carriage behind the cab. It is located near the fire extinguishers.

Read operation instructions given on the fire extinguishers.

Fig. 2-62:

Hydraulic fluid level (30 and 32) This message is located at the hydraulic fluid reservoir near the inspection glass.

Refer to Operation and Maintenance Manual, “Hydraulic System” for further information.

Fig. 2-63:

Fan rotation (27) This message is located in two locations. This message is located inside the oil cooler module and inside the counterweight near the cooling fan wheels.

The message shows the direction of rotation.

Fig. 2-64:

2-37

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

CE – Sign (25) This message is located inside the cab on the left window pane (in Europe only).

This message indicates that the machine has been built in compliance with European directives.

Fig. 2-65:

Machine Operation (20,21) This message is located inside the cab on the left window pane.

The message shows the function of the operator controls, one message is for machines with backhoe attachment, one is for machines with shovel attachment.

Refer to Operation and Maintenance Manual, “Monitoring, Warning and Control Elements” for further information.

Fig. 2-66:

2-38

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Machine number

Engine number

The identification plate with the machine number (Fig. 2-67:) is attached to the front side of the Aframe (arrow, Fig. 2-68:).

The serial number plate (1, Fig. 2-69:) for the diesel engine is located on the engine block.

Fig. 2-67: Fig. 2-69:

Engine information decal The engine information decal (2, Fig. 2-70:) is located on the oil cooler. The decal gives information about the engine like horsepower, high idle, full load engine speed and others.

Fig. 2-68:

Component numbers Other larger units also have identification plates indicating, among other things, their serial number.

On steel components, the CGM HMS GmbH part number or the serial number may be stamped into the metal at a clearly visible place.

Fig. 2-70:

2-39

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Eurasian Economic Union

CE-Plate, European Union

For machines compliant to the Eurasian Economic Union requirements, the EAC mark plate (Fig. 2-71:) is positioned near the Machine Identification Plate at the A-frame (see Safety Films and Warning Messages section of the machine Operation and Maintenance Manual). The EAC mark plate is placed on machines certified to the Eurasian Economic Union requirements effective at the time of market entry.

The CE plate (Fig. 2-72:) is on machines that are certified to the European Union requirements of the Machinery Directive “2006/42/EC” that is effective at that time.

If the machine is equipped with the plate for the European Union, this plate will be attached inside the cab on the left window pane.

Fig. 2-72:

Fig. 2-71:

The month and year of Manufacture are on the Machine Identification Plate.

Manufacturer Information Manufacturer: Caterpillar Global Mining HMS GmbH Karl-Funke-Straße 36 44149 Dortmund, Germany Entity authorized to communicate on request as required by Customs Union Technical Regulations of the Eurasian Economic Union: Caterpillar Eurasia LLC 75, Sadovnicheskaya Emb. Moscow 115035, Russia

2-40

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Entering and leaving the machine Safety instructions Risk of injury due to slipping.

Clean off oil, grease, soil, mud, snow, ice and other substances from footwear, grab handles, ladders and steps.

Keep ladders, steps, platforms and grab handles in a non-slippery condition.

For entering and leaving use only the ladders, steps, platforms and grab handles provided (see: illustration in Fig. 2-73:).

Always face the machine when entering or leaving it.

Always maintain a three point contact with the steps and grab handles.

Access ladder lighting The access ladder of the machine can be illuminated.

From outside: The pull-switch (2, Fig. 2-74:) of the lighting system is located beneath the upper structure. The lights are switched on from the ground by means of the pull-rope.

From the cab: The switch is located besides the door (arrow, Fig. 2-75:).

The lighting remains on during a presettable ON time. The ON time of the lighting is factory-adjusted to three minutes.

Fig. 2-74:

Fig. 2-73:

Fig. 2-75:

2-41

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Swinging ladder (optional) Raising resp. lowering the swinging ladder (Fig. 2-76:).

Lowering the swinging ladder from the upper structure (for leaving the machine)  Start an engine.  Push lever (1, Fig. 2-77:) on control valve (2) downwards to position “ II “ and hold.

The swinging ladder is lowered (Fig. 2-76:).

The swinging ladder can also be lowered when the engine ist stopped.

Fig. 2-76:

Raising the swinging ladder from the upper structure (after entering the machine)  Start an engine.  Pull lever (1, Fig. 2-77:) on control valve (2) upwards to position “ I “ and hold.

The swinging ladder is raised (Fig. 2-78:).

Fig. 2-78:

 Leave the lever on the control valve in position “ I “ while operating the machine.

This keeps the swinging ladder in the upper position (fully retracted).

Lowering the swinging ladder from the ground (in case of emergency)  Pull down rope (3, Fig. X).

The swinging ladder is lowered (Fig. 2-76:).

Fig. 2-77:

The upper structure can only be swung when the swinging ladder is raised completely (Fig. 2-78:).

2-42

Fig. 2-79:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Folding ladder Raising resp. lowering the folding ladder (Fig. 2-80:).

Lowering the folding ladder from the upper structure (for leaving the machine)  Start an engine.  Push lever (1, Fig. 2-81:) on control valve (2) downwards to position “ II “ and hold.

The folding ladder is lowered (Fig. 2-80:).

The folding ladder can also be lowered when the engine is stopped.

Fig. 2-80:

Raising the folding ladder from the upper structure (after entering the machine)  Start an engine.  Pull lever (1, Fig. 2-81:) on control valve (2) upwards to position “ I “ and hold.

The folding ladder is raised (Fig. 2-77:).

Fig. 2-82:

 Leave the lever on the control valve in position “ I “ while operating the machine.

This keeps the swinging ladder in the upper position (fully retracted).

Lowering the folding ladder from the ground (in case of emergency)  Pull down rope (3, Fig. X).

The folding ladder is lowered (Fig. 2-81:).

Fig. 2-81:

The upper structure can only be swung when the folding ladder is raised completely (Fig. 2-77:).

Fig. 2-83:

2-43

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Emergency exit in operator’s cab and escape ladder The sliding window (arrow, Fig. 2-84:) on the lefthand side of the operator’s cab serves as an alternative opening / emergency exit.

To open the sliding window from inside the cab:  Lift latch (1).  Grasp handle (2) and slide window pane to the left.

The escape ladder (arrow, Fig. 2-85:) is located beside the operator´s cab.

Function of ladder locking as well as free movement of the ladder must be regularly checked according to the maintenance plans.

Before unlocking the ladder: Be sure that no person is near to the position the ladder moves to.

Fig. 2-84:

 Pull out locking pin (1, Fig. 2-86:). The escape ladder is now unlocked and the release lever (2) is free to move.  Move release lever (2) away from the machine.

The escape ladder is now free and moves down quickly to the ground.  Swing barrier (3) to the right and use the ladder to escape downwards.

Fig. 2-85:

Fig. 2-86:

2-44

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Escape ladder near engine compartment (optional) The escape ladder (Fig. 2-87:) is located at the right side of the upper structure between oil cooler module and engine compartment.

Function of ladder locking as well as free movement of the ladder must be regularly checked according to the maintenance plans.

Before unlocking the ladder: Be sure that no person is near to the position the ladder moves to.  Pull out locking pin (1, Fig. 2-87:).  Swing lever (2) inside. The escape ladder is now unlocked and moves down quickly to the ground.  Use the ladder to escape downwards.

Fig. 2-87:

2-45

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Switching the cab interior lighting on and off The cab interior lighting can be switched on and off with the switches (arrow, Fig. 2-88:), (96, Fig. 2-89:) and (arrow, Fig. 2-90:) The cab interior light is supplied with power even when the electrical system is shut down.

When leaving the machine, the interior light must therefore be switched off. The batteries could be discharged if the interior light is allowed to remain on for a prolonged period.

Fig. 2-88:

Fig. 2-89:

Fig. 2-90:

2-46

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Switching the maintenance lights on and off The maintenance lights in the various modules can be activated from a central point with the switches (arrow, Fig. 2-91:) or (95, Fig. 2-92:).

The invidual modules are also equipped with switches, for example the engine module: Switch at the switchgear cabinet behind the hydraulic oil reservoir (1, Fig. 2-93:).

Fig. 2-91:

Fig. 2-92:

Fig. 2-93:

2-47

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Emergency shut-off function The emergency shut-off function can be triggered from six different places on the machine:  by pressing the switch (red) on the front panel of the control column (35, Fig. 2-94:),

Emergency shut off switch in the operator’s cab

 by pressing the switch (red) at the entrances to the engine compartments on the right-hand and on the left-hand side (Fig. 2-95:),  by pressing the switch (red) on the control cabinet in the engine module (Fig. 2-96by pulling the pull-switch between the left fuel tank and the counterweight (5, Fig. 2-97:),  by pressing the switch (red) on the control box at the servicestation (tanklift) (Fig. 2-98:).

The emergency shut-off function disconnects all power outputs of the electronic control units. In this case, all engines are shut off so that no working movements can be performed anymore.

The power supply of the electronic control units of the engines and of the machine is, however, not interrupted. For this reason, the trouble shooting and failure analisis functions continue to remain active.

Other auxiliary functions such as:  the fire extinguishing system,

Fig. 2-94:

Emergency shut off switch at the engine compartments

 the service station (tank-lift) and,  the radio, the cab interior lighting and the access ladder lighting and maintenance lighting remain functional as well.

The emergency shut-off function can also be triggered before maintenance operations are performed on the machine. For this purpose, one of the switches is depressed and secured with a padlock. Any inadvertent starting of the engine is thus prevented.

Fig. 2-95:

Putting the machine back into operation The machine can only be put back into operation when all switches listed above are again in their basic position (i.e. not actuated).

Emergency shut off switch on the control cabinet engine module

(continued next page)

Fig. 2-96

2-48

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Emergency shut off switches, continued

Putting the machine back into operation, reset of emergency shut off function

Emergency shut off pull switch between left fuel tank and counterweight

The machine can only be put back into operation when all switches listed above are again in their basic position (i.e. not actuated).

Additionally the Reset button (arrow, Fig. 2-66) has to be pushed. The Reset button is located in the front door of the 24Volt-control cabinet in the cab module.

Please note the message film near the Reset button (Fig. 2-67).

Fig. 2-97:

Emergency shut off switch on the servicestation (tanklift)

Fig. 2-99:

Fig. 2-98:

Fig. 2-100:

2-49

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Battery isolator switch, shutting off supply voltage The battery isolator switch (1, Fig. 2-102:) is located inside the control cabinet on the deck of the engine module (Fig. 2-101:).

The supply voltage is shut off when the battery isolator switch has been turned to position “OFF”.

This function shuts off the complete electrical system of the machine by disconnecting the two poles from the batteries (battery main switch).

In this case, all engines are shut off so that no working movements can be performed anymore.

The power supply of the electronic control units of the engines and of the machine is shut off after a brief delay. The delay ensures that the current operating data can be saved and the systems shut down properly.

Lock the battery isolator switch in position “OFF” by means of a padlock.

The machine can only be put back into operation when the battery isolator switch is unlocked and switched in the “ON” position. A green LED located near the switch comes on.

Fig. 2-101:

Starter isolator switch, shutting off starter voltage The starter isolator switch (2, Fig. 2-103:) is located inside the control cabinet on the deck of the engine module (Fig. 2-101:).

After turning the “Starter Isolator” switch to position “OFF” the engines could not be started.

All other sections of the electrical system are supplied with voltage.

This is to ensure personal safety during testing and trouble shooting purposes.

Lock the starter isolator switch in position “OFF” by means of a padlock.

The engines can only be put back into operation when the starter isolator switch is unlocked and switched into the “ON” position. A green LED located near the switch comes on.

Fig. 2-102:

Fig. 2-103:

2-50

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Operator’s seat The operator’s seat (Fig. 2-104: and Fig. 2-105:) can be adjusted in several positions.

Never adjust the seat while driving. Concentrate on the road to avoid accidents.

Before carrying out any seat adjustments stop the machine and set the control levers to "0"

Fig. 2-104:

2-51

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-105:

2-52

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Reducing the operators exposure to vibrations Vibrations, oscillations and movements of the machine cannot be avoided when the machine is in operation. They also have an effect on the operator.

These effects on the operator can however be avoided, if the operator's seat is adjusted correctly.

Therefore, make use of the seat's various adjustment features (see Fig. 2-104: and Fig. 2-105:):  shock absorption (Absorber), 

body weight setting (Weight adjustment),



horizontal movement damping (Fore/aft isolator).

Trainer's / instructor's seat For operator training / instructing purposes it is often required that a trainer / instructor accompanies the operator in the cab.

For the safety of the trainer / instructor during hydraulic shovel operation the cab is equipped with a second seat. This seat is installed behind the operator's seat (Fig. 2-106:).  Sit down on this seat and do not forget to fasten the seat-belt (if installed, see arrow, Fig. 2-106:).  Do not leave this seat during the training / instruction session and / or as long as the machine is in operation.

Adjust the seat before beginning work to suit your personal requirements. Check whether all adjustments are functional. If this is not possible, have the seat checked and repaired as soon as possible.

Fig. 2-106:

2-53

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Fire extinguisher The hydraulic shovel can be equipped with fire extinguishers. Base plates for mounting brackets are located at the rear side wall of the cab (arrow, Fig. 2-107:) and in the pump compartment.

Fig. 2-107:

The hydraulic shovel operator and the maintenance personnel must inform themselves about how to handle the fire-extinguisher in order to be able to act fast and efficiently in case of beginning fires. Such instruction should be given by a qualified instructor.

Have the extinguisher inspected at regular intervals by an expert. This is required by local authorities and insurance companies and is in the interest of your own safety.

2-54

Automatic fire-extinguishing system The automatic fire-extinguishing system prevents fire from spreading. It is, however, assumed that the machine is thoroughly cleaned of combustible and easily flammable substances.

Please contact your local Cat dealer for more detailed information on the installation of automatic fire-extinguishing systems..

The hydraulic shovel operator and the maintenance personnel must familiarize themselves with the automatic fire-extinguishing system.

Such instruction should be given by a qualified instructor.

The fire-extinguishing system is activated automatically in an emergency.

Have the extinguishing system inspected regularly by an expert. This is required by authorities and insurance companies and is in the interest of your own safety.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Windscreen washer The fluid reservoir (1, Fig. 2-108:) of the windscreen washer is located in the cab module. The capacity of the reservoir is indicated under "Refilling quantities - Other".

Operating hours meter (if equipped) Three operating hours meters (Fig. 2-109:) are located in the left front door of the “24 Volts switchgear cabinet” in the cab module.

1 2 3

LH engine hours meter RH engine hours meter Travel hours meter

Fig. 2-108:

Fig. 2-109:

2-55

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Emergency escape device / seat (optional) Elements of the harness (Fig. 2-110:- Fig. 2-112:) Pos. Designation 1

Back support

2

Shoulder belt

3

Shoulder belt

4

Loop (chest belt)

5

Loop (chest belt)

6

Loop (back support)

11

Holding device with fastening eye

12

Snap hook for fall arrester

13

Fall arrester

14

Hanging up line

15

Handbag with harness

16

Snap hook

17

Hook safety device

Fig. 2-111:

Fig. 2-112:

Important hints Fig. 2-110:

Read and observe also: Operation and Maintenance Manuals of the supplier.

Before using operator shall have received adequate training.

The harness must be used by one person only.

He is responsible for the appropriate use and maintenance.

Visual inspection is recommended prior to each use; if necessary it must be checked by an expert.

Harness must be checked annualy (every 12 month) by an expert.

2-56

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Taking on harness  Take harness out of handbag (15, Fig. 2-113:)

 Pull loop (6) of the back support (1) between your legs to the front (Fig. 2-115:)  Pull loop (5, Fig. 2-116:) through loop (6).

Fig. 2-116:

 Pull loop (4, Fig. 2-116:) through loop (5).  Take on shoulder belts (2 and 3, Fig. 2-114:)

 Press the hooking safety device (17, Fig. 2-116:) of the snap hook (16).

Fig. 2-114:

Fig. 2-117:

Fig. 2-113:

 Pull back support (1, Fig. 2-114:) behind your body (Fig. 2-115:) The loops (4 and 5) are in front of your body.

Fig. 2-115:

2-57

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation  Hang up loop (4, Fig. Fig. 2-118:) into snap hook (16)

If you have the harness put on in such a way in case of danger you can escape from the hydraulic shovel (Fig. Fig. 2-120:).

Fig. 2-118:

 Release hooking safety device (17, Fig. 2-119:)

Fig. 2-119:

2-58

Fig. 2-120:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

2-59

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-121:

2-60

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-121:) BCS, Board-Control-System No. 1

2

Element BCS

Monitor

Function

Symbol

Electronic system Board Control System, acquisition and disfor measured data play of important operating data of the hyacquisition and pro- draulic shovel cessing The surface of the monitor is sensitive to the touch (touch-screen technology). A touchscreen permits selecting menus and programs by touching graphic control symbols and to recall, for instance operating data of the hydraulic shovel.

For further information please refer to section 5 of this Operation and Maintenance Manuals, chapter “Board-Control-System”.

BCS The monitor displays collected operating data, warning messages and – if needed – instruction for help.

3

4

Push-button

Push-button

Navigation in menus Control of cursor movements, program selection within the BCS, confirmation of inputs / displayed values (Enter), quitting of menus / sub-menus Numeric keypad Input of numeric values.

2-61

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-122

2-62

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-122:) BCS, Board Control System, display screen example (For further information please refer to section 5 of this Operation and Maintenance Manuals, chapter “Board-Control-System”).

No. 1

2

3

4 5 6

Element

Function

Status line

Indicates activated functions and operating hours.

The symbols displayed are those of the switches in the control column

Touch-screen Monitor

BCS

Indicates collected operating data graphically and / or numerically, displays warning messages, fault messages and – if needed – instructions for help.

Pushbutton

Navigation in menus

Control of cursor movements, program selection within the BCS, confirmation of inputs / displayed values (Enter), quitting of menus / sub-menus

Push-button

Numeric keypad

Input of numeric values.

Touch-screen buttons Status line

Examples Fault messages

Symbol

Displays fault messages as a code number and as plain text. The "Fault" button permits displaying further fault messages stored in the system.

2-63

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-123:

2-64

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-123:)

No.

Element

Function

Key-switch

Switches the electrical system on and off.

33

Buzzer (inside the control column)

Gives three acoustic warning signals if a fault is reported. The signals appear every 30 seconds.

34

Socket connectors

Connection of electronic devices for fault diagnosis purposes.

32

35

Switch

Emergency shut-off

Symbol

De-energizes the outputs of the electronic control units: The engines are shut off, working movements no longer possible. (see: "Emergency shut-off function").

2-65

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-124:

2-66

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-124:)

Engine 1 (LH), control and monitoring All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. 41 42 43

44 45

46 47 48

Element

Function

Push-button

Start

Starting of the engine. For starting, press the push-button face with the symbol.

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

Push-button

Idle

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol (“Idle Shut Down”).

Warning lamp

Engine oil pressure

Lit up when the engine oil pressure is too low.

Warning lamp

Alternator

Lit up when the batteries are not being charged or in the event of an alternator defect.

Warning lamp

Engine oil temperature

Lit up when the engine oil temperature is too high.

Warning lamp

Cooling liquid temperature

Lit up when the engine cooling liquid temperature is too high.

Switch

Engine speed

Press switch face without symbol: the speed of the engine increases.

Symbol

Press the switch face with the symbol: the speed of the engine reduces.

49

50

Diagnosis lamp

Diagnosis lamp

Engine monitoring

Engine monitoring

Lits up when malfunctions occur on the engine. The indication uses so-called flashcodes (see section 5 of this Operation and Maintenance Manuals: “Engine monitoring, Control lamps”).

Check the BCS display for further fault messages and give an information to the responsible service personnel.

STOP! Lits up when a serious fault occurs on the engine. The diagnosis lamp (49) provides the event code at the same time (flashing). (see section 5 of this Operation and Maintenance Manuals: “Engine monitoring, Control lamps”).

Shut off the engine immediately.

Check the BCS display for further fault messages and give an information to the responsible service personnel.

2-67

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-125:

2-68

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-125:)

Engine 2 (RH), control and monitoring All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. 51 52 53

54 55

56 57 58

Element

Function

Push-button

Start

Starting of the engine. For starting, press the push-button face with the symbol.

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

Push-button

Idle

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol (“Idle Shut Down”).

Warning lamp

Engine oil pressure

Lit up when the engine oil pressure is too low.

Warning lamp

Alternator

Lit up when the batteries are not being charged or in the event of an alternator defect.

Warning lamp

Engine oil temperature

Lit up when the engine oil temperature is too high.

Warning lamp

Cooling liquid temperature

Lit up when the engine cooling liquid temperature is too high.

Switch

Engine speed

Press switch face without symbol: the speed of the engine increases.

Symbol

Press the switch face with the symbol: the speed of the engine reduces.

59

60

Diagnosis lamp

Diagnosis lamp

Engine monitoring

Engine monitoring

Lits up when malfunctions occur on the engine. The indication uses so-called flashcodes (see section 5 of this Operation and Maintenance Manuals: “Engine monitoring, Control lamps”).

Check the BCS display for further fault messages and give an information to the responsible service personnel.

STOP! Lits up when a serious fault occurs on the engine. The diagnosis lamp (59) provides the event code at the same time (flashing). (see section 5 of this Operation and Maintenance Manuals: “Engine monitoring, Control lamps”).

Shut off the engine immediately.

Check the BCS display for further fault messages and give an information to the responsible service personnel.

2-69

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-126:

2-70

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-126:) All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. 61

Element Push-button

Function Upper structure holding brake

Symbol

Blocks the upper structure.

Press this button when the upper structure is stationary.

Do not use this button while the upper structure is still in motion.

Risk of damage to the brake and the slewing gearboxes.

Not connected.

62 63

Switch

Hydraulic shovel parking brake

Not actuated: The parking brake is applied automatically ca. 5 secs after the hydraulic shovel has stopped moving.

The parking brake is released automatically when the "Travel" function is activated.

Press the switch face with the symbol: The parking brake is applied permanently.

The hydraulic shovel cannot be moved.

Actuate this switch only when the hydraulic shovel is stationary.

Do not use this switch while the hydraulic shovel is still in motion.

Risk of damage to the brakes and the travel gearboxes.

64

Push-button

Central greasing system reset

Reset function of the central greasing system control (Press for at least 3 sec.).

Press switch face without symbol: Resets the control of the upper structure.

Press the switch face with the symbol: Resets the control of the undercarriage.

65

Push-button

Emergency lowering Lowering of the attachment, for instance, if the engines have failed.

Press and hold the switch face with the symbol using at the same time the control lever to lower the attachment.

66

Switch

Automatic speed reduction

Reduces the speed of the diesel engines to about 1000 min-1, if no working movement is being executed during about 8 seconds.

2-71

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-127:

2-72

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-127:) All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. 71

72

Element

Function

Switch

Servo-control

Press the switch face with the symbol: The electro-hydraulic servo-control is enabled.

Switch

Traveling speed

Not actuated: 1st traveling stage traveling forwards / backwards is possible.

Symbol

Press the switch face with the symbol: 2nd traveling stage, traveling forwards / backwards is possible.

Not connected.

73 74

Monitoring lamps

Engine oil interval prolongation

Not connected.

75 76

81 82 83 84 85 86

Lamp is lit up, when the right or the left pump of the prolongation system is running.

Push-button

When the machine has to be manoeuvered out of dangerous situations

Press the switch face with the symbol: The machine can be driven and the upper structure be slewed although these functions are automatically deactivated.

Use this function only in dangerous situations to manouever yourself or the machine out of hazard zones. Risk of damaging parts of the machine, e.g. the hydraulic ladder or the tanklift.

Switch

Floodlamps

Switches the floodlamps on the operator´s cab on and off.

Switch

Floodlamps

Switches the floodlamps on the hydraulic oil cooler module on and off.

Switch

Floodlamps

Switches the floodlamps on the cab module on and off.

Switch

Floodlamps

Switches the floodlamps on the boomon and off.

Switch

Floodlamps rear

Switches the floodlamps on the counterweight on and off.

Switch

Not connected.

2-73

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-128:

2-74

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-128:) All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No.

Element

Function

91

Push-button

Dumper count

Press the switch face with the symbol: Resets the loaded dumper count.

92

Switch

Windscreen wiper

Press the switch face with the symbol: Windscreen wiper in intermittent operation mode.

Symbol

Press the switch face without symbol: Windscreen wiper in permanent operation mode.

93

Pushbutton

Windscreen washer

Press the switch face with the symbol: Windscreen wiper in wipe/wash operation.

94

Switch

Rotary beacon (option)

Press the switch face with the symbol: Rotary beacon ON.

95

Switch

Lighting

Press the switch face with the symbol: Switches on the maintenance lights in the modules.

96

Switch

Lighting

Press the switch face with the symbol: Switches on the lights in the operator's cab.

97

Outlet

For connecting electrical driven devices, e. g. for charging accumulators.

Operating voltage: 12 Volts.

Maximum power output : 120 Watts.

2-75

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-129:

2-76

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-129:) No.

Element

101

Push-button

(Free for options)

102

Push-button

Stick floating position (shovel attachment only)

Function Can be used as a push-to-speak button on a radio, or to switch over from one camera to another one.

Button is pressed: The stick cylinders are pressurized on retracting.

Symbol

Press button (102) only in position "0" of control lever (115).

103

Push-button

Boom floating position

Button is pressed: The boom cylinders are pressurized on retracting.

Press button (103) only in position "0" of control lever (116).

104 105

111 112 113 114 115

116

117 118

119

120

Push-button

Warning signal

Push-button inside the seat

Electronic hydraulic shovel control (servocontrol)

Pedal Pedal

Shovel trap (shovel attachment only) Travel, left track

Pedal

Travel, right track

Button is pressed: Acoustic warning signal / horn is activated.

Button in the seat.

The electronic hydraulic shovel control (servocontrol) is activated when the operators sits down on the seat.

The electronic hydraulic shovel control (servocontrol) is deactivated when he leaves the seat.

Forwards – shovel trap is opened; Backwards – shovel trap is closed.

Forwards – forward travel Backwards – backward travel.

Forwards – forward travel; Backwards – backward travel.

Footrest Control lever

Forwards – raising the stick Backwards – lowering the stick.

To the left / right – slewing and braking of the upper structure.

Forwards – lowering the boom; Backwards – raising the boom.

To the left – backwards tipping of shovel / bucket; To the right – dumping of shovel / bucket.

Not used on this machine.

Control lever

Push-button Thumb wheel

Push-button

Thumb wheel

Shovel trap (shovel attachment only)

Turn forwards – shovel trap is opened; Turn backwards – shovel trap is closed.

Function can be overridden with pedal 111.

(Thumb wheel is spring centered).

By-pass for the autoTo the left – automatically stopped stick- and/or matically switch off for backhoe cylinders can be driven slowly to the limit stick- and /or backhoe stopps. cylinders (Option) To the right – Each press on the button increments the loaded dumper count for by "1".

(Count reset with button (91)) Not used on this machine.

2-77

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-130:

2-78

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-130:)

Engine 1 (left) monitoring No.

Element

Function

121

Monitoring device

Engine monitoring Indicates different parameters on the display (engine 1 left) (E) Use push buttons (C and D) to scroll through parameter list.

Indicator lamps (A and B) lit when an active fault occurs.

122

Thermometer

Engine temperature (engine 1 left)

123

Pressure gauge

Engine oil pressure Indicates the oil pressure in the diesel en(engine 1 left) gine lubricating system.

124

Warning device

Engine monitoring (engine 1 left)

Symbol

Indicates the cooling-water temperature.

Gives an acoustic warning signal if a fault is reported, e.g.  Engine oil pressure too low, 

Engine temperature too high.

Lower the attachment to the ground and shut off engine immediately if the warning device (124) sounds. The warning device (124) continues to sound until the fault has been rectified.

Lits up when engine is in idle phase.

125

Indicator lamp

Idle (engine 1 left)

126

Warning lamp

Cooling water level Lits up when the cooling-water level is too (engine 1 left) low.

127

Warning lamp

Alternator (engine 1 left)

Lits up when the batteries are not recharged.

2-79

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-131:

2-80

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-131:)

Engine 2 (right) monitoring No.

Element

Function

131

Monitoring device

Engine monitoring Indicates different parameters on the display (engine 2 right) (E) Use push buttons (C and D) to scroll through parameter list.

Indicator lamps (A and B) lit when an active fault occurs.

132

Thermometer

Engine temperature (engine 2 right)

133

Pressure gauge

Engine oil pressure Indicates the oil pressure in the diesel en(engine 2 right) gine lubricating system.

134

Warning device

Engine monitoring (engine 2 right)

Symbol

Indicates the cooling-water temperature.

Gives an acoustic warning signal if a fault is reported, e.g.  Engine oil pressure too low, 

Engine temperature too high.

Lower the attachment to the ground and shut off engine immediately if the warning device (134) sounds. The warning device (134) continues to sound until the fault has been rectified.

Lits up when engine is in idle phase.

135

Indicator lamp

Idle (engine 2 right)

136

Warning lamp

Cooling water level Lits up when the cooling-water level is too (engine 2 right) low.

137

Warning lamp

Alternator (engine 2 right)

Lits up when the batteries are not recharged.

2-81

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-132:

2-82

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-132:)

Optional equipment: Auxiliary heating; Fuel Pre-Heating (Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

Nr. 140 141 142

143

144

Element

Function Auxiliary heating (option) Auxiliary heating blower (option) Auxiliary heating (option)

Auxiliary heating for operator's cab ON / OFF. Blower levels 1,2,3.

Switch

Fuel Pre-heating (option)

Switches the fuel pre-heating function of RH engine on and off.

Switch

Fuel Pre-heating (option)

Switches the fuel pre-heating function of LH engine on and off.

Switch Switch Switch

Symbol

Auxiliary heating for operator's cab ON / OFF. Automatic regulation.

2-83

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-133:

2-84

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-133:)

Optional equipment: Air conditioner (Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

No. 150 151 152

Element Rotary switch

Function Blower levels 1,2,3.

Knob

Blower of air conditioner Thermostat

Rotary switch

Selector

Selects the following functions: heating, cooling, ventilation, defrosting.

Symbol

Presetting of desired temperature.

2-85

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Fig. 2-134 :

2-86

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation (Fig. 2-134)

Optional equipment: Air filter monitoring (Depending on the options ordered with the machine, the described elements can be found on different positions on or near the control column).

No.

Element

Function

191

Underpressure Air filters (left engine 1, gauge outside)

192

Underpressure Air filters (left engine 1, gauge inside)

193

Underpressure Air filters (right engine gauge 2, inside)

194

Underpressure Air filters (right engine gauge 2, outside)

Indicates the underpressure in the air filters.

Underpressure must be less than 635 mm (25 inches) water column.

Otherwise clean / replace the filterelements.

Indicates the underpressure in the air filters.

Underpressure must be less than 635 mm (25 inches) water column.

Otherwise clean / replace the filterelements.

Indicates the underpressure in the air filters.

Underpressure must be less than 635 mm (25 inches) water column.

Otherwise clean / replace the filterelements.

Indicates the underpressure in the air filters.

Underpressure must be less than 635 mm (25 inches) water column.

Otherwise clean / replace the filterelements.

Symbol

2-87

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

2-88

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation PUTTING THE MACHINE INTO OPERATION

Reducing the operator's exposure to noise

Before daily start-up, carry out works in accordance with servicing plan T (see: Part 3 "Inspection and servicing").

All noise protection devices of the machine must be in place and fully functional when the machine is in operation. e.g.  doors, flaps and covers of the engine compartments must be closed,

Increased fire and explosion hazard will exist.

Prior to your daily start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

Electrical Storm Injury Prevention When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures:  Mount the machine. 

Dismount the machine.



access doors to the compartments of the radiator fans must not be left open,



the cab door must be closed,



the exhaust silencer must be checked for holes,



the bolted conections of all components fastend with bolts must be checked for tightness. Loose components tend to vibrate and to rattle, thus increasing the noise level.

Wear ear protectors when leaving the operator's cab with the engines on and running.

If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

2-89

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Refuelling Refuelling - Safety instructions Explosion hazard. Risk of fire.

Fuels and fuel gases are inflammable.

Avoid open flames and stop smoking.

Back-up heating (option), filling in fuel The fuel reservoir for the back-up heating system is located in the module below the operator’s cab (Fig. 2-135:).

Fill in clean fuel through the filler neck.

Fuel may cause skin injury. Wear protective gloves or use a barrier cream.

Stand attachment on the ground.

Shut off the engines.

Fuel is to be filled in using the service station (tanklift), see the following chapter "Service station (tanklift), Fuel Tank".

Do not spill fuel and do not allow fuel to penetrate into the soil. Fuel pollutes the environment.

Wipe off spilt fuel immediately with cleaning rags or soak up with binding agents.

Fuel and cleaning material must be disposed of without polluting the environment.

Report fuel accidents immediately to the owner of the machine or his representative.

Check the grounding straps (equipotential bonding) at the tank lift regularly for proper fastening.

Grounding straps can remove voltages and prevent fire during refuelling only when properly fastened.

Diesel fuel – recommendations Diesel fuel must meet the “Caterpillar Specification for Destillate Fuel” and the latest versions of “ASTM D975” (Nr. 1-D or Nr. 2-D fuel) or “EN 590” in order to ensure optimum engine performance.

Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for the latest fuel information and for Cat fuel specification. This manual may be found on the Web at www.safety.cat.com or contact your Cat dealer.

Failures that result from the use of improper fuels are not Caterpillar factory defects. Therefore the costs of repairs would not be covered by a Caterpillar warranty.

2-90

Fig. 2-135:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Service station (tanklift) The hydraulic shovel is equipped with a central service station (Fig. 2-136: resp. Fig. 2-137:) for refuelling. A service vehicle is needed for filling and/or draining of the fluids.

The service station is accessible from the ground below the upper structure.

Risk of injury. Always stay clear of the moving service station.

The service station is moved downwards and upwards by means of a hydraulic driven cylinder.

The up and down movement of the service station is initiated the switch (1, Fig. 2-137:). The switch is located in a control box at the hydraulic ladder (arrow).

To lower the service station:  Push momentary switch (1, Fig. 2-137:) downwards and hold until the service station is in its lower position.

Fig. 2-136:

To bring the service station in the upmost position:  Push switch (1) upwards. Service station is moved upwards until it reaches its upmost position.

With switch (1) in its middle position, movement of the service station is stopped.

Fig. 2-137:

2-91

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Express couplings are provided for refilling / draining the following consumables (fluids).

Note: Connections used may vary depending on how the machine is equipped.

Pos. Consumable Express couFig. pling for 2-138 : 1 Diesel fuel for lefthand Filling and righthand fuel tank Filling and/or 2 Cooling fluid for draining lefthand engine Filling and/or 3 Cooling fluid for draining righthand engine Filling and/or 4 Gearbox oil for left draining pump drive gearbox Filling and/or 5 Gearbox oil for right draining pump drive gearbox 6 Tank for engine oil Filling and/or change interval prodraining longation lefthand engine (if equipped) 7 Tank for engine oil Filling and/or change interval prodraining longation righthand engine (if equipped) 8 Engine oil for lefthand Filling and/or draining engine Filling and/or 9 Engine oil for draining righthand engine 10 Hydraulic oil tank Filling and/or draining 11 Grease container Filling 12 Swing gear Filling 13-15 Not used

Refilling and draining For filling in or for draining consumables / fluids, unscrew the cap of the corresponding express coupling (Fig. 2-138:).

Attach express coupling of filling hose from the service vehicle to the corresponding express coupling at the service station. Fill in or drain off consumable / fluid.

Take off filling hose and refit cap on the express coupling.

Emergency off switch The control box at the service station is equipped with an emergency off switch (Fig. 2-139:).

In case of emergency press the button. The electrical system is switched off.

Fig. 2-139:

Fig. 2-138:

2-92

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Assemblies resp. Measuring device reservoirs Fuel tank BCS fuel indicator (Fig. 2-140:)

Fig. 2-140:

Remarks Switch on the monitoring system by using toggle switch (23, Fig. 2-141:). The indicator light (22) comes on.

Fill in fuel using express coupling (1).

The indicator light (32) comes on when the LH fuel tank is full.

Stop filling when the fuel tank is full.

The indicator light (33) comes on when the RH fuel tank is full.

Stop filling when the fuel tank is full.

Switch off the monitoring system by using toggle switch (23), indicator light (22) is off.

Fig. 2-141:

2-93

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Assemblies resp. Measuring device reservoirs Pump drive gearDipstick (1, Fig. 2-142:) boxes

Engines

Dipstick (Fig. 2-144:)

Tank for engine oil Monitoring lamps (1 and 2, change interval Fig. 2-145:) prolongation (if equipped)

Remarks Fill in gear oil using express couplings (4 and 5, Fig. 2-143:).

Stop filling when the oil reaches the "max" mark on the dipstick (see: Part 3, chapter "Pump drive gearbox Checking the gearbox oil level/Filling in oil").

Fill in engine oil using express couplings (8 and 9, Fig. 2-145:).

Stop filling when the oil reaches the "max" mark on the dipstick (see: chapter "Engine - engine oil level/filling in oil").

Small amounts of oil can be filled in through the filler neck at the engine.

Fill in engine oil using express couplings (6 and 7, Fig. 2-145:).

Stop filling when monitoring lamps (1 and / or 2) lit up, (see: chapter "Engine , filling in oil").

Fig. 2-142:

Fig. 2-144:

Fig. 2-143:

Fig. 2-145:

2-94

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Assemblies resp. Measuring device reservoirs Hydraulic oil tank

Remarks

Checking the oil level: Inspection glass (1, Fig. 2-146:), signs (2, Fig. 2-146: Extend the piston rods of stick and bucket cylinders halfway. and Fig. 2-147:) Stand attachment on the ground.

Check oil level at an oil temperature of ca. 50 °C / 122°F, with the engines stationary.

Fill in oil through express coupling (10, Fig. 2-148:) when the oil level in the inspection glass has dropped below the "min" mark on sign (2).

Stop filling if the acoustic warning signal “Travel Alarm” sounds and oil reaches the "max" mark on sign (2) near the inspection glass (see: chapter "Hydraulic system Checking the hydraulic oil level / Refilling hydraulic oil").

Fig. 2-146: Fig. 2-148:

Fig. 2-147:

2-95

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

Assemblies resp. Measuring device reservoirs

Remarks

Cooling system reservoir

Fill in cooling fluid using express couplings (2 and/or 3, Fig. 2-151:). Stop filling when the level indicator indicates maximum filling level. (see: chapter "Cooling system - Cooling liquid").

BCS gives a warning if the grease container is nearly empty.

Switch on the display system with the toggle switch (23), indicator lamp (22) comes on.

Fill in grease using express coupling (11, Fig. 2-152:).

Stop filling when the grease container is full, the indicator lamp (34) lights up.

On completion of filling, switch the display system off again with the toggle switch (23), indicator lamp (22) is off.

Level indicator (4, Fig. 2-149:)

Grease container – BCS display (Fig. 2-150:) cental lubricating system

Fig. 2-149:

Fig. 2-151:

Fig. 2-150:

Fig. 2-152:

2-96

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Switching the electrical system on and off

Engines, emergency shut-off

If the electrical system cannot be switched on, check first whether the battery main switch is on (see chapter: "Battery isolator switch, shutting off supply voltage").

In an emergency, the engines can be stopped out of full load.

To do so:  Depress the emergency shut-off switch (35, Fig. 2-154:). The engines are stopped. (see chapter: "Emergency shut-off function").  Switch off the electrical system with key-switch (32).

Fig. 2-153:

Fig. 2-154:

The electrical system is switched on with keyswitch (32, Fig. 2-153:).  Insert key into key-switch and turn to the right.

2-97

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Preheating system for engine and hydraulic oil (optional) Preheating system for engine and hydraulic oil, function The preheating system consists of heating elements for engine oil, engine coolant and hydraulic oil.

At low outside temperatures, the system facilitates starting of the engine and ensures that the hydraulic system reaches its operating temperature faster.

The preheating system is operated electrically with an external supply voltage. This voltage is available at a socket outlet at the service-station (tanklift) (Fig. 2-155:).

(The system has been set at the factory for a standard supply of 400 volts, threephase AC. Other voltages are available on request as well as socket outlets meeting other standards).

Switch and pilot lamp are located at the switchgear cabinet in the engine module behind the hydraulic oil reservoir (Fig. 2-156:).

When the temperatures of the engine oil, engine coolant and the hydraulic oil are below -10°C / 14°F:  Connect the system to the external power supply.  Switch on the preheating system with switch (1, Fig. 2-156:).

The pilot lamp (2, Fig. 2-156:) lights up.  Switch off the preheating system with switch (1, Fig. 2-156:) when the engine and the hydraulic system have reached a temperature above 0°C / 32°F. The pilot lamp (2, Fig. 2-156:) goes out.  Switch on the fuel preheating system (see "Fuel preheating system (option)").

Switching the preheating system for engine and hydraulic oil on and off Risk of an electric shock.

Check first: Insulation of the socket outlet on the machine in good condition?

Insulation of the connecting cable in good condition?

Connect the system to the power supply only if the insulation of the components is in perfect condition.

Observe the national safety regulations to be applied in the presence of electric current.

Fig. 2-155:

Fig. 2-156:

2-98

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Fuel preheating system (optional) Fuel preheating system, function At temperatures below 0°C / 32°F, the paraffin particles contained in the diesel fuel begin to clump together. They form flakes which clog up the fuel lines and the filters. Starting of the engine is then no longer possible.

To prevent this, the diesel fuel must be preheated.

Preheating is effeceted by means of two heating elements in the fuel line. The heating elements are attached to the engines.

They are equipped with internal thermostats ensuring an automatic temperature regulation.

Switch on the fuel preheating only after preheating of the engine and of the hydraulic oil is terminated (see "Preheating system for engine and hydraulic oil (option)").

The preheating time is dependent on the outside temperature.

Fig. 2-157:

Switching the fuel preheating system on and off  Switch on the ignition by turning key-switch (32, Fig. 2-157:) to position 1.  At temperatures below 0°C / 32°F, switch on the fuel preheating: switch (144, Fig. 2-158:) for the lefthand engine, switch (143) for the righthand engine.

The pilot lamp located above the resp. switch lights up.

Fig. 2-158:

 After a short time start up the engines (see also "Starting and stopping the engines").  Switch off the fuel preheating with switches (143 and 144), when the engines has reached their operating temperatures.

The pilot lamp (Fig. 2-158:) goes out.

2-99

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation STARTING AND STOPPING THE ENGINES Starting the engines

Starting the left-hand engine

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Start and operate combustion engines only on well-ventilated premises. In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system an do not make any modifications to it.

All control levers and pedals must be in position "0".

Pull out all emergency shut-off switches.

Pull out both switches for the battery main switch.

Check for persons on the machine. Do not start engines until all persons have left the machine.

Activate the horn before you start the engines to give a warning signal to people around.

Start the engines one after another.

Fig. 2-159:

Starting the right-hand engine

 Switch on the electrical system with key-switch (32).

Warning lamps (44 – 47, Fig. 2-159:) and (54 – 57, Fig. 2-160:) light up.  Press button (41, Fig. 2-159:) to start the lefthand engine. Release button (41) as soon as the engine has fired.

Warning lamps (44 – 47) go out.  Press button (51, Fig. 2-160:) to start the righthand engine. Release button (51) as soon as the engine has fired.

Warning lamps (54 – 57) go out.

2-100

Fig. 2-160:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Repeat the starting procedure if one of the engines does not fire. Repeat starting procedure not more often than three to four times. Do not operate the starter for more than 10 seconds.

If warning lamps (44 – 47, Fig. 2-159:) or (54 – 57, Fig. 2-160:) do not go out or when the BCS (Fig. 2-161:) displays a fault message after starting, the engine concerned must be stopped immediately.

Locate the cause of the fault and rectify before restarting the engine.

Do not run engines at full load unless they have been allowed to run for at least 3 minutes at idling.

Starting the engines at low temperatures If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is bolted into an electro-mechanical metering valve. When the engine is started at temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Ether is toxic and highly inflammable. Safety instructions and information concerning the handling of pressure vessels for cold-starting fluids (ether) can be found in the following chapters: "Fundamental safety instructions", "Inspection and servicing - Safety instructions", "Cold-starting fluid (ether) - Replacing the pressure vessel".

Fig. 2-161:

Engines – adjusting the speed Adjust the speed of the left-hand engine with switch (48, Fig. 2-159:).

Adjust the speed of the right-hand engine with switch (58, Fig. 2-160:).  Press the switch face without symbol the engine speed is raised up to maximum speed.  Press the switch face with the symbol the engine speed is reduced to idling speed.

2-101

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Shutting off the engines

Shutting off the left-hand engine

During interruptions of the work and after the work, stand attachment on the ground.

Do not shut off the engines before the attachment rests on the ground.

Do not shut off the engine out of full load. The engine should be run at no more than one-half of the rated rpm for another 5 minutes to allow the lubricating oil and the cooling liquid to dissipate the combustion heat from the combustion chamber and from bearings and shafts.  Reduce the speed of the engines to idling by pressing the left side of the speed adjusting switches (48, Fig. 2-162:) and (58, Fig. 2-163:).  Press button (42, Fig. 2-162:) for the left-hand engine. The left-hand engine is stopped.

Warning lamps (44 – 47) light up.  Press button (52, Fig. 2-163:) for the righthand engine. The right-hand engine is stopped.

Warning lamps (54 – 57) light up.

Fig. 2-162:

Shutting off the right-hand engine

 Switch off the electrical system with key-switch (32).

Warning lamps (44 – 47, Fig. 2-162:) and (54 – 57, Fig. 2-163:) go out.

The engines will be shut off with a delay of a few seconds. During this time, the current operating data are saved and the electronic units shut down.

Fig. 2-163:

2-102

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation AIR CONDITIONER (OPTIONAL) Control unit (SIGMA dual)

Control unit

The air conditioning system (single or dual) is installed under the cab roof (Fig. 2-164:).

The illustration (Fig. 2-165:) shows a control unit for a dual air conditioner.

The control unit of a single air conditioning system contains the control elements only once.

Unit 1 Pos. Element 1 Rotary switch

Do not switch on the air conditioner when the backup heating is set to ”heating”.

(Fig. 2-165:)

2

Thermostat

3

Rotary switch

Unit 2 Pos. Element 4 Rotary switch 5

Thermostat

6

Rotary switch

Function selects the intensity level of the blower (3 levels) sets the desired temperature inside the cab selects the desired control function (heating, cooling, ventilation, defrosting)

Function selects the intensity level of the blower (3 levels) sets the desired temperature inside the cab selects the desired control function (heating, cooling, ventilation, defrosting)

Fig. 2-164:

Fig. 2-165:

2-103

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Back-up heating operator’s cab (optional) The back-up heating for the operator’s cab is located in the module below the operator’ cab (Fig. 2-166:). The heating consists of one or two heating units (1) and the fuel reservoir (2).

The outlets are behind the operator’s seat (Fig. XX). They are adjustable in several directions.  Switch on the back-up heating using switch (142, Fig. 2-167:). The pilot lamp above switch (142) lights up.

The heating system has an automatic regulation.

Do not switch on the back-up heating when the air conditioner is set to ”cooling”.

Fig. 2-166:

Fig. 2-167:

Fig. 2-168:

2-104

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Back-up heating (optional) The back-up heating is located in the module below the operator’ cab (Fig. 2-169:).

The outlets are below the operator’s seat (Fig. 2-170:). They are adjustable in several directions.

The heating system uses the engine cooling fluid.

Therefore full heating power is available after the engines reach their operating temperature.

Before switching on the blower, turn the valves (arrow, Fig. 2-169:) into direction of flow.

The back-up heating control elements are located at the control column unit (Fig. 2-171:).

Control unit (Fig. 2-171:):

Do not switch on the back-up heating when the air conditioner is set to ”cooling”.

Fig. 2-171:

Pos. Element

Fig. 2-169:

Function

1

Indicator lamp

heating ON

2

Indicator lamp

blower ON

3

Indicator lamp

heating

4

Indicator lamp

cooling

5

Switch

heating ON

6

Switch

blower ON

7

Indicator lamp

blower level 3

8

Indicator lamp

blower level 2

9

Indicator lamp

blower level 1

Fig. 2-170:

2-105

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Maximum Machine Inclinations The machine must not exceed the inclinations indicated for working, traveling and servicing operations and during downtimes. The values specified in the tables below are valid for all types of attachment.

If the maximum travel inclinations are exceeded there is a risk of machine movement from the travel parking brake. In extreme inclinations the machine has risk of toppling over or severe damage to the engines due to insufficient lubrication.

The working performance of the machine is especially economical when the machine stands on firm and level ground.

A loss of performance and higher wear must be accepted when the machine works in an inclined position, e.g. when building a ramp or when slewing uphill.

For the building of ramps, the values specified in the table "Maximum inclinations during working operations" may be exceeded. In this case, however, a reduced service life of the components can be expected.

During downtimes, the machine must be parked in such a way that its inclination does not exceed 3° / 5.4%.

Maximum machine inclinations during working operations:

Application of upper structure swing holding brake when machine is positioned above maximum working operation inclinations could result in unintended rotation of the upper structure. Failure to follow the warnings could result in personal injury or death.

forward inclination

rearward inclination

side inclination

5° / 8.7%

5° / 8.7%

5° / 8.7%

Maximum machine inclinations during traveling:

The travel inclination is limited by the functionality of the park brake system. Attempting to activate the park brake while exceeding these limitations could result in unintended machine motion and personal injury or death.

Type

Forward deg / %

Rearward deg / %

Side deg / %

6040

22° / 40.4%

22° / 40.4%

22° / 40.4%

Maximum machine inclinations during maintenance operations:

2-106

forward inclination

rearward inclination

side inclination

0° - 2° / 3.4%

0° - 2° / 3.4%

0° - 2° / 3.4%

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation

2-107

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation TRAVELING, SAFETY INSTRUCTIONS Have the attachment raised only so far as to permit the machine to be driven under overhead power lines without any risk.

Close the cab door.

If the machine is fitted with a safety belt for the operator, fasten the belt.

If the upper structure is turned by more than 90° from the BASIC POSITION, the hydraulic shovel travels in the opposite direction to that selected.

If the position of the upper structure in relation to the undercarriage is not exactly known, touch the accelerator lightly to see which direction the machine takes, before initiating the full traveling movement.

Never drive across slopes.

Take the utmost care on slippery, greasy ground.

Sound the horn to warn persons in the immediate vicinity before starting traveling.

Sound the horn and allow adequate time for bystanders to clear the area before moving the machine into a restricted visibility area. Follow local practices for your machine application. For more information refer to Operation and Maintenance Manual, "Restricted Visibility".

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

Fig. 2-173:

Running-in specifications for components of the crawler tracks: Prior to initial commissioning and/or after repair work, run in the idlers, track rollers and upper rollers as follow:  Raise the attachment (Fig. 2-172: and Fig. 2-173:)  Drive the hydraulic shovel in reverse approx. 50 m (164 ft).  Drive the hydraulic shovel in forwards approx. 50 m (164 ft).  Stop the hydraulic shovel.  Measure the temperature at each dler, track roller and upper roller with an infrared thermometer. (at a temperature of approx. 100° C (212°F) wait for idlers, track rollers and upper rollers to cool down).  Repeat this running-in procedure up to 10 times.  Check all idlers, track rollers and upper rollers for leaks.

The engines must be at operating temperature before being subjected to full load.

If the machine is to be driven a longer distance, the upper structure must be secured against turning by means of the upper structure holding brake.

Fig. 2-172:

2-108

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation TRAVELING

Traveling forwards/backwards

Upper structure basic position

Traveling forwards:  depress pedals (112 and 113) forwards.

Travel direction and sense of actuation of pedals (112 and 113, Fig. 2-175:) are identical only when the hydraulic shovel is in its BASIC POSITION (Fig. 2-174:).

The hydraulic shovel travels in the direction of the idler (2, Fig. 2-174:).

Traveling backwards:  depress pedals (112 and 113, Fig. 2-175:) backwards.

The hydraulic shovel travels in the direction of the drive sprocket (4, Fig. 2-174:).

During traveling, an acoustic warning signal sounds (Travel Alarm).

Fig. 2-174:

If the upper structure is swung out of its basic position by more than 90° (Fig. 2-176:), the hydraulic shovel moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-175:) are depressed.

Fig. 2-176:

The pedals return automatically to their "0" positions when released.

Reverse the hydraulic shovel only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

Do not travel across slopes.

Fig. 2-175:

If the operator is not completely sure of the position of the upper structure with regard to the undercarriage, pedals (112 and 113) should be depressed slightly in order to find out which way the hydraulic shovel moves before initiating the full traveling movement.

When traveling uphill or downhill, the travel drive must always be at the rear.

Travel only in the basic position of the hydraulic shovel and only forwards.

Be extremely careful on slippery and greasy ground.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

All instructions with regard to traveling speed regulation and travel direction control are applicable only as long as the crawler tracks have sufficient grip and do not slip.

2-109

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Regulating the traveling speed Traveling on level ground Regulate the traveling speed with  pedals (112 and 113, Fig. 2-177:) and  Switch (72, Fig. 2-178:) to the left (slow gear).

All forward/reverse travel movements are possible with this gear.  Switch (72, Fig. 2-178:) to the right (fast gear).

All forward/reverse travel movements are possible with this gear.

Change speed range only when the hydraulic shovel is stationary.

Press engine speed regulator switches (48 and 58) to the left (full-throttled position).

Fig. 2-178:

Traveling uphill and downhill Read and observe the "Traveling Safety instructions" chapter.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).  Depress padals (112 and 113, Fig. 2-177:) fully to the limit stop.  Regulate the travel speed only with the engines speed control.

Fig. 2-177:

When traveling downhill, the travel retarder valve acts as a speed limiter.

The travel retarder valve works correctly if pedals (112 and 113) are fully depressed down to the limit stop.

Should the traveling speed become too high when traveling downhill release pedals (112 and 113) to stop the hydraulic shovel.

2-110

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Cornering To take a right-hand corner forwards  depress only pedal (112, Fig. 2-179:) forwards.

Never use the attachment to raise one side of the undercarriage and then turn the undercarriage by initiating the swinging and/or the traveling function.

To take a lefthand corner forwards  depress only pedal (113) forwards.

Turning To turn to the right  depress pedal (112) forwards and pedal (113) backwards.

To turn to the left  depress pedal (113) forwards and pedal (112) backwards.

This way of working is contrary to the hydraulic shovel's designated use.

There is a risk of accident. Moreover, the tracks, swing gear, roller bearing swing ring, backhoe or bucket back-wall and the front part of the bucket are subjected to inadmissibly high stresses.

Fig. 2-180: Fig. 2-179:

Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-180:).

Cornering to the left: forwards from pos. 1 to pos. 2 backwards from pos. 2 to pos. 3 forwards from pos. 3 to pos. 4 The same procedure should be adopted if the hydraulic shovel is to be driven out of depressions (Fig. 2-181:): Cornering to the left from pos. 1 to pos. 2 Cornering to the right from pos. 2 to pos. 3

Fig. 2-181:

2-111

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Traveling over long distances Travel only forwards with the hydraulic shovel in its basic position.

Traveling backwards over longer distances could damage parts of the undercarriage.

Read and observe the "Traveling – Safety instructions" chapter.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

When traveling, pay attention to sufficient headroom, e. g. under cable bridges or high-tension cables.

Keep the loading or the backhoe bucket close to the ground. For a more uniform loading of the tracks, the attachment must, however, be kept at a steep angle (Fig. 2-182: / Fig. 2-183:).

Fig. 2-183:

Lower the attachment when traveling underneath obstacles.

If the attachment position must be changed:  stop the hydraulic shovel,  change the position,  continue to travel.

Track roller temperature After traveling for 15 minutes without interruption, stop the hydraulic shovel and check the temperature of the track rollers.

If the temperature does not exceed 70 °C (158 °F):  Continue traveling.

Fig. 2-182:

Face shovel attachment (Fig. 2-182:):  Fully extend boom cylinder (1).  Extend bucket cylinder 2.  Extend stick cylinder 3.  Retract bucket cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the attachment (Fig. 2-182:).

Backhoe bucket attachment (Fig. 2-183:):  Fully extend boom cylinder 1.  Retract backhoe cylinder 2.  Retract stick cylinder 3.  Extend backhoe cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the attachment shown in (Fig. 2-183:).

2-112

If the temperature is between 70 °C and 90 °C (158 °F and 194 °F):  Monitor the temperature of the track rollers.  Continue traveling but check temperature in short intervals.

In case of higher temperatures above 90 °C (194 °F):  Stop traveling.  Resume traveling only after the track rollers have cooled down to approx. 40° C (104°F).

Note: Do not walk beside the machine and try to cool down track rollers by hand with a bucket of water or with a water hose.

In principle it is possible to use a water truck to sprinkle water on the track rollers from a safe distance. This will rapidly cool down the track rollers.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Upper structure holding brake

Track parking brake

The hydraulic shovel is equipped with three upper structure holding brakes which are integrated in the swing gearboxes. The upper structure holding brakes lock the upper structure with respect to the under-carriage.

The gearbox brakes are holding brakes only.

The hydraulic shovel is equipped with four traveling gear brakes which are integrated in the travel drives.

The traveling gear brakes are parking brakes. They protect the hydraulic shovel from rolling for-wards or backwards. When the machine is parked, travel brakes are activated automatically. The brakes are deactivated during operation of the machine.

Note: As travel brakes are deactivated, machine could slightly move in direction of excavating during operation. Whenever loading operation is interrupted, stand attachment on the ground. This avoids slight movement of the machine and possible consequential damage of lowered ladder, in case ignition remains engaged.

Application of upper structure swing holding brake when machine is positioned above maximum working operation inclinations could result in unintended rotation of the upper structure. Failure to follow the warnings could result in personal injury or death. See Maximum Machine Inclinations section.

Note: Do not press the button unless the upper structure is stationary. Do not use this button while the upper structure is still in motion. Risk of damage to the brakes and the slewing gears.

Apply the holding brake:  When the hydraulic shovel is parked.  When traveling longer distances.  To apply the holding brakes, press switch (61, Fig. 2-184:).

Fig. 2-185:

Fig. 2-184:

For Service and Maintenance purposes the travelling gear brakes can also be applied with switch (63, Fig. 2-184:).

Actuate this switch only when the hydraulic shovel is stationary. Do not use this switch while the hydraulic shovel is still in motion. Risk of damage to the brakes and the travel gearboxes.

Press the switch face with the symbol (63): The parking brake is applied permanently. The hydraulic shovel cannot be moved.

For more detailed information refer to the Service Manual, chapters eight and nine.

2-113

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation TRANSPORTING THE MACHINE Transport - Safety instructions The machine must be loaded and transported only after all safety regulations have been observed and complied with.

Entrust loading and transporting of the machine to a company experienced in the transport of heavy equipment.

The responsability for loading and transporting lies with the transport company or their representative.

Remove oil, grease, soil, mud, snow, ice and other materials from the hydraulic shovel's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Secure the transport vehicle against rolling away.

Use only tying equipment of sufficient strength (the weights and dimensions of the hydraulic shovel are set out in the "Product Specification Sheet") which can be found in the annex.

Transport The dimensions and the service weight of the fully assembled hydraulic shovel do not allow the hydraulic shovel to be transported in an undismantled state on a low-bed trailer over public roads.

Therefore, the following components and modules must be dismantled beforehand.

Suspensions points as well as the center of gravity are marked on the modules (see example, Fig. 2-186:).

Dimensions and weights of the machines modules can be found in the annex, chapter “Technical Data” as well as in the “Service Manual”.

Fig. 2-186:

2-114

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation WORKING OPERATION - SAFETY INSTRUCTIONS Read the sections "Fundamental safety instructions" and "Operation, safety instructions" carefully and observe the instructions given in them.

Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life!

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements.

Sound the horn to warn persons in the immediate vicinity before starting work.

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk.

Ensure that the attachment has adequate clearance below overhead power lines and structures.

Trenches and working faces may give way. Keep well clear of them.

Do not operate the machine,  when several track rollers or upper rollers have been removed; 

when one or several slewing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Running-in instructions for hydraulic cylinders Compression of an oil/air compound in a hydraulic cylinder may result in detonations which might damage pistons and sealing rings.

Prior to initial commissioning and/or after repairs, run in the hydraulic cylinders as follows:  Start up the engines and run at low speed.

The pressure-limiting valve in the hydraulic system must not respond  In the first two working cycles, retract and extend the pistons of the hydraulic cylinders to max. ½ to ¾ (not to the limit stop).

Never change direction suddenly. The waiting time between changes of direction must be at least 4 seconds.  In the next eight working cycles, retract and extend the pistons of the hydraulic cylinders to the limit stop. The waiting time between changes of direction must be at least 4 seconds.  When all hydraulic cylinders have been run in, the hydraulic shovel can operate at a higher engine speed.

Warming up the hydraulic system At low temperatures, bring the engines down to moderate speed, then activate all hydraulic functions for about 10 minutes (bring to service temperature). For further instructions, see section „LUBRICANTS / CONSUMABLES“.

If the BCS indicates problems with the cooling liquid temperature, engine oil pressure, coolant level, alternator or hydraulic oil filter control (with hydraulic oil at service temperature) light up: Lower the attachment and shut off engines.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by CGM HMS GmbH as "unauthorized utilization".

CGM HMS GmbH refuses to assume the guarantee for damage and consequential damage caused by an abusive utilization of the machine.

2-115

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Avoid extreme positions of the attachment Parts of the attachment may damage the machine if they are moved into extreme positions (see illustrations Fig. 2-187 - Fig. 2-191).

Work carefully, avoiding extreme positions of this kind.

Fig. 2-189

Fig. 2-187

Fig. 2-190

Fig. 2-188

Fig. 2-191

2-116

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation WORKING OPERATION Before starting work Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded attachment for abt.

5 minutes.

This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts.

Warming up: At low outside temperatures it is necessary to run the hydraulic system up to operating temperature.

The temperatures at which warming up is necessary depend on the type of hydraulic oil used; see also "Oils for hydraulic systems".  Run the diesel engines at ca. 2/3 full speed and start to perform no-load working movements for abt. 10 minutes with the hydraulic shovel.

Activating the electronic hydraulic shovel control (pilot control) The hydraulic shovel can execute working movements only after the electronic hydraulic shovel control (pilot-control) has been activated.

The pilot-control block is enabled by switch (71, Fig. 2-192:).

At the beginning of the work, the electronic hydraulic shovel control (pilot-control) is activated by a contact in the operator's seat (105):  Electronic hydraulic shovel control ON The operator is sitting on his seat.  Elektronic hydraulic shovel control is OFF The operator's seat is empty.

Note: During operation it is absolutely necessary that the operator keeps sitting on his seat.

Otherwise working movements may be interrupted suddenly, risk of damaging the holding brakes and the gearboxes.

Fig. 2-192:

2-117

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Swinging the upperstructure Swinging of the upperstructure is only possible when:  the upperstructure holding brake is released and 

when the hydraulic shovel operator is sitting on his seat and



the hydraulic ladder is raised and



the service station (tanklift) is raised and



the BCS swing circuit test was successful.

 To swing the upperstructure to the right control lever to the right (115, Fig. 2-193:).  To swing the upperstructure to the left control lever to the left (115).

After releasing, the control lever returns automatically to position "0".

Releasing the control lever (115) is not sufficient to brake the upper structure automatically. In order to brake the upper structure, the control lever must be moved in the direction opposite the swing movement (reversing).

Fig. 2-193:

Braking the upper structure The upper structure can only be braked by moving control lever (115) in the direction opposite the swing movement (reversing).

The upper structure does not stop automatically by simply releasing the swing control lever (115).

To brake the upper structure, the swing control lever (115) must be moved in opposite direction.

In an emergency, activate the holding brake by pressing switch (61, Fig. 2-194:).

Fig. 2-194:

2-118

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Working operation When released, all control levers for working operation return automatically to position "0".

Sound the horn to warn persons in the immediate vicinity before starting work.

Wait until all persons have left the hazard zone before starting work.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

Level a surface only in the bucket's digging direction. Never "beat" or "sweep" with the bucket.

Do not level off a surface with the front shell of the face shovel open.

Close face shovel completely before beginning to dig.

Fig. 2-195:

Extending and retracting the shovel stick or backhoe stick  To extend the stick: push control lever (115, Fig. 2-195:) forwards.  To retract the stick: pull control lever (115) backwards.  To retract the stick with pressure: (only on face shovel attachment) depress button (102) and push control lever (115) backwards.

Opening and closing the face shovel  To open the face shovel: press pedal (111, Fig. 2-195:) forwards or press button (117) to the left.  To close the face shovel: press pedal (111) backwards or press button (117) to the right.

Raising and lowering the boom  To raise the boom: pull control lever (116, Fig. 2-196:) backwards.  To lower the boom: push control lever (116) forwards.  To lower the boom with pressure: depress button (103) and push control lever (116) forwards.

Fig. 2-196:

Filling and emptying the face shovel or the backhoe bucket  To fill/tip back the face shovel / backhoe bucket: shift control lever (116, Fig. 2-196:) to the left.  To empty the face shovel / backhoe bucket by dumping/tipping: shift control lever (116) to the right.

2-119

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation After daily operation Parking the machine  Park the machine on level and stable ground.

This is particularly important in winter to avoid freezing of the tracks.

Escaping oil pollutes the environment.

 Shift both control levers into all directions to depressurize the hydraulic cylinders.

Repair leaks immediately (or have them repaired).

Report oil accidents to the responsible person.  Check the upper structure, undercarriage and the attachment for damage and all steel components for cracks or fractures.

 Withdraw the key from the electrical system key-switch.

 Report detected damage immediately to the responsible person.

 Close the cab window.

 Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler.

 Stand the attachment on the ground.  Shut off the engines.

 Lock the cab door and all lockable hatches and covers on the machine.  Clean the machine of coarse dirt as well as of combustible and easily flammable substances, if possible with a stream jet (rubber parts and electric components with compressed air - refer to information label). Otherwise, the fire and explosion hazard will exist.  Fill up the fuel tanks.  Inspect the engines, the hydraulic system, the track rollers, upper rollers, idlers and gearboxes visually for leaks.

2-120

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation ASSEMBLING ATTACHMENT SAFETY INSTRUCTIONS Personel Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM HMS GmbH. The Operation and Maintenance Manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Personal protective equipment and working clothes Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear your personal protective equipment: a safety helmet, safety goggles, safety footwear and gloves.

Safety line on attachment When carrying out work on the attachment, f.ex. on the monobloc boom (Fig. 3-132:), use a fall arrester. Falling down from great hight may cause severe injuries. Connect the fall arrester to the safety line on the attachment. For example shown here on the monobloc boom (arrow, Fig. 3-132:).

Tools and auxiliaries Tools, hoists, slings, trestles and other devices must be in a reliable, safe state.

Metal splinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Use only the steps, platforms and handrails when climbing onto or off the machine.

Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing the attachment Stand attachment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Secure any attachment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out work on the attachment only if the machine is secured as described in the "Securing the machine" section.

Selecting the attachments The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the attachment and component combinations expressly approved by CGM HMS GmbH for this type of machine.

Never install and commission other attachment and component combinations without CGM HMS GmbH first having inspected and approved the project in writing.

Protective roof against falling objects The machine is equipped with an integrated cabprotection roof (FOPS).

Fig. 2-197:

2-121

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation Securing the machine Risk of injury The machine must not be started by unauthorized persons.

Therefore, secure the machine.

Observe the accident prevention regulations.

Depressurize pipeline systems, on which work is to be carried out, by appropriate measures.

Protective shrouds of moving machine parts may only be opened or removed when the drive unit is stationary and protected against inadvertent starting.

Before carrying out fitting works, the machine and the attachment must be protected against inadvertent starting by placing chocks under the tracks and by standing the attachment on the ground.

Hydraulic and lubricating systems: Close all open bores, pipe and hose connections with pressureresistant plugs.

Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of non re-usable oils without polluting the environment.

All components of CGM HMS GmbH machines have been carefully purpose-coordinated. Troublefree operation and a long service life can only be achieved with original CGM HMS GmbH spare parts.

Respect the sequence of working operations when fitting or replacing the attachments. The sequence has been determined and tested by qualified experts.

2-122

Secure the machine as described below:  before carrying out any fitting and modification work on the attachment, 

before carrying out any servicing and repair work on the machine.

 Park the machine on level and stable ground.  Stand the attachment on the ground.  Shut off the engines.  Depressurize the hydraulic system.  Withdraw the key from the key-switch.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) Use “GLEITMO 815” anti-corrosive agent only.

Other agents are not approved by CGM HMS. All pins and bearings (bushings and hubs) of the attachment or in attachment components must be treated “GLEITMO 815” anti-corrosive agent before fitting.

“GLEITMO 815” 

permits easy fitting and dismantling,



protects against rust, oxidation and similar wear,



prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminum and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden.

“GLEITMO 815” is available from CGM HMS Spare-Parts-Service, SAP part-no. 1519702.

Application of "GLEITMO 815"  Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel.

Rust patches must be thoroughly removed, if any.

All parts must present a dry, bright metal surface.  Apply a thin layer of "GLEITMO 815" on pins and all bearings using a brush or a spray can.

Pin shafts and bearings must be completely covered by the protective layer.

If the protective layer of a pin already treated with "GLEITMO 815" is damaged, these areas must be touched up before fitting the part.  Fitting and securing of pins.

If the pin is too heavy to be fitted manually, apply "GLEITMO 815" at first only on abt. a quarter of the pin's length.

Then position pin by means of a lifting gear ready for fitting.

Apply "GLEITMO 815" on the remaining length of pin shaft, fit pin and secure.

2-123

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation ON-BOARD CRANE (OPTIONAL) The on-board crane is designed for lifting heavy parts only.

Do not lift persons.

Observe all national directives as well as specific regulations relevant to crane operation.

On-board crane - monitoring, warning and control elements (Fig. 2-198:)

Personnel Crane work may be carried out only by operators who have the necessary know-how and the permission to operate cranes.

If such know-how or such permission is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM HMS. Incorrect operation of the crane may give rise to life-threatening situations.

Fig. 2-198:

Pos. Element 1 Monitoring lamp 2 Warning lamp 3 Warning lamp 4 Monitoring lamp 5 Key-switch 6 7

10 11 12

Button Monitoring lamp Knob Monitoring lamp Warning lamp Button Button

21

Control lever

22 23 24

Control lever Control lever Control lever

8 9

2-124

Function Alternator Engine oil pressure Engine temperature Air filter Electrical system ON/OFF Start engine of drive unit Preheating system (option) Engine speed variation Crane in operation Malfunction EMERGENCY STOP Emergency lowering of winch Extending and retracting of boom extension Folding the boom Swinging the boom Winch up / down

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation On-board crane - putting into operation Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

Do not exceed the maximum lifting capacity (observe the lift capacity chart attached to the boom).

On-board crane - drive unit The drive unit (Fig. 2-199:) supplies the crane with hydraulic power. So the on-board crane is functional without the shovel’s engines running.

The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

The drive unit is equipped with an Emergency OFF push switch (arrow, Fig. 2-199:).

In case of emergency push the switch, the engine of the drive unit comes to standstill.

Prior to each deployment: Carry out all maintenance work as listed in the “Inspection and Servicing Plans “T” and “W”.

To start the drive unit:  Turn key-switch (5, Fig. 2-198:) to position ON.  Press button (6), engine will start.

The crane control unit is equipped with an Emergency OFF push switch (11).

In case of emergency push the switch, the engine of the drive unit comes to standstill.

After finishing work block the boom, then stop the engine (see chapter “On-board crane, - blocking the boom in position of rest”).

Fig. 2-199:

2-125

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation On-Board crane – blocking the boom in position of rest Movements and accelerations produced by working operations of the machine can cause damage to the swing drive of the on-board crane, if the crane is not blocked.

The hydraulic on-board crane must therefore be blocked in its position of rest.

Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

To block the boom:  Retract the boom completely.  Swing the boom in the direction of the blocking device (Fig. 2-200:) and lower it.  Withdraw the cotter pin at the tip of the boom.  Extend the boom carefully until the tip engages the blocking device (arrow, Fig. 2-200:).  Reinsert and lock the the cotter pin.

Fig. 2-200:

2-126

On-board crane - checking Extract from the inspection and testing regulations The on-board crane is approved in accordance with the Accident Prevention Regulations for Cranes (BGV D6, applicable only in Germany).

The on-board crane must be inspected regularly in accordance with the regulations in force in the country of use.

The inspections must be requested by the user of the crane. The expert or specialist entrusted with the inspection can be appointed at the user's discretion.

The user must ensure, however, that the appointed person meets the requirements.

The user is obliged to make available all documents required for the inspection and to ensure the smooth running of the inspection. He is furthermore obliged to provide, if required, crane operators and auxiliary personnel and the required test loads.

The result of the inspection is to be documented in an inspection record signed by the inspector.

The inspection record serves as proof on the part of the user that the inspections have been carried out. The inspection record must contain all data required for crane identification and for the performance of further regular inspections.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation MONITORING CAMERAS (OPTIONAL) Monitoring cameras – function This hydraulic shovel can be equipped with two monitoring cameras:  one mounted on the counterweight, looking backwards;  one mounted on the hydraulic oil cooler module, looking to the right.

The two cameras and the belonging LCD-display are operational after the electrical system of the machine has been activated with the key operated switch.

The LCD-display is mounted near the control column (arrow, Fig. 2-167).

To switch the LCD-display on, press key “PWR” on the display housing.

Both cameras transmit their images to the same LCD-display.

For toggling between the camera images being displayed, press the key in the left joystick (arrow, Fig. 2-202:) or the resp. keys located below the LCD-display.

Additional information can be found in the manuals of the camera manufacturer (see Volume 5 of the Technical Documentation "Components").

Fig. 2-201:

Fig. 2-202:

2-127

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Operation NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

2-128

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing 3 INSPECTION AND SERVICING

Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

3-1

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

3-2

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing INSPECTION AND SERVICING SAFETY INSTRUCTIONS Operation and Maintenance Manual No inspection and servicing work must be carried out until the Operation and Maintenance Manual has been read and understood.

Pay special attention to: „Fundamental safety instructions" and all warnings and safety instructions attached to the machine.

The Operation and Maintenance Manual lists all jobs to be done. The descriptions of job sequences, however, provide only experienced personnel with the necessary instructions.

The Operation and Maintenance Manual must be kept with the machine at all times.

Securing the machine Carry out servicing work only if the machine is secured as described in the section "Securing the machine".

Climbing onto and off the machine Use only the ladders, steps, platforms and handrails provided when climbing onto or off the machine.

Always keep ladders, steps, platforms and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately.

Always maintain a three point contact with the steps and grab handles.

Always face the machine when climbing on and off.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

The necessary know-how can be acquired in a several day's instruction, e.g. by an CGM HMS GmbH mechanic or by attending an CGM HMS GmbH training course.

Checking the state of tools Use only fully functional, reliable tools.

Select the right tool for the job.

Wrenches of the wrong size, for example, may slip and cause injury.

Cleaning jobs Personal protective equipment and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

Securing the attachment Stand attachment on the ground in such a way that no movements can be made if mechanical or hydraulical connections become detached.

Secure any attachment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging / supporting devices to prevent them from moving, slipping or falling inadvertently.

Prior to commencing work, clean your working area, if necessary and possible, with a steam-jet (rubber parts and electric components with compressed air - refer to information label).

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spraywashed with steam-jet cleaners or highpressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

Use only lint-free cleaning rags when working on the hydraulic system or the engines.

Cleaning agents and solvents may give off harmful, readily flammable vapours. Never work with such agents except on well ventilated premises; never inhale the vapours and never smoke.

Prevent solvents and cleaning agents from coming into contact with your skin.

Wear gloves.

Observe the instructions on the packaging.

3-3

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Handling flammable liquids

Visible oil losses

When handling flammable liquids:  never smoke,

Have any visible leakage repaired immediately.

Escaping oil is an environmental hazard.

Soak up any oil that has escaped with a binding agent.

Sweep up binding agent and dispose of it separately from other waste.



keep away from unshielded light sources and naked flames,

Fuel and other consumables often have low flash points and are readily ignited. Never attempt to extinguish burning liquids with water.

Use:  dry powder, 

carbon dioxide or



foam extinguishers.

Water used for extinguishing purposes would vapourize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing hazards.

Notify the fire brigade.

Fastening and securing elements Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

Spare parts Use only the original spare parts of CGM HMS GmbH. They are the only ones to fulfill the technical specifications of the machine.

Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Never set foot withing reach of the emerging oil jet.

Avoid contact with the skin. Wear gloves and firm protective clothing.

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with warm soapy water and apply a barrier cream. Never use fuels or solvents for cleaning the skin.

If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

3-4

Relieving residual pressure in the hydraulic system Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with its attachments supported on the ground and its driving motors switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, the system must be depressurized: (do not leave the operator's seat)  Stand attachment on the ground,  Shut off the engines,  Move all control levers and pedals repeatedly into all directions.

Bolted connections, piping, hydraulic hoses Repair any leakage in the piping and hose system immediately.

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

If oil has penetrated into the skin, consult a doctor immediately.

Never repair damaged piping; always replace them.

Replace hydraulic hoses immediately on detecting any damage or moist areas.

Tighten leaking Screw plug s only when the system is depressurized.

Escaping oil is an environmental hazard.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Non-polluting disposal

Engine exhaust gases

Dispose of oils, greases, cooling liquids, detergents, solvents and oil-containing components, such as filters, cleaning rags, replaced wearing parts and unusable machine parts, without polluting the environment and separately from other waste.

Do not dispose of these substances together with household wastes.

Fill these substances into the containers provided for such purposes.

Like any other oil, also bio-degradable, "environmental-friendly" hydraulic oil must be disposed of separately.

Do not allow oils and oily wastes to penetrate into the soil or into water. They are an environmental hazard.

Used pressure vessels for cold-starting fluid (ether) must be disposed of properly. Contact the supplier with regard to disposal / return of the vessels.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine.

Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system and do not make any modifications to it;.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.



Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

Sealing elements After replacing parts or after opening housings replace seals.

Always use new seals and gaskets.

Clean sealing faces prior to assembly.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Handling batteries Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Batteries give off explosive gases.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Wear gloves, firm protective clothing and goggles / face protection shield when handling batteries.

If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Before working on the electrical system Before performing work on the electrical system where tools, spare parts, etc. can come into contact with electrical conductors or contacts, the battery must be disconnected.

Disconnect first the negative and then the positive terminal.

After the work: Reconnect first the positive and then the negative terminal.

3-5

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Handling of cold-starting fluid (ether)

Filters

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapours of escaping cold-starting fluid.

In contact with the skin, ether can cause frostbites and irritations. Avoid skin contact.

Wear suitable protective gloves and goggles.

Even apparently empty pressure vessels can still contain rests of ether and therefore explode if they are damaged or heated up above 49°C. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine.

Replace / clean all filter elements or filter cartridges within the specified periods.

All filters are coordinated carefully with the equipment. Original CGM HMS GmbH parts must be used to ensure smooth running and a long service life of the engine and the hydraulic units.



Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

Selecting oils and greases Use the recommended qualities only, matching viscosities with the temperature level.

3-6

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

After servicing To prevent corrosion, coat all bright metal parts with a grease film.

On completing work, re-install all protective devices.

Never start up the drive motors while work is being done on the machine.

Carry out performance tests with the machine.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

3-7

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

3-8

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing INSPECTION AND SERVICING PLANS - INSTRUCTIONS Intervals The inspection and Servicing plan lists all jobs which have to be done on the machine at regular intervals.

The individual inspection and Servicing plans are marked with letters providing a link between the operating hours (OH) recorded by the hours-run meter of the machine and the inspection and Servicing plans.

Plan

Do all jobs ....

The air filter must be serviced only if the BCS so indicates. Replace the filter elements after one year at the latest.

Oils / Greases For the specification of oils and greases to be used refer to the „LUBRICANTS / CONSUMABLES“ section.

The numerals mentioned in the "Oil / Grease" column in the inspection and Servicing plans have the following meaning:

V

...once prior to initial commissioning.

I

N

...after initial commissioning and during the running-in period (up to 100 OH).

Oils for combustion engines and compressors

II

Oils for hydraulic systems

IIIa, b

T

...every 10 OH or every working shift 1)

V

W

...every 60 OH or weekly .2

A

...after every 250 OH.

Cleaning jobs

B

...after every 500 OH.

C

...after every 1000 OH.

Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

D

...after every 5000 OH.

E

...after every 10000 OH.

OH = Bh = Operating hours

Change of engine oil The intervals stated for changing the engine oil apply to fuels with a sulphur content of  0.5% and a permanent ambient temperature down to –10° C (14 °F).

In case of higher sulphur content and/or a permanent ambient temperature of below –10° C (14 °F), shorter intervals are required.

If the engine oil change intervals are not reached within 6 months, the oil must be changed at least after 6 months.

2

Air-intake system

Oils for gearboxes Greases for bearings and swing rings

Components The maintenance intervals for components, e.g. engine and gearbox, are listed in the following CGM HMS GmbH maintenance schedules.

It is possible that the manufacturer's documentation for these components states intervals deviating from the above-mentioned intervals.

In such case, only the maintenance intervals specified by CGM HMS GmbH shall apply.

Whichever comes first.

3-9

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing C32 Engine Maintenance Interval Schedule – Notes Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals.

Products that operate in severe operating conditions may require more frequent maintenance.

Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals.

Note: The aftertreatment system can be expected to function properly for emissions durability period, as defined by regulation. All prescribed maintenance requirements must be followed.

Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

3-10

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan V Plan V - Once prior to initial commissioning Location

Servicing work

Engine Engine oil tank (if equipped) Cooling system Cooling liquid Fuel system Electrical system Battery

Check oil level Check oil level

Lighting Monitoring, warning and control elements

Board Control System (BCS) Swing system Hydraulic system Pressure accumulators - track tensioning system - hydraulic ladder - pilot system - engine-off attachment lowering - service station (tanklift) Hydraulic oil reservoir Hydraulic system Hydraulic cylinders

Pump drive gearbox and cooling system - Pre-chambers expansion reservoir Swing gearbox Travel gearbox - Pre-chamber / spur wheel section (Gearbox

Page 1 of 2 Quantity/ No. 2 2

Check level Fill in fuel

2

Check charge condition and liquid level (Not applicable when maintenance-free batteries build in) Check operation Check function of monitoring, warning and control elements Check emergency OFF function Check function Perform „Slew brake test“ (see chapter „Service- Slew brake test screen“)

6

Check, fill in the correct nitrogen pressure (see Service Manual, chapter 8)

Check oil level Check pressure (see Service Manual) Vent (see chapter “Venting hydraulic system“) Check function of working attachment and traveling movement Check oil level Check oil level Check oil level Check oil level Check oil level

1

2 2 3 2 2x1

PartNo. 2763213 only)

- Hydraulic motor chambers Swing ring internal gearing Undercarriage Track roller Upper roller Track tensioning system Idler

3

Check oil level Check grease filling

2x2

Check for leaks and free movement Check grease filling, fill in grease3 Check for leaks and free movement Check grease filling, fill in grease3 Check pressure (see Service Manual) Check for leaks and free movement

2x7 2x2 2 2

Valid for machines with automatic greasing system for the undercarriage

3-11

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan V – Once prior to initial commissioning Location Central lubricating system Grease container Greasing and pause cycles Level control Service – Station (tanklift) - Arm bearing grease nipple - Hydr. cylinder bearing grease nipple Air conditioner (optional) - Compressor - Refrigerant Hydraulic ladder - Lubricating points On-board crane (optional) - Fastening bolts - Bearings - Joint (column / boom) - Cylinder bearing - Swing ring Hydraulic oil reservoir

Crane drive engine - Battery

Escape ladder near operator’s cab - Locking device - Ladder Escape ladder at engine compartment (optional) Emergency escape device / seat (optional) - Harness holding device on cab roof Fall arrest static line on boom

All lines, fittings and connections All articutated joints and hinges

3-12

Servicing work

Check filling level Check setting Check function Check operation Lubricate Lubricate

Page 2 of 2 Quantity/ No.

1 2

Check oil level Check correct filling Lubricate Check for tightness Lubricate Lubricate Lubricate Lubricate Check oil level (see chapter: “On-Board Crane, drive unit“) Check oil level (see chapter: “On-Board Crane, drive unit“) Check liquid level For more detailed information see: "OnBoard Crane" documentation.

Check function Check function Check free movement Check function Check completeness and condition Check for tightness Check condition Check function Check proper fastening Inspect visually for leaks, wearing marks Lubricate

16 4 2 5 1 1

1

2

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan N Plan N – After initial commissioning and during the running-in period (up to 100 OH) (For the C32 engines up to the initial 500 Service Hours) Page 1 of 2 Location

Servicing work

Engine Belts Engine mounts

Check tension, check condition Inspect

when required: Air filter primary element Air filter secondary element Air filter precleaner

Clean / replace Replace Clean

Initial 250 service hours: Engine oil Engine oil filter

Change Change

Initial 500 service hours: Electronic unit injector Engine valve lash Engine valve rotators

Cooling system Cooling liquid Radiator bearing fastening bolts Hydraulic system Hydraulic oil cooler - Bearing fastening bolts Return-flow filter Magnetic rod Filter housing (cooling system) - Return-flow filter - Magnetic rod Pressure accumulators: – engine-off attachment lowering – hydraulic ladder – track tensioning system – pilot system – service station (tanklift) Pump drive gearbox and cooling system - Pre-chambers - Fastening bolts - Gearbox oil filter (cooling circuit)

4

Quantity/ No.

Inspect / adjust Check / adjust Inspect For more information on engine maintenance work contact your Cat dealer.

Carry out cooling liquid analysis after 250 OH (contact your Cat dealer) Check for tightness (see Service Manual)

Check for tightness (see Service Manual) Replace Clean Replace Clean Check function (see Service Manual)

Change oil Change oil Check for tightness (see Service Manual) Replace

7 1 2 2

24 2 x 54 2x1

see: “Refilling quantities – Oil“ table

3-13

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan N – After initial commissioning and during the running-in period (up to 100 OH) Page 2 of 2 Location

Servicing work

Swing gearbox - Fastening bolts Travel gearbox - Pre-chamber / spur wheel section (Gearbox

Change oil Check for tightness (see Service Manual) Change oil Change oil

Quantity/ No. 35 25 2x15

PartNo. 2763213 only)

- Hydraulic motor chambers - Fastening bolts Swing ring Fastening bolts (swing ring, undercarriage and upper structure) Upper structure Fastening bolts, especially at upper structure / pedestal / operator´s cab All lines, fittings and connections

5

see: “Refilling quantities – Oil“ table

3-14

Change oil Check for tightness (see Service Manual) Check for tightness (see Service Manual)

Check for tightness (see Service Manual) Inspect visually for leaks, wearing marks

2x25

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan T and W Plan T – Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Page 1 of 3 Location

Servicing work

Hydraulic shovel

Visual check / overall cleaning

Quantity/ No.

Plan T

Plan W 

2





Undercarriage - Tracks

Inspect track tension visually

- Track roller

Check for leaks and free movement

2x7



- Upper roller

Check for leaks and free movement

2x2



- Idler

Check for leaks and free movement

2



Service station (tanklift)

Inspect visually for leaks and damages

Travel gearbox

Check for leaks





2





2x1













Face shovel - Clam cylinder chambers

Inspect, remove all accumulated debris, rocks, soil and so on.

- Mechanical stops on face shovels rearwall and stick

Check for wear

All lines, fittings and connections Inspect visually for leaks, wearing marks Engine

Check oil level

2





Walk-around inspection

2

















- Belts

Inspect / replace

- Engine oil tank (if equipped)

Check oil level

- Engine monitoring (Board Control System)

2

Check monitoring lamps and BCS display for fault messages

Cooling system - Cooling fluid

Check level

2





- Radiator

Check / clean

2





- Fuel filter

Drain off water

2x2





- Water trap (optional)

Drain off water

2x1





- Fuel tanks

Drain off water and sediment if necessary

2





Air-intake system

Check BCS – indication

1

Intake and clean-air lines

Check for tightness and leaks

Fuel system

 

-

Dust trap

Remove dust

4x1





-

Cyclon prefilter

Check, remove dust

4x1





3-15

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Page 2 of 3 Location

Servicing work

Hydraulic system

Check function of working and travelling movement

Quantity/ No.

Plan T

Plan W



 

Inspect visually for leaks - Hydraulic oil reservoir

Check oil level

1

- Oil cooler

Check / clean

2

- Fan wheel

Check condition

2

Pump drive gearbox and cooling system

Check oil level

2

- pre-chambers expansion reservoir

Check oil level

- Oil filter (tell-tale)

Check

Swing gearbox

Check oil level

2



 

 



 

2x1 3







Central lubricating system - Grease container

Check filling level





- Lubricating points

Check visually





On-board crane (optional) 6 - Fastening bolts

Check for tightness

16

- Crane drive engine

Check oil level

1



(see: “Crane drive Engine“ operating instructions) Hydraulic oil reservoir

Check oil level

1

- Reflow filter (contamination indicator)

Check

1

Reservoirs for used grease at the A-frame

Check, depollute used grease

2

Fire extinguisher (if equipped)

Inspect





Escape ladder near operator’s cab - Locking device - Ladder

Check function Check function Check free movement

  

  

6 Before each deployment of the crane

3-16



EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Page 3 of 3 Location

Servicing work

Escape ladder at engine compartment (optional) - Locking device - Ladder

Quantity/ No.

Plan T

Plan W

Check function Check function Check free movement

  

  

Emergency escape device / seat (optional) - Harness holding device on cab roof

Check completeness and condition





Check for tightness





Fall arrest static line on the attachment

Check condition





Check proper fastening





Check function





Operator’s cab - Window panes - Mirrors - Cameras (if equipped) - ROPS structure - Operator’s seat belt - Trainer’s seat belt

Clean Check/Clean/Adjust Check/Clean/Adjust Inspect for damage Check condition Check condition

     

     

Monitoring, warning and control elements

Check function of monitoring, warning and control elements





Board Control System (BCS)

Check function





- Lighting

Check operation





- Horn

Test





- Travel Alarm

Test





- EMERGENCY OFF button

Check function





Electrical system

6

- CAN-BUS wiring connections

Inspect



- Switchgear cabinet breather filter dust trap

Remove dust



Air conditioner (optional)

Carry out all servicing work, see “Air Conditioning manual“



Automatic fire-extinguishing system (if equipped)

Inspect





3-17

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

3-18

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan A – E Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location Servicing in acc. with W or T Monitoring, warning and control elements - Joystick - Control spool - Pedal - Control spool (machine with loading shovel) - Control spool (machine with backhoe bucket) Operator’s cab - Fastening bolts to cab module Operator’s seat belt Trainer’s seat belt

7

Servicing work

Quant. / Nos.

Page 1 of 7 Plan Plan Plan Plan Plan A B C D E     

grease lightly

2x47







grease lightly

3x27







grease lightly

2x27













Check for tightness (see „Service Manual“ for tightening torque) Replace within 3 years of the date of installation Replace within 3 years of the date of installation

apply a thin layer of low temperature grease

3-19

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location Servicing in acc. with plans W or T Engine Every 250 Service Hours: Engine oil Engine oil and filter

Servicing work

Carry out oil analysis (see: Engine oil service interval table) Change – severe duty (see: Engine oil service interval table)

Every 500 Service Hours or 3 months: Belts Inspect / replace Engine crankcase breather Clean Engine oil and filter Change (see: Engine oil service

Quant. / No.

Page 2 of 7 Plan Plan Plan Plan Plan A B C D E     

2x1



28

 

27

interval table)

Fuel system primary filter (water separator) Fuel system secondary filter Engine Engine mounts - Fastening bolts - Rubber bearing

Replace Replace Clean Inspect Check tightness Check condition

Every 4000 Service Hours or 2 years: Electronic unit injector Inspect / adjust Engine valve lash Check / adjust Engine valve rotators Inspect Every 6000 Service Hours or 4 years: Cooling system water tem- Replace perature regulator Every 851,625l (225,000 US gal) of fuel - TLD prefix: Every 755,000l (200,000 US gal) of fuel - TZB prefix: Engine components

Rebuild / install / reman

Every 1,703,250l (450,000 US gal) of fuel - TLD prefix: Every 1,514,000l (400,000 US gal) of fuel - TZB prefix: Engine components Overhaul: Overhaul considerations

8

Clean / inspect, rebuild / install / reman, install new For more information on engine maintenance work contact your Cat dealer.

see: “Refilling quantities – Oil“ table

3-20

 

   

   

   

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Page 3 of 7

Location

Servicing work

Cooling system Radiator - Fastening bolts - Rubber bearing Cooling liquid ELC (contact your Cat dealer)

Inspect visually for leaks Clean Check tightness Check condition Carry out cooling liquid analysis (after 1 year at the latest) Change Check Check for leaks Inspect / Replace Check tightness

Anti-freeze Lines Hose clamps Fuel system Fuel lines, grommets and mounting hardware Fuel filter Primary fuel filter Water trap (optional) Air-intake system Main filter element Secondary filter element Air-intake line and clean-air line Intercooler Hoses Electrical system Battery cable connections Battery

Switchgear cabinet breather filter Horn

9

Quant. / Nos.

Plan Plan Plan Plan Plan A B C D E  

 

    

    

 

 







    









  

  

  

  

  

  

  

 19



Inspect Replace Replace Clean

2x1 2x1 2x1

Check / replace Replace Check for tightness and leaks

2 x 2 10 2 x 2 11

  

    

Check / Clean Replace







 

 

Check for tightness Check fluid level (not applicable when maintenance-free batteries are installed) Clean

 6

 

 

 

 

1









 

 

Replace Inspect / Replace

1

Cooling-liquid (ELC) replacement after 12000 OH or after six years at the latest

10

Replacement of main filter element after one year resp. after 3 cleaning cycles

11

Replacement of secondary filter element after one year resp. after 3 cleaning cycles of the main filter element at the latest 3-21

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

Hydraulic system

Check pressure (see: Service Manual)

Oil cooler - Bearing - Fastening bolt - Rubber bearing Return-flow filter - O-Ring in press ring High-pressure filter

Magnetic rod

Check for tightness Check condition Replace Replace Check for contamination and damage/ clean Replace Check / clean

Bypass valve (working circuit) Check / clean filter sieve Filter housing (cooling system) - Return-flow filter - Bypass valve - Magnetic rod Filter (pilot control circuit)

Filter (control circuit)

Filter (auxiliary control circuit)

Filter (swing pump feed circ.)

Breather filter Hydraulic oil reservoir Pressure accumulators Cylinder (seals and guide rings)

12

Replace Check sieve / clean Check / clean Check for contamination and damage Replace Check for contamination and damage Replace Check for contamination and damage Replace Check / clean Replace Replace Carry out oil analysis Change oil Check pressure (see: Service Manual) Replace

Quant. / Nos.

Page 4 of 7 Plan Plan Plan Plan Plan A B C D E   

7 7

   

   

   

4







4 1



 

 

4







2 2 2 2x1

   

   

   



 

 



 

 

    

      

1 1 1 1 1 2x2 2x2 2 1 12 13 1









see: “Refilling quantities – Oil“ table Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

13

3-22

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

Pump drive gearbox and cooling circuit

Carry out oil analysis

- Breather filter - Pre-chamber - Breather filter Fastening bolts Oil filter

Swing gearbox - Breather filter Travel gearbox

- Magnetic plug Pre-chamber / spur wheel section (PartNo. 2763213 only) - Magnetic plug Hydraulic motor chambers Breather filter

14

Quant. / Nos. 2

Change oil Clean Replace Change oil Clean Check for tightness Check for contamination and damage Replace Carry out oil analysis Change oil Replace Carry out oil analysis Check oil level Change oil Clean Check oil level

2 14 2x1 2x1 2x5 2x1

Change oil Clean Check oil level Change oil Replace

2 x 1 14 2x2 2x2 2 x 2 14 2x1

Page 5 of 7 Plan Plan Plan Plan Plan A B C D E    





2x1 2x1 3 3 14 3x1 2 2 2 14 2x6 2x1

 

 

   

   

      

        

        

    

    



 

 

 



 



 

see: “Refilling quantities – Oil“ table

3-23

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

Swing ring Gearing / pinion Fastening bolts (swing ring, undercarriage and upper structure)

Check grease filling Check condition Check for tightness (see Service Manual)

Undercarriage

- Diaphragm

Check wear (see Service Manual) Check pressure (see Service Manual) Replace

Central lubricating system

Check function

Oilfilter (hydraulic circuit grease pump)

Check for contamination and damage Replace Check for contamination and damage Replace Check for contamination and damage Replace Replace

1

- Air suction, filter mat

Carry out all maintenance work accord. to manufacturers manual.

Clean, replace if damaged

3

- Fan motors brushes

Inspect / Replace

Diaphragm accumulator

Grease filter (filling grease container) Grease filter (grease lines)

Breather filter Air conditioner (optional)

Quant. / Nos. 1

Page 6 of 7 Plan Plan Plan Plan Plan A B C D E          























1







1 1



 

 

1 2



 

 

 

 























2 2 

2 1

Hydraulic ladder - Greasing points

Lubricate

Service – Station (tanklift)

Check function

- Arm bearing grease nippel

Lubricate

1







- Hydr. cylinder bearing

Lubricate

2







3-24

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location On-board crane (Option) 15 - Bearing - Joint (column / boom) – Cylinder bearing – Swing ring Hydraulic system – Return-flow filter – Breather filter

Crane drive engine - Oil filter – Fastening bolts – Fuel filter – Air filter – Battery cable connection

Steel components

Attachment - boom - stick Modules – Fastening bolts All articulated joints and hinges

Servicing work

Lubricate Lubricate Lubricate Lubricate Change oil Replace Replace see: “On-Board Crane“ operating instructions Clean Change oil Replace Check for tightness Replace Replace Check for tightness see “Crane Drive Engine“ operating instructions Visual inspection acc. to "Structural Inspection Report every 500 OH" 17 If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonic test.

Quant. / Nos.

Page 7 of 7 Plan Plan Plan Plan Plan A B C D E

4 2 5 1 1 16 1 1 



































Check welding seams Check welding seams

 

 

 

Check for tightness Lubricate

 

 

 

1 1 16 1 1 1 1 2

15

Do all servicing jobs at least once a year and when necessary see: “Refilling quantities – Oil“ table 17 "Structural Inspection Reports" for inspections every 500 OH can be downloaded from the SIS-Web 2.0, 16

Media-ID-No. M0133693.

3-25

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing LUBRICATING CHART – GREASE

Fig. 3-1:

3-26

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Lubricating chart – Grease (legend) No. Greasing point 1 3

Central lubricating system – grease container Track roller (Option)

4 5

Hydraulic ladder (optional) On-board crane

6

Lubricant properties

1 2x7

V 18 Tribol CGM HMS GmbH SAP part no.

1521949

Grease every .... operating hours 10 1000

V 18

1000 250

V 18

250 250

- Bearing - Joint (column / boom)

4 2

- Cylinder bearing

5

- Swing ring

1

Graphitespray

250

2 x 4 19 3 x 2 19

V 18

1000 1000

1 2

V 18

1000 1000

250

Monitoring, warning and control elements - Joystick - Pedal

7

Number

Servicestation (tanklift) - Arm bearing - Hydraulic cylinder bearing

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities - Grease Greasing point Central lubricating system – grease container (different containers available) Internal gearing – Roller-bearing swing ring Idler (permanent grease filling) Track rollers (permanent grease filling) (Not in use when connected to the optional undercarriage greasing system) Upper rollers (permanent grease filling)

18

see: „LUBRICANTS / CONSUMABLES“ section.

19

apply a thin layer of low temperature grease

Lubricant properties

Filling quant. in kg lb appr. 1000

appr. 2205

appr. 300 2 x appr. 25

appr. 662 2 x appr. 55

14 x appr.

15

14 x appr.

33

4 x appr. 14

4 x appr. 31

V 18

Tribol CGM HMS GmbH SAP part no. 1521949

3-27

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-2:

3-28

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Inspection plan – Oil (legend)

1

Engine

2

I

Check oil level every ... OH 10

2

Engine oil reservoir (if equipped)

2

I

10

See Engine Oil Service Interval Table with ReserveTM Oil Tank

3

Hydraulic system

1

10

10000 21

4

Pump drive gearbox

2

II III.a

60

1000

10

1000

10

1000

500

5000

500

5000

500

5000

10

250 22

10

1000 23

No. Location

Lubricant properties 20

- Pre-chambers

2x1

5

Swing gearbox

3

6

Travel gearbox

2

7

20

Number

- Pre-chamber / spur wheel section (PartNo. 2763213 only)

2x1

- Hydraulic motor chambers

2x2

III.b III.a

Change oil every ... OH See Engine Oil Service Interval Table

On-board crane (optional) - Crane drive engine

1

- Hydraulic oil reservoir

1

I II

see: „LUBRICANTS / CONSUMABLES“ section

21

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

22

Change oil at least once a year.

23

Change hydraulic oil at least once a year.

3-29

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine oil service interval table

Engine Oil Service Interval

Engine Oil Change Interval Operating Conditions Severe Multigrade Oil Type

CAT DEO Preferred

Initial

Normal

250 hr

250 hr

Fuel Sulfur >0.3%

Altitude >6000ft (1830m)

500 hr

250 hr

250 hr

250 hr

125 hr

125 hr

ECF-2 Preferred ECF-1-a

A 500 hour engine oil change interval is achievable provided that normal operating conditions are met, recommended multigrade oil types are used, and an S·O·S oil sampling analysis program is utilized.

Normal operating conditions include altitude below 6000 ft and fuel sulfur levels below 0.3%. When these requirements are not met, shorten the oil change interval and use an S·O·S Services oil sampling and analysis program to determine an acceptable change interval. For assistance with optimizing oil change intervals, contact your local CAT dealer.

For sulfur content above 0.1% refer to SEBU6250 Caterpillar Machine Fluid Recommendations.

3-30

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine oil service interval table with ReserveTM Oil Tank (if equipped)

Engine Oil Service Interval – ReserveTM Oil Tank (if equipped)

Engine Oil Change Interval Operating Conditions Severe Multigrade Oil Type

Initial

Normal

500 hr

500 hr

Fuel Sulfur >0.3%

Altitude >6000ft (1830m)

1000 hr

500 hr

500 hr

500 hr

250 hr

250 hr

CAT DEO Preferred ECF-2 Preferred ECF-1-a

A 1000 hour engine oil change interval is achievable provided that normal operating conditions are met, recommended multigrade oil types are used, and an S·O·S oil sampling analysis program is utilized.

Normal operating conditions include altitude below 6000 ft and fuel sulfur levels below 0.3%. When these requirements are not met, shorten the oil change interval and use an S·O·S Services oil sampling and analysis program to determine an acceptable change interval. For assistance with optimizing oil change intervals, contact your local CAT dealer.

For sulfur content above 0.1% refer to SEBU6250 Caterpillar Machine Fluid Recommendations.

3-31

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Filling quantities - oil Location Engine (with filter changed)

Filling quantity liters gal 2 x approx. 114 2 x approx. 30.1

Engine oil tank (if equipped)

2 x approx. 430

2 x approx. 113.6

Hydraulic oil reservoir Hydraulic system

approx. 3400 approx. 5800

approx. 898 approx. 1532

Pump drive gearbox

2 x approx. 55

2 x approx. 14.5

- Pre-chambers (working pumps)

4 x approx. 1,4

4 x approx. 0.37

- Pre-chambers (hydraulic pumps)

4 x approx. 0.2

4 x approx. 0.05

- Pre-chambers (cooling pumps)

2 x approx. 0.4

2 x approx. 0.1

Swing gearbox

3 x approx. 38

3 x approx. 10

Travel gearbox (PartNo. 2763213)

2 x approx. 85

2 x approx. 22.5

- Pre-chamber / spur wheel section

2 x approx. 8.5

2 x approx. 2.25

- Hydraulic motors chambers

4 x approx. 0,5

4 x approx. 0.13

Travel gearbox (PartNo. 614-2403)

2 x approx. 110

2 x approx. 29

- Hydraulic motors chambers

4 x approx. 0,75

4 x approx. 0.2

- Crane drive engine

approx. 5,5

approx. 1.45

- Hydraulic oil reservoir

approx. 50

approx. 13.2

Oil

I I II III.a III.b III.a III.a

On-board crane (optional)

I II

Filling quantities – other Location

Filling quantity liters

Cooling system - engine

gal

2 x approx. 220 2 x approx. 58.1

Fuel tank

2 x approx.

3900

2 x approx.

1030

Fuel tank, crane drive engine (optional)

approx. 20

approx. 5.3

Screen washer

approx. 13

approx. 3.4

3-32

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing LUBRICANTS / CONSUMABLES Notes on the selection of oils and greases Original CGM HMS GmbH oils and greases Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies.

The lubricants tables in the CGM HMS GmbH Operation and Maintenance Manual contain specifications for the oils and greases that are approved for use in CGM HMS GmbH machines. These oils and greases are especially adapted to CGM HMS GmbH machines and their units and assemblies.

Other oils and greases which do not fulfil the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies.

For this reason, CGM HMS GmbH only approves the use of the specified oils and greases.

All other qualities are not approved.

Alternative oils and greases The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the CGM HMS GmbH Operation and Maintenance Manual.

In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with CGM HMS GmbH specifications, CGM HMS GmbH does not assume any responsibility and does not accept any warranty claims.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with CM Long Term Hydraulic Fluid HSS (SAP Part-No. 1526545). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the CM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the CM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-33

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

I.

Fig. 3-3:

3-34

Oils for combustion engines

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

II.

Fluids for hydraulic system

Fig. 3-4:

3-35

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

III.a Oils for pump drive gearboxes and travel gearboxes

Fig. 3-5:

3-36

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

III.b Oil for swing gearboxes

Fig. 3-6:

3-37

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing V. Grease for bearings, slew rings and track system (Central lubrication system)

Fig. 3-7:

3-38

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Grease for idlers, track rollers and upper rollers (Lifetime lubrication)

Fig. 3-8:

3-39

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Coolant for use on all combustion engines

Fig. 3-9:

3-40

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing SERVICING WORK Hose line for oil and cooling liquid changes Collect escaping oil and cooling liquid and discard without polluting the environment.

The engines, the hydraulic oil reservoir, the pump drive gearboxes, the swing gearboxes and the radiators (engine cooling liquid) can moreover be equipped with automatic drain valves (1, Fig. 3-11:).

These automatic drain valves permit oil- and cooling-liquid changes without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more easily.

Filling and draining can be done by means of a hose through the service station (tanklift) (Fig. 3-10:).

For filling and draining, a flexible hose is connected to the express coupling on the service station and to the service vehicle at the other end.

The filling operations require an overpressure, whereas the draining operations require low pressure.

Fig. 3-11:

Change oil or cooling liquid as follows:  Place a collecting recipient for used oil or cooling liquid under the corresponding automatic drain valve. For the recipient capacity refer to the "Refilling quantities - Oil" table or to the "Refilling quantities - Other" table.  Unscrew protective cap from automatic drain valve.  Bolt on hose line (2) to open the valve, so that the oil or the cooling liquid can flow out.  When the oil or the cooling liquid has drained away, unscrew hose line to allow the valve to close automatically.  Bolt protective cap back in place.

Fig. 3-10:

3-41

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing ENGINE Engine - Safety instructions Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system an do not make any modifications to it.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Read and observe: "Inspection and Servicing – Safety Instructions" and the engine operating instructions.

Risk of injury from hot or rotating parts of the engine.

Shut off engines and allow to cool down.

Secure the machine as described in the "Securing the machine" section.

Skin contact with cooling liquid is a potential health hazard.

Protect the skin from potentially harmful contact with engine oil.

Wear protective gloves and firm working clothing.

3-42

Attention, Ether!

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Secure the machine as described in section “Securing the machine” before starting Inspection and Servicing.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged.

Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Walk-Around Inspection



Inspect the lubrication system for leaks at the following locations: front crankshaft seal, rear crankshaft seal, oil pan, oil filters, valve cover, turbocharger, external oil lines and connections.



Inspect the fuel system for leaks. Look for loose fuel line clamps or connections.



Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps or connections.



Ensure that the exhaust system is properly clamped. Ensure that the connections are tight. Check for leaks. Check the condition of all connections and components of the exhaust system.



Inspect the alternator belt and the accessory drive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break.



Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system.



Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires.



Inspect the ground strap for a good connection and for good condition.



Inspect the engine-to-frame ground strap for a good connection and for good condition.



Disconnect any battery chargers that are not protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery.



Check the condition of the gauges. Replace any gauges which are cracked. Replace any gauges that can not be calibrated.

Inspect the Engine for Leaks and for Loose Connections A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks, coolant leaks, exhaust leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:  The guards must be in the proper place. Repair damaged guards or replace missing guards. 

Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination.

Note: For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.

Note: Accumulated grease and/or oil on an engine or deck is a fire hazard. Remove this debris with steam cleaning or high pressure water.

Note: Use care when you use steam cleaning. Use care when you use high pressure water. Direct spray to rotating electrics or electronic components can cause nonfixable damage.

Note: Water and/or condensation can cause damage to electrical components. Protect all electrical components from exposure to water.  Ensure that the coolant lines are properly clamped. Ensure that the fittings are tight.

Check for leaks. Check the condition of all pipes. 

Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract.

Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of water pump and the installation of water pump and/or seals, refer to the Service Manual for the engine or consult your Caterpillar dealer.

3-43

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Belts - Inspect/Replace Belt tension should be checked initially during the first 100 hours of engine operation (refer to the Inspection and Servicing Plan N in this Operation and Maintenance Manual).

To maximize the engine performance, inspect the belts for wear and for cracking. Replace belts that are worn or damaged.

For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break.

If the belts are too loose, vibration causes unnecessary wear on the belts and pulleys. Loose belts may slip enough to cause overheating.

If the belts are too tight, unnecessary stresses are placed on the pulley bearings and on the belts.

This may shorten the service life of the components.

Remove the belt guard. Inspect the condition and adjustment of the alternator belts and accessory drive belts (if equipped). To check the belt tension, apply 110 N (25 lb ft) of force midway between the pulleys. A correctly adjusted belt will deflect 9 mm (0.35 inch) to 15 mm (0.59 inch).

If the belt does not require replacement or adjustment, install the belt guard.

If the belt requires adjustment or replacement, contact your local Cat dealer. The engine has an automatic belt tensioner. You cannot retighten the belt by hand.

If new belts are installed, check the belt tension again after 30 minutes of engine operation at the rated rpm.

Fuel Injector - Inspect/Adjust Be sure the engine cannot be started while this maintenance is being performed. To prevent possible injury, do not use the starting motor to turn the flywheel.

Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting the unit injectors.

The electronic unit injectors use high voltage.

Disconnect the unit injector enable circuit connector in order to prevent personal injury. Do not come in contact with the injector terminals while the engine is running.

Adjust the electronic unit injector at the same interval as the valve lash adjustment. The operation of Cat engines with improper adjustments of the electronic unit injector can reduce engine efficiency.

This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

Contact your Cat dealer for more information.

Engine Mounts - Inspect Inspect the engine mounts for deterioration and for proper bolt torque. Engine vibration can be caused by the following conditions:  Improper mounting of the engine 

Deterioration of the engine mounts

Any engine mount that shows deterioration should be replaced. Refer to the Specifications Manual, SENR3130, “Torque Specifications”. Refer to your Caterpillar dealer for more information.

3-44

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine Oil Sample – Obtain In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals. S·O·S oil analysis provides infrared analysis, which is required for determining nitration and oxidation levels.

Consult your Cat dealer for complete information and assistance in establishing an S·O·S program for your engine.

Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury.

Do not allow hot oil or hot components to contact the skin.

Before you take the oil sample, complete the Label, PEEP5031 for identification of the sample. In order to help obtain the most accurate analysis, provide the following information:  Engine model 

Service hours on the engine



The number of hours that have accumulated since the last oil change



The amount of oil that has been added since the last oil change

To ensure that the sample is representative of the oil in the crankcase, obtain a warm, mixed oil sample.

To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean.

Caterpillar recommends using the sampling valve in order to obtain oil samples (arrow, Fig. 3-12:).

The quality and the consistency of the samples are better when the sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation.

Fig. 3-12:

The 169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The fluid sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also provided.

Note: Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.

Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion into the sump.

For instructions, see Special Publication, PEGJ0047, “How To Take A Good S·O·S Oil Sample”. Consult your Cat dealer for complete information and assistance in establishing an S·O·S program for your engine.

3-45

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine Valve Lash – Check

Engine Valve Rotators – Inspect

The initial valve lash adjustment on new engines, rebuilt engines, or remanufactured engines is recommended at the first scheduled oil change. The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components.

This maintenance is recommended by Cat as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life.

Note: Only qualified service personnel should perform this maintenance. Refer to the Systems Operation/Testing and Adjusting Manual, “Valve Lash and Valve Bridge Adjustment” article or consult your Caterpillar dealer for the complete valve lash adjustment procedure.

Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency.

This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

Ensure that the engine cannot be started while this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn the flywheel.

Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuring the valve lash. To obtain an accurate measurement, allow the valves to cool before this maintenance is performed.

Refer to the Service Manual for more information.

Fig. 3-13:

When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to help prevent being burned by hot oil or spray.

Engine valve rotators rotate the valves when the engine runs. This helps to prevent deposits from building up on the valves and the valve seats.

Perform the following steps after the engine valve lash is set, but before the valve covers are installed:  Start the engine according to Operation and Maintenance Manual, “Engine Starting” (Operation Section) for the procedure.  Operate the engine at low idle.  Observe the top surface of each valve rotator.

The valve rotators should turn slightly when the valves close.

Note: A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life. If a damaged rotator is not replaced, valve face guttering could result and cause pieces of the valve to fall into the cylinder.

This can cause piston and cylinder head damage.

If a valve fails to rotate, consult your Caterpillar dealer.

3-46

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Coolant Temperature Regulator – Replace Replace the water temperature regulator before the water temperature regulator fails. This procedure is a recommended preventive maintenance practice.

Replacing the water temperature regulator reduces the chances for unscheduled downtime. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for the proper maintenance interval.

A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine.

A water temperature regulator that fails in the closed position can cause excessive overheating.

Excessive overheating could result in cracking of the cylinder head or piston seizure problems.

A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation.

Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner.

Note: Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage.

Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed.

If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature regulator is installed in the original position.

Ensure that the water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket or cylinder head surface.

Refer to two articles in the Disassembly and Assembly Manual, “Water Temperature Regulators Remove and Water Temperature Regulators Install” for the replacement procedure of the water temperature regulator, or consult your Cat dealer.

Note: If only the water temperature regulators are replaced, drain the coolant to a level that is below the water temperature regulator housing.

3-47

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine Hoses and Clamps - Inspect/Replace Hoses and clamps must be inspected periodically and replaced at the recommended interval to ensure safe and continuous operation of the engine.

Failure to replace a fuel hose at the recommended change interval may result in a hazardous situation. Take proper safety precautions before inspecting or replacing hoses and clamps.

Note: Always use a board or cardboard when the engine components are checked for leaks. Leaking fluid that is under pressure can cause serious injury or possible death. Leaks that are the size of a pin hole are included. Refer to Operation and Maintenance Manual, “General Hazard Information” for more information.

Note: Ensure that the hose is compatible with the application.

Note: Contact your Cat dealer or refer to Disassembly and Assembly Manual RENR9217 for more information.

Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions. Replace any hose which exhibits any of the following conditions. Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation.  Hoses which are cracked 

Hoses which are soft



Outer covering that is chafed or cut



Exposed wire that is used for reinforcement



Outer covering that is ballooning locally



Flexible part of the hose that is kinked or crushed



Armoring that is embedded in the outer covering



Hoses which exhibit signs of leakage which arenot the result of loose couplings or clamps

Inspect all clamps for the following conditions.

Replace any clamp which exhibits signs of any of the following conditions.  Cracking 

Looseness



Damage

Inspect all couplings for leaks. Replace any coupling which exhibits signs of leaks.

Each installation application can be different. The differences depend on the following factors:  Type of hose 

Type of fitting material



Anticipated expansion and contraction of the hose



Anticipated expansion and contraction of the fittings

Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen which can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.

Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses that show signs of damage. Replace hose clamps that are cracked or damaged. Tighten or replace hose clamps which are loose.

3-48

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Replace the Hoses and the Clamps Note: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, “Cat Dealer Service Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Cooling System

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.  Stop the engines.  Allow the engines to cool.  Before servicing a coolant hose, slowly loosen the filler cap for the cooling system in order to relieve any pressure.  Remove the filler cap for the cooling system.  Drain the coolant from the cooling system to a level that is below the hose that is being replaced. Drain the coolant into a suitable clean container. The coolant can be reused.  Remove the hose clamps.  Disconnect the old hose.

 Clean the coolant filler cap. Inspect the gaskets on the filler cap. Inspect the gasket seat.

Inspect the vacuum valve and seat for debris or damage. Replace the filler cap if the gaskets are damaged. Install the filler cap.  Start the engine. Inspect the cooling system for leaks.

Fuel System Personal injury can result from removing hoses or fittings in a pressure system.

Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

Note: All third-party installations must meet prescribed installation guidelines. Third-party components must not come in contact with Caterpillar components.

Note: Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.

Note: Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components.

 Replace the old hose with a new hose.  Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and installing the proper hose clamps.  Refill the cooling system.

Note: High-pressure fuel lines may be installed between the high-pressure fuel pump and the fuel injectors.

High-pressure fuel lines are constantly charged with high pressure. Do not check the high pressure fuel lines with the engine or the starting motor in operation. Wait for 10 minutes after the engine stops before you perform any service or repair on 3-49

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing high-pressure fuel lines. Waiting for 10 minutes will to allow the pressure to be purged.  Drain the fuel from the fuel system to a level that is below the hose that is being replaced.

Lubrication System Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

 Remove the hose clamps.  Disconnect the old hose.

Note: When servicing fuel system, use cap/s or cover/s as required to protect the system and maintain fuel system cleanliness.  Replace the old hose with a new hose.  Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and installing the proper hose clamps.  Carefully inspect the engine for any spilled fuel. Make sure that no fuel remains on or close to the engine.

 Drain the oil from the lubrication system to a level that is below the hose that is being replaced.  Remove the hose clamps.  Disconnect the old hose.  Replace the old hose with a new hose.  Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and installing the proper hose clamps.  Refill the lubrication system. Refer to this Operation and Maintenance Manual, “Engine Oil Level - Check” in order to ensure that the lubrication system is filled with the proper amount of engine oil.

Note: Fuel must be added to the fuel system ahead of the fuel filter.  Refill the fuel system. Refer to this Operation and Maintenance Manual, “Fuel System Prime” for information about priming the engine with fuel.

 Start the engine. Inspect the lubrication system for leaks.

 Start the engine. Inspect the fuel system for leaks.

 Replace the old hose with a new hose.

Air System  Remove the hose clamps.  Disconnect the old hose.  Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and installing the proper hose clamps.

Note: The bellows and the V-clamps that are used on the exhaust bellows should never be reused.  Start the engine. Inspect the air lines for leaks.

3-50

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine oil - check level / top up The engine oil temperature is constantly monitored by the BCS (Fig. 3-14:) when the machine is in operation. It can be displayed on the BCS screen.

The actual pressure and temperature of the engine oil is also displayed on the screen (Fig. 3-14:).

BCS give acoustic warnings to the operator if the engine oil temperature too high or the oil pressure is too low.

 Draw out dipstick a second time. The oil level should now lie between the marks (arrows, Fig. 3-15:). If the oil level is at the "min" mark or below, top up with engine oil through filler tube (2, Fig. 3-16:).

Fig. 3-16:

Fig. 3-14:

Engine oil can also be filled in from the service station (Fig. 3-17:) through  express coupling (8) for the lefthand engine, 

express coupling (9) for the righthand engine,

(see chapter "Engine oil, change").

Fig. 3-15:

 Park the machine on a horizontal surface and secure against inadvertent movements.  Shut off engines.  Draw out oil dipstick (2, Fig. 3-16:).

Fig. 3-17:

 Wipe oil off the dipstick with a clean, lintfree cleaning rag and re-insert.

3-51

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine oil reservoir (if equipped) – check oil level / top up Each engine has its own engine oil reservoir. The reservoirs are located:  Between the righthand fuel tank and the oil cooler module. 

Between the lefthand fuel tank and the cab module.

 Park the machine on a horizontal surface and secure against inadvertent movements.  Shut off engines.  Unlock the oil dipstick (Fig. 3-18:) and withdraw.  Wipe oil off the dipstick with a clean, lintfree cleaning rag and re-insert.  Draw out dipstick a second time. The oil level should lie at the mark. If the oil level is below, the engine oil is filled in from the service station (Fig. 3-19:) through

Fig. 3-18:

- express coupling (6) for the lefthand engine oil reservoir, - express coupling (7) for the righthand engine oil reservoir.

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

Fig. 3-19:

3-52

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine oil - change Risk of scalding from hot engine oil.

The engines may also be hot. Wear protective gloves and firm working clothing.

Read and observe: "Inspection and servicing – Safety instructions".

Collect escaping oil and discard without polluting the environment.

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

Drawing off engine oil with the service station  Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure.  Shut off the engines.  Draw off the engine oil through: 

express coupling (8, Fig. 3-20:) for the lefthand engine,



express coupling (9) for the righthand engine.

 Unscrew cap of express coupling and connect hose line of the service vehicle.

After the engine oil has been drawn off:  Replace the engine oil filters.

Draining off engine oil  Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure.

 Remove the hose line. The express coupling closes automatically.  Bolt on protective cap.

 Shut off the engines.  Place a collecting recipient for used oil under the oil sump.

(The required recipient capacity is set out in the "Filling quantities - Oil" table).  Drain oil from the engine through express coupling located at the lowest part of the oil sump.  Unscrew cap of express coupling.  Connect the hose line.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.

After draining of the oil:  Replace the engine oil filters.

Fig. 3-20:

 Remove the hose line.

The automatic drain coupling closes automatically.  Bolt on protective cap.

3-53

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Filling in engine oil  Fill in engine oil through filler tube (1, Fig. 3-21:) until the oil level has reached the "max" mark (Fig. 3-22:) on dipstick (2, Fig. 3-21:).

Filling in engine oil through the service station Fill in engine oil through:  express coupling (8, Fig. 3-23:) for the lefthand engine, 

express coupling (9) for the righthand engine,

until the oil level has reached the "max." mark (Fig. 3-22:) on dipstick (2, Fig. 3-21:).  Unscrew cap of express coupling and connect filling hose of the service vehicle.

Fig. 3-21:

 Start the engines and allow to run at idling for abt. 2 minutes.  Check oil level at dipstick (2, Fig. 3-21:) and top up with oil to the "max" mark (Fig. 3-22:) if required.  Remove the filling hose.

The express coupling closes automatically.  Bolt on protective cap.

Fig. 3-22:

Fig. 3-23:

3-54

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine oil reservoir (if equipped) - drain the oil off Risk of scalding from hot engine oil.

The engine oil reservoirs may also be hot. Wear protective gloves and firm working clothing.

Read and observe: "Inspection and servicing – Safety instructions".

Each engine has its own engine oil reservoir. The reservoirs are located:  Between the righthand fuel tank and the oil cooler module. 

Between the lefthand fuel tank and the cab module.

Collect escaping oil and discard without polluting the environment.

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

Draining the oil off the engine oil reservoir  Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure engine oil reservoir.  Shut off the engines.

Draw off engine oil with the service station (Fig. 3-24:) through  express coupling (6) for the lefthand engine oil reservoir, 

express coupling (7) for the righthand engine oil reservoir.

 Unscrew cap of express coupling and connect hose line of the service vehicle.  Remove the hose line.

The express coupling closes automatically.  Bolt on protective cap.  After the engine oil has been drawn off: Replace the engine oil filter.

Fig. 3-24:

3-55

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Filling in engine oil The engine oil is filled in with the service station (Fig. 3-25:) through  express coupling (6) for the lefthand engine oil reservoir, 

express coupling (7) for the righthand engine oil reservoir,

until the oil level has reached the mark on dipstick (Fig. 3-26:).  Unscrew cap of express coupling and connect hose line of the service vehicle.  Start the engines and allow to run at idling for abt. 2 minutes.  Check oil level and top up with engine oil until the oil level has reached the mark on dipstick (Fig. 3-26:).

Fig. 3-25:

 Remove the hose line.

The express coupling closes automatically.  Bolt on protective cap.

Fig. 3-26:

3-56

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine oil filter - replace

Engine oil reservoir (if equipped) - replace the oil filters

Risk of scalding from hot engine oil.

The filter housing may also be hot.

Wear protective gloves and firm working clothing.

Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot engine oil.

The filter housing may also be hot.

Wear protective gloves and firm working clothing.

Read and observe: "Inspection and servicing – Safety instructions".

Collect escaping oil and discard with-out polluting the environment.

Collect escaping oil and discard with-out polluting the environment.

Carry out servicing of the oil filters (Fig. 3-27:) in accordance with the maintenance plan.

Replacement:  Shut off the engines.

The filterelements are placed  near the door of the oil cooler module and

 Unscrew the filters.  Install new filter together with slightly oiled sealing ring and tighten by hand.

Thereafter:  Start the engines and allow to run at idling for a short while.  Check filters for leaks, shut off engines.  Check oil level after 10 minutes, top up if neccessary.

 near the door of the cab module.

Carry out servicing of the oil filters together with the engine oil reservoir.

Replacement:  Shut off the engines.  Unscrew the filters (arrow, Fig. 3-28:).  Install new filter together with slightly oiled sealing ring and tighten by hand.

Thereafter:  Allow engines to run at idling for a short while and check filters for tightness and leaks before shutting off the engines.  Check oil level after abt. 10 minutes and top up, if required.

Fig. 3-28: Fig. 3-27:

3-57

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Engine crankcase breather Crankcase breathers can be mounted at different positions on the engine, please refer to Fig. 3-30 and Fig. 3-31.

Engine crankcase breather – clean The crankcase breather is located on the back of the engine.  Remove the tube (2, Fig. 3-29:) from the outlet of the breather and loosen the clamp.  Remove the bolts (1) and remove the breather from the engine.  Check the condition of the seal. Replace the seal if the seal is damaged.  Remove the breather element. Wash the breather element and wash the breather in a clean nonflammable solvent.  Shake the breather element until the breather element is dry. You may also use pressurized air in order to dry the breather element.

Engine crankcase breathers – clean The crankcase breathers are located on the valve covers of the engine (2, Fig. 3-31).  Remove the clamp (1) and the tube (4) from the outlet of the breather.  Remove the clamp (3) and remove the breather (2).  Remove the breather element. Wash the breather element and wash the breather in a clean nonflammable solvent.  Shake the breather element until the breather element is dry. You may also use pressurized air in order to dry the breather element.  Check the condition of the tube. Replace the tube if the tube is damaged.  Install the element into the breather and install the breather. Tighten clamp (3)  Install the tube onto the outlet of the breather and tighten the clamp (1).  Fix the tube with all clamps.

 Check the condition of the tube. Replace the tube if the tube is damaged.  Install the element into the breather and install the breather.  Install the tube onto the outlet of the breather cover and tighten the clamp.

Fig. 3-30: Fig. 3-29:

3-58

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Cold-starting fluid (ether) - Replacing the pressure vessel Read and observe: "Inspection and servicing Safety instructions" Risk of injury Cold-starting fluid is composed mainly of ether.

Ether is toxic when the mists and vapours are inhaled. Ether is harmful to the eyes, the skin, the respiratory system and the central nervous system.

Prolonged inhalation of ether can be fatal.

In contact with the skin, ether can cause frostbites and irritations.

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Before replacing an empty pressure vessel: Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation of the surroundings.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapours of escaping cold-starting fluid (ether).

Avoid skin contact. Wear suitable protective gloves and goggles.

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is bolted onto an electro-mechanical metering valve. At temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Replacing the pressure vessel:  Remove the clamp around the pressure vessel (2, Fig. 3-31:).  Unscrew the pressure vessel carefully from the metering valve.  Remove the used seal from the metering valve.  Insert a new seal into the valve (supplied with the new pressure vessel).  Bolt the new pressure vessel onto the metering valve and tighten by hand.  Fasten the clamp round the pressure vessel.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine.  Do not damage or open the vessels.  Do not expose the vessels to great heat or direct sunlight.  Do not dispose of in fire.  Keep the vessels in a place unaccessible to unauthorized persons.  Dispose of the vessels properly.

Fig. 3-31:

3-59

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing COOLING SYSTEM Risk of scalding from hot cooling liquid.

Shut off the engines and allow to cool down.

Read and observe: "Inspection and servicing - Safety instructions".

Temperature The cooling liquid circuit is controlled by a thermostat. The max. admissible temperature is ca. 100° C (212°F).

In case of higher temperatures, the BCS displays a warning on the screen (Fig. 3-32:).

Secure the machine as described in the "Securing the machine" section.

Collect escaping cooling liquid and discard without polluting the environment.

Protect the skin from contact with cooling liquid.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Fig. 3-32:

3-60

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Radiators The radiators are located on the upper structure in the counterweight module.

Weekly checks:  Check radiator fins for dirt and clean, if required.

Cooling liquid level - check An insufficient cooling-liquid level is displayed on the BCS screen (Fig. 3-33:).

The level indicator (4, Fig. 3-34:) at the expansion reservoirs shows the liquid level as well.

The cooling-liquid level should be between the “FULL” and the “LOW” marking. Top up with cooling liquid, if required (see “Topping up cooling liquid”).

Fig. 3-33:

Fig. 3-34:

3-61

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Topping up cooling liquid Fill cooling liquid through filler tube (1, Fig. 3-35:) or through express couplings of the ServiceStation (2 and 3, Fig. 3-36:) into the cooling system (see “Topping up cooling liquid using the ServiceStation”).

The radiator caps (1, Fig. 3-35:) are accessible from above.

Risk of scalding from hot cooling liquid under pressure.

Before opening the radiator cap: Release pressure by lifting the red lever on top of the radiator cap.

Open radiator cap cautiously.

Fig. 3-36:

 Turn radiator cap (1) back to the first notch.  When the pressure has been released turn cap into the "open" position and remove.

Do not fill in cold cooling liquid when the engine is at operating temperature.

Before refilling, allow engine to cool down to below 50° C (122°F).

For topping up of the cooling system use specially prepared cooling liquid CAT ELC, CGM HMS GmbH SAP Part No. 4275599 only.

This gives an anti-freeze protection down to -37 °C / -34.6°F. For use at lower temperatures, contact your CATdealer.

After filling in cooling liquid allow the engines to run for short period to eliminate air voids before topping up with cooling liquid to the lower edge of the filler tube.  Remove hose from express coupling.

The express coupling closes automatically.  Bolt on protective cap.

In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks.

Check regularly:  all lines for leaks and all hose clamps for tightness.

Checking the SCA concentration

Fig. 3-35:

3-62

Observe the instructions of the engine manufacturer with regard to the SCA concentration (Refer to SEBU6250 Caterpillar Machine Fluid Recommendations).

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Topping up cooling liquid using the Service-Station A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

The cooling liquid can also be filled in with the service station (Fig. 3-37:) through  express coupling (2) for the lefthand engine, 

express coupling (3) for the righthand engine.

 Prior to topping up cooling liquid release pressure from the cooling system.

To do so move lever of the ball valves in the direction of the arrow (Fig. 3-37:).

The pressure is released then and the express couplings are then accessible.  Remove cap of express coupling. Connect the filling hose of the service vehicle.

Fig. 3-37:

 Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator at the expansion reservoirs.  Remove hose.

The express coupling closes automatically.  Push on protective cap.  Close ball valves (Fig. 3-37:).

3-63

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Cooling liquid - change Risk of scalding from hot cooling liquid.

The radiators may also be hot. Wear protective gloves and firm working clothing.

Read and observe: “Inspection and servicing – Safety instructions”.

Drawing off cooling liquid Cooling liquid can be drained from the cooling system by means of the express couplings located at the counterweight, below the engine cooling radiators (Fig. 3-41:).

The cooling liquid can also be drawn off faster with the service station (Fig. 3-38:) through  express coupling (2) for the lefthand cooling circuit, 

The cooling liquid must be analized and changed after 12000 operating hours or after six years at the latest.

Collect escaping cooling liquid and discard without polluting the environment or recycle.

Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems.

The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. For information regarding the disposal and the recycling of used coolant, consult your Cat dealer or consult Cat Dealer Service Tool Group.

Only use “ELC” cooling liquid, see: “Topping up cooling liquid”. Do not use pure water.

Refer to SEBU6250 Caterpillar Machine Fluid Recommendations.

express coupling (3) for the righthand cooling circuit.

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Prior to drawing off cooling liquid release pressure from the cooling system.

To do so move lever of the ball valves in the direction of the arrow (Fig. 3-38:).

The pressure is released then and the express couplings are then accessible.  Remove cap of express coupling. Connect hose line of the service vehicle.  Draw off cooling liquid.  Fill in fresh cooling liquid, see “Filling in cooling liquid”.

Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:  The engine overheats frequently. 

Foaming is observed.



The oil has entered the cooling system and the coolant is contaminated.



The fuel has entered the cooling system and the coolant is contaminated.

Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.

Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained.

3-64

Fig. 3-38:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Flush the cooling system

Filling in cooling liquid

 Flush the cooling system with clean water in order to remove any debris.

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

 Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Specifications Manual, SENR3130, “Torque Specifications” for more information on the proper torques.

Note: Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.  Fill the cooling system with clean water. Install the cooling system filler cap.  Start and run the engine at low idle until the temperature reaches 49 to 66 °C (120 to 150 °F).  Stop the engine and allow the engine to cool.  Loosen the cooling system filler cap slowly in order to relieve any pressure.  Remove the cooling system filler cap.  Open the drain valve (if equipped) or remove the cooling system drain plugs.  Allow the water to drain. Flush the cooling system with clean water.  Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Specifications Manual, SENR3130, “Torque Specifications” for more information on the proper torques.

Note: Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.  Shut off the engines.  Fill in coolant ELC with the service station (Fig. 3-39:) through:  express coupling (2) for the lefthand cooling circuit,  express coupling (3) for the righthand cooling circuit.

Refer to the Operation and Maintenance Manual, “Filling quantities - other” and “LUBRICANTS / CONSUMABLES” for more information on cooling system specifications. Do not install the cooling system filler cap.  Check ball valves (Fig. 3-39:).

They must be open. The express couplings are then accessible.  Remove cap of express coupling. Connect hose of the service vehicle.

Fig. 3-39:

3-65

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing  Fill with coolant ELC until the cooling-liquid level is between the “FULL” and the “LOW” marking of the level indicator at the expansion reservoirs (4, Fig. 3-40:).  Start and run the engine at low idle. Increase the engine rpm to high idle. Run the engine at high idle for 1 minute in order to purge the air from the cavities of the engine block. Stop the engine.  Check the coolant level. Top up if necessary.  Remove hose from express coupling.

The coupling closes automatically.  Push on protective cap.  Close ball valves (Fig. 3-39:).  Clean the cooling system filler cap. Inspect the gasket that is on the cooling system filler cap.

If the gasket that is on the cooling system filler cap is damaged, discard the old cap and install a new filler cap. If the gasket that is on the cooling system filler cap is not damaged, use a 9S‐8140 Pressurizing Pump to pressure test the filler cap.  The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap.  Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

The cooling liquid can also be filled in through filler neck (1, Fig. 3-40:).

Coolant Extender (ELC) – Add Cat ELC (Extended Life Coolant) does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants. The Cat ELC Extender is to be added once.

Note: Use only Cat Extended Life Coolant (ELC) Extender with Cat ELC. Do NOT use conventional supplemental coolant additive (SCA) with Cat ELC. Mixing Cat ELC with conventional coolants and/or conventional SCA reduces the Cat ELC service life.

Check the cooling system only when the engine is stopped and cool.

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure.

The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.

Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

Note: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, “Caterpillar Dealer Service Tools Catalog” for tools and sup-plies suitable to collect and contain fluids on Cat-erpillar products.

Dispose of all fluids according to local regulations and mandates.

Fig. 3-40:

 Loosen the cooling system filler cap slowly in order to relieve pressure. Remove the cooling system filler cap.  Drain enough coolant from the cooling system in order to add the Cat ELC Extender.

3-66

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing  Add Cat ELC Extender according to the requirements for your engine cooling system capacity. Refer to the Operation and Maintenance Manual, “Filling quantities - other” article for more information.  Clean the cooling system filler cap. Inspect the gaskets on the cooling system filler cap. Replace the cooling system filler cap if the gaskets are damaged. Install the cooling system filler cap.

Coolant Sample (Level 1) - Obtain Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling system is filled with Cat ELC (Extended Life Coolant).

Cooling systems filled with Cat ELC should have a Coolant Sample (Level 2) that is obtained at the recommended interval as stated in the maintenance interval schedule.

Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant instead of Cat ELC including the following coolants:  Commercial long life coolants that meet the Caterpillar Engine Coolant Specification -1 (Caterpillar EC-1)  Cat DEAC (Diesel Engine Antifreeze/Coolant)  Commercial heavy-duty coolant/antifreeze Recommended Interval Type of Coolant

Level 1

Level 2

Note: Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.

Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

Note: Level 1 results may indicate a need for Level 2 Analysis.

Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Cat dealer.

Use the following guidelines for proper sampling of the coolant:  Complete the information on the label for the sampling bottle before you begin to take the samples.  Keep the unused sampling bottles stored in plastic bags.  Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location.  Keep the lids on empty sampling bottles until you are ready to collect the sample.  Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination.

Cat DEAC

 Never collect samples from expansion bottles.

Conventional heavy dutycoolant

 Never collect samples from the drain for a system. Submit the sample for Level 1 analysis. For additional information about coolant analysis, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” or consult your Cat dealer.

Commercial coolant that meets the requirements of the Caterpillar EC-1 standard Cat ELC or conventional EC-1 coolant

Every 250 service hours

Every year(1)

Optional

Every year(1)

(1) The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified.

3-67

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

Coolant samples can be taken at the couplings located at the counterweight, below the engine cooling radiators (Fig. 3-41:).

Release pressure from the cooling system before taking a cooling liquid sample. To do so use the levers at the caps of the expansion reservois or the ball valves at the service station. See chapter “Cooling liquid, change / Drawing off cooling liquid”.

Coolant Sample (Level 2) - Obtain Note: Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.

Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

Note: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, “Cat Dealer Service Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.

Fig. 3-41:

3-68

Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Ob-tain” for the guidelines for proper sampling of the coolant. Submit the sample for Level 2 analysis.

For additional information about coolant analysis, see Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engines Fluids Recommenda-tions” or consult your Cat dealer.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Cooling System Supplemental Coolant Additive (SCA) - Test/ Add Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with the skin and eyes. Do not drink cooling system coolant additive.

Note: Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components.

Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water pump seal.

Do not exceed the recommended amount of supplemental coolant additive concentration.

Note: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, “Cat Dealer Service Tools Catalog” for tools and supplies suitable to collect and con-tain fluids on Cat products.

Dispose of all fluids according to applicable regula-tions and mandates.

Note: Caterpillar recommends an S·O·S coolant analysis (Level 1).

Cooling Systems that Use Conventional Coolant This maintenance procedure is required for conventional coolants such as DEAC. This maintenance is NOT required for cooling systems that are filled with Extended Life Coolant.

Test the Concentration of the SCA Note: Do not exceed the recommended six percent supplemental coolant additive concentration.

Test the concentration of the SCA with the 8T5296 Coolant Conditioner Test Kit. Add the SCA, If Necessary Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.  Remove the cooling system filler cap slowly.  If necessary, drain some coolant in order to allow space for the addition of the SCA.  Add the proper amount of SCA. For the proper amount of SCA, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic. The proper concentration of SCA depends on the type of coolant that is used. For the proper concentration of SCA, refer to Special Publication, SEBU6251, “Cat Commercial Diesel Engine Fluids Recommendations”.  Clean the cooling system filler cap. Install the cooling system filler cap.

3-69

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Cooling Systems that Use Water and SCA Test the Concentration of the SCA Test the concentration of the SCA with a 298-5311 Coolant Nitrite Test Kit for SCA or perform an S·O·S Coolant Analysis. The test kit includes the following items: a tool for the testing, 30 ampoules for testing nitrite, instructions and a case. 2947420 Test Kit contains the refill ampoules for the 298-5311 Coolant Nitrite Test Kit. Use the instructions that are included with the test kit in order to properly conduct the testing.

Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for the times at which the procedures should be conducted. Test the concentration of the SCA more frequently if more frequent testing is indicated by the results of the S·O·S Coolant Analysis.

3-70

Note: Do not exceed the recommended eight percent supplemental coolant additive concentration.

Add the SCA, If Necessary Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 

Remove the cooling system filler cap slowly.



If necessary, drain some coolant in order to allow space for the addition of the SCA.



Add the proper amount of SCA. For the proper amount of SCA, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic. For the proper concentration of SCA, refer to Special Publication, SEBU6251, “Cat Commercial Diesel Engine Fluids Recommendations”.



Clean the cooling system filler cap. Install the cooling system filler cap.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing AIR-INTAKE SYSTEM Risk of injury when falling down.

Put on your fall protection equipment before entering the upper structure.

Risk of injury caused by hot parts of the engine exhaust system.

Let exhaust cool down.

Read and observe the "Engine - Safety instructions" chapter.

Dust trap - clean The dust trap (arrow, Fig. 3-43:) collects dust and dirt that infiltrates the air filter housing.  To remove dust and dirt, squeeze the flexible part of the dust trap several times. Dust and dirt will be detached and come off.

Do not start the engine when parts of the air-intake system have been detached.

Engine damage may occur if the engine is allowed to draw in unfiltered air.

Secure the machine as described in the "Securing the machine" section.

Each engine is equipped with two dry-air filters (Fig. 3-42:) consisting of pre-cleaner, main filter element and secondary filter element.

Fig. 3-43:

Fig. 3-42:

3-71

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Main filter elements

Removal and installation

Insufficient air-intake performance, caused by a contaminated main filter element, is displayed on the BCS-screen (Fig. 3-44:).

Clean or renew main filter elements only if the BCS displays a warning on the screen (Fig. 3-44:) with the engines running at high speed.

New or cleaned main filter elements should always be at hand to shorten hydraulic shovel downtimes.

 Loosen clamps (1, Fig. 3-45:) at the air filter housing and remove cover (2).  Withdraw main filter element (3).

Do not remove secondary filter element (4).  Replace or clean main filter element.  Before installing the filter element, clean contact faces at cover (2, Fig. 3-45:) and at filter housing.  Put on cover (2) using clamps (1).

Fig. 3-44:

Fig. 3-45:

3-72

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Main filter element – check / clean  Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 3-46:). Any damage is then clearly visible.

Replace damaged or deformed elements immediately.

 Check element seal. When the seal is damaged, the filter element must be replaced, too.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.  Blow filter element (Fig. 3-47:) clean with dry compressed air from the inside by moving the compressed-air gun up and down.

Fig. 3-46:

The pressure at the nozzle must not exceed 3 bars / 43 psi.

Cleaning is terminated when all visible dust has been blown out of the filter element.

Never clean filter element by beating against hard objects.

 Replace the main filter element after 1000 operating hours or 3 cleaning cycles; and, after one year of operation at the latest.

Fig. 3-47:

3-73

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Secondary filter element – replace Removal and installation  Replace the secondary filter elements (4, Fig. 3-48:) after 1000 operating hours or 3 cleaning cycles of the main filter elements. After one year of operation at the latest.

Never clean the secondary filter element, but always renew.

 Remove cover (2, Fig. 3-48:) and main filter element (3) as described above.  Withdraw secondary filter element (4).  Clean the air filter housing.  Install the new secondary filter element and a cleaned or a new main filter element.

Fig. 3-48:

3-74

Air-intake lines – inspect At regular intervals:  Check intake lines for leaks and hose clamps for tightness.  Replace hoses between filter housing and engine.

During all work on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engines.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing FUEL SYSTEM Fuel system - Safety instructions Read and observe the "Inspection and servicing – Safety instructions" chapter.

Fuel filter - replace Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping fuel and discard without polluting the environment.

Before working on the fuel system:  shut off the engines, 

secure the machine as described in the "Securing the machine" section,



keep away naked flames,



do not smoke.

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Fig. 3-49:

 Relieve residual fuel pressure from the fuel system by carefully loosen one of the fuel supply connections at the filter head (1, Fig. 3-49:).  Unscrew fuel filter (2).  Clean gasket sealing surface at the filter head.  Do not fill new filter with fuel. This prevents the injection system from beeing contaminated by unfiltered fuel after fuel filter change.  Apply clean diesel fuel to the new filter gasket and bolt it onto the filter head by hand. Continue to tighten filter by a further ½ to ¾ turn.

Tightening the filter element with a tool may damage or deform the filter head.

Refer to SEBU6250 Caterpillar Machine Fluid Recommendations and contact your Cat dealer for more information.

3-75

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Primary fuel filter - drain water

Primary fuel filter - replace

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping fuel and discard without polluting the environment.

Collect escaping fuel and discard without polluting the environment.  Open valve (3, Fig. 3-50:) and drain off fuel.  Close valve (3).  Remove the fuel filter bowl (2) and wash the fuel filter bowl with clean diesel fuel.  Unscrew primary fuel filter (1).  Clean gasket sealing surface at the filter head.  Do not fill new primary filter with fuel. This prevents the injection system from beeing contaminated by unfiltered fuel after fuel filter change.

Fig. 3-50:

The primary fuel filter (1, Fig. 3-50:) serves also as a water separator:  Open valve (3) and drain off water until fuel emerges.  Close valve (3).

Refer to SEBU6250 Caterpillar Machine Fluid Recommendations and contact your Cat dealer for more information.

 Apply clean diesel fuel to the new primary filter gasket and bolt it onto the filter head by hand.

Continue to tighten filter by a further ½ to ¾ turn.

Tightening the filter element with a tool may damage or deform the filter head.  Bolt fuel filter bowl (2) onto the new primary fuel filter (1) by hand.

Tightening the fuel filter bowl with a tool may cause damage or destroys the filter bowl.  Vent fuel filters, see "Venting the fuel system".  Start engine and check fuel system for leaks.

Refer to SEBU6250 Caterpillar Machine Fluid Recommendations and contact your Cat dealer for more information.

3-76

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Fuel system – vent

Fuel tanks – clean

Venting fuel filters  Place a collecting recipient under the air bleed valve (1, Fig. 3-51:).

Explosion hazard.

Read and observe the "Inspection and servicing. Safety instructions" chapter.

 Unscrew air bleed valve (1) and switch on the pre-fuel pump with switch (2).  Close air bleed valve (1) and switch off pre-fuel pump (2) when fuel emerges at the air bleed valve without any bubbles.

Do not use white spirit, paraffin oil or other solvents.

For flushing and cleaning use diesel fuel.

Avoid skin contact.

Skin contact with diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier ccream.

Fuel must be prevented from penetrating into the soil. Keep fuel for re-use or discard without polluting the environment.  Use up as much fuel as possible.  Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plugs of the tanks.

Fig. 3-51:

Venting the fuel tanks The fuel tanks are vented with breather valves (arrow, Fig. 3-52:).

 Loosen drain plugs (5, Fig. 3-53:) at the fuel tank and drain off fuel.  Flush tank with diesel fuel.  Bolt drain plugs back in place.

Breather filter fuel tanks - replace  Replace breather filters regularly according to the maintenance plan.

To do so unsrew cap (1, Fig. 3-52:) of breather valve and replace with a new one. The filter element in integrated in the cap.

Fig. 3-53:

Fig. 3-52:

3-77

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing  Fill in fuel through the strainer in filler tube (2, Fig. 3-54:)  Fuel can also be filled into both fuel tanks through the service station (1, Fig. 3-55:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Unscrew cap of express coupling. Connect filling hose of the service vehicle.

The filling level is displayed on the BCS screen (Fig. 3-56:).  Remove filling hose.

The express coupling closes automatically.  Bolt on protective cap.

Fig. 3-54:

Fig. 3-55:

Fig. 3-56:

3-78

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Water trap (optional) – clean / replace Water contained in the fuel is removed by the water trap (Fig. 3-57:).

Draining off water Carry out the following works in accordance with the servicing schedule and at regular intervals:  Loosen venting plug (9, Fig. 3-58:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

Fig. 3-57:

Fig. 3-58:

The liquid flowing out of the valve flushes and cleans the filter element(6) von from top to bottom.  Close drain valve (3) and tighten venting plug (9).

3-79

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Checking / cleaning the filter element

Fuel System – Prime Personal injury or death may result from failure to adhere to the following procedures.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.

Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.

Replace filter element (6, Fig. 3-59:) only when the suction resistance is too high.

Prime the fuel system in order to purge trapped air and in order to fill the fuel filter.

Fig. 3-59:

 Loosen venting plug (9) and leave drain valve (3) open until the reservoir is completely empty.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.  Remove cover (5).  Remove spring holder (7) and filter element (6) from filter housing (4).  Check / replace filter element (6).  Clean filter housing (4) using diesel fuel.  Check cover sealing and replace,if necessary.  Insert filter element (6) and spring housing (7) into filter housing (4).  Fasten cover (5) on filter housing (4).

Check for proper sealing.

 Clean recipient (1) and filter housing (4).  Loosen flange (2).  Take off recipient (1) and clean with diesel fuel  Check cover sealing and replace, if necessary.  Attach recipient (1) with flange (2) at filter housing (4).

Check for proper sealing.

Fig. 3-60:

 Turn the keyswitch to the ON position, but do not start the engine.

Note: The engine start switch must be in the OFF position in order to prime the fuel system.  Place a suitable container under air purge valve (1, Fig. 3-60:).  Open air purge valve (1).  Hold priming pump switch (2) upward in order to activate the electric fuel priming pump. The priming pump will fill the engine fuel lines and the fuel filters with fuel.  Release the priming pump switch, and close the air purge valve when fuel emerges from the air purge valve without any bubbles.  Start the engine at low idle.  If the engine starts but the engine runs rough, continue to run the engine at low idle until the engine runs smoothly.  If the engine does not start after several attempts, consult your Cat dealer.

3-80

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing ELECTRICAL SYSTEM Electrical system - Safety instructions Risk of injury caused by battery acid and gases and short circuits.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Carry out every work on the electrical / electronical systems only if you are a qualified electrician and after having received special trainings.

Wear goggles, working gloves and firm working clothing.

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the electronic modules of the PMS.

Alternator - Instructions Never disconnect cables from the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator.

Do not interchange the cables when connecting the battery (observe polarity).

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the regulator.

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

Electrical circuit diagrams The electrical circuit diagrams and wiring diagrams are annexed to the spare-parts list. Further information can be found in the CGM HMS GmbH Service Manual "Working with circuit diagrams".

Electrical system switch-cabinets The electrical system switch-cabinets are located in the cab module, in the pump compartment and behind the hydraulic reservoir. The cabinets are described in the spare-parts list (electrical circuit diagram) together with the designation of the electrical components.

Fuses and their function are listed on a sheet inside the switch-cabinets in the cab module.

Use only original fuses with the specified current rating.

Replacing lamps and bulbs If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Xenon-working floodlights are operated with high voltage.

Read and observe the chapter: “Floodlight projector, replacing the lamp”.

Floodlights working with LED-technology do not have replaceable lamps / bulbs. The floodlight must be replaced if defective.

3-81

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Battery – check the state of charge Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Risk of injury caused by battery acid and gases.

Wear goggles, working gloves and firm working clothing.

Do not eat, drink or smoke when handling batteries.

Wash hands after handling.

Read and observe the “Inspection and servicing – Safety instructions” chapter.

Checking the battery fluid level (Not applicable in case of maintenance-free batteries).  Unscrew caps (Fig. 3-61:).  If checking inserts are provided, the battery acid must reach up to their bottom.  If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm / 0.4“.  If the fluid level is too low, top up with distilled water only.

Fig. 3-61:

3-82

Checking charge of batteries The acid temperature must be 20 ° C / 68° F.  Unscrew caps of the battery (Fig. 3-61:).  Measure the acid density of the battery using a commercial acid tester (Fig. 3-61:).

The acid density measured is in direct correlation with the battery charge.

Acid density kg / dm3 Charge Normal Tropical condicondition tions 1,28 1,23 fully charged 1,20 1,12 half charged, recharge 1,12 1,08 discharged, recharge immediately

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Battery charging inside the machine - safety instructions Explosion hazard.

Battery gases are highly flammable.

Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

Risk of injury from acid splashes and battery gases.

Wear safety goggles or a face protection shield and acid proof protective gloves.

Do not lean over the batteries while charging.

The batteries of the machine can also be charged while installed in the machine.

For this purpose, the arm of the service station (Fig. 3-62:) is equipped with a socket outlet for a charging cable.

Risk of fire.

Do not use the socket outlet (Fig. 3-62:) for jump-starting of the engines.

The connectors and the cables are not designed for the high currents flowing during the starting phase.

Check before charging why the batteries are discharged and replace the batteries if they are defective.

Check the connecting cables of the battery set for damage, corrosion and tight fit.

Never charge the batteries while they are frozen.

Warm them up beforehand and check for proper functioning.

Do not charge the batteries when they are warmer than "warm to the touch" (45 °C / 113 °F).

Use only approved chargers for 24 volts DC. Read and observe the instructions for the charger.

The charging cable must have a conductor crosssection of at least 70 mm2.

Charging the batteries  Cut out the battery main switch.  For battery ventilation unscrew the cover of the battery cabinet.  Connect the charging cable to the socket outlet (Fig. 3-62:).  Switch on the charger and watch the charging process.

Stop the charging process:  if the batteries are getting hot,  if acid escapes from the batteries,  if the charge current is still insignificantly low even after 15 minutes of charging.

Before starting a new charging cycle, check the batteries and the connecting cable thoroughly and replace any damaged components. It may be necessary to remove the batteries and to charge them one by one.

When the batteries are full:  Shut off the charger first before withdrawing the charging cable from the socket outlet.

Read the instructions of the charger in order to know when the charging cycle has ended.

The batteries are fully charged, if  the charging current and voltage remain constant (for voltage-controlled chargers);  the charging current does not any rise longer for two hours (current-controlled chargers);  the charger shuts off or switches over to trickle charge (automatic chargers).

Fig. 3-62:

3-83

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Battery - Removing and installing Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Risk of injury caused by battery acid and gases.

Wear goggles, working gloves and firm working clothing.

Do not eat, drink or smoke when handling batteries.

Wash hands after handling.

Read and observe the “Inspection and servicing – Safety instructions” chapter.

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

The batteries (1, Fig. 3-63:) are located behind the hydraulic reservoir. The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

 Shut off the engines before removing the batteries to avoid damaging the alternator and the regulator.  Turn key in key-switch to position “0” and withdraw.  Switch battery-isolator-switch to position “0” (if equipped with).  Switch battery-main-switch to position “0” (if equipped with).  Open battery cabinet.  Unscrew wingnuts (4, Fig. 3-63:).  Detach battery holder (3).  Disconnect the cable lug from the negative terminal of the battery.  Disconnect the cable lug from the positive terminal of the battery.  Insulate the cable lugs.  Lift battery out of battery box.

Before installing new batteries, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.  Install the new batteries.  Connect the cable lug to the positive terminal of the battery. Tighten the clamping bolts of the cable lugs. Do not use too much force to avoid deformation.  Connect the cable lug to the negative terminal of the battery.  Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs. Loose or corroded clamping lugs will lead to alternator or regulator overloading.  Attach battery holder (3). Fasten with wingnuts (4).  Close battery cabinet.

Fig. 3-63:

After putting the machine back to operation:  Check battery cabling for tightness, retighten if necessary.  Check battery holders and wing nuts for tightness, retighten if necessary.  Repeat these checks regularly.

3-84

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Switchgear cabinet - aeration Breather filter In the switchgear cabinet, the air is drawn in by a ventilator via the filter (Fig. 3-64:).

Emptying dust trap  Press dust trap (14, Fig. 3-64:) and hold until the dust trap is empty.

Emptying the dust collector  Loosen clamps (11, Fig. 3-64:).  Remove dust collector (12) and empty.

Fig. 3-64:

Filter element  Remove the dust collector (12, Fig. 3-64:).  Withdraw filter element (13, Fig. 3-65:).  Replace or clean filter element (13).  Refit dust collector (12, Fig. 3-64:).

Fig. 3-65:

3-85

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Checking and cleaning the filter element  Check the filter paper of the element by inserting a lamp into the element (Fig. 3-66:). Any damage can then be seen.

Replace damaged or distorted element immediately.

 Check element seal. If damaged, replace filter element too.

Cleaning with compressed air allows the filter element to be re-used immediately.  Blow filter element (Fig. 3-67:) dry with compressed air by moving the compressed-air piston up and down inside it.

Fig. 3-66:

The pressure at the nozzle must not exceed 3 bars / 43 psi.

Cleaning is completed when no more dust is seen to leave the filter element.

Never clean filter element by beating it against hard objects.

 Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Fig. 3-67:

3-86

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Xenon floodlight projector - replacing the lamp Safety instructions The floodlight projectors use xenon technology.

The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector.

When the projector is turned on, the ballast unit generates a high-voltage pulse of more than 25000 volts to start the xenon lamp.

Warning!

This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance,  if the lamp is operated improperly, 

if the projector housing is opened in an inapropriate way or



by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp.

Allow the xenon lamp to cool off before removing it from the projector.

Wear googles and safety gloves when replacing the lamp.

Never stick your hand into the lampholder. The contacts may still be live with residual voltage.

Never switch on the projector when the xenon lamp has been removed.

There is a risk of voltage discharge and damage to the lampholder.

The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters).

If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector.

If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol.

The replaced Xenon lamp must be disposed of as special waste.

Never switch on projectors when housing or electrical wiring is damaged.

Have damaged projectors be replaced by a qualified electrician as soon as possible.

3-87

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Replacing a defective Xenon-lamp Read and observe the: „Xenon floodlight projector, replacing the lamp, Safety instructions“.  Switch off the projector, shut off the engine and cut out the battery main switch.  Wait until the housing of the floodlight projector has cooled down.  Withdraw the power supply connector from the projector.  Remove four bolts (1, Fig. 3-68) and withdraw the reflector (2) from the projector housing.

Fig. 3-68

 Withdraw connector (Fig. 3-69) from Xenon lamp socket.  Unscrew Xenon lamp holding clamp (Fig. 3-70).  Remove the defective Xenon lamp and replace by a new one. Do not touch the glass bulb of the lamp.  Reinstall the new lamp. Bolt lamp holding clamp back in place.  Plug the power supply connector onto the lamp.  Re-assemble the housing.

Fig. 3-69

Fig. 3-70

3-88

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Lighting systems in LED technonogy - instructions The lights of the maintenance lighting system (Fig. 3-71) as well as the working floodlights (Fig. 3-72) are equipped with lamps in LED technology (lightemitting diodes).

High-performance LEDs ensure the emission of light with high luminance. If the light is allowed to shine directly into the eyes from a short distance and over prolonged periods, there is a risk of injury to the retina.

Do not look for a prolonged period into the light cones of the LEDs. Adjust the lights in such way that they do not shine directly into the eyes and that you are not blinded by the glare.

The lights become hot in operation.

The heat is dispersed via the ribbed metal housing.

For this reason, the housings must not be covered up and cleaning rags or similar things placed over them.

Fig. 3-71

The high-performance LEDs in these lights have a very long service life and can therefore not be replaced. If one or more of these LEDs fail, the light can remain in service if the remaining luminance is still sufficient.

Fig. 3-72

3-89

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing CAN-Bus wiring connections – inspect The CAN bus wiring connects the manual control levers (joysticks), the travel pedals and the pedal for the bucket lid to the switch cabinet in the cab module.

Before inspecting  Stand the attachment on the ground.  Shut off the engines.  Switch off the electrical system.  Switch off the battery main switch.

Inspect

Fig. 3-73:

 Check CAN Bus wiring inside the cab module (Fig. 3-73: and Fig. 3-74:) for damage.

Note: Damaged wiring needs to be replaced immediately. Contact your Cat dealer. Bring the machine back to operation only after the repair is completed.  Inspect wiring connections (arrows, Fig. 3-73: and Fig. 3-74:). All connections must be interconnected to the stop and secured.

Fig. 3-74:

3-90

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing HYDRAULIC SYSTEM Hydraulic system - Safety instructions Risk of injury caused by hydraulic fluid under high pressure. Never open hydraulic connections while the system is pressurized. Depressurize the hydraulic system section before starting any work on the section.

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

Allow hydraulic components to cool down before starting any work.

Contact with hydraulic oil can cause skin injury.

Avoid skin contact with hydraulic oil.

Wear protective gloves and firm working clothing.

Secure the machine as described in the "Securing the machine“ section.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Hydraulic system – depressurize Hydraulic systems may only be opened if they are completely depressurized. Even when an hydraulic shovel is parked on a horizontal surface with the attachment resting on the ground (Fig. 3-75: and Fig. 3-76:) and with its drive engines stationary, there may still be a considerable amount of residual pressure in parts of the hydraulic system, as e.g. the primary pressure resulting from the last hydraulic movements before the immobilization.

Residual pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be freed from pressure, i.e. depressurized:  Locate the system section to be opened.  Depressurize the section to be opened. If required, the necessary measures described must be combined.  Open the depressurized system section with caution.

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated.

Fig. 3-75:

Fig. 3-76:

3-91

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Examples of system sections:  working hydraulics

Hydraulic oil level – check



servo control circuit

 Bring hydraulic oil to operating temperature (abt. 50 °C / 122 °F).



precharged return-flow line

 Park the machine on a horizontal surface.

Depressurizing  Park the hydraulic shovel on a horizontal surface.

 Move all hydraulic cylinders to their central positions.

The oil level must be between the “min” and “max” marks of the decal (2) beside the inspection glass (1, Fig. 3-78:).

 Set the attachment on the ground.  Shut off the drive engines, keep sitting on the operator’s seat.  Do not switch off the electrical system Sections servo control circuit and working hydraulics:  Shift both control levers and all pedals repeatedly into all directions (Fig. 3-77:).

Fig. 3-78:

The hydraulic oil level is monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-79:) if the hydraulic oil level is too low or too high.

Shut off the engines, locate cause and rectify.

Fig. 3-77:

Section Return-flow line: After shutting down the engine, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

Detailled information on depressurizing other hydraulic circuits on the machine can be found in the “Service Manual, chapter 8: Hydraulic System”.

Fig. 3-79:

3-92

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

Fig. 3-82:

Fig. 3-80:

 Stand attachment on the ground as shown on the sign (Fig. 3-80:).

Signs (2, Fig. 3-81:) are attached beside the inspection glass tube (1).

Hydraulic oil (oil grade see: "LUBRICANTS/ CONSUMABLES") can also be filled in by means of the service station (Fig. 3-83:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Unscrew cap of express coupling (10).

Connect filling hose express coupling of the service vehicle.  Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of the decal (2) beside the inspection glass (1, Fig. 3-81:). Ensure the oil temperature the oil is at a minimum of 50 C / 122 F when filling the hydraulic tank. The acoustic warning signal “Travel Alarm” sounds.  Unscrew the hose line; the express coupling closes automatically.  Bolt protective cap back in place.

Fig. 3-81:

Fill in hydraulic oil through the return-flow filters:  Remove cover (16, Fig. 3-82:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of the decal (2) beside the inspection glass. Ensure the oil temperature the oil is at a minimum of 50 C / 122 F when filling the hydraulic tank. (oil grade see: "LUBRICANTS/ CONSUMABLES").  Before fitting the cover (16), check the sealing ring and replace, if damaged.

Fig. 3-83:

 Fit cover together with sealing ring.

3-93

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic oil return-flow filter (hydraulic oil reservoir) – replace (up to machine no. 170129 / DHX40129) Risk of scalding caused by hot hydraulic fluid.

The hydraulic oil reservoir itself may also be hot.

Allow hydraulic fluid to cool down before start working at the reservoir.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Removing filter elements  Loosen plug (1, Fig. 3-85:) for pressure compensation.  Remove cover (3) together with sealing ring (5), remove bracket (7).  Remove press rings (8) with O-rings (10) and (11).  Withdraw filter elements (9) from basket (12).  Check filter elements (9) for damage.

If filter elements are undamaged, insert new filter elements. Dispose of used filter elements.

If a filter element is damaged, remove the filter basket (12) and check (see: “Removing and checking the filter basket”).

Shut off the engines.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves, firm working clothing and protective goggles.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose of used filter elements according to the environmental regulations.

The return-flow filters must be replaced:  when servicing works in accordance with the servicing plan are carried out; 

when the BCS displays a warning on the screen (Fig. 3-84:). In this case, the filter elements (9, Fig. 3-85:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-84:

Fig. 3-85:

3-94

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Installing filter elements  Insert new filter elements (9, Fig. 3-86:) paying attention to the correct direction (observe the “TOP” marking).  Insert new O-rings (10) and (11) into the press rings (8).  Put press rings (8) on filter elements (9).  Assemble bracket (7).  Clean the magnetic rod (17, Fig. 3-87:). The magnetic rod is located under cap (16).

If metal filings are detected, contact the Caterpillar dealer service. The origin of filings must necessarily be located and rectified.

Otherwise there is a risk of extraordinarily damages in the hydraulic system.  Refit cap with magnetic rod (16).  Refit cover (3) together with sealing ring (5).

Tighten bolts (18) crosswise with a torque wrench (tightening torque 79Nm / 58lbf ft).

Fig. 3-86:

 Replace also the return-flow filter in the filter housing (cooling-system).

The return-flow filters are located under the caps (20, Fig. 3-88:).

(See: "Replacing the hydraulic oil return-flow filters (filter housing“).

Fig. 3-87:

Fig. 3-88:

3-95

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Removing and checking the filter basket In case one of the filter elements (9, Fig. 3-89:) is damaged, remove filter basket (12) and check / clean. To do so:  Unscrew bolts (13), take away washers (15) and brackets (14).  Draw out filter basket (12) and clean with white spirit or paraffin oil.  Check the filter chamber inside the hydraulic reservoir, clean if necessary.

If considerable pollution or foreign objects are detected, contact your Caterpillar dealer service. The origin of those pollution or foreign objects must necessarily be located and rectified.

Otherwise there is a risk of extraordinarily damages in the hydraulic system.  Re-assemble filter basket (12) with brackets (14), washers (15) and bolts (13).  Tighten bolts (13) using a torque wrench (tightening torque 54Nm / 40lbf ft).  Refit filter elements (9), (see: “Installing filter elements”).

3-96

Fig. 3-89:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic oil return-flow filters replace (from machine no. 170130 / DHJ40130) Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Remove return flow filter elements  Remove covers (3, Fig. 3-91:) together with sealing rings (5).  Unscrew ring nuts (6) and remove retaining disk (7).  Remove press parts (8) with o-rings (10).  Withdraw filter elements (9) with o-rings (11) from filter-baskets (12).  Inspect filter elements for damage.

If no damages are visible, insert new filter elements (9) with new o-rings (11) into filterbasket (12), (see: “Install return flow filter elements”).

If a filter element (9) is damaged, remove filterbasket (12) and inspect / clean, (see: “Remove filter-basket, inspect / clean”).

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose of used filter elements accordding to the environmental regulations.

The return-flow filters must be replaced:  when servicing works in accordance with the servicing plan are carried out; 

when the BCS displays a warning on the screen (Fig. 3-90:). In this case, the filter elements (9, Fig. 3-91:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-90:

Fig. 3-91:

3-97

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Install return flow filter elements  Insert new filter elements (9, Fig. 3-92:) into filter-basket with marking “TOP” upwards.  Attach new o-rings (10 and 11) to press parts (8).  Put press parts (8) onto filter elements (9).  Fasten retaining disk (7) with ring nuts (6).  Clean magnetic rod (17, Fig. 3-93:).

The magnetic rod is located under cap (16).

If metal filings are detected, locate cause and rectify. Contact your Caterpillar dealer service, if required.

It is essential to find the source of the metal filings and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.  Reattach cap (16) together with magentic rod and sealing ring to cover (3).  Install covers (3) together with sealing rings (5). Tighten bolts (18) crosswise using a torque wrench (torque = 79 Nm / 58.3 lbf ft).  Replace also the return-flow filter in the filter housing (cooling-system).

The return-flow filters are located under the caps (20, Fig. 3-88:).

(See: "Replacing the hydraulic oil return-flow filters (filter housing“).

Fig. 3-92:

Remove filter-basket, inspect / clean If you found one of the return flow filter elements (9, Fig. 3-92:) damaged, remove the filter-basket (12) and inspect / clean the filter-basket as well as the filter chamber of the hydraulic tank. To do so:  Unscrew bolts (13) and brackets (14).  Remove filter-basket (12) and clean in paraffin oil.  Inspect the filter chamber inside the hydraulic oil tank for contamination.

If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.

It is essential to find the source of contamination and foreign objects and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.  Replace o-ring (15) located in the filter brackets top plate.  Reinsert the filter-baskets (12).  Place brackets (14) in the correct position and screw in bolts (13).  Tighten bolts (13) using a torque wrench (torque = 46 Nm / 34 lbf ft).  Install new return flow filter elements (9), see “Install return flow filter elements”.

3-98

Fig. 3-93:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Bypass valves (hydraulic oil reservoir) – clean / replace Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose off used filter elements according to the environmental regulations.

Fig. 3-94:

Cleaning the filter screens  Remove cover (3, Fig. 3-94:) together with sealing ring (5).  Unscrew bolts (22). Withdraw bypass valve.  Take off screen (23) together with sealing ring and clean in white spirit or paraffin oil. Replace, if required.  Check sealing ring for damage and replace, if required.  Re-assemble the bypass valve.  Check sealing ring (24) for damage and replace, if required.  Insert bypass valve and fasten with bolts (22).  Clean also the screen of the bypass valve in the filter housing (cooling-system).

The bypass valve is located under the cover (10, Fig. 3-95:). (See: "Bypass valves (filter housing - cooling-system").

Fig. 3-95:

Replacing the bypass valves and sealing rings  Remove bypass valve as described under "Cleaning the filter screens".  Re-assemble the bypass valve with a new screen (23, Fig. 3-94:) and a new sealing ring.  Insert bypass valve with new sealing ring (24) and fasten with bolts (22).  Replace also the bypass valve and sealing ring in the filter housing (cooling-system).

The bypass valve is located under the cover (10, Fig. 3-95:). (See: "Bypass valves (filter housing - cooling-system").

3-99

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic oil return-flow filters (filter housing cooling system) – replace

Replace the return-flow filters (25, Fig. 3-96:) together with the return-flow filters in the hydraulic oil reservoir.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose off used filter elements according to the environmental regulations.

Fig. 3-96:

 Detach cover (20) together with sealing ring (26).  Draw out plate (23) together with sealing ring (27).  Withdraw filter element (25).  Insert a new filter element.  Clean magnetic rod (24).

If metal filings are detected, locate cause and rectify.

Contact your Cat dealer, if required.  Refit cover (20) with new sealing ring (26).

3-100

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Bypass valves (filter housing cooling system) – clean / replace Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Cleaning the screens Clean/replace the bypass valves (Fig. 3-97:) together with the bypass valves in the hydraulic oil reservoir.  Detach cover (10) together with sealing ring (15).  Unscrew bolts (12) and withdraw bypass valve.  Take off screen (13) together with sealing ring (14) and clean in white spirit or paraffin oil; replace, if required.  Re-assemble the bypass valve.  Insert bypass valve and fasten with bolts (12).  Refit cover (10) with a new sealing ring (15).

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose off used filter elements according to the environmental regulations.

Replacing the bypass valves and sealing rings Replace the bypass valves and sealing rings together with the bypass valves in the hydraulic oil reservoir.  Remove the bypass valve as described under "Cleaning the screens".  Re-assemble the bypass valve with a new screen (13) and a new sealing ring.  Insert bypass valve with new sealing ring (14) and fasten with bolts (12).  Refit cover (10) with a new sealing ring (15).

Fig. 3-97:

3-101

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic oil tank breather filters - replace Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose off used filter elements according to the environmental regulations.

Replacing the filter elements Two breather filters (Fig. 3-98:) on top of the hydraulic tank ensure venting of the hydraulic oil tank at varying hydraulic oil levels.

Inspect and replace the filter elements according to the maintenance plans.

In case the machine is working in very dusty conditions or in an environment with high air humidity, the filter elements must be inspected and replaced in shorter intervals.

This protects the hydraulic tank from beeing contaminated.

To replace the filter elements:  Unscrew bolts (2, Fig. 3-98:) and remove holding brackets (1).  Withdraw filter elements (4).  Check foam rings (3), replace if damaged.  Attach new filter elements (4) with foam rings (3) to their cylindrical connections  Install holding brackets (1) using bolts (2).

Fig. 3-98:

3-102

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Filter (control circuit and auxiliary control circuit) – check / replace Each of the control circuits is equipped with a highpressure filter (Fig. 3-99:).

Replacing the filter element Change filter element regulary and when the BCS indicates a contamination.  Unscrew filter housing (5, Fig. 3-99:) by counterclockwise rotation. Pour out the oil.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselfes may also be hot Wait until the hydraulic oil has cooled down before starting work on the filters.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

 Withdraw filter element (6) with a slight turn from the centering spigot in the filter head (9).

Shut off the engines.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose off used filter elements according to the environmental regulations.

 Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

 Check filter housing (5) as well as used filter surface for debris.  Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.  Install the new filter element (6) with a new, lightly oiled sealing ring (8) on the filter heads spigot by slightly turning it.

 Check for leaks after putting the hydraulic system into operation.

Checking for contamination and damage  Unscrew filter housing (5, Fig. 3-99:) by counterclockwise rotation. Pour out the oil.  Withdraw filter element (6) with a slight turn from the centering spigot in the filter head (9).  Clean filter element (6) in white spirit or paraffin oil and check for contamination and damage.  If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.

Fig. 3-99:

 Replace filter element (6) if it is damaged.  Check seal (8) and replace, if required.  Re-assemble the filter element in reverse order.  Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check for leaks after putting the filter into operation.

3-103

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing High-pressure filter for working hydraulics – check / replace

Checking for contamination and damage

To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with four high-pressure filters (9, Fig. 3-100:).

The filters are attached to the valve block in front of the hydraulic oil tank, they are accessible from the pump compartment.

 



 

   



Unscrew drain plug (11, Fig. 3-101:) and drain the hydraulic oil from the filter housing (9).

(Place a suitable resipient under the filter housing).

Unscrew bottom part of filter housing (9).

Disengage filter element (15) with a slight turn from ist retaining catch and withdraw from filter housing (9).

Clean filter element (15) in white spirit or paraffin oil and check for contamination and damage.

If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.

Replace filter element (15) if it is damaged.

Check seals (10 and 14) and replace, if required.

Re-assemble the filter element in reverse order.

Screw in the filter housing (9) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Check for leaks after putting the filter into operation.

Fig. 3-100:

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose off used filter elements according to the environmental regulations.  Shut off the engines.  Depressurize the hydraulic system.  Clean the filter block and the filter housings carefully.

3-104

Fig. 3-101:

Replacing the filter elements  Detach the filter element as described under "Checking / cleaning the filter elements".  Clean filter housing (9, Fig. 3-101:) and the sealing faces at the filter head with white spirit or paraffin oil.  Insert new filter element into filter housing (9) and refit to the filter head with new, lightly oiled sealing rings (10 and 14) and a new retaining ring (13).  Screw in the filter housing (9) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check high-pressure filter for leaks after putting it into operation.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing High-pressure filters for the servo circuit – check / replace The hydraulic shovel is equipped with two highpressure filters (Fig. 3-102:) for the servo circuit.

Both filters are located in front of the hydraulic oil reservoir.

Checking for contamination and damage  Detach flange (4, Fig. Fig. 3-103:).  Remove filter housing and pour out used oil.  Withdraw filter element (6) from filter housing (5).  Clean filter housings and sealing faces at filter head with white spirit or paraffin oil and check for contamination and damage.  If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.  Insert new filter element into filter housing (5) and refit to filter head with a new, lightly oiled sealing ring (8).  Check the high-pressure filter for leaks after putting it into operation.

Fig. 3-102:

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose off used filter elements according to the environmental regulations.

Fig. 3-103:

 Shut off the engines.  Depressurize the hydraulic system.

Replacing the filter elements

 Clean the filter block and the filter housings carefully.

 Detach the filter elements as described under "Checking the filter elements".  Install new filter element (6, Fig. 3-103:) and re-assemble with a new, lightly oiled sealing ring (7).  Check the high-pressure filter for leaks after putting it into operation.

3-105

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing High-pressure filters for feeding circuits and slewing pumps – check / replace The hydraulic shovel has four high-pressure filters (Fig. 3-104:) for the feeding circuits of the slewing pumps. Two high-pressure filters each are installed beside the pump drive gearbox.

Checking/cleaning the filter element  Detach flange (4, Fig. 3-105:).  Remove filter housings and pour out used oil.  Withdraw filter element (6) from filter housing (5).  Clean filter housings and sealing faces at filter head with white spirit or paraffin oil and check for contamination and damage.  If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.  Insert new filter element into filter housing (5) and refit to filter head with a new, lightly oiled sealing ring (8).  Check the high-pressure filter for leaks after putting it into operation.

Fig. 3-104:

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping hydraulic oil and discard without polluting the environment.

Dispose off used filter elements according to the environmental regulations.

Fig. 3-105:

Replacing the filter elements  Shut off the engines.  Depressurize the hydraulic system.  Clean the filter block and the filter housings carefully.

 Detach the filter elements as described under "Checking the filter elements".  Install new filter element (6, Fig. 3-105:) and re-assemble with a new, lightly oiled sealing ring (7).  Check the high-pressure filter for leaks after putting it into operation.

3-106

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic oil – change Read and observe the "Inspection and servicing - Safety instructions" chapter.

Avoid mixing of different hydraulic fluids (see chapter “Avoid mixing of different hydraulic fluids” for more information).

Shut off the engines.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Skin contact with hydraulic oil may cause skin injury.

Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Do not start up the drive engines when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with CM Long Term Hydraulic Fluid HSS (SAP Part-No. 1526545). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the CM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the CM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-107

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Drawing off hydaulic oil  Bring the hydraulic oil to operating temperature (abt. 50 ° C / 122°F).  Retract the hydraulic cylinders as far as possible and stand the attachment on the ground.  Shut off the engines.  Drain the hydraulic oil at express couplings (1, Fig. 3-106: and 2, Fig. 3-107:).

Drawing off hydaulic oil using the service station The hydraulic oil can also be drawn off through the service station (Fig. 3-108:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Bring hydraulic oil to operating temperature (ca. 50° C / 122°F).  Retract hydraulic cylinders as far as possible and stand attachment on the ground.  Shut off the engines.  Unscrew cap of express coupling (10).  Connect hose line of the service vehicle.  Draw off hydraulic oil.  Remove hose line. The coupling closes automatically.  Bolt on protective cap.

Fig. 3-106:

 Place suitable recipients under the drain valve (1) of the hydraulic oil reservoir. For the required capacity refer to the "Filling quantities Oil" table.

The use of the hose line is described in the "Hose line for oil and cooling-liquid changes" section.  Unscrew the hose line; the oil drain valve closes automatically.  Bolt protective cap back in place.

Fig. 3-108:

Fig. 3-107:

3-108

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Cleaning the hydraulic oil reservoir Explosion hazard.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engines.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Use diesel fuel or a special flushing oil.

Skin contact with hydraulic oil may cause skin injury.

Avoid skin contact.

Wear protective gloves and firm working clothing.

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.

 Drain off hydraulic oil as described under "Draining off the hydraulic oil".  Remove cap (3, Fig. 3-109:).  Detach the return-flow filter.  Place a collecting recipient for the flushing oil under the hydraulic oil reservoir.  Clean the inside of the hydraulic oil reservoir with diesel fuel or flushing oil.

Remove all sediments and also the residues of the cleaning agent thoroughly.  Refit cap (3).

Fig. 3-109:

3-109

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Filling in hydraulic oil Fill in hydraulic oil through the return-flow filters.  Remove cap (16, Fig. 3-110:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of the decal (2) beside the inspection glass (1, Fig. 3-111:). (oil grade see: "LUBRICANTS/ CONSUMABLES").

 Connect filling hose express coupling of the service vehicle. Fill in hydraulic oil until the oil level is between the “min” and the “max marks of the decal (2) beside the inspection glass (1, Fig. 3-111:). (oil grade see: "LUBRICANTS/ CONSUMABLES").

 Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir.

Top up with oil, if required.  Refit cap (16, Fig. 3-110:).  Start the engines and monitor the hydraulic oil level. Bring the hydraulic oil to operating temperature (approximately 50 ° C / 122°F).  Move the attachment in the position where the stick is vertical and the bucket leveled on the ground.  Shut off the engines.  Verify the oil level is between the “min” and “max” marks of the signs (2) near the level indicator glass tube (1, Fig. 3-111:).

Fig. 3-110:

Fig. 3-112:

 The oil level is also displayed on the BCSscreen (Fig. 3-113:).  Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir.

Top up with oil, if required.  Unscrew the hose line. The express coupling closes automatically.  Bolt protective cap back in place.  Start the engines and monitor the hydraulic oil level. Bring the hydraulic oil to operating temperature (approximately 50 ° C / 122°F).  Move the attachment in the position where the stick is vertical and the bucket leveled on the ground.  Shut off the engines.  Verify the oil level is between the “min” and “max” marks of the signs (2) near the level indicator glass tube (1, Fig. 3-111:).

Fig. 3-111:

Hydraulic oil can also be filled by means of the service station (Fig. 3-112:).  Unscrew cap of express coupling (10).

3-110

Fig. 3-113:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic system – vent Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented  after assembly on site and prior to initial commissioning, 

before each recommissioning of the hydraulic shovel, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes,



after each hydraulic oil change,



after replacement of hoses or lines.

Fig. 3-115:

Venting the hydraulic components 

Hydraulic pumps and hydraulic motors (with electric motors shut off):

Always admit oil first to that side of the cylinder where the piston (2) is. This is

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

 the piston-side port (3) when the piston rod is retracted (1, Fig. 3-114:),  the rod-side port (4) when the piston rod is extended (1, Fig. 3-115:).

If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the pistonside port (4).

When oil is admitted for the first time to the cylinder, the oil flow must be reduced. Therefore extend or retract the piston rod as slowly as possible.

The bolts/nozzles of the following components must be opened until oil emerges bubble-free from the opening:

Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the attachment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions. 

Hydraulic cylinder: Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-114: and Fig. 3-115:) must be either completely retracted or completely extended.

Always vent only the system section that has been opened.



the travel brake valve at the venting bolt,



the oil cooler manifold at the mini-measuring ports,



the servo system at the venting bolts of the control blocks (under the servo caps),



the intake line at the venting bolt (with drive motors stationary).

Fig. 3-114:

3-111

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic oil cooler – Clean Risk of injury from rotating cooler fan blades.

Never start cleaning work until the cooler fan blades have stopped turning.

Shut off the engines.

Switch off the electrical system.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

Allow the hydraulic oil cooler to cool down.

Wear protective gloves and firm protective clothing.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan.

The speeds of the fan motors (1, Fig. 3-117:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C / 140°F. Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded.

Do not clean radiators with a wire brush or similar hard objects.

Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the air flow. Hold the nozzle approximately 6 mm (0.25 inch) away from the fins. Slowly move the air nozzle in a direction that is parallel with the tubes.

This movement will remove debris that is between the tubes.

Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides.

Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

Inspect the radiators for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and

3-112

other debris. Clean the radiator or repair, if necessary.

Clean The hydraulic oil coolers are located in the oil cooler module (3, Fig. 3-116:).

Fig. 3-116:

Radiators located in the oil cooler module: 3 – Hydraulic oil coolers.

4 – Pump drive gearbox oil coolers.

 Shut off the engines.  Remove any accumulated dirt.  Clean the fan blades (2, Fig. 3-117:).  Clean the radiators with a jet of water or compressed air from outside to inside.  Leave hydraulic oil coolers to dry.  Check the hydraulic motors (1) for free movement.

In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

Fig. 3-117:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Electronic hydraulic shovel control – clean / lubricate Joystick At regular intervals acc. to the maintenance plans:  Loosen gaiter and move upwards.  Apply a thin layer of low temperature grease on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-118:) to prevent jamming of the joysticks.

Pedal At regular intervals acc. to the maintenance plans:  Remove old grease and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-119:).  Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

 Refit gaiter using a cable strap.

Fig. 3-119:

Fig. 3-118:

3-113

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Pressure accumulator - Emergency lowering To permit the attachment to be lowered in an emergency, the machine is equipped with a pressure accumulator (1, Fig. 3-120:).

The pressure accumulator (1) is located in the upper structure and is accessible from the ground.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been released

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Fig. 3-120:

Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Group II p  l bar and p·x l  200

3-114

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Inspections prior to commissioning at the factory at the place of use Pressure testing Inspection certificate Prototype and pressure test (Check of correctness and certified by the manufacturer correct installation) issued by an expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and fluid.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing PUMP DRIVE GEARBOX Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the engines.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Park and secure the machine as described in the "Securing the machine" section.

Read and observe: "Inspection and servicing Safety instructions”.

Pump drive gearbox oil level check / top up with oil The pump drives must be in operation for at least 30 minutes prior to checking the oil level, because oil is accumulated in the pump mounting flanges for lubrication of the profile hollow shaft. Checking the oil level when the pump drives are cold give wrong results.

Observe the information decals attached to the gearbox housings near the dipsticks.  Unscrew dipstick (1, Fig. 3-121: and Fig. 3-122) and wipe clean.

Fig. 3-121:

 Insert dipstick (1) again until the thread lies on top of the dipsticks tube (2, Fig. 3-122).

Do not screw in.  Pull out dipstick (1) a second time. Oil level should be between the two dipstick markers “min” and “max” Top up with fresh gearbox oil if required through opening of breather filter (2, Fig. 3-121:).

(Oil grade see: “LUBRICANTS / CONSUMABLES”).

Fig. 3-122

 Inspect dipstick’s sealing ring and replace if damaged.  Screw in dipstick (1) back in place.

In case of significant oil losses check for leaks at the gearbox and on all components of the gearbox oil cooling system.

Too much oil in the gearbox may be a signal of defective seals at hydraulic components. Contact your Caterpillar dealer service.

3-115

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Pump drive gearbox oil sample – obtain Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Pre-chambers oil level – check / top up with oil The oil level in the pre-chambers is visually at the inspection glas (3, Fig. 3-123) of the expansion reservoir (1).

The oil level should reach up at least to the middle of the inspection glas (3).

Top up with gearbox oil, if required (Oil grade see: „LUBRICANTS / CONSUMABLES“).  Unscrew breather valve (2).  Top up with fresh oil.

Obtain an oil sample of the pump drive gearbox oil through the opening for the oil level dipstick (1, Fig. 3-121: and Fig. 3-122).

Refer to CGMHMS publication EM031023, “Service Manual for Oil Samples and Oil Analysis” for more information.

 Screw breather valve (2) back in place.

For additional information about taking an oil sample, refer to:  Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”, 

Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

Fig. 3-123

3-116

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Pump drive gearbox oil - change Change the oil when the machine is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Recommendation: If the gearbox oil is heavily soiled, the gearbox should be flushed with fresh gearbox oil. In this case contact your Caterpillar dealer.

Note: The oil level is to be checked after about 30, 60 and 240 minutes running time as oil collects in the mounting flanges or is dammed there to lubricate the splined hollow shafts. The gearbox oil cooling system is also to be filled with oil. Therefore it is absolutely necessary to check the oil level and top up with oil up to the correct level.

Draining off oil The gearbox oil is drained with the service station (Fig. 3-124:) through  express coupling (4) for the lefthand pump drive gearbox, 

express coupling (5) for the righthand pump drive gearbox.

 Unscrew cap of express coupling and connect hose line of the service vehicle.  Remove hose after the oil has been drawn off.

The coupling closes automatically.  Screw on protective cap.

Fig. 3-124:

Filling in oil (Oil grade see “LUBRICANTS / CONSUMABLES”).

The gearbox oil is filled in with the service station (Fig. 3-124:) through  express coupling (4) for the left-hand pump drive gearbox 

express coupling (5) for the right-hand pump drive gearbox.

 Unscrew protective cap of express coupling and connect hose line of the service vehicle.  Fill in gearbox oil until the oil level reaches the ”max” mark on dipstick (1, Fig. 3-125:).  Remove hose after the oil has been filled in.

The coupling closes automatically.

Fig. 3-125:

 Screw on protective cap.  Start engine and run for a maximum of two minutes at idle speed, then stop. The pump drive oil cooling circuit has now been filled with oil.  Check gearbox oil level and top up to the correct filling level.  Check for leaks and for correct filling level after putting the machine back into operation. Top up with gearbox oil if required.

3-117

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Filling in oil (oil grade see: „LUBRICANTS / CONSUMABLES“).  Fill in oil through the bore of breather valve (2, Fig. 3-126:). The oil level must reach the upper mark on dipstick (1, Fig. 3-127:).

The gearbox oil can also be filled in with the service station (Fig. 3-128:) through  express coupling (4) for the lefthand pump drive gearbox, 

 Remove cap of express coupling and connect hose line of the service vehicle.  Fill in oil. The oil level must reach the upper mark on dipstick (1, Fig. 3-127:).  Remove hose after the oil has been filled in.

The coupling closes automatically.  Push on protective cap.

express coupling (5) for the righthand pump drive gearbox.

Fig. 3-128:

Fig. 3-126:

Fig. 3-127:

3-118

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Pump drive gearbox prechambers - change the gearbox oil Draining off oil  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Filling quantities - Oil" table.  Unscrew plug (7, Fig. 3-129) and drain off oil.  Drain off oil from the expansion reservoir.  Screw plug (7) back in place.

Pump drive gearbox breather replace The pump drive gearbox is vented through a breather valve, mounted on top of the gearbox housing (2, Fig. 3-130:).  Replace breather valve in accordance with the servicing plan.  Clean area around the breather to prevent contamination of the gearbox.  Unscrew breather filter and replace by a new one.

Filling in oil  Filling in oil see “Pre-chambers – Checking oil level / Topping up with oil”

Fig. 3-130:

Fig. 3-129

3-119

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Pre-chamber breather - replace The pre-chambers of the pump drive gearbox are vented through a breather valve, mounted on top of the expansion reservoir (2, Fig. 3-131:).  Replace breather valve in accordance with the servicing plan.  Clean area around the breather to prevent contamination of the gearbox.  Unscrew breather filter and replace by a new one.

Fig. 3-131:

3-120

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Pump drive gearbox lube oil filters - replace Check filter tell-tales (1, Fig. 3-132:) regulary - at operating temperature - for indication of contamination.

If the red sector is visible through the transparent cap (2), the filter element must be cleaned or replaced.

Filter element (5) must be replaced after having been cleaned 8 - 10 times; at the latest however, after 1000 operating hours.  Remove flange (3, Fig. 3-133:).  Pour oil out of filter pot (4) and remove filter element (5).  Clean filter element in white spirits or petroleum, replace if damaged

Fig. 3-132:

 Clean filter head (6, Fig. 3-132:) and filter pot (4). Check o-ring (7, Fig. 3-133:) for damage; replace if necessary.  Oil the o-ring lightly. Place filter element into filter pot and re-assemble.  Check filters for leakages after recommencing operation.

Fig. 3-133:

3-121

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing SWING GEARBOX Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the engines.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Park and secure the machine as described in the "Securing the machine" section.

Read and observe: "Inspection and servicing Safety instructions”.

Swing gearbox oil sample – obtain

Swing gearbox oil level - check the oil level / top up with oil  Park the machine as described under "Securing the machine".  Screw out dipstick (1, Fig. 3-134:) and wipe clean.  Insert dipstick (1) fully again (do not screw in) and withdraw a second time.

The oil level must reach up at least to the lower mark on dipstick (1).  Top up with gearbox oil through the opening of plug (4), if required.

(Oil grade see: „LUBRICANTS / CONSUMABLES“).

To reach plug (4) remove cover plate above swing gearbox.  Screw dipstick (1) back in place.

Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Obtain an oil sample of the swing drive oil through the opening for the oil level dipstick (1, Fig. 3-134:).

Refer to CGMHMS publication EM031023, “Service Manual for Oil Samples and Oil Analysis” for more information.

For additional information about taking an oil sample, refer to:  Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”, 

Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

3-122

Fig. 3-134:

Swing gearbox - vent The gearbox is vented through breather filter (2, Fig. 3-134:).

Clean breather filter in accordance with the servicing plan.  Unscrew breather filter (2), clean in white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter (2) back in place.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Swing gearbox oil - change Carry out oil change when gearoil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Draining off oil  Remove cover plate from the gearboxes.  Unscrew plug (4, Fig. 3-136:) to ventilate the gearbox.  Attach draining hose to the drain valve and drain off oil completely.

The drain valves (arrow, Fig. 3-135:) are accessible from the undercarriage.

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid changes" chapter.

Fig. 3-135:

 Drain off gearbox oil.  Remove hose. The oil drain valve closes automatically.  Fill in fresh gearbox oil, see: “Filling in new oil / Topping up”.

Fig. 3-136:

3-123

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Filling in new oil / Topping up (oil grade see: „LUBRICANTS / CONSUMABLES“).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Remove cap of express coupling (12, Fig. 3-137:) and connect hose line for filling swing gearbox oil of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Connect the gearbox filling hose (Fig. 3-138:) to express coupling near to the hydraulic reservoir (arrow, Fig. 3-139:).  Connect other end of the filling hose (end with ball valve) to express coupling at the swing gearbox (arrow, Fig. 3-140:).

Fig. 3-138:

 Open ball valve at the filling hose (Fig. 3-138:) and fill swing gearbox with gearbox oil.  Check filling level at dipstick.  After filling in oil, disconnect filling hose.  Screw in plug (4, Fig. 3-136:) again.  Attach cover plates to the gearboxes.

Fig. 3-139:

Fig. 3-137:

Fig. 3-140:

3-124

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing TRAVEL GEARBOX (PN 2763213)

Pre-chamber / spur wheel section oil level - check / top up with oil

Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the engines.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

 Check oil level at inspection glass (2, Fig. 3-142:). The oil level should reach up to the middle.

If required, screw out plug (4) and top up with oil (oil grade see: „LUBRICANTS / CONSUMABLES“).

Park and secure the machine as described in the "Securing the machine" section.

Read and observe: “Inspection and ServicingSafety Instructions”.

Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

Travel gearbox oil level - check / top up with oil  Move the hydraulic shovel into such a position that the Screw plugs (1, 2 and 3, Fig. 3-141:) are in the displayed position.  Unscrew checking screw (1).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required. (oil grade see: „LUBRICANTS / CONSUMABLES“).

Fig. 3-142:

Hydraulic motor chamber oil level - check / top up with oil  Unscrew checking bolt (6, Fig. 3-143:). The oil level should reach up to the lower edge of the opening. If required, screw out plug (5) and top up with oil through the opening.  Screw checking plug (6) back in place.

 Screw checking plug (1) back in place.

Fig. 3-143: Fig. 3-141:

3-125

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Travel gearbox oil - change Draining off oil Carry out oil change when gearoil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-144:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2) and drain off the oil completely.

Slackening plug (3) allows the oil to run out more readily.  Clean screw plugs (2 and 3).

Pre-chamber / spur wheel section oil - change Draining off oil  Place a collecting recipient for used oil under the pre-chamber.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (3, Fig. 3-145:) and drain off the oil completely.

Slackening plug (4) allows the oil to run out more readily.  Clean screw plugs (3 and 4).  Screw plug (3) back in place.

Filling in oil

 Screw plug (2) back in place.

(Oil grade see: „LUBRICANTS / CONSUMABLES“).  Unscrew screw plug (4).

Filling in oil

 Fill in oil through opening of plug (4) until it reaches the middle of inspection glass (2).

(Oil grade see: „LUBRICANTS / CONSUMABLES“).  Unscrew screw plugs (1 and 3).

 Screw plug (4) back in place.

 Fill in oil through opening in plug (3) until it flows out of opening in plug (1).  Screw plugs (1 and 3) back in place.

Fig. 3-145:

Fig. 3-144:

3-126

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic motor chamber oil change

Travel gearbox oil sample – obtain

Draining off oil  Place a collecting recipient for used oil under the hydraulic motor chamber.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

 Unscrew drain plug (7, Fig. 3-146:) and drain off the oil completely.

Slackening plug (5) allows the oil to run out more readily.  Clean screw plug (7).  Screw plug (7) back in place.

Filling in oil (Oil grade see: „LUBRICANTS / CONSUMABLES“).  Unscrew screw plug (6).  Fill in oil through opening of plug (5) until it flows out of opening of plug (6).

Obtain an oil sample from the following travel gearbox housings: • Planetary housing (1, Fig. 3-144:).

• Spur gear housing (4, Fig. 3-145:).

Refer to CGMHMS publication EM031023, “Service Manual for Oil Samples and Oil Analysis”.

For additional information about taking an oil sample, refer to: 

Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”,



Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

 Screw plugs (5) and (6) back in place.

Travel gearbox breather filter clean / replace  Unscrew breather filter (1, Fig. 3-147:) and clean in white spirit or parafin.

Replace according to maintenance plan.

Fig. 3-146:

Fig. 3-147:

3-127

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing TRAVEL GEARBOX (PN 614-2403) Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the engines.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Hydraulic motor chambers oil level - check / top up with oil  Unscrew plugs (5, Fig. 3-149:) at the side of the hydraulic motor chambers. The oil level should reach up to the lower edge of the opening. Top up with gearbox oil through the opening if required.(oil grade see: „LUBRICANTS / CONSUMABLES“).  Screw plugs (5) back in place.

Park and secure the machine as described in the "Securing the machine" section.

Read and observe: “Inspection and ServicingSafety Instructions”.

Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

Travel gearbox oil level - check / top up with oil  Move the hydraulic shovel into such a position that the plugs (1, 2 and 3, Fig. 3-148:) are in the displayed position.  Unscrew checking plug (1).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

(Oil grade see: „LUBRICANTS / CONSUMABLES“).

Fig. 3-149:

Travel gearbox oil sample – obtain Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot, too.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

 Screw checking plug (1) back in place.

Fig. 3-148:

Obtain an oil sample of the travel gearbox oil through the bore of plug (1, Fig. 3-148:).

Refer to CGMHMS publication EM031023, “Service Manual for Oil Samples and Oil Analysis”.

For additional information about taking an oil sam-ple, refer to:  Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” “S·O·S Oil Analysis”, 

3-128

Special Publication, PEGJ0047, “How To Take A Good Oil Sample”.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Travel gearbox oil - change Draining off oil Carry out oil change when gearoil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil  Move the hydraulic shovel into such a position that the screw plug s (1, 2 and 3, Fig. 3-150:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2) and drain off the oil completely.

Slackening plug (3) allows the oil to run out more readily.  Clean screw plugs (2 and 3).  Screw plug (2) back in place.  Unscrew plugs at the hydraulic motor side of the gearbox (2, Fig. 3-151:) and drain the residual oil.  Clean plugs and screw back in place.

Hydraulic motor chambers oil change Draining off oil  Place a collecting recipient for used oil under the pre-chamber.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plugs (4, Fig. 3-151:) and drain off the oil completely.

Slackening plug (1) allows the oil to run out more readily.  Clean screw plugs (1 and 4).  Screw plugs (4) back in place.

Filling in oil (Oil grade see: „LUBRICANTS / CONSUMABLES“).  Unscrew plugs (1) and (5).  Fill in oil through opening of plug (1) until it flows out of opening of plugs (5).  Screw plugs (1) and (5) back in place.

Filling in oil (Oil grade see: „LUBRICANTS / CONSUMABLES“).  Unscrew plugs (1 and 3).  Fill in oil through opening in plug (3) until it flows out of opening in plug (1).  Screw plugs (1 and 3) back in place.

Fig. 3-151:

Fig. 3-150:

3-129

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing CRAWLER TRACKS

Upper roller fastening – check

Cleaning

 Check fastening bolts (3, Fig. 3-153:) regularly for tightness.

Clean tracks, track and upper rollers, sprockets and idlers regularly and whenever required. Cleaning is especially important in winter to prevent:  the tracks from being thrown off, 

oil from leaking out of track and upper rollers, sprockets and idlers,



excessive wear,



the track from breaking.

 Tighten screws with a torque wrench to the prescribed tightening torque (see: "Service Manual").

To clean the tracks:  Raise one side of the hydraulic shovel with the attachment and allow track to turn.  Clean the side member supporting the track.  Clean support and track rollers (1 and 2, Fig. 3-152:) thoroughly.  Clean the sliding planes on the idler guides.

Fig. 3-153:

Undercarriage – check for leaks and free movement

Fig. 3-152:

Track roller fastening – check Track roller fastening  Check fastening bolts (4, Fig. 3-153:) regularly for tightness.  Tighten screws with a torque wrench to the prescribed tightening torque (see: "Service Manual").

3-130

Check the upper rollers, the track rollers, and the idler wheels for possible leakage.

Check the upper rollers, the track rollers, and the idler wheels for free movement.

Check the surface of the track, the upper rollers, the track rollers, the idler wheels, and the drive sprockets. Look for signs of wear and loose mounting bolts.

Listen for any abnormal noises while you are moving slowly in an open area.

If abnormal wear exists or abnormal noises or leaks are found, consult your Caterpillar dealer.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Track roller - lubricate (Not applicable at machines equipped with undercarriage lubricating system).

The track rollers (2, Fig. 3-153:) have a lifetime grease filling with Tribol® (see chapter “LUBRICANTS / CONSUMABLES”).

To check the correct filling level, unscrew hex head screw (7) on the visible front side of the roller.

Grease must reach the lower edge of the bore.

Lubricating the track rollers is necessary only after repair work.

To do so:  Remove plate below the skid plate (arrow, Fig. 3-145). The lubrication lines are accessible then.  Unscrew plug (6, Fig. 3-155:) from breather line.

Fig. 3-154:

 Remove dust cap (1) from coupling (2).  Remove dust cap (4) from plug (5).  Connect grease hose (3) to coupling (2).  Press in grease as long as used grease emerges from breather line.  Screw on plug (6) to breather line.  Disconnect the grease hose (3).  Fix dust caps (1 and 4) back in place.

Fig. 3-155:

3-131

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Track tensioning system

Technical data

Function

Track tensioning pressure ca. 70 bars / 1015 psi Pressure limiting valve 330 bars / 4786 psi Gas pressure in pressure accumulator (nitrogen 50 bars / 725 psi filling pressure)

Each crawler track is kept automatically and constantly tensioned by a hydraulic track tensioning system. After starting one or both engines the track tensioning system is pressurized.

Prior to start of operation and after repair work on the track tensioning system make sure that the stop cocks (5, Fig. 3-156:) are opened to make the system functional.

Fig. 3-156: and Fig. 3-157: show parts of the tracks and the tensioning system:

Releasing the track tension For cleaning and servicing work, the tracks can be slackened.

To do so:  Stop the engines.  Open both pressure limiting valves (7, Fig. 3-157:) to slacken the tracks.  After the work, screw down the pressure limiting valves (7) to the limit stop.

Fig. 3-156:

1 2 3 4 5

Pressure accumulator Pressure cylinder Pressure limiting valve Mini- measuring port Stop cock valve

The tensioning system is under permanent pressure of ca. 70 bars / 1015 psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engines have been started. Retensioning is not required.

The pressure-limiting valves (3) are preset to a pressure of 330 bars / 4786psi and sealed in this position. The lead seal must not be removed and the pressure setting of 330 bars / 4786psi must not be changed.

The pressure accumulators have to be checked for correct nitrogen pressure every 1000OH. Diaphragm has to be replacd every 5000OH (see “Service Manual, chapter 8”).

3-132

Fig. 3-157:

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner.

They are no substitute for the inspections as required by the "Pressure Vessel Regulations".

Before checking the gas charging pressure (nitrogen filling pressure) in the pressure accumulator, the track must first be slackened, i.e. the hydraulic part of the tensioning system must be depressurized. See: "Function".

Tab. 3-1

Group IV p  l bar p·x l  1000

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Internal inspection: every 10 years for noncorrosive fluids; otherwise pressure testing every 5 years: every 10 years by an expert

3-133

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing (1, Fig. 3-159:) and the pinion (2) are enclosed in a housing (3, Fig. 3-160:). The housing forms a grease-filled trough in which the pinion of the swing mechanism moves.

Shut off the engines.

Wear protective gloves and firm protective clothing.

Swing ring – Instructions The grease filling must be replaced:  when repairs have been carried out on the swing ring, the swing ring seals or the swing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the swing ring.

Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

Bearing races

Fig. 3-159:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-158:). The amount of grease used up during operation is replenished by the central lubricating system.

The housings have a check opening which is closed with a cover (2, Fig. 3-160:). For checking, the cover must be removed.

The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing .

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-158:).

Fig. 3-160:

Fig. 3-158:

3-134

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Swing ring grease filling – check Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines.

Wear protective gloves and firm protective clothing.

At regular intervals:  check internal gearing and teeth of swing mechanism pinion for condition

Swing ring - fill in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Add grease when  the housing has been replaced, 

old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never swing the upper structure when refilling grease.

 check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm / 0.78“ of grease over its whole circumference (Fig. 3-161:).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued swing movements.

Swing ring bolts - check for tightness The fastening bolts of the swing ring in the upper structure and the undercarriage are tightened with their respective torques (see: "Service Manual").

When these values are reached, the fastening bolts are perfectly tight.

Loosen slack bolts before tightening them with a torque wrench to the prescribed torques (see: "Service Manual").

Fig. 3-161:

3-135

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing CENTRAL LUBRICATING SYSTEM Central lubricating system - Design The hydraulic shovel is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those mentioned in the "Lubricating chart - Grease".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and at least one engine is running.

All greasing points connected to the system are greased at regular intervals.

The automatic greasing is interrupted when the engines are stopped with the idle timers.

The central lubricating system is controlled electrohydraulically by the PLC (Programmable logical controller).

The PLC is located in a switch box underneath the cab.

Fig. 3-163:

If a fault occurs, BCS gives a warning on the screen (Fig. 3-163:). This happens, for example, if the filter element in the hydraulic line is contaminated.

If one of the following faults occurs, BCS gives a warning and at the same time the grease pump is switched off:  Grease container is empty, 

Greasing pressure in the grease lines is below 250 bars (3626psi).

In this cases, BCS switches off the hydraulic function of the shovel/backhoe cylinders after 15 minutes. This prevents damages from lack of greasing.

Inform the responsible maintenance personnel immediately.

Keep on working after the fault has been fixed.

Fig. 3-162:

3-136

After the fault has been fixed, actuate the "Reset" button in the control column (64, Fig. 3-162:) or the “Reset” button in the control box located at the grease container. The buttons must be actuated for at least one second.

For further information on the function and setting refer to the Service Manual, chapters 9 and 11.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Central lubricating system - Function The grease is pumped by hydraulically driven pumps (2 and 3, Fig. 3-164:) via greasing lines from the grease container to the main distributors on the upper structure and on the undercarriage.

Pump (2) supports greasing points on upper structure and attachment, pump (3) supports the undercarriage (optional).

The control elements of the lubricating system are installed on a control panel (1) attached to the grease container.

As soon as the grease container is empty, the BCS (Fig. 3-165:) gives a warning signal (fault). In the event of a fault, the "dumping” function (shovel or backhoe cylinder) is switched off automatically after 15 min.

Work can be continued when the grease container is filled with grease.

Fig. 3-164:

Fig. 3-165:

3-137

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Grease container – fill up Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing system may cause malfunctions.

Fill up the grease container through the service station (Fig. 3-166:).  Switch on the indicator system with toggle switch (23, Fig. 3-166:). Monitoring lamp (22) lights up.  Unscrew the cap of the express coupling (11).  Connect the filling hose of the service vehicle.  When the grease container is full, the indicator lamp (34) lights up.

Grease container breather filter check / replace Check/change the breather filter of the grease container at regular intervals.  Unscrew wing nut on top of the breather filter.  Withdraw cover (1, Fig. 3-167:) and filter element (2).  Check the filter element (2) and replace if it is soiled or damaged.  Replace sealing rings of the filter element.  Re-install breather filter.

 Switch off the indicator system with toggle switch (23). Monitoring lamp (22) is off.  Remove the filling hose.

The express coupling closes automatically.  Refit the protective cap.

Fig. 3-167:

Fig. 3-166:

3-138

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Checking the greasing pressure

Grease line – unblock

Check regularly (accord. to the maintenance plan), whether the oil pressure indicated by pressure gauge (3, Fig. 3-168:) at the hydraulic oil filter is 55 - 60 bars / 798 - 870 psi.

The pressure is depending on temperature and viscosity of the oil and may vary.

This oil pressure is reduced so that the pressure indicated by pressure gauge (2) is 35 – 40 bars / 507 – 580 psi and by pressure gauge (1) is 49 – 51 bar / 711 – 740 psi.

The necessary greasing pressure of 320 bar / 4641 psi for the upper structure and 180 bar / 2611 psi for the lower carriage is generated by means of a pressure translator.

The greasing pressure for upper structure and attachment is indicated by pressure gauge (4). The greasing pressure for the undercarriage (optional) is indicated by pressure gauge (5).

In the event of deviating pressure values, shut off the engines and inform the responsible maintenance personnel. The central greasing system has to be checked.

In the event of faults at the central greasing system inform the responsible maintenance personnel immediately. Detailled information about the central greasing system can be found in the “Service Manual” chapter 11.

Even when the grease pump isn’t active, there can be residual pressures in the grease lines up to 30 bars (435psi).

Relieve this residual pressure before opening a grease line.

Put the hydraulic shovel back into operation only after the greasing system works properly and after having actuated the unloaded attachment for abt. 5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

Lower oil / grease pressure means that not all of the greasing points are supplied with grease.

Higher oil / grease pressure may cause bursting of a greasing line.

Fig. 3-168:

3-139

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Grease filter (filling the grease container) – check / replace Read and observe the "Inspection and servicing –Safety instructions" chapter.

Shut off the engines.

A grease filter (arrow, Fig. 3-169:) is installed in the grease filling line to the grease container.

Check / replace filter element regularly according to the maintenance plans.

Checking for contamination and damage  Unscrew the filter housing (4, Fig. 3-169:).  Withdraw the filter element (2) from the filter housing (4).

Replacing the filter element  Unscrew filter housing (4, Fig. 3-169:).  Withdraw filter element (2) from housing.  Remove the grease.  Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert the new filter element into filter housing and refit to the filter head with new, lightly oiled sealing rings (1 and 3).  Screw in the filter housing (4) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can easily loosened in case of maintenance work.  Check for leaks after putting the filter into operation.

 Remove the grease.  Clean the filter element (2) in white spirit or paraffin oil and check it for contamination and damage.  If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.  Replace the filter element (2) if it is damaged.  Insert the filter element (2) and a new sealing ring (1) into the filter housing (4) and reassemble it with a new, lightly oiled sealing ring (3) to the filter head.  Check for leaks after putting the lubricating system back into operation.

Fig. 3-169:

3-140

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Grease filter (grease lines) - replace Read and observe the "Inspection and servicing –Safety instructions" chapter.

Shut off the engines.

Two grease filters (arrows, Fig. 3-170:) are installed in the greasing lines to the grease distributors.

(Machines without a lubrication system for the under carriage do have one grease line filter only).

Check / replace filter element regularly according to the maintenance plans.

Checking for contamination and damage

Replacing the filter element  Unscrew filter housing (4, Fig. 3-170:).  Withdraw filter element (2) from housing.  Remove the grease.  Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert the new filter element into filter housing and refit to the filter head with new, lightly oiled sealing rings (1 and 3).  Screw in the filter housing (4) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can easily loosened in case of maintenance work.  Check for leaks after putting the filter into operation.

 Unscrew the filter housing (4, Fig. 3-170:).  Withdraw the filter element (2) from the filter housing (4).  Remove the grease.  Clean the filter element (2) in white spirit or paraffin oil and check it for contamination and damage.  If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.  Replace filter element (2) if it is damaged.  Insert the filter element (2) and a new sealing ring (1) into the filter housing (4) and reassemble it with a new, lightly oiled sealing ring (3) to the filter head.  Check for leaks after putting the lubricating system back into operation.

Fig. 3-170:

3-141

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing OTHER MAINTENANCE Engine – Clean Personal injury or death can result from high voltage.

Moisture can create paths of electrical conductivity.

Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “DO NOT OPERATE” .

Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on the engine.

Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Periodic cleaning of the engines is recommended.

Steam cleaning the engines will remove accumulated oil and grease. A clean engine provides the following benefits:  Easy detection of fluid leaks 

Maximum heat transfer characteristics



Ease of maintenance

If the engine is cleaned with a steam-jet cleaner, make sure that the jet is not directed towards electrical components.

If no steam-jet cleaner is available, the engines must be cleaned with suitable cleaning agents (cold cleaners).

Note: Caution must be used in order to prevent electrical components from being damaged by excessive water when you clean the engine. Avoid electrical components such as the alternator, the starter, and the ECM. Further servicing works not described are carried out by your Caterpillar dealer.

Travel Alarm – Test Move the machine in order to test the travel alarm.

Start the engines.

Raise the work tool in order to avoid any obstacles.

Make sure that there is adequate overhead clearance.

Use the travel pedals to move the machine forward. The travel alarm should sound.

Release the travel pedals in order to stop the machine.

Use the travel pedals to move the machine backward. The travel alarm should sound.

Stop the machine.

Lower the work tool to the ground.

Stop the engines.

3-142

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Radiator – Clean Radiators are located in the counterweight (Fig. 3-171:) and in the oil cooler module (Fig. 3-172:).

Note: Adjust the frequency of cleaning according to the effects of the operating environment.

Inspect the radiators for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the radiator, if necessary.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded.

Do not clean radiators with a wire brush or similar hard objects.

Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the air flow. Hold the nozzle approximately 6 mm (0.25 inch) away from the fins. Slowly move the air nozzle in a direction that is parallel with the tubes.

This movement will remove debris that is between the tubes.

Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides.

Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

In case of firmly adhering dirt, remove radiator and clean.

After cleaning, start the engines and accelerate the engines to high idle rpm. This procedure will help in the removal of debris and drying of the core.

Stop the engines. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.

Inspect the fins for damage. Bent fins may be opened with a “comb”. Inspect these items for good condition:  welds, mounting brackets, air lines, connections, clamps and seals.

Fig. 3-171:

Radiators located in the counterweight: 1 – Engine intake air aftercooler 2 – Engine cooling liquid

Fig. 3-172:

Radiators located in the oil cooler module: 3 – Hydraulic oil coolers 4 – Pump drive gearbox oil coolers

Make repairs, if necessary.

3-143

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Aftercooler Core - Clean/Test

Air conditioning filter - clean

Note: Adjust the frequency of cleaning according to the effects of the operating environment.

Inspect the aftercooler for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the aftercooler, if necessary.

For air-to-air aftercoolers, use the same methods that are used for cleaning radiators.

Note: If parts of the aftercooler system are repaired or replaced, a leak test is highly recommended.

Inspect these items for good condition:  welds, mounting brackets, air lines, connections, clamps and seals.

Clean or replace the filter mats in the air suction regulary.

The filter mats are located in the air conditioner housing (Fig. 3-174:) below the roof of the cab.  Open housing of air conditioner.  Clean or replace filter mats.  Close housing.

Make repairs, if necessary.

Contact your Caterpillar dealer for more information.

Fig. 3-174:

Fig. 3-173:

Radiators located in the counterweight: 1 – Engine intake air aftercooler 2 – Engine cooling liquid

3-144

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Attachment - check for cracks Check the welded joins of the attachment regulary.

Inspections must be carried out acc. to the "Structural Inspection Reports" every 500 OH. "Structural Inspection Report" forms for those inspections can be downloaded from the CGM HMS website, section "Support, Warranty".

If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonic test.

The inside located joins are accessible through the man-holes in stick (arrow, Fig. 3-175:) and boom (arrow, Fig. 3-176:).

Clam cylinder chamber - check for soiling In unfavourable circumstances during working operation loose material can reach the clam cylinders chambers in the shovel rearwall.

To avoid damage to the clam cylinders and their hydraulic lines and hoses, inspect the clam cylinder chambers before starting each working shift.

Fig. 3-177:

 Lift up the rubber cover plate of the clam cylinder chambers (arrows, Fig. 3-177:).  Remove all accumulated material from the chamber.

Fig. 3-175:

 Check cylinders and all hydraulic lines, hoses and connections for damage and leaks.

Fig. 3-176:

3-145

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Window panes - clean  Clean the outside of the cab windows from the walkways (see Fig. 3-178:).  Use a clean sponge or a soft cloth.  Wash the windows with a mild soap or with a mild detergent. Also use plenty of lukewarm water.  Rinse the windows thoroughly.  Dry the windows with a moist chamois or with a moist cellulose sponge.

Mirror – check / clean / adjust Adjust all mirrors as specified in this Operation and Maintenance Manual. Failure to heed this warning can lead to personal injury or death.

Slips and falls can result in personal injury. Use the machine's access systems when adjusting the mirrors.

Mirrors provide additional visibility around your machine.

Make sure that the mirrors are in proper working condition and that the mirrors are clean.

Adjust the rearview mirrors (if equipped) for the best visibility close to the machine.

Adjust all mirrors at the beginning of each work period and adjust the mirrors when you change operators.  Park the machine on a level surface.  Lower the work tool to the ground.  Stop the engine.  Adjust rear view mirrors in order to provide maximum visibility besides and behind the machine (arrow, Fig. 3-179:).

Hand tools may be needed in order to adjust the mirrors.

Fig. 3-178:

Fig. 3-179:

3-146

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Cameras – check / clean / adjust (If equipped) There are two remotely mounted cameras (1 and 2, Fig. 3-180:) on the machine that allow the operator greater visibility while machine operation.

The cameras can be positioned for best view but as a minimum should optimize the operator's visibility to the rear and far right side of the machine.

Check/Clean/Adjust all cameras as specified in this Operation and Maintenance Manual. Failure to heed this warning can lead to personal injury or death.

Slips and falls can result in personal injury. Use the machine's access systems when adjusting the cameras.

Note: In order to access the cameras it may be necessary to use a portable access system (ladder, stair assembly, man lift, or other portable access system) that is suitable and compliant to local regulations.

Make sure that the cameras are in proper working condition and that the cameras are clean.

Adjust the cameras for the best visibility close to the machine.

Check/Clean/Adjust all cameras at the beginning of each work period and check/clean/adjust the cameras when you change operators.  Park the machine on a level surface.

Fig. 3-180:

Note: The cameras are equipped with an internal heater to help counteract the effects of condensation, snow, or ice.

The cameras are sealed units. The cameras are not affected by high-pressure spray.

For more information on the camera system refer to: - Operation and Maintenance Manual, “Monitoring Cameras - Function”, - Camera manufacturer documentation which can be found in volume 5 “Components” of the shovels Technical Documentation.

 Lower the work tool to the ground.  Stop the engines.  Verify that there is no damage to: -

the camera housing, the camera lens window, the cameras mounting brackets and to the camera wiring.

 Use a soft, damp cloth or water spray in order to clean the camera lens windows. Avoid dry rubbing to protect the lens windows against scratches.  Adjust cameras in order to provide maximum visibility besides and behind the machine.

Hand tools may be needed in order to adjust the cameras.

3-147

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Horn – inspect / replace

Inspect

The horn is an important signal instrument to warn people around the hydraulic shovel.

Therefore, the signal horn has to be inspected and replaced at regular intervals according to the maintenance plans.

Fig. 3-181: shows a typical mounting location of the horn. The horn can be mounted elsewhere.

There can also be mounted several horns.

 Park the machine.

Note: Use a working platform or a man lift machine for work carried out in great height. Wear your personal protective equipment and approved fall protection equipment.

 Check the tight fit of the mounting screws of horn and bracket (Tightening torque = 79Nm / 58 lbf ft).  Check the condition of the bracket. Repair or replace if damaged.  Check the electrical connection. Repair or replace if the connection cable or plug connection is damaged or in case the plugs contacts are corroded.  Check the condition of the horn. If it is dirty, clean the horn. Replace the horn immediately if it is damaged.  Check the function.

Note: Wear hearing protection in the immediate vicinity of the horn.

If the horn does not sound or sounds inadequately / too quiet, it must be replaced immediately.

Replace  Disconnect the electrical connector in the power cable.  Unscrew the screws (1, Fig. 3-182:).  Remove the old horn from the bracket.  Mount the new horn with the screws (1) (Tightening torque = 79Nm / 58 lbf ft).  Connect the electrical connector to the power cable.

Fig. 3-181:

 Check the function.

Note: Wear hearing protection in the immediate vicinity of the horn.

Fig. 3-182:

3-148

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Seat belt – inspect

Seat belt – replace

Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. Replace any parts that are damaged or worn before you operate the machine.

Inspect buckle (1, Fig. 3-183:) for wear or for damage.

If the buckle is worn or damaged, replace the seat belt.

Inspect seat belt (2) for webbing that is worn or frayed. Replace the seat belt if the webbing is worn or frayed.

Inspect all seat belt mounting hardware for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight.

If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension.

Contact your Cat dealer for the replacement of the seat belt and the mounting hardware.

Note: The seat belt should be replaced within 3 years of the date of installation. A date of installation label is attached to the seat belt retractor and buckle. If the date of installation label is missing, replace belt within 3 years from the year of manufacture as indicated on belt webbing label, buckle housing, or installation tags (non-retractable belts).

The seat belt should be replaced within 3 years of the date of installation. A date of installation label is attached to the seat belt retractor and buckle (See Fig. 3-184: for example). If the date of installation label is missing, replace belt within 3 years from the year of manufacture as indicated on belt webbing label, buckle housing, or installation tags (non-retractable belts).

Consult your Cat dealer for the replacement of the seat belt and the mounting hardware.

Determine age of new seat belt before installing on seat. A manufacture label is on belt webbing and imprinted on belt buckle. Do not exceed install by date on label.

Complete seat belt system should be installed with new mounting hardware.

Date of installation labels should be marked and affixed to the seat belt retractor and buckle.

Note: Date of installation labels should be permanently marked by punch (retractable belt) or stamp (nonretractable belt).

If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.

Fig. 3-184:

Fig. 3-183:

Typical Example (Fig. 3-184:) (1) Date of installation (retractor) (2) Date of installation (buckle) (3) Year of manufacture (tag) (fully extended Web) (4) Year of manufacture (underside) (buckle)

3-149

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Hydraulic ladder, pressure accumulator To allow the hydraulic ladder (Fig. 3-185: and Fig. 3-186:) to be lowered in an emergency, the ladder mechanism is equipped with a pressure accumulator (1, Fig. 3-187:).

The pressure accumulator (1) is located in the upper structure and is accessible from the ground.

Fig. 3-185:

Fig. 3-186:

Fig. 3-187:

3-150

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

3-151

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing ON-BOARD CRANE, DRIVE UNIT (OPTIONAL) The drive unit supplies the crane with hydraulic power. The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

Crane engine More and detailed information about the diesel engine can be found in the Operating and Maintenance Manual for the crane engine.  Before each shift check engine oil level. If necessary top up with engine oil through opening of dipstick (3, Fig. 3-188:).  After each shift fill up fuel tank (1).  Regularly check batteries (4) and cable connections.  Regularly, at least once a year: - change engine oil, - replace engine oil filter, - check / replace air filter (2), - replace fuel filter.

Do not start engine with air filter (2) removed.

Hydraulic system For more and detailed information, see crane operating instructions.  Prior to each deployment, check the hydraulic oil level at the inspection glass (1, Fig. 3-189:); top up with hydraulic oil if necessary.  Check contamination of hydraulic oil filter regularly at contamination indicator (4, Fig. 3-188:).  Regularly, but at least once a year replace the hydraulic oil filter (3) and the breather filter (2).

On-board crane – lubricate Servicing work  Lubricate all bearings regularly and as required, and spray swing ring with a graphite spray (Fig. 3-190:) 1234-

bearing joint (column/boom) cylinder bearing swing ring

Fig. 3-188:

Fig. 3-190:

Fig. 3-189:

3-152

4 lube points 2 lube points 5 lube points Graphite spray

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing On-Board crane – check tightness of fastening bolts The hydraulic driven on-board crane (Optional) is fixed on the upper structure of the machine by means of 16 fastening bolts. The upper and lower fastening bolts (Fig. 3-191:) are important and safety relevant components, they carry all loads and forces of the crane.

Check tightness of all fastening bolts:  in regular intervals according to the maintenance plans and 

before every start of the on-board crane.

Check tightness of the fastening bolts by means of a torque wrench. The tightening torque for fastening bolts M20, quality 10.9, lightly oiled is: 557 Nm.

Fig. 3-191:

3-153

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING Hydraulic shovel – putting out of operation

Battery - storage

 Park the hydraulic shovel on firm and level ground.

 Check the acid density and the electrolyte level of the battery every two weeks.

 Set the attachment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.

 Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.

 Set all control element to "0".

During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C / 68°F. Observe the following points with regard to maintenance:  Clean the batteries.

 Keep the batteries clean and dry on the outside.

 Clean the machine.  Carry out a visual inspection of the hydraulic shovel.  Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.  Carry out engines preservation.  Protect all bright metal parts (e.g. piston rods) from rust and dirt.  Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.  Fill up the fuel tanks.  Remove the batteries; see: "Battery storage".  Secure the machine against unauthorized starting by: withdrawing the key from the key-switch, locking the cab door, securing all lockable hatches.  Cover up all openings.

Hydraulic shovel – recommissioning  Remove the covers.  Degrease / clean all protected components.  Remove engines preservation in acc. with the engine operationg anstructions.  Check the fuel level in tanks.  Check track tension (visual inspection).  Check level and condition of the cooling liquid in the cooling system.  Check grease filling in grease container.  Oil level

- drive engines, - swing gearboxes, - pump drive gearboxes, - travel gearboxes.

 Check oil level in hydraulic oil reservoir.  Check battery acid density and level.  Install batteries and reconnect.  Function checks:

- superstructure holding brake, - track brake, - lighting system, - signalling equipment.

 Vent the hydraulic system.

3-154

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing

3-155

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Inspection and servicing NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

3-156

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work 4 REPAIR WORK Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

4-1

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work

4-2

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work REPAIR WORK - SAFETY INSTRUCTIONS Operating instructions Never carry out repair work without having read and understood the operating instructions.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The Operation and Maintenance Manual must be kept with the machine at all times.

Repair personnel Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from CGM HMS GmbH or your Cat dealer.

Working in greater heights Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Prestressed units Never open defective prestressed units but replace them as an entirety.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

The Operation and Maintenance Manual contains no information on this point.

Dismantling components Never do dismantling while the machine is at operating temperature.

Oils, greases, or coolants may have a high temperature and result in burning or scalding.

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of CGM HMS GmbH. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the drive engines while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

4-3

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work CONFINED SPACES - SAFETY INSTRUCTIONS Work in confined spaces can lead to unexpected dangerous situations, such as  the formation of flammable vapours exploding during welding operations or 

the lack of oxygen and harmful gases causing loss of consciousness.

What are "confined spaces"?

Confined spaces on this machine are, for instance, components of the attachment such as the monoblock boom, the lower part of the boom, the stick or the hydraulic reservoir (Fig. 4-1: - Fig. 4-3:).

These components are provided with manholes.

Manholes offer access to the inside of these components in order to carry out inspections or repairs such as welding work.

Dangerous situations can also exist in other spaces which are not very often visited or which are badly ventilated. In these spaces, harmful or flammable gases can accumulate unnoticed.

Fig. 4-1:

Work in such spaces may only be carried out by specially qualified persons who have been instructed as to the situational risks.

Before visiting these spaces, the following safety precautions must be taken:  The narrow space must be ventilated for a prolonged time, e.g. with a blower. Do not blow oxygen into the space. Oxygen increases the risk of fire.

Fig. 4-2:

 Use your personal protective equipment, e.g. respiratory mask.  Use a safety harness and have a second person stand by with a rescue rope attached to the harness.  Evacuate the gases produced during welding.

Fig. 4-3:

4-4

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work REPAIR WORK - FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

4-5

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work REPAIR WORK - ENGINE Read and observe the "Repair - Safety instructions" chapter and the engine operating instructions before working on the engine.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine and allow to cool down.

Overhaul Considerations Reduced hours of operation at full load will result in a lower average power demand. A decreased average power demand should increase both the engine service life and the overhaul interval.

The need for an overhaul is generally indicated by increased fuel/oil consumption and/or by reduced power.

The following factors are important when a decision is being made on the proper time for an engine overhaul:  The need for preventive maintenance 

The quality of the fuel that is being used



The operating conditions



The results of the S·O·S analysis

Note: The aftertreatment system can be expected to function properly for emissions durability period, as defined by regulation. All prescribed maintenance requirements must be followed.

Oil Consumption as an Overhaul Indicator Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Carry out repair work only if the machine has been secured as described in the "Securing the machine" section of these operating instructions.

Check and replace V-belts only when the engine is stationary.

Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals.

Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases.

The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake specific oil consumption (BSOC) depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine.

When the oil consumption of engine has increased to three times the nominal oil consumption due to normal wear, the engine should be considered for overhaul. There may be a corresponding increase in blowby and a slight increase in fuel consumption.

Using Fuel Consumption for Calculating the Overhaul Intervals Experience has shown that overhaul life is most accurately based on fuel consumption. Use the actual records of fuel consumption, when possible.

These fuel consumption targets are a guide and may vary based upon actual customer applications, load factors, site conditions and maintenance practices.

4-6

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work Overhaul Options

Overhaul Recommendation

Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons:  Costly unplanned downtime can be avoided.

To minimize downtime, Caterpillar Inc. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. This will provide you with the best cost/value relationship.

Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life.



Parts can be reused according to Guidelines for Reusable Parts and Salvage Operations



The engine service life can be extended without the risk of a major catastrophe due to engine failure.



The best cost/value relationship per hour of extended life can be attained.

After Failure Overhaul If a major engine failure occurs and the engine must be removed, many options are available. An overhaul should be performed if the engine block or the crankshaft needs to be repaired.

A lower rebuild cost can be achieved by utilizing:  Specially designed Caterpillar engine features 

Caterpillar dealer exchange components



Caterpillar Inc. remanufactured exchange components

Rebuild or Exchange Cylinder Head Assembly, Connecting Rods, Pistons, Cylinder Liners, Turbocharger, Cylinder Packs, Oil Pump, and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications. The Special Publication, SEBF8029 lists the reusability publications that are needed for inspecting the engine parts.

If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline, the parts should be reused.

Parts that are not within the established inspection specifications should be dealt with in one of the following manners:  Salvaging 

Repairing



Replacing

Using out-of-spec parts can result in the following problems:  Unscheduled downtime 

Costly repairs



Damage to other engine parts



Reduced engine efficiency



Increased fuel consumption

Reduced engine efficiency and increased fuel consumption translates into higher operating costs.

Therefore, Caterpillar Inc. recommends repairing out-of-spec parts or replacing out-of-spec parts.

4-7

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work Inspection and/or Replacement Piston Rings, Crankshaft Bearings, Valve Rotators, and Crankshaft Seals The following components may not last until the second overhaul.  Thrust bearings 

Main bearings



Rod bearings



Valve rotators



Crankshaft seals



Nonmetallic fuel lines (if equipped)

Caterpillar Inc. recommends the installation of new parts at each overhaul period.

Inspect these parts while the engine is disassembled for an overhaul.

Inspect the crankshaft for any of the following conditions:  Deflection 

Damage to the journals



Bearing material that has seized to the journals

Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:  Rod bearing 

Main bearings

Note: If the crankshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the crankshaft.

Inspect the camshaft for damage to the journals and to the lobes.

Note: If the camshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the camshaft.

Inspect the following components for signs of wear or for signs of scuffing:  Camshaft bearings 

Camshaft followers

Caterpillar Inc. recommends replacing the crankshaft vibration damper.

4-8

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work HALF LIFE Every 851,625l (225,000 US gal) of Fuel -TLD Every 755,000l (200,000 US gal) of Fuel -TZB 1. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

2. Refer to Disassembly and Assembly manual for removal and installation instructions Caterpillar recommends this maintenance for the following engine components. Consult your Caterpillar dealer for further information.

The quantity of consumed fuel is a better indicator for this service interval than service hours. If the load factor is higher, the number of service hours for service interval will be lower. If the load factor is lower, the number of service hours for service interval will be higher. The following list contains components that should be rebuilt or replaced with a remanufactured product.

Engine Components – Install new For installation instructions of following components, refer to A&I guidelines publication,  Fuel Lines (Low Pressure and Nonmetallic) 

Water Regulators

Engine Components – Inspect, Reuse or Replace (if necessary) Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts".

Heat Shields  Inspect heat shields for any physical damage(s)

Engine Components – Rebuild/Install Reman For the following components refer to Disassembly and assembly instructions RENR9217, “C27 and C32 Engines for Caterpillar Built Machines”  Fuel Transfer Pump 

Injectors



Turbochargers



Water Pump

4-9

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work FULL LIFE Every 1,703,250l (450,000 US gal) of Fuel -TLD Every 1,514,000l (400,000 US gal) of Fuel -TZB Refer to this Operation and Maintenance Manual in order to determine the maintenance interval for a major overhaul.

The need for a major overhaul is determined by several factors.  An increase of oil consumption

Replacement of Components Replace the following components during the major overhaul. Refer to Disassembly and assembly instructions RENR9217, “C27 and C32 Engines for Caterpillar Built Machines”  All seals, Gaskets and O-rings 

Camshaft Bearings



Engine Mounts



Updated Engine Software



Fuel Pressure Regulating Valve



Fuel Priming Pump



Gear train bushings, Bearings and thrust plates



An increase of crankcase blowby



The total amount of fuel consumption



The wear metal analysis of the lube oil



An increase in the levels of noise and vibration



Heat Shields

An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced. An increase in the levels of noise and vibration indicates that rotating parts require service.

Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute the wear metals.

Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about scheduling a major overhaul.

Note: The driven equipment may also require service when the engine is overhauled. Refer to the literature that is provided by the OEM of the driven equipment.

For the major overhaul, all of the bearings, seals, gaskets, and components that wear are disassembled. The parts are cleaned and inspected. If necessary, the parts are replaced. The crankshaft is measured for wear. The crankshaft may require regrinding. Alternatively, the crankshaft may be replaced with a Caterpillar replacement part.

Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.

If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the following recommendations.



Main Bearings, Rod Bearings and Crankshaft thrust plates



Piston Rings,



Wiring Harness

Reuse (Clean and Inspect for Reusability) Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”.  Aftercooler Core 

Camshaft



Connecting Rods



Crankshaft



Cylinder Block



Cylinder Liners



Damper



Fan Drive (if equipped)



Gear Train



Pistons



Piston Pins



Rocker Arm Assemblies



Rocker Arm Shaft



Spacer Plates (Head)

Inspect the camshaft for damage to the journals and the lobes. Inspect the following components for signs of wear and/or for signs of fatigue:  camshaft bearings

4-10

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work 

camshaft followers

Inspect the crankshaft for any of the following conditions:  deflection 

damage to the journals



bearing material that has seized to the journals

Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:  rod bearing 

main bearings

Note: If crankshaft or the camshaft is removed for any reason, use the magnetic particle inspection process to check for cracks.

Replace the crankshaft vibration damper if any of the following conditions occur:  Engine failure due to a broken crankshaft 

Excessive wear of the front bearing for the crankshaft



Excessive wear of the gear train that is not caused by a lack of lubrication

Inspect the gears of the gear train and inspect the gear train bushings for the following conditions:  Worn gear teeth 

Unusual fit



Unusual wear

Rebuild or Remanufactured Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”.  Cylinder Heads 

Oil Coolers – If applicable



Oil Pump



Scavenge Oil Pump – If applicable



Variable speed fan clutch (if equipped)



NRS Valve

Cleaning of Components Clean the oil cooler core and the aftercooler core.

Then, pressure test both of these cores. For instructions on cleaning the cores, see this Operation and Maintenance Manual, "Aftercooler Core Clean/Test" topic.

Clean the oil suction screen. Also, remove side covers in order to clean the oil sump. For instructions on removal and installation of components, see the Service Manual, "Disassembly and Assembly" module.

In addition to the inspection of components, inspect the alignment of the driven equipment. See the Application and Installation Guide for the engine or see the literature that is provided by the OEM of the driven equipment.

4-11

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work HYDRAULIC SYSTEM Hydraulic system - repair instructions Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair Safety instructions".

Replace damaged and leaking hydraulic hoses and pipes as soon as possible by new ones.

Use original spare parts from CGM HMS GmbH. They are adapted to the respective function.

Do not re-use old hoses.

Never repair damaged hoses.

Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

4-12

Hydraulic hoses – Instructions Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years).

Check the date of manufacture on the hose or on the hose fitting regularly.

The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading.

The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multi-shift operation and round-the-clock work).

Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection:  Damage to the outer fibre reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks). 

Embrittlement of the outer fibre reinforcement layer (cracks in the hose material).



Changes in the ususal shape of the hose under pressure or in pressureless condition in bends or curves such as detachment of fibre layers, formation of bubbles or bulges.



Leaks.



Non-observance of fitting requirements.



Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.



Detachment of the hose from the fitting.



Corrosion in fittings reducing the strength of the function of the fitting.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So:  Never handle accumulators mechanically, never weld or solder.  Testing and servicing work must be carried out by experts only.  Prior to any testing and servicing work, depressurize the hydraulic part of the system.  To dismantle the accumulator, always wear goggles and working gloves.  Fill accumulator with nitrogen only, never with compressed air or oxygen.  Report any defects or damage to the machine owner without delay.  Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately.

4-13

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work".

Read these safety instructions before starting any welding or flame-cutting operations.

Welding work by qualified personnel only Carry out welding work only if you have received special training and if you have been ordered to perform such work.

Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country.

Observe all warning and instruction signs attached to the machine.

Wear the prescribed personal protective equipment such as:  protective clothing,  protective gloves,  protective mask and,  a fall-arrest system for persons working at height.

4-14

Increased risk of fire during welding work Always bear in mind that the heat, the sparks or dripping red-hot metal or slag produced in the process constitute a considerable risk of fire.

The present safety instructions provide information on how to minimize the risk of fire.

Remove all combustible materials close to the welding location or cover them up with noncombustible materials.

If works in the vicinity of combustible materials cannot be avoided, further persons with firefighting equipment must be present on site as fireguards.

Observe the instructions of the machine owner and of the mine.

Health hazards Welding operations produce harmful gases. Do not inhale the fumes and gases and make sure the surroundings of the welding location are well ventilated or equipped with an exhaust system.

Remove all kinds of paint and all coatings as well as all residues of oils and greases from the weld area.

Do not wind the welding cables round your body or parts of your body. The electromagnetic fields produced may damage your health.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work Tanks, pressure vessels and pressure accumulators Any work on vessels containing or having contained  combustible or combustion-accelerating substances,  potentially explosive substances or  substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work.

This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease.

Welding work on pressure vessels and pressure accumulators is forbidden.

Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the vessels against damage and high temperatures.

Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured.

Inform yourself about the locations in the machine where the pressure accumulators of the hydraulic system are installed. Do not perform welding work in the vicinity of these pressure accumulators before they have been covered up safely against accidental contact or flying sparks. Have the pressure accumulators removed from the machine, if safe protection cannot be ensured.

Slewing rings and articulated joints The welding current must not flow through ballbearing or roller-bearing slewings rings, through bolted connections or articulated joints or through hydraulic cylinders.

An electric current flowing through an air gap (e.g. in the bearing or in the articulation) produces a spark which damages the metallic surface.

The welding clamps must therefore always be connected very close to the weld area (max. 2 - 3 m away (6.6-9.8 ft)).

Information relating to the electrical system and to electronic modules Electric arc welding produces electromagnetic fields, electrostatic charges and voltage spikes which can cause damage to electronic modules.

Although the electronic modules of the machine are carefully protected against these influences, it is nevertheless necessary to take additional precautions in order to prevent such damage to the greatest possible extent.

Switch off the electrical system ("ignition OFF").

Open the battery main switch (or disconnect the starter batteries from the machine).

Lay the welding cables as far away from electric lines as possible.

If it is not possible to implement all of the abovementioned precautions, all connectors must be removed from the electronic modules before beginning any welding work.

Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.

Never touch the enclosures of electrical and electronic modules with the welding electrode.

Protect electric lines against the heat emanating from the weld area.

Restore all electrical connections when the welding operations are terminated.

Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

4-15

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work Welding on the counterweight

Welding on the cab

Counterweights may contain a build-up of flammable gases. In case these flammable gases were ignited, deflagrations may occur.

Therefore any work listed below must not be carried out on counterweights:  Welding,

The driver's cab is designed in such a way that it meets the FOPS (Falling Objects Protective Structure) requirements in accordance with DIN EN ISO 3449.

Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.



Flame cutting,



Grinding,

Further information



Drilling, milling and



All other mechanical work that generates heat.

More detailed information concerning the state-ofthe-art execution of welding operations can be found in the technical handbook "Welding for maintenance and repair".

For problems or queries please contact the competent service personnel.

If parts of the machine have to be removed or dismantled, please read and observe the chapters: "Assembly of working equipment, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

For more information please contact your local Caterpillar dealer.

Welding on components of the working equipment and on other fully or partly closed steel structures Components may be equipped with pipelines routed inside. These lines can contain combustible substances such as hydraulic oil or lubricating grease which may be set on fire by welding operations.

Check whether pipes or hosepipes are connected to the steel component.

Depressurize these lines.

Open the screwed connections and empty the lines routed inside the component.

Start welding only after these operations have been carried out.

Electric lines may also be be laid inside partly open steel structures in order to protect them against damage. They are not always visible from each viewing direction. Electric lines may catch fire as a result of the heat produced during welding.

Therefore check carefully whether electric lines are laid in the vicinity of the weld area.

Protect electric lines against the heat produced at the weld area or have them removed before starting the welding operations.

4-16

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work DISPOSAL AT THE END OF THE SERVICE LIFE Decommissioning and Disposal When the product is removed from service, local regulations for the product decommissioning will vary. Disposal of the product will vary with local regulations. Consult the nearest Cat dealer for additional information.

Dismantling and removal instructions Before beginning work, think about the risks involved, e.g.:  Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity. 

Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

Read the following text attentively and observe the instructions given. Respecting the instructions will help you to protect yourself against health hazards and injuries and to prevent avoidable environment pollution.

Risk of deflagrations In the course of time, flammable gases may have formed or accumulated in the hollow spaces of welded constructions, e.g. the counterweight. To remove these flammable gases, the hollow spaces must be purged carefully with compressed air before work with hand grinders, flame cutters or other sparking tools is being undertaken.

substances) and must therefore be disposed of properly.

Observe the national laws and regulations governing the non-polluting disposal of these substances.

Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly.  Fuel system: fuel tanks, fuel filters, fuel lines, filling station.

Auxiliary attachment and units, such as an onboard crane or an auxiliary heater have their own fuel tanks with the corresponding line systems.  Hydraulic oil: hydraulic oil reservoir, hydraulic cylinders, hydraulic motors, hosepipes, piping, hydraulic pumps, hydraulic valves, hydraulic oil filter, filling station.  Engine coolant: engine, radiator, expansion reservoir, piping and hosepipes, filling station.  Gearbox oil in slewing, travelling and transfer gearbox systems, expansion tanks, piping and hospipes, filling station; idlers, support and track rollers.  Have the refrigerant (R134A) sucked out of the air conditioner system.  Grease from the central lubricating system, grease drum, piping and hosepipes, distributors, filling station; grease accumulations in bearings of the working equipment, grease filling in the slewing ring, grease filling in track and support rollers as well as in idlers.

Risk of fire Remainders of fuel or oils may lead to the formation of flammable gases in tanks or other hollow spaces. When these tanks or hollow bodies are cut into pieces, the gases may ignite or even explode.

For this reason, remove all fuel or oil remainders from these components and purge them carefully with compressed air in order to eliminate flammable gases (other efficient methods of removing flammable gases can also be applied) before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Disposing of the machine without polluting the environment Before stripping down the machine at the end of its service life observe the following instructions: The assemblies of the machine contain various operating fluids or lubricants. These substances may pollute the environment (so-called hazardous 4-17

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work Further hazardous substances

Appropriate disposal of batteries

 

The machine is equipped with batteries containing lead and other harmful and polluting substances.

Damaged or used batteries must therefore not be disposed of in the environment. They must be disposed of properly and separately from other waste.

The batteries are marked with the corresponding symbols (Fig. 4-4:).

Since batteries contain also reusable materials, they are taken back free of charge by the manufacturer, dealer or by other specialized companies.

In the European Community, the final consumer is obliged by law to to dispose of used batteries in designated waste collections centers.

Observe the current regulations and laws of your country with regard to the handling of damaged or used batteries.





  

Batteries contain lead and acid.

Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.

Pressure accumulators contain nitrogen under high pressure and possibly remainders of hydraulic oil.

Lamps of Xenon working lights contain mercury.

The required electronic control circuits are integrated in the housings of the working lights.

The fluorescent lamps of the maintenance lighting (discharge types) contain mercury.

Insulating material of cables can contain PVC. The fire extinguishing system (if installed) contains trigger charges (ATTENTION, explosion risk) on the extinguishing agent containers.

Pressure accumulators, extinguishing gas and extinguishing powder.

For more detailed information please refer to the manufacturer's safety datasheets.

Fig. 4-4:

The symbols in Fig. 4-4: have the following meaning:  Crossed-out waste bin= Do not dispose of batteries with normal household waste.

4-18



Pb……= Chemical symbol for lead.



Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

4-19

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Repair work

4-20

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex 5 ANNEX Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

5-1

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex

5-2

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex BOARD-CONTROL-SYSTEM BCS III, what’s that?

What it is The BCSIII is the third generation of the Board Control System. This generation represents the current stage of development of this reliable monitoring and control system for hydraulic mining hydraulic shovels from CGM HMS GmbH. The BCSIII communicates with other electronic units in the hydraulic shovel and makes up the CAMP system, the Control And Monitoring Platform.

Controllers actuate and monitor functions such as the motor management, drive and control of the hydraulic pumps, the servo control and others. The controllers are basically computers that have been configured for their special application.

Other electronic units of the CAMP system that communicate with the BCSIII are located in cabinets in the module below the driver’s cab, the pump compartment and the engine compartment.

The exchange of data between sensors, controllers, the BCSIII and other involved components takes place via the CAN bus.

What it does The Board Control System, abbreviated to BCS, monitors all the essential functions of the hydraulic shovel and its components.

It releases an appropriate signal if any maximum value is exceeded and also sends a report to be archived in the memory bank.

If a normal operating status can be reached by temporarily reducing the hydraulic shovel's output, then this is monitored by BCS and done by the CAMP system.

If it is necessary for the operator to take certain action, e.g. to stop one of the engines a relevant command is sent to the BCS display screen.

BCS also gives information on servicing and trouble-shooting.

Sensors installed at various points on the hydraulic shovel constantly transmit their readings to the controllers of the CAMP system.

All essential pieces of operating data are displayed on the BCSIII screen in the form of simulated instruments as well as they are archived and can be called up as and when required.

Fig. 5-1:

Benefits for the operator Because BCS automatically warns of any abnormal conditions that require a corrective action, the operator can concentrate fully on the work in hand, and is not distracted by constantly having to keep an eye on many instruments or by having to decide upon appropriate actions to be taken in case of limit values being exceeded.

The operator and the servicing crew also have the means of calling up particular background information from the BCS archive.

The housing – installed in the control column inside the driver’s cab (Fig. 5-1:) – integrates the computer, the monitor, the control elements and the interfaces.

SIL2 functionality Safety related functions on the machine have been checked to minimize the risk of faults in their own function. Tests were performed according to the standards of functional safety (ISO 61508).

To fulfill the requirements for reaching the Safety Integrated Level 2 (SIL2) new components and electronic units had to be used on the machine.

These components and units are servo-controllers, sensors, switches, hand levers (joysticks), foot pedals and valves.

Want more information?

More detailed and more technical information for service personnel could be found in the “Technical Handbook”, chapter 9.

There are more extensive information given about the communicating units and about troubleshooting.

5-3

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex The keys on the front side

Other elements on the front side

A membrane keypad is located on the front side of the housing (Fig. 5-2:). The keys can be used to navigate through the screen pages.

The keys in the row below the screen (1 – 0) will perform the same task as the active area on the screen above.

Example: In (Fig. 5-2:) the key (1) lies directly below the active area "Service". Touching the "Service" area or pressing key "1", will take you to the same screen page.

They can also be used for numerical inputs.

The keys provided with arrows on the right side of the screen are used to navigate in a screen page.

Pressing the key with the "door symbol" gives access to the previous screen page.

Pressing the bottom key in the row confirms an input (like “Enter”).

(located on top of the column of keys on the right side) The green LED lights up when the electrical system of the machine is switched on, operating voltage is available. The green LED flashes with each keypress and when the background lighting of the screen is turned off.

The yellow LED flashes if the temperature inside the device lies outside the permissible range. The automatic heating system is then active.

The brightness sensor measures the ambient brightness. The BCS automatically controls the background illumination of the screen and the illumination of the keypad.

Fig. 5-2:

5-4

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex BCSIII - the start screen The screen displays the graphical user interface of the Board Control System. The basic screen (Fig. 5-3:) appears when all electronic units of the CAMP system have started and when their selftests have been completed.

Note: At low outside temperatures it is possible that the basic screen appears a few minutes after switching on the electrical system (warming up phase).

Starting from this basic screen, the user can access a number of other screens. This does not require an input device such as a keyboard, mouse or similar.

The BCS screen is designed as a touch-screen. By slightly touching the active areas, the user can perform activities such as changing to another screen page.

Active areas are shown on the screen as threedimensional graphics. In the basic configuration – not activated - they seem to project out of the user interface. When touched, they appear to be lowered.

Note: Do not remove the film visible on the screen surface. This is a polarization film which makes the displayed graphics much better visible.

Never use pointed objects such as a ball pen, screwdriver, nail or similar.

This could damage the active surface of the touch-screen.

Do not press on the sensitive areas, just slightly touch them!

Fig. 5-3:

5-5

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Information given on the start screen, top section The symbols shown in the top row of the start screen (Fig. 5-4:) appear in grey colour if function is not activated, in green colour if everything is OK or in red if a warning is given. In this case more information is displayed in the red “failure row” below.

6

Operating hours meter.

7

Right engine monitoring.

8

Service station, turns to red colour if lowered. Swinging superstructure or travelling the machine not possible then.

9

Hydraulic ladder, turns to red colour if lowered. Swinging superstructure or travelling the machine not possible then.

1

Left engine monitoring.

2

Central lubrication system monitoring.

3

The number of dumpers you loaded is displayed here (if counted with the key in the right joystick).

10

Track parking brakes monitoring.

11

Superstructure holding brakes monitoring.

4

Connection to Remote Service System (optional).

12

Servo-switch inside seat monitoring.

5

Hydraulic system monitoring.

Fig. 5-4:

5-6

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Information given on the start screen, central section 1

Left engine data during operation: bar = engine oil pressure, Rpm = revolutions per minute, Ltr = fuel in fuel reservoir, red means: top up with fuel soon.

Water = temperature of cooling fluid in degrees Celcius, left arrowhead-shaped symbol slides up and down displaying the current temperature. The symbol showing a halfed arrowhead is a trailing pointer displaying the maximum temperature. Slide to “0” with your fingertip.

2

Hydr. Oil = Hydraulic oil temperature in degrees Celcius, displayed graphically and numerically.

V = on-board voltage, displayed graphically and numerically.

Spanner symbol = operating time until next service is to be due, symbols are red then.

3

Right engine data during operation: bar = engine oil pressure, Rpm = revolutions per minute, Ltr = fuel in fuel reservoir, red means: top up with fuel soon.

Water = temperature of cooling fluid in degrees Celcius, left arrowhead-shaped symbol slides up and down displaying the current temperature. The symbol showing a halfed arrowhead is a trailing pointer displaying the maximum temperature. Slide to “0” with your fingertip.

Fig. 5-5:

5-7

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Information given on the start screen, lower section 1

Button “Service”.

Tapping with your fingertip opens a gate to much more information about the hydraulic shovels current behavior.

A menu will appear where you can select the section you want information about (see chapter “Service screen”).

Note: Modifying parameters in BCS must be carried out by skilled, trained personnel only. Misuse could lead to serious damage on the hydraulic shovel. A passcode for BCSIII Service Level I and Level II is requested. Refer to Service Magazine 2014-005 “BCS Passcodes” (Media-Id-No. BI644793-01) for more information.

Fig. 5-6:

5-8

2

Button “Setup”.

Tapping with your fingertip opens a login window that permits access to the BCS section that is exclusively for service personnel.

A password is needed to get access.

3

Button “Fault”.

Tapping this button opens a list of failures stored in the failure memory.

A detailed description can be found in the “Technical Handbook”, chapter 9.

4

The red “failure row”.

Here the system displayes detailed information about the failure occurred and gives instructions about what to do.

5

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

6

Clock.

Can be adjusted in the “Setup” section by service personnel.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Emergency Stop, reset function In case the Emergency Stop function has been activated by one or more of the Emergency Stop switches or by operating the battery circuit breaker, the main screen changes and displays the reset button (1, Fig. 5-7:). The machine is inactivated then, engines cannot be started.

Call the responsible service personnel immediately. The fault has to be located and eliminated.

Before being able to restart the engines the reset button, located in the front door of the 24Voltswitch cabinet (X1) must be pressed. The switch cabinet is located in the cab module.

After pushing the reset button, the green LED inside the push switch lights up. This signalizes that the Emergency Stop function is back in function again.

1

This symbol appears on the main screen when the Emergency Stop function has been activated.

Fig. 5-7:

5-9

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Swing circuit lock-out function If the system detects an error with the swing function the swing circuit lock-out screen pops up on the main page displaying the faulty component(s).

Call the responsible service personnel immediately. The fault has to be located and eliminated.

The pop-up window disappears after touching anywhere in the window. It will stay in the background until another fault happens or the operator navigates to a different screen and goes back to the main screen.

The fault can be reviewed on the “Servo Controller Menu”, available after logging in to the Setup-Level I-Menu (password required).

Fig. 5-8:

5-10

Squared symbols meanings: Green color = OK Yellow color = Minor fault detected, 48 hours to solve the problem before status changes to red and safe stop sequence is initiated.

Red color = Major fault detected, safe stop sequence is initiated.

The all-over status (green, yellow, red) of the swing circuit is displayed at the end of the chain and correlates with the three conditions mentioned above.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Information given on the “Service” screen 1

Tapping on the photo of the engine opens a screen displaying current engine data (see “Engine data screen”).

Same result when tapping on button “Engine” or pressing key “1” on the housing.

2

Tapping on the photo of the hydraulic pumps opens a screen displaying current hydraulic data (see “Hydraulic data screen”).

Same result when tapping on button “Hydraulic” or pressing key “3” on the housing.

3

Tapping on the photo of the lubrication control opens a screen displaying current lubrication data (see “Lubrication data screen”).

Same result when tapping on button “Lubrication” or pressing key “5” on the housing.

4

Tapping on the photo of the control lever (joystick) opens a screen displaying control elements adjusting data (see “Controls adjustment data screen”).

Same result when tapping on button “Servosystem” or pressing key “7” on the housing.

5

Tapping on this button opens the “View documents” screen (see: “View documents screen”).

6

Adjusting screen brightness. Sliding the green button sets screen brighter / darker.

Tapping on button “Autom.” sets brightness to automatic mode.

7

Tapping on this button opens the “Signal Table” screen (see: “Signal Table screen”).

8

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-9:

5-11

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Engine data screen This screen displays data of the left engine. Same data for the right engine are available after tapping on the button “right engine”.

1

This section of the screen displays current engine data.

2

Here the oil change interval is displayed as well as the remaining operating hours (h) until the next oil change.

After carrying out oil change tap on button “done”, this resets the graphical oil change bar and the (h) counter.

Fig. 5-10:

5-12

3

In this section information about faults and malfunctions are displayed. Fault description follows the SAE J1939 standard.

SPN Number = Suspect Parameter Number, FMI = Failure Mode Indentifier.

The “failure row” below displays a failure description.

4

All data displayed can be saved to an USBstick after tapping this button (see: “Saving data to an USB-stick”).

5

Tapping on this button opens a window displaying all the faults / malfunctions the system is able to display (see: “Code Table screen”).

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Hydraulic data screen 1

This screen displays data related to the hydraulic system.

2

All data displayed can be saved to an USBstick after tapping this button (see: “Saving data to an USB-stick”).

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-11:

5-13

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Lubrication data screen 1

2

This screen displays data related to the central lubrication system.

Here are information about the status of the lubricating system of the upper structure.

If the system detects faults or malfunctions in the lubrication system of the upper structure they are marked here with a red dot.

Call the responsible service personnel.

Fig. 5-12:

5-14

3

Here you get information about the status of the lubricating system of the under carriage.

4

If the system detects faults or malfunctions in the lubrication system of the under carriage they are marked here with a red dot.

Call the responsible service personnel.

5

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Controls adjustment data screen The characteristic curves of control levers (1, Fig. 5-13:) and control pedals (2) are adjustable by service personnel. The adjusted values are shown here graphically and numerically.

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

If adjustment is needed, call the responsible service personnel.

Adjustment is to be done in the “Setup” section of BCSIII. Access to this area is for service personnel only (password required).

Fig. 5-13:

5-15

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex View documents screen Technical documentation for the machine is stored in memory.

Tapping on the buttons opens the appropriate pdf file and displays it on the screen by means of the build in viewer.

You can navigate inside the documents using the navigation elements known from other computer usage, like buttons, sliders, links from the contents page and so on.

Fig. 5-14:

5-16

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Signal table screen 1

To identify and localize sensors and units on the machine, some photos were attached. If you tap on a “Name” and then the button “Location” became readable, a photo is available. Otherwise the button is greyed.

In Fig. 5-15: ID 110 “Main Pump 1/3 Pressure” is marked and button “Location” (1) is readable. When tapping on it, a photo appears and shows where the sensor is located (see Fig. 5-16:).

2

Tapping on button “Diagram” opens a screen showing the data coming from four sensors in a diagram (see Fig. 5-17:).

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

This is a listing of all the signal sources that are connected to the BCS- and CAMP-system.

In the “Status” column small icons visualize the signal status: green=ok; red=malfunction.

In column “Code” you can find the identifier for the sensor or unit that helps the maintenance personnel to localize the sensor in the electric schematics (in this example the identifier for the sensor is “3B22”) .

Fig. 5-15:

5-17

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Signal table screen, location Button “Location” has been tapped, a photo appears showing where the sensor “3B22” is located at the machine.

Fig. 5-16:

5-18

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Signal table screen, diagram This is a diagram showing the data coming from four signal sources (sensors) for a longer period of time.

The signal sources (channel 1-4) can be selected from a listing after tapping the “Config” button (see: “Signal table screen, diagram configuration”).

1

2

3

Rec = starts recording the data from the selected sources; Stop = stops recording data; Rev = scrolls the diagram in reverse; Fwd = scrolls the diagram forwards.

4 Tapping on button “Config.” opens a window listing all the signal sources available for BCS and CAMP (Fig. 5-18:).

Diagram window, displays the data from four sources as four lines in different colours.

5

Listing of the four signal sources selected: ID, Name, actual value and value at cursor in the diagram.

Save = save data to memory; Load = load older data from memory; Delete = delete data displayed.

6

Buttons to scroll, scale up, scale down the diagram window.

7

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-17:

5-19

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Signal table screen, diagram configuration Button “Config.” has been tapped, a window appears displaying all the signal sources available.

In column “Channel” you can mark four signal sources whose data you want to display in the diagram (Fig. 5-17:).

Mark the line with the signal source you want and press the appopriate numeric key on the BCS housing: “1” for channel 1; “2”, “3” and “4” for the other channels.

Fig. 5-18:

5-20

1

For example: This signal source is selected and marked to be displayed on channel 3.

2

For example: This signal source is selected and marked to be displayed on channel 2.

3

Tapping the button will confirm your selection.

4

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Code table screen Coming from the “Engine data screen” (Fig. 5-10:) after tapping the “Code Table” button.

This screen displays a listing of all available trouble codes according to the SAE J1939 standard.

Active faults or malfunctions are displayed on the “Engine data screen” with their “SPN Number” and their “FMI Number”. To get the description for the fault or malfunction, key in both numbers at (1) and tap on the button left aside.

The appropriate description will be displayed (2).

1

SPN = Suspect Parameter Number, according to SAE J1939 standard, For example: 94

2

FMI = Failure Mode Identifier, according to SAE J1939 standard, For example: 18

3

Tapping these buttons will scroll the listing: forward, reverse, to beginning, to end.

4

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-19:

5-21

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Slew brake test screen The slew brake test screen (Fig. 5-20:) is available after logging in to the Setup-Level I-Menu (password required).

A slew brake test must be performed during commissioning of the machine and after repair work or maintainance work carried out on the slewing system.

The slew brake test should be performed at every maintenance scheduled by the customer.

This is to ensure proper functioning of the slew brake system. Proper functioning of the slew brake system has influence to machine safety.

Before performing the slew brake test, ensure the machine is in a safe workplace where the machine can rotate 360° without hitting an obstacle. Check that all persons have left the area around the machine. Activate the horn.

To perform the slew brake test, follow the instrucions (4) given on the screen.

Fig. 5-20:

5-22

1

2 3 4 5 6

Preconditions to be fulfilled before performing the slew brake test, from left to right: - swing brake applied, - servo control switch in control column must be in position OFF, - operator sitting on his seat.

Symbols change to green with precondition fulfilled.

Time limit to fulfill preconditions is 60 sec.

Button to start the test.

Hydraulic pressures in the units of the slewing systems, lefthand and righthand.

Instructions to perform the slew brake test.

Instruments displaying hydraulic pressure in lefthand / righthand slewing system.

Indicators showing the progress during testing: - “pending”, colour red after starting the test, - “in progress”, colour yellow when 300 bar, - “passed”, colour green when test OK.

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex BCS III, interfaces The BCS system comes with different data interfaces. This feature allows the communication with external electronic devices.

Three connectors are located on the right-hand side-wall of the control column (Fig. 5-21:): 1

USB 2.0, jack type A. This jack accepts, for example, a USB stick used to save operating data for evaluation on an external computer.

2

Jack D sub, 9 pins.

Used to connect a computer with a diagnosis software with access to the CAN bus.

This connection is reserved for service personnel.

3

Fig. 5-21:

Ethernet, jack type RJ45.

For the connection of future extensions, for example, the remote servicing system.

USB interface, data storage A USB stick can be connected to the USB plug-in connection of type A (1, Fig. 5-21:).

Suitable are such USB sticks that would also work on computers with WINDOWS® operating systems; they may be formatted with the NTFS or the FAT32 file system.

If a screen page displays the symbol of a USB stick, the operating data of this screen page can be saved. The BCS will create a text file.

For a detailed description see: “Saving data to a USB stick”.

5-23

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Saving data to a USB stick All screens which have the “USB-stick-button” (1, Fig. 5-22:) offer the functionality to store data for external use.

All data related to the current screen will be stored to a USB stick. In this example all data from the “Service, left engine” screen will be saved to a file.

Fileformat is RTF (Rich Text Format).

The file name will be automatically created following this pattern: “Shovel type+serial number+screen name.rtf”.

For example: “RH120172_Engine_LH.rtf”.

If this file already exists, an extension with increment numbers will be added to the file name: “RH120172_Engine_LH_(1).rtf”.

“RH120172_Engine_LH_(2).rtf”. ……

Fig. 5-22:

5-24

Save data: Plug a USB stick into the USB jack (see: “BCSIII, interfaces”).

To save the data, tap on button (1, Fig. 5-22:).

The BCS system checks the USB interface before saving the data. If no USB stick is detected, a new window appears showing the folder structure on the CF-card as well as the message “Please plug a USB stick”.

If a USB stick is found, a new window appears, see next page (Fig. 5-23:).

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Saving data to a USB stick, continued This window shows the current data you want to save in a file and askes for confirmation.

If you want to save the data tap on the “Yes” button (1, Fig. 5-23:). The file will be written on the USB stick.

Otherwise tap on the “No” button and return to the screen you want.

If you want to see the files stored on the USB stick, tap on the “Open” button (2).

A new window appear showing the folder / file structure on the USB stick, see next page (Fig. 5-24:).

Fig. 5-23:

5-25

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Saving data to a USB stick, continued This window (Fig. 5-24:) displays the folder / file structure on the USB stick plugged into the USB jack.

Mark the file you want to see by tapping on the filename (2).

Tapping an button “show” (1) opens another window which shows the file.

Tapping the button with the door icon (3) leaves the current screen and opens the previous screen.

Fig. 5-24:

5-26

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex BCSIII, cleaning

BCSIII, disposal

Clean dirty screens with a soft, slightly moist cloth.

In order to remove persistent dirt, you can use in addition a conventional cleaning agent for LCD monitors.

This electronic device contains substances that might be harmful to the environment.

The electronic components and the tubes of the background illumination contain, for example, lead (Pb) and mercury (Hg).

The background illumination lamps are CCFL-typelamps (Cold Cathode Fluorescent Lamps).

The battery for backing up the memory contains lithium.

Therefore, this device must not be disposed of with your regular household waste. It must be disposed of properly as electronic scrap.

Never use solving or scouring cleaning agents.

This could damage the surface of the screen.

Do not use compressed air or water under pressure (high pressure cleaner or steam cleaner).

This could damage the electronic components.

The escaping liquid from a damaged LCD screen may be harmful.

Do not come in contact with escaping liquids. In case of skin contact, wash immediately with water and soap.

5-27

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex TROUBLESHOOTING Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

For this reason, it is vital to read through the relevant section of the operating instructions once again before rectifying any faults.

If you are unable to detect the cause of the fault or to rectify it, apply to your Cat dealer service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on your Cat dealer service. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified.

The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

Fault The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

Study the problem carefully. First think, then act.

Ask yourself the following questions:  Which warning signals preceded the fault? 

What repair and servicing work was carried out previously?



Has this defect already occurred?



Is it one or several simultaneously occurring faults?

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the operating instructions. If there is no entry, please contact your Cat dealer.

5-28

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex FAULT TABLES Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts, but runs enevenly or intermittently Engine gets too hot, temperature warning activated Engine not working at full power Engine not working on full cylinder papacity Engine without oil pressure or oil pressure too low Engine oil comsumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly Cause Oil level too low 

  

 

Oil level too high

  

Engine oil of wrong SAE-class 









 

Fuel filter contaminated

Fuel filter

Charge-air line leaking



Cooling air gets too hot / heat buid-up



Battery defective or discharged



Cable connections in starter circuit loose or corroded

 

 





 

   

 

  



 

S W W



Cooling fan or water pump defective or loose

   

Lubricants Air intake syst.

Radiator / cooling fins contaminated

A P

Air filter contaminated / turbo-charger defective





Engine oil level

Fuel quality not corresponding to specification





Chapter ref.

Engine oil level



  

1) Contact your Cat dealer

Engine inclination too big

 

Remedial action Check P Adjust E Replace W Top up A Reduce S Clean R

P P/W P

Cooler cleaning R P/W P Battery

P P

Starter defective or pinion not in mesh

P

Shut-off relay jamming

1)

Incorrect valve setting

E

Injection line leaking

P

Injection valve defective

P/W

Combustion engine blocked on output side

1)

 PMS malfunction  Celect coding lamp flashing/lit Celect defective (software error)

1) 1) 1)

5-29

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Working hydraulics – Fault table Fault

Remedial action

Working and swing functions not operational No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact your Cat dealer

1) Contact your Cat dealer

Cause Electronic hydraulic shovel control not activated/defective  Malfunction of pressure-relief valve     Servo system pump defective       Malfunction of primary / sencondary pressure-relief valves Engine speed too low  ECO-power switch in 80%-position  Fuel filter contaminated  Insufficient engine power   

 

5-30

Abschnitt Working

P 1) 1) 1) P P Fuel filter P/W Engine mal- 1) function Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R lamp lit) oil cooler contaminated cooler cleaning 1) Engine coolant temperature too high (warning lamp lit and PMS fault indicator lamp flashing) 1)  Malfunction of solenoid valves 1)  Malfunction of control spool Engine coupling defective

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Track drive – Fault table Fault

Remedial action

No forward travel and no reversing travel Maximum travel speed cannot be reached Insufficient traction power

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact your Cat dealer

  

        

   

Cause Malfunction of pressure-relief valves Servo system pump defective Malfunction of travel valve (pedal) Engine nominal speed too low Malfunction of control spool ECO-power switch in 80%-position Insufficient engine power

Chapter ref.

1) 1) 1) 1) 1) Travelling P Engine mal- 1) fuction Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil P/R cator lamp lit) oil cooler contaminated cooler cleaning 1) Engine coolant temperature too high (warning lamp lit and PMS fault indicator lamp flashing)

5-31

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Swing mechnism – Fault table Fault

Remedial action

No swing possible No righthand or lefthand swinging Slewing performance insufficient Uncontrolled swinging movement

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact your Cat dealer

     



 

    

5-32

Cause Electronic hydraulic shovel control not activated / defective Limiting switch optional, hydraulic ladder not complete retracted Superstructure holding brake applied Pressure-relief valve adjusted too low level / defective Servo system pump defective Malfunction in feed-pressure circuit of swing pump Malfunction in high-pressure circuit of swing system Malfuction of moment-regulating valve Malfunction in swing pump displacement cylinder Excessive leakage in swing motor

Chapter ref.

Working Operation

P P P 1) 1) 1) 1) 1) 1) 1)

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex Central lubricating system – Fault table Fault

Remedial action

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

Check Adjust Replace Top up Reduce Clean Vent

P E W A S R L

1) Contact your Cat dealer

   

  



  

    

Cause Timer defective Lines between timer and hydraulic motor defective Hydraulikmotor defektive Grease pump defective Grease sieve clogged Distributor defective Grease container empty Grease pump does not suck grease Leaky lines Non-return valve defective Pressure switch defective

Chapter ref.

P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

5-33

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex ENGINE MONITORING, CONTROL LAMPS

Warning lamp, red (50 and 60): Das v erk nüpfte Bild k ann nicht angezeigt werden. Möglicherweise wurde die Datei v erschoben, umbenannt oder gelöscht. Stellen Sie sicher, dass die Verk nüpfung auf die k orrek te Datei und den k orrek ten Speicherort zeigt.

The control lamps  (49 and 50, Fig. 5-25:) for the left engine, 

(59 and 60, Fig. 5-25:) for the right engine,

indicate malfunctions and signal when certain limit values have been exceeded.

An automatic check is performed after switching on the electrical system of the machine; both lamps will light up for approx. 5 seconds and turn off afterwards.

Ignoring the signal lamp may lead to a potential engine breakdown.

The warning lamp lights up as soon as certain limit values for the following operating parameters of the engine have been exceeded: (An "Event“ occurred):  Charge air temperature at engine intake, 

Temperature of coolant,



Engine oil pressure,



Engine speed (protection against overspeed),



Fuel pressure,



Fuel temperature.

In case of an event (e.g. temperature of coolant is too high), the lamp will light up. The diagnosis lamp provides the event code at the same time (flashing).

In case of a previously specified threshold value, the engine will reduce the output (so-called "engine derate“). This is not indicated by the lamps, e. g.:  Engine oil pressure approx. 1bar (14.5psi) (rotation speed dependent), Fig. 5-25:



Temperature of coolant above 111°C (231.8°F),



Temperature of intake air above 86°C (186.8°F),



Temperature of fuel above 91°C (195.8°F).

Diagnosis lamp, yellow (49 and 59): The diagnosis lamp indicates malfunctions of the electronic control of the engine.

For example: faulty sensors, cable breaks etc.

The indication uses so-called flash codes.

In case of a malfunction, the diagnosis lamp represents two digits, the "diagnosis code" or an "event code“.

This takes place by the flashing of the diagnosis lamp in quick succession.

The first and second digits of the flash code are derived by counting the flash signals.

There is a time interval of approx. 2 seconds between the flashing sequence of the first and second digit.

In case of several diagnosis codes, the time interval between two different diagnosis codes is approx. four seconds.

Refer to the engine's operating and maintenance manual for matching the diagnosis and event codes with the cause of malfunction.

Diagnosis codes are intended to isolate an error and are not suitable for detailed fault diagnostics.

Please contact your Cat dealer for more information.

5-34

In case of a reduced output, for example by exceeding the maximum working height, none of the lamps will light up or flash.

The limit values and the engine's response when those values are exceeded can be adjusted in the so-called monitoring system within certain limits (service provided by your Cat dealer).

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex HYDRAULIC CIRCUIT DIAGRAM Detailed information can be found in the "Service Manual“ chapter 8 or contact your Cat dealer.

5-35

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex ABBREVIATIONS A abt.

AC acc.

Ah API approx. bar BH CAMP CAN CE CECE

CEN cm cm3/rev CCW CW

Ampere (SI base unit of electric current) about Alternating Current according to Ampere hours (SI base unit of quantity of electricity) American Petroleum Institute approximately

I

Transmission ratio

IN

Rated current

i.e.

Id est = that is

IFN

ISO standard rating, blocked

in

Inch (unit of distance) 1in = 25.4mm

Incl.

ISO

Including, inclusive of International Standardization Organization

unit of pressure, 1 bar = 14.5 psi Backhoe (attachment)

kg kg/dm3

Control and Monitoring Platform Controller Area Network Communauté Européenne = European community Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee centimeter (= 1/100 m) Cubic centimeters per revolution counterclockwise clockwise

km/h kNm

Kilogram (unit of weight), 1 kg = 2.2 lb Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour KiloNewtons per meter (unit of torque) 1 kNm = 1000 Nm Kilovolt (unit of electric voltage) 1kV = 1000V Kilowatt (1 kW = 1.36 hp)

dia.

DIN

Decibel (sound intensity according measuring method A) Diameter German Industrial Standard

ECM eff. e.g. etc.

Electronic Control Module on engines effective for example etcetera

Fig. FMI

Figure, serial number of illustration Failure Mode Identifier, description malfunctions according to SAE J1939 Falling objects protective structures Rock shovel (working equipment) foot (unit of distance), 1 ft = 0.30 meter

dB(A)

FOPS FS ft

to

kW L LAN lb lbf Lb/in² LC LED l/min LpA LwA

Liter (unit of volume), 1 liter = 0.26 gal Local Area Network pound (unit of mass), 1 lb = 0.45 kg Pound force (unit of force) 1lbf = 4.45N Pounds per square inch (= psi) Long crawler Light-emitting diode Liters per minute Sound pressure at workplace Sound power level of the machine in stationary operation

m MA mA max.

MDG min. min-1 mm

Meter (unit of distance), 1 m = 3.28 ft Tightening torque Milliampere (=1/1000 A) maximal, maximum Mining Design Guideline (Australian Standards in Mining Industry) minimal, minimum Revolutions per minute Millimeter (=1/1000 m)

N N, kN NLGI NLGI– Klasse Nm No.

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency – lubricant classification acc.

To DIN 51 818 Newtonmeter (unit of torque) Number

OH .OMM oz

Operating hour Operation and Maintenance Manual ounce (unit of volume) 1 oz = 0.03 liter

of

gal GET GLR

gallon (unit of volume), 1 gal = 3.78 liters Ground Engaging Tool Full-load controller (electronic module for PMS)

HD Hp Hydr.

Hz

Heavy duty Horse power (unit of power) 1Hp = 0,75kW Hydraulic, Hydraulics Hertz (unit of frequency)

5-36

kV

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex ABBREVIATIONS

PLC PPE

Portable Document Format (trademark of ADOBE Inc.) Pump Managing System Part number Metric horsepower (1 PS = 0.74 kW) pound per square inch (unit of pressure), 1 psi = 0.069 bar Programmable logic controller Personal Protection Equipment

Qty.

Quantity

R, r resp.

RH RTF ROPS rpm

Radius Respectively Crawler hydraulics (hydraulic shovel) Rich Text Format, textbased file format Roll-over protective structures Revolutions per minute (= min-1)

PDF PMS P/No. PS psi

SAE sec./s.

SM SN SPN SW t TCP/IP TBG tm typ.

Society of Automotive Engineers (USA) Second (unit of time) Service Manual CGM HMS GmbH partnumber Suspect Parameter Number, description of malfunctions according to SAE J1939 Width across flats

U/min U.S./EPA

USB

V VDMA

Revolutions per minute United States Environmental Protection Agency Universal Serial Bus, interface for fast data exchange Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

yd

Yard (unit of distance) 1yd = 0.91m

W

Watt (unit of electric power)

µm

Micrometer (unit of distance) 1µm = 0.001mm

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

Metric ton (= 1000 kg) Transmission Control Protocol / Internet Protocol Civil Engineering Employer’s Liability Insurance Association Tons by meters (obsolescent unit of swing torque) Typical

5-37

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex PRODUCT SPECIFICATION SHEET

5-38

6040/ 6040 FS Hydraulic Shovel We understand the challenges you face, the importance of reliability, and the relationship between uptime and productivity. That’s why we continually strive to produce the safest, most reliable and productive hydraulic mining shovels possible. Offering the widest payload range of any manufacturer in the industry, the ability to optimally pair with our popular line of mining trucks, and the support of our world-class Cat® dealer network, we are uniquely positioned to partner with you to help achieve your productivity targets. We understand what matters to you.

Our hydraulic mining shovels are built with you in mind.

Because in mining, every day matters and every load counts.

The model of reliability for Cat hydraulic mining shovels, the 6040/6040 FS offers improved uptime with a new undercarriage design, and enhanced safety with standard features designed in accordance with the principles of MDG 41 and 15. These upgrades, combined with proven features like TriPower (FS only), fully independent oil cooling, and the CAMP system, make this model a top performer in our hydraulic mining shovel line-up.

General Data

Operating Weight

Operating Weight Face Shovel Backhoe Engine Output SAE J1995 Cat C32 Standard Bucket Capacity Face Shovel (heaped 2:1) Backhoe (heaped 1:1)

405 tonnes 407 tonnes

446 tons 449 tons

6040 FS Standard track pads Operating weight Ground pressure

1516 kW

2,032 hp

• Other track pads available on request

22.0 m3 22.0 m3

28.8 yd3 28.8 yd3

6040 Standard track pads Operating weight Ground pressure

Features

• Other track pads available on request • TriPower shovel attachment • Independent oil cooling system • Spacious walk-through machine house • 5-circuit hydraulic system • On-board electronics system: Control and Monitoring Platform (CAMP) • Board Control System (BCS III) • Torque control in closed-loop swing circuit • Automatic central lubrication system • LED working lights

1200 mm 404 600 kg 24.1 N/cm 2

3 ft 11 in 891,980 lb 35.0 psi

1200 mm 407 300 kg 24.3 N/cm 2

3 ft 11 in 897,930 lb 35.3 psi

6040/6040 FS Hydraulic Shovel Specifications Diesel Engines Make and model Total rated net power ISO 3046/1 Total rated net power SAE J1349 Total rated gross power SAE J1995 No. of cylinders (each engine) Bore Stroke Displacement Aspiration Max. altitude without deration – at 10° C above sea level Emissions Alternators Fuel tank capacity

Hydraulic System with Pump Managing System 2 × Cat C32 (Tier 2) 2,032 hp 1516 kW 1,750 min-1 1,750 min-1 1516 kW 2,032 hp 1,750 min-1 1,750 min-1 1516 kW 2,032 hp 1,750 min-1 1,750 min-1 12 145 mm 5.71 in 162 mm 6.38 in 32.1 L 1,959 in3 Turbocharged and air-to-air aftercooled 2500 m 8,200 ft

Main pumps Diesel version

U.S. EPA flex 2 × 150 A 7800 L 2,060 gal

AC version

AC version Maximum oil flow Diesel version AC version Maximum pressure, attachment Maximum pressure, travel Swing pumps Diesel version

Maximum oil flow Diesel version

• Hydraulically driven radiator fan with electronically controlled fan speed • Microprocessed engine management • Heavy-duty air fi lters • Two-stage fuel fi lter including water separator • Additional high-capacity water separator

AC version Maximum pressure, swing pumps Total volume of hydraulic oil – approximately Diesel version AC version Hydraulic tank capacity – approximately Diesel version AC version

Electric Motor – 6040 AC/6040 AC FS Type Output Voltage Rated Current IN Frequency Revolutions Starting current

Squirrel cage induction motor 1400 kW 6.6 kV ± 10% (other on request) 156 A (at 6.6 kV) 50 Hz (60 Hz on request) 1,500 min-1 (1,800 min-1 at 60 Hz) 350% of IN (197% of IN Optional)

4 × variable swash plate pumps 4 × variable flow axial piston pumps 4 × 724 L/min 4 × 746 L/min 300 bar 350 bar

4 × 191 gal/min 4 × 197 gal/min 4,350 psi 5,080 psi

4 × reversible swash plate pump 3 × reversible swash plate pump 4 × 321 L/min 3 × 491 L/min 350 bar

4 × 85 gal/min 3 × 130 gal/min 5,080 psi

5800 L 6400 L

1,532 gal 1,585 gal

3400 L 4000 L

898 gal 1,057 gal

• Pump Managing System contains: – Electronic load limit control – Flow on demand from main pumps depending on joystick position – Automatic regulation of main pumps to zero flow without demand – Automatic rpm reduction of engine speed during working breaks – Reduced oil flow of main pumps at high hydraulic oil temperature or at high engine temperature • Pressure cut-off for main pumps • Cooling of pump transmission gear oil • Filters: – Full-flow high-pressure fi lters (100 μm) for the main pumps, installed directly behind each pump – Full-flow fi lters (10 μm) for the complete return circuit – Full-flow fi lters (10 μm) for the cooling return circuit – Pressure fi lters (6 μm) for servo circuit – Pressure fi lters (40 μm) for the feed pumps of the closed swing circuit – Transmission oil fi lters (40 μm)

• Custom-made electric motor with increased gap between rotor and stator to withstand severe mining conditions • Power limit control by Pump Managing System

Electrical System (diesel drive) System voltage 24V Batteries in series/parallel installation 6 × 210 Ah – 12V each 630 Ah – 24V in total • Battery isolation relays and switches • Emergency stop switches accessible from ground level, in engine module and in operator’s cab • 10 LED high-brightness working flood lights – 8 for working area – 2 for rear end • 2 LED high-brightness access flood lights • 13 LED service lights

2

6040/6040 FS Hydraulic Shovel Specifications Hydraulic Oil Cooling Oil flow of cooling pumps Diesel version AC version Diameter of fans

Operator’s Cab Operator’s eye level – approximately Internal dimensions of cab Length Width Height

2 × 799 2 × 211 L/min gal/min 4 × 379 4 × 100 L/min gal/min 2 × 1524 mm 2 × 60 in

Swing System

Parking brake

Maximum swing speed Diesel version AC version Swing ring

22 ft 4 in

2200 mm 1600 mm 2150 mm

7 ft 3 in 5 ft 3 in 7 ft 1 in

• Under roof mounted heating ventilating and air conditioning system • Pneumatically cushioned and multi-adjustable comfort seat with lumbar support, seat heating, safety belt, head- and armrests • Switch in seat cushion to automatically neutralize the hydraulic controls when operator leaves the seat • Joystick controls integrated in independently adjustable seat consoles • Fold-away auxiliary seat with safety belt • FOPS (rock guard; approved according to DIN ISO 3449) integrated into cab structure • All-round safety glass, armored windshield and sliding side window • Windshield with parallel intermittent wiper/washer • Roller blinds at all windows • External sun shields at side and rear windows • Robust instrument panel including large colored BCS screen with transflective technology • Board Control System (BCS III); electronic monitoring, data logging and diagnostic system for vital signs and service data of engines, hydraulic system and lubrication system, featuring: – Robust instrument panel including large (12 in) colored touch screen for intuitive handling – On-screen PDF documentation (e.g. operating instructions, technical handbook, spare parts catalog, electric circuit diagram) – On-screen troubleshooting assistance – Graphic charts of logged data – Fault memory with storage of related conditions – USB, Lan (TCP/IP) and CAN BUS interfaces for data export • Machine access via retractable access stairway, stairway angle approximately 45°, hydraulically operated • Sliding emergency ladder (kick-down type) with ladder cage

• Cooling system is fully independent of all main circuits, i.e. controlled cooling capacity is available whenever engine is running • Gear type cooling pumps supplying high-volume, low-pressure oil to aluminum coolers • Variable axial piston pumps supplying low-volume, high-pressure oil to fans • Fan speed is thermostatically controlled • Extremely high cooling efficiency to ensure optimum oil temperature

Swing drives

6.8 m

3 compact planetary transmissions with axial piston motors Wet multiple disc brake, spring-loaded/ hydraulically released 4.7 rpm 5.1 rpm Triple-race roller bearing with sealed internal gearing

• Closed-loop swing circuit with torque control • Hydraulic braking of the swing motion by counteracting control • All raceways and the internal gearing of swing ring supplied by automatic central lubrication system • Dirt wipers at swing ring to prevent build-up of debris between swing ring and carbody

Retractable Service Station Retractable service station installed underneath the engine module and easily accessible from ground Equipped with: – Quick couplings for: – Diesel fuel – Engine coolant – left/right – Pump transmission gear oil – left/right – Engine oil – left/right – Hydraulic oil tank – Grease container • Cat jump-start socket • Indicator lights for fuel tanks left/right full and grease container full

3

6040/6040 FS Hydraulic Shovel Specifications Undercarriage Travel speed (2 stages) 1st stage – maximum 2nd stage – maximum Maximum tractive force Gradeability of travel drives – maximum Track pads (each side) Bottom rollers (each side) Support rollers (each side) Travel drives (each side)

Parking brake

Attachments 1.5 km/h 2.5 km/h 2097 kN 57%

• Boom and sticks are torsion-resistant, welded box design of high-tensile steel with massive steel casting at pivot areas • Welding procedures allow for internal counter-welding (double prep weld) wherever possible • Boom and sticks are stress-relieved after welding • Inspection hole in monoboom BH • Guards for shovel cylinders (FS) • Catwalks with rails at boom (FS and BH) • Pressure-free lowering of boom (FS and BH) and stick (FS) by means of a float valve • Shovel attachment with unique TriPower kinematics ensuring the following main features: – Horizontal automatic constant-angle bucket guidance – Vertical automatic constant-angle bucket guidance – Automatic roll-back limiter to prevent material spillage – Kinematic assistance to hydraulic forces – Constant boom momentum throughout the whole lift arc – Crowd force assistance • All buckets (FS and BH) are equipped with a wear package consisting of: – Special liner material covering main wear areas inside and outside of bucket – Lip shrouds between teeth – Wing shrouds on side walls – Heel shrouds at bottom edges • Special wear packages for highly abrasive materials on request

0.93 mph 1.55 mph 471,260 lbf

42 7 2 plus a skid plate in between 1 planetary transmission with 2 two-stage axial piston motors Wet multiple disc brake, spring applied/ hydraulically released

• Cast double-grouser combined pad-links with bushings connected by hardened full floating pins • All running surfaces of sprockets, idlers, rollers and track links, as well as teeth contact areas of sprocket and pad links, are hardened • Fully hydraulic self-adjusting track tensioning system with membrane accumulator • Automatic hydraulic retarder valve to prevent over-speed on downhill travel • Acoustic travel alarm

Automatic Lubrication System Capacity of grease container

1000 L

264 gal

• Dual-circuit system with hydraulically driven heavy-duty pumps and electronic time relay control adjust the pause/lube times • Connected to the lubrication system are: – raceways of the swing roller bearing – two greasing pinions for the internal gearing of the swing ring – pivot points of attachment, bucket and cylinders • System failures displayed by Board Control System • Grease fi lters (200 μm) between service station and container, as well as directly behind grease pump

4

6040/6040 FS Hydraulic Shovel Specifications Dimensions All dimensions are approximate.

10

8 11

9

14 1 3

4

2

5 12

6 7

13

1

6800 mm

22 ft 4 in

8

7000 mm

23 ft

2

2250 mm

7 ft 5 in

9

6780 mm

22 ft 3 in

3

5620 mm

18 ft 5 in

10

8050 mm

26 ft 5 in

4

2620 mm

8 ft 7 in

11

6100 mm

20 ft

5

1030 mm

3 ft 5 in

12

1200 mm

3 ft 11 in

6

6170 mm

20 ft 3 in

13

6600 mm

21 ft 8 in

7

8090 mm

26 ft 7 in

14

7920 mm

26 ft

Dimensions and weights of AC machine differ slightly. Separate drawings, dimensions and weights can be provided upon request.

5

6040/6040 FS Hydraulic Shovel Specifications Working Range – TriPower Face Shovel Attachment (FS) All dimensions are approximate. ft 50 45

m 15 14 13

40 35

12 11 10

30 25

9 8 7

20 15

6

785D

5 4

10

3 2

5 1 0

0 –1

–5 –2 –10

–3 17 55

16

15

14

50

45

13

12 40

11

10

35

9 30

8

7 25

Boom

7.3 m

23 ft 11 in

Stick

4.6 m

15 ft 1 in

Digging Forces Maximum crowd force Maximum crowd force at ground level Maximum breakout force Face Shovels Type Capacity heaped 1:1 Capacity heaped 2:1 Total width Inner width Opening width Number of teeth Weight including wear package Maximum material density (loose)

1730 kN 1200 kN 1200 kN

6 20

388,780 lbf 269,680 lbf 269,680 lbf

5

4 15

3 10

2

1 5

0 m 0 ft

Working Range Maximum digging height

14.4 m

47 ft 3 in

Maximum digging reach

15.4 m

50 ft 6 in

Maximum digging depth Maximum dumping height Crowd distance on level

2.6 m 10.9 m 5.1 m

8 ft 6 in 35 ft 9 in 16 ft 9 in

Iron Ore Shovel Heavy Rock Shovel Heavy Rock Shovel Standard Rock Shovel 22.4 yd3 20.6 m3 26.9 yd3 23.2 m3 30.3 yd3 25.3 m3 33.1 yd3 17.1 m3 15.0 m3 19.6 yd3 18.0 m3 23.5 yd3 20.0 m3 26.2 yd3 22.0 m3 28.8 yd3 4220 mm 13 ft 4 in 4220 mm 13 ft 4 in 4680 mm 15 ft 4 in 4680 mm 15 ft 4 in 3840 mm 12 ft 7 in 3840 mm 12 ft 7 in 4300 mm 14 ft 1 in 4300 mm 14 ft 1 in 1940 mm 6 ft 4 in 1940 mm 6 ft 4 in 2010 mm 6 ft 7 in 2010 mm 6 ft 7 in 5 5 6 6 34 000 kg 74,960 lb 34 500 kg 76,060 lb 36 400 kg 80,250 lb 37 300 kg 82,230 lb

Light Rock Shovel 27.5 m3 36.0 yd3 24.0 m3 31.4 yd3 5020 mm 16 ft 6 in 4640 mm 15 ft 3 in 2010 mm 6 ft 7 in 6 37 600 kg 82,890 lb

2.8 t/m3 4,720 lb/yd3 2.2 t/m3 3,710 lb/yd3 2.0 t/m3 3,370 lb/yd3 1.8 t/m3 3,030 lb/yd3 1.6 t/m3 2,700 lb/yd3

6

6040/6040 FS Hydraulic Shovel Specifications Working Range – Backhoe Attachment (BH) All dimensions are approximate. ft 60

18

m

55

17 16

50

15

45

14

40

12

35 30 25 20 15 10 5 0 –5 –10 –15

13 11 10 9 8 7 6 5 4 3 2 1 0 –1 –2 –3 –4 –5

–20

–6

–25

–7 –8

–30

–9

20 19 18 17 16 15 14 13 12 11 10 9

8

65

25

60

55

50

45

40

35

Boom

9.5 m

31 ft 2 in

Stick

4.6 m

15 ft 1 in

Digging Forces Maximum tearout force Maximum breakout force Backhoes Type

1020 kN 1120 kN

30

229,220 lbf 251,700 lbf

7

6

5

20

15

4

3 10

2

1 5

0

m

0

ft

Working Range Maximum digging depth

7.0 m

23 ft

Maximum digging reach

17.7 m

58 ft 1 in

Maximum digging height

16.8 m

55 ft 1 in

Capacity heaped 1:1 Capacity heaped 2:1 Capacity struck Total width Inner width Number of teeth Weight including wear package

Heavy Rock Bucket 23.5 yd3 18.0 m3 3 16.1 m 21.1 yd3 3 14.0 m 18.3 yd3 4150 mm 13 ft 7 in 3800 mm 12 ft 6 in 6 21 000 kg 46,300 lb

Heavy Rock Bucket 20.0 m3 26.2 yd3 3 17.7 m 23.2 yd3 3 15.3 m 20.0 yd3 4150 mm 13 ft 7 in 3800 mm 12 ft 6 in 6 22 900 kg 50,490 lb

Standard Rock Bucket 22.0 m3 28.8 yd3 3 19.5 m 25.5 yd3 3 17.2 m 22.5 yd3 4150 mm 13 ft 7 in 3800 mm 12 ft 6 in 6 23 800 kg 52,470 lb

Maximum material density (loose)

2.2 t/m3

2.0 t/m3

1.8 t/m3

7

3,710 lb/yd3

3,370 lb/yd3

3,030 lb/yd3

6040/6040 FS Hydraulic Shovel Optional Equipment Optional equipment may vary. Consult your Cat dealer for details.

GENERAL • Custom paint SUPERSTRUCTURE • Hydraulic service crane on superstructure with auxiliary engine • One or two round container(s) for standard 200 L (53 gal) barrels (instead of 1000 L (264 gal) grease container) • Filling of round container(s) via service station • Various cold-weather options

CAB • Dual (redundancy) heating ventilating and air conditioning system • Cab heating • Camera monitoring system

UNDERCARRIAGE • Track pad width 1400 mm (4 ft 7 in) or 1600 mm (5 ft 3 in) • Automatic lubrication of rollers by central lube system • Cover plate under carbody (belly plate)

Additional optional equipment available on request.

Materials and specifications are subject to change without notice.

Featured machines in photos may include additional equipment.

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.cat.com © 2014 Caterpillar All Rights Reserved.

CAT, CATERPILLAR, SAFETY.CAT.COM, their respective logos, “Caterpillar Yellow” and the “Power Edge” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Product ID: 6040/6040 FS

AEHQ6524-04 Replaces AEHQ6524-03 April 2014

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

5-39

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Annex

5-40

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Index 6 INDEX Operation and Maintenance Manual

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

6-1

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Index

6-2

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Index

A ABBREVIATIONS...................................... 5-36 Access ladder lighting................................ 2-41 Activating the electronic hydraulic shovel control (pilot control) ............................ 2-117 Additional messages (ANSI) – Description 2-36 Additional messages (ISO) – Description.. 2-22 After daily operation................................. 2-120 Aftercooler Core - Clean/Test .................. 3-144 AIR CONDITIONER (OPTIONAL) ........... 2-103 Air conditioning filter - clean .................... 3-144 Air-intake lines - inspect ............................ 3-74 AIR-INTAKE SYSTEM............................... 3-71 ALL PRODUCTS FOREWORD................... 1-3 Alternator - Instructions ............................. 3-81 Appropriate disposal of batteries ............... 4-18 ASSEMBLING ATTACHMENT - SAFETY INSTRUCTIONS .................................. 2-121 Attachment - check for cracks ................. 3-145 Automatic fire-extinguishing system .......... 2-54 Automatic reset to idling ............................ 2-11 Avoid mixing of different hydraulic fluids .. 3-33, 3-107

B Back-up heating (option), filling in fuel ...... 2-90 Back-up heating (optional)....................... 2-105 Back-up heating operator’s cab (optional)2-104 Battery – check the state of charge ........... 3-82 Battery - Removing and installing .............. 3-84 Battery - storage ...................................... 3-154 Battery charging inside the machine - safety instructions ............................................. 3-83 Battery isolator switch, shutting off supply voltage.................................................... 2-50 BCS III, interfaces ...................................... 5-23 BCS III, what’s that? .................................... 5-3 BCSIII - the start screen .............................. 5-5 BCSIII, cleaning ......................................... 5-27 BCSIII, disposal ......................................... 5-27 Bearing races .......................................... 3-134 Before starting work................................. 2-117 Belts - Inspect/Replace.............................. 3-44 BOARD-CONTROL-SYSTEM ..................... 5-3 Board-Control-System (BCS) .................... 2-11 Braking the upper structure ..................... 2-118 Breather filter fuel tanks - replace ............. 3-77 Bypass valves (filter housing - cooling system) ) – clean / replace ................................ 3-101 Bypass valves (hydraulic oil reservoir) – clean / replace ................................................... 3-99

C C32 Engine Maintenance Interval Schedule Notes ...................................................... 3-10

Cameras – check / clean / adjust (If equipped) .............................................................. 3-147 CAN-Bus wiring connections – inspect ...... 3-90 CENTRAL LUBRICATING SYSTEM ....... 3-136 Central lubricating system - Design ......... 3-136 Central lubricating system – Fault table..... 5-33 Central lubricating system - Function ...... 3-137 CE-Plate, European Union ........................ 2-40 Checking the gas charging pressure in the pressure accumulator ................ 3-133, 3-151 Checking the greasing pressure .............. 3-139 Clam cylinder chamber - check for soiling3-145 Code table screen ...................................... 5-21 Cold-starting fluid (ether) – Replacing the pressure vessel ...................................... 3-59 Combustion engine - Fault table ................ 5-29 Component numbers ................................. 2-39 CONFINED SPACES - SAFETY INSTRUCTIONS ...................................... 4-4 Control and Monitoring Platform (CAMP) .. 2-10 Controls adjustment data screen ............... 5-15 Coolant Extender (ELC) – Add .................. 3-66 Coolant for use on all combustion engines 3-40 Coolant Sample (Level 1) - Obtain ............ 3-68 Coolant Sample (Level 1) - Obtain ............ 3-67 Coolant Temperature Regulator – Replace3-47 Cooling liquid - change .............................. 3-64 Cooling liquid level - check ........................ 3-61 COOLING SYSTEM................................... 3-60 Cooling System Supplemental Coolant Additive (SCA) - Test/ Add ..................... 3-69 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) . 2-123 CRAWLER TRACKS ............................... 3-130

D Decommissioning and Disposal................. 4-17 Demand control / Zero-flow regulation....... 2-11 DESCRIPTION OF THE HYDRAULIC SHOVEL ................................................... 2-6 DESIGNATED USE, UNAUTHORIZED USE 18 Diesel fuel – recommendations ................. 2-90 Dismantling and removal instructions ........ 4-17 DISPOSAL AT THE END OF THE SERVICE LIFE ........................................................ 4-17 Disposing of the machine without polluting the environment............................................ 4-17 Drive unit .................................................... 2-10 Dust trap - clean......................................... 3-71

E Electrical circuit diagrams .......................... 3-81 Electrical Storm Injury Prevention.............. 2-89 Electrical system ........................................ 2-11 ELECTRICAL SYSTEM ............................. 3-81 Electrical system - Safety instructions ....... 3-81 3

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Index Electrical system switch-cabinets .............. 3-81 Electronic hydraulic shovel control – clean / lubricate................................................ 3-113 Emergency escape device / seat (optional 2-56 Emergency exit in operator’s cab and escape ladder ..................................................... 2-44 Emergency off switch ................................ 2-92 Emergency shut-off function ...................... 2-48 Emergency Stop, reset function .................. 5-9 ENGINE ..................................................... 3-42 Engine – Clean ........................................ 3-142 Engine - Safety instructions ....................... 3-42 Engine 1 (LH), control and monitoring....... 2-67 Engine 2 (RH), control and monitoring ...... 2-69 Engine crankcase breather........................ 3-58 Engine crankcase breather – clean ........... 3-58 Engine crankcase breathers – clean ......... 3-58 Engine data screen.................................... 5-12 Engine Hoses and Clamps - Inspect/Replace 348 Engine information decal ........................... 2-39 ENGINE MONITORING, CONTROL LAMPS 534 Engine Mounts - Inspect ............................ 3-44 Engine number .......................................... 2-39 Engine oil - change .................................... 3-53 Engine oil - check level / top up ................. 3-51 Engine oil filter - replace ............................ 3-57 Engine oil reservoir (if equipped) – check oil level / top up ........................................... 3-52 Engine oil reservoir (if equipped) - drain the oil off ........................................................... 3-55 Engine oil reservoir (if equipped) - replace the oil filters .................................................. 3-57 Engine Oil Sample – Obtain ...................... 3-45 Engine oil service interval table ................. 3-30 Engine oil service interval table with ReserveTM Oil Tank (if equipped) ......... 3-31 Engine Valve Lash – Check ...................... 3-46 Engine Valve Rotators – Inspect ............... 3-46 Engines – adjusting the speed ................ 2-101 Engines, emergency shut-off ..................... 2-97 Entering and leaving the machine Safety instructions ............................................. 2-41 Escape ladder near engine compartment (optional) ................................................ 2-45 Eurasian Economic Union ......................... 2-40 European Union, Declaration of Conformity 1-6 Extract from the German regulations ...... 3-151

F FAULT TABLES ........................................ 5-29 Filling quantities - Grease .......................... 3-27 Filling quantities - oil .................................. 3-32 Filling quantities - other ............................. 3-32 Filter (control circuit and auxiliary control circuit) – check / replace ...................... 3-103 FIRE AND EXPLOSION HAZARD ..... 1-14, 2-5 Fire extinguisher ........................................ 2-54 4

Fluids for hydraulic system ........................ 3-35 Folding ladder ............................................ 2-43 Fuel filter - replace ..................................... 3-75 Fuel Injector - Inspect/Adjust ..................... 3-44 Fuel preheating system (optional) ............. 2-99 FUEL SYSTEM .......................................... 3-75 Fuel System – Prime.................................. 3-80 Fuel system - Safety instructions ............... 3-75 Fuel system – vent ..................................... 3-77 Fuel tanks – clean ...................................... 3-77 FULL LIFE.................................................. 4-10 Further hazardous substances .................. 4-18 Further machine documentation .................. 1-4

G Gas, dust, steam and smoke ..................... 1-12 Grease container – fill up ......................... 3-138 Grease container breather filter - check / replace.................................................. 3-138 Grease filter (filling the grease container) – check / replace ..................................... 3-140 Grease filter (grease lines) - replace ....... 3-141 Grease for bearings, slew rings and track system (Central lubrication system) ....... 3-38 Grease for idlers, track rollers and upper rollers (Lifetime lubrication) .................... 3-39 Grease line – unblock .............................. 3-139

H HALF LIFE ................................................... 4-9 High-pressure filter for working hydraulics – check / replace ..................................... 3-104 High-pressure filters for feeding circuits and slewing pumps – check / replace ......... 3-106 High-pressure filters for the servo circuit – check / replace ..................................... 3-105 Horn – inspect / replace ........................... 3-148 Hose line for oil and cooling liquid changes .. 341 HYDRAULIC CIRCUIT DIAGRAM............. 5-35 Hydraulic data screen ................................ 5-13 Hydraulic equipment .................................. 1-13 Hydraulic hoses – Instructions ................... 4-12 Hydraulic ladder, pressure accumulator .. 3-150 Hydraulic motor chamber - change.......... 3-129 Hydraulic motor chamber oil - change ..... 3-127 Hydraulic motor chamber oil level - check / top up with oil ............................................. 3-125 Hydraulic motor chambers oil level - check / top up with oil ....................................... 3-128 Hydraulic oil – change ............................. 3-107 Hydraulic oil cooler – Clean ..................... 3-112 Hydraulic oil level – check ......................... 3-92 Hydraulic oil return-flow filter (hydraulic oil reservoir) – replace (up to machine no.

170129 / DHX40129) ............................. 3-94 Hydraulic oil return-flow filters - replace (from machine no. 170130 / DHJ40130) ......... 3-97

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Index Hydraulic oil return-flow filters (filter housing cooling system) – replace .................... 3-100 Hydraulic oil tank breather filters - replace .... 3102 Hydraulic shovel – putting out of operation ... 3154 Hydraulic shovel – recommissioning ....... 3-154 Hydraulic shovel layout – undercarriage and attachment ............................................... 2-9 Hydraulic shovel layout – upper structure ... 2-7 Hydraulic system ....................................... 2-10 HYDRAULIC SYSTEM .............................. 3-91 HYDRAULIC SYSTEM .............................. 4-12 Hydraulic system – depressurize .............. 3-91 Hydraulic system - repair instructions ....... 4-12 Hydraulic system - Safety instructions ...... 3-91 Hydraulic system – vent .......................... 3-111

I Information given on the ............................ 5-11 Information given on the start screen, central section ...................................................... 5-7 Information given on the start screen, lower section ...................................................... 5-8 Information given on the start screen, top section ...................................................... 5-6 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...................................... 3-3 INSPECTION AND SERVICING PLANS INSTRUCTIONS ...................................... 3-9 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................... 3-7 INSPECTION PLAN - OIL ......................... 3-28 Inspection plan – Oil (legend) .................... 3-29 Instructions on troubleshooting ................. 5-28

L Layout of the fault table ............................. 5-28 Lighting systems in LED technonogy instructions ............................................. 3-89 LUBRICANTS / CONSUMABLES ............. 3-33 LUBRICATING CHART – GREASE .......... 3-26 Lubricating chart – Grease (legend) .......... 3-27 Lubrication data screen ............................. 5-14

M Machine number ........................................ 2-39 Main filter element - check / clean ............. 3-73 Main filter elements ................................... 3-72 MAXIMUM MACHINE INCLINATIONS, INFORMATION .................................... 2-106 Measures ................................................... 5-28 Mirror – check / clean / adjust.................. 3-146 Monitoring cameras – function ................ 2-127 MONITORING CAMERAS (OPTIONAL). 2-127 MONITORING, WARNING AND CONTROL ELEMENTS ............................................ 2-60

N Noise emission information .......................... 1-7 NOTES ....................................................... 4-19 NOTES .......................................1-1, 2-1, 3-156 NOTES ....................................................... 5-39 Notes on the selection of oils and greases 3-33

O Oil for swing gearboxes ............................. 3-37 Oils for combustion engines ...................... 3-34 Oils for pump drive gearboxes and travel gearboxes............................................... 3-36 On-Board crane – blocking the boom in position of rest ...................................... 2-126 On-Board crane - check tightness of fastening bolts ...................................................... 3-153 On-board crane - checking ...................... 2-126 On-board crane - drive unit ...................... 2-125 On-board crane – lubricate ...................... 3-152 On-board crane - monitoring, warning and control elements ................................... 2-124 On-board crane - putting into operation ... 2-125 ON-BOARD CRANE (OPTIONAL) .......... 2-124 ON-BOARD CRANE, DRIVE UNIT (OPTIONAL) ......................................... 3-152 Operating hours meter (if equipped) .......... 2-55 OPERATION - SAFETY INSTRUCTIONS .. 2-3 Operation and Maintenance Manuals, where to store it in the operator’s cab ..................... 2-4 Operator’s seat .......................................... 2-51 ORGANIZATIONAL MEASURES ................ 1-9 Other elements on the front side ................. 5-4 OTHER MAINTENANCE ......................... 3-142 Overhaul Considerations ............................. 4-6 Overhaul Recommendation ......................... 4-7

P Plan A - E ................................................... 3-19 Plan N ........................................................ 3-13 Plan T and W ............................................. 3-15 Plan V ........................................................ 3-11 Possible causes ......................................... 5-28 Pre-chamber / spur wheel section oil - change .............................................................. 3-126 Pre-chamber / spur wheel section oil level check / top up with oil ........................... 3-125 Pre-chamber breather - replace............... 3-120 Pre-chambers oil level – check / top up with oil .............................................................. 3-116 PREFACE .................................................... 1-4 Preheating system for engine and hydraulic oil (optional) ................................................ 2-98 Pressure accumulator - Emergency lowering 3114 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS .................................... 4-13 Pressure-accumulator inspection regulations 3133 5

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Index Pressure-accumulator inspection regulations 3151 Primary fuel filter - drain water................... 3-76 Primary fuel filter - replace......................... 3-76 PRODUCT SPECIFICATION SHEET ....... 5-38 PUMP DRIVE GEARBOX ....................... 3-115 Pump drive gearbox – replace ................ 3-119 Pump drive gearbox lube oil filters – replace 3121 Pump drive gearbox oil - change ............. 3-117 Pump drive gearbox oil level - check / top up with oil .................................................. 3-115 Pump drive gearbox oil sample – obtain . 3-116 Pump drive gearbox pre-chambers - change the gearbox oil ..................................... 3-119 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING .......................... 3-154 Putting the machine back into operation, reset of emergency shut off function ............... 2-49 PUTTING THE MACHINE INTO OPERATION ............................................................... 2-89

R Radiator – Clean ...................................... 3-143 Radiators ................................................... 3-61 Reducing the operator's exposure to noise 2-89 Reducing the operators exposure to vibrations ............................................................... 2-53 Refuelling ................................................... 2-90 REPAIR WORK - ENGINE .......................... 4-6 REPAIR WORK - FIRE AND EXPLOSION HAZARD .................................................. 4-5 REPAIR WORK - SAFETY INSTRUCTIONS 43 Replacing lamps and bulbs ....................... 3-81 Restricted Visibility ...................................... 1-9 Risk of deflagrations .................................. 4-17 Risk of fire .................................................. 4-17

S Safety films and warning messages – overview and description ....................................... 2-12 Safety instructions governing specific operational phases................................. 1-10 Safety messages (ANSI) – Description ..... 2-32 Safety messages (ISO) – Description ....... 2-18 Saving data to a USB stick ........................ 5-24 Saving data to a USB stick, continued . 5-25, 526 Seat belt – inspect ................................... 3-149 Seat belt – replace ................................... 3-149 Secondary filter element – replace ............ 3-74 Section ....................................................... 5-28 Securing the machine .............................. 2-122 Selection and qualification of personnel; basic responsibilities ....................................... 1-10 Service station (tanklift) ............................. 2-91 6

SERVICING WORK ................................... 3-41 Shutting off the engines ........................... 2-102 Signal table screen .................................... 5-17 Signal table screen, diagram ..................... 5-19 Signal table screen, diagram configuration 5-20 Signal table screen, location ...................... 5-18 Slew brake test screen .............................. 5-22 Sound Level Information for Machines in Eurasian Economic Union Countries ....... 1-7 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ........ 1-11 Starter isolator switch, shutting off starter voltage .................................................... 2-50 STARTING AND STOPPING THE ENGINES2100 Starting the engines ................................. 2-100 Starting the engines at low temperatures 2-101 Swing circuit lock-out function ................... 5-10 SWING GEARBOX .................................. 3-122 Swing gearbox - vent ............................... 3-122 Swing gearbox oil - change ..................... 3-123 Swing gearbox oil level - check the oil level / top up with oil ....................................... 3-122 Swing gearbox oil sample – obtain .......... 3-122 Swing mechnism – Fault table ................... 5-32 SWING RING ........................................... 3-134 Swing ring - Instructions .......................... 3-134 Swing ring bolts - check for tightness ...... 3-135 Swing ring grease filling – check ............. 3-135 Swinging ladder (optional) ......................... 2-42 Swinging the upperstructure .................... 2-118 Switchgear cabinet - aeration .................... 3-85 Switching the cab interior lighting on and off . 246 Switching the electrical system on and off . 2-97 Switching the maintenance lights on and off . 247

T Temperature .............................................. 3-60 The keys on the front side ........................... 5-4 Track drive – Fault table ............................ 5-31 Track parking brake ................................. 2-113 Track roller - lubricate .............................. 3-131 Track roller fastening - check................... 3-130 Track tensioning system .......................... 3-132 Trainer's / instructor's seat ......................... 2-53 Transport - Safety instructions ................. 2-114 TRANSPORTING THE MACHINE .......... 2-114 Travel Alarm – Test.................................. 3-142 TRAVEL GEARBOX (PN 2763213)......... 3-125 TRAVEL GEARBOX (PN 614-2403)......... 3-128 Travel gearbox breather filter - clean / replace .............................................................. 3-127 Travel gearbox oil - change .......... 3-126, 3-129 Travel gearbox oil level - check / top up with oil ................................................... 3-125, 3-128

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

Index Travel gearbox oil sample – obtain .... 3-127, 3128 TRAVELING ............................................ 2-109 Traveling forwards/backwards ................. 2-109 TRAVELING, SAFETY INSTRUCTIONS 2-108 TROUBLESHOOTING .............................. 5-28

U Undercarriage ............................................ 2-10 Undercarriage – check for leaks and free movement ............................................ 3-130 Upper structure .......................................... 2-10 Upper structure basic position ................. 2-109 Upper structure holding brake ................. 2-113 USB interface, data storage ...................... 5-23 Useful Life .................................................... 1-8

V Vibration information.................................... 1-7 View documents screen ............................ 5-16 Visibility aids ................................................ 2-4

Visibility Information ..................................... 1-7

W Walk-Around Inspection ............................. 3-43 Warning of special dangers ....................... 1-12 Warnings and symbols ................................ 1-6 WARRANTY ................................................ 1-5 Water trap optional) – clean / replace ........ 3-79 WELDING AND FLAME CUTTING WORKS SAFETY INSTRUCTIONS ..................... 4-14 Window panes - clean ............................. 3-146 Windscreen washer ................................... 2-55 Working hydraulics – Fault table................ 5-30 WORKING OPERATION ......................... 2-117 WORKING OPERATION - SAFETY INSTRUCTIONS .................................. 2-115 Working operations .................................. 2-119

X Xenon floodlight projector - replacing the lamp ................................................................ 3-87

7

EM030935-01 OMM 6040, 6040FS (3 725 089.06)-EN

© Copyright Caterpillar Global Mining HMS GmbH 2022

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Printed in Germany