Cat 6040 AC,6040 AC FS Hydraulic Shovel Operation and Maintenance Manual EM029995

EM029995-0 (en-us)

Operation and Maintenance Manual 6040 AC, 6040 AC FS Hydraulic Shovel Machines with converted Board Control System from BCSIV-eCAMP to BCS3e: DHJ40152 DHX40138, -139, -140, -141, -143, -144, -145, -146, -147, -148

Language: Original Instructions

EM029995-0 (en-us)

EM029995-0 (en-us)

OMM 6040AC, 6040ACFS(3 847 037.00)-EN 10 / 2019

Operation and Maintenance Manual 6040 AC, 6040 AC FS Hydraulic Shovel

No.

Machines with converted Board Control System from BCSIV-eCAMP to BCS3e: DHJ40152 DHX40138, -139, -140, -141, -143, -144, -145, -146, -147, -148

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Published by:

Caterpillar Global Mining HMS GmbH Dept. Technical Publications D-44149 Dortmund, Caterpillarstrasse 1 Tel. 49 (0) 231 922-3 Fax 49 (0) 231 922-4055 https://mining.cat.com

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2019. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization 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

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

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TABLE OF CONTENTS TABLE OF CONTENTS 1 INTRODUCTION ___________________________________________________________________ 1-1 ALL PRODUCTS FOREWORD________________________________________________________ 1-2 Literature Information ______________________________________________________________ 1-2 Safety __________________________________________________________________________ 1-2 Operation _______________________________________________________________________ 1-2 Product Information ________________________________________________________________ 1-2 Maintenance _____________________________________________________________________ 1-2 Maintenance Intervals ______________________________________________________________ 1-2 Product Capacity __________________________________________________________________ 1-2 CALIFORNIA PROPOSITION 65 WARNING _____________________________________________ 1-3 PREFACE ________________________________________________________________________ 1-4 About this Operation and Maintenance Manual __________________________________________ 1-4 Further machine documentation ______________________________________________________ 1-4 WARRANTY ______________________________________________________________________ 1-5 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-6 Warnings and symbols _____________________________________________________________ 1-6 Sound Level Information for Machines in Eurasian Economic Union Countries _________________ 1-6 Visibility Information _______________________________________________________________ 1-6 Restricted Visibility ________________________________________________________________ 1-7 DESIGNATED USE _________________________________________________________________ 1-8 Useful Life _______________________________________________________________________ 1-8 ORGANIZATIONAL MEASURES ______________________________________________________ 1-9 Restricted Visibility ________________________________________________________________ 1-9 Selection and qualification of personnel; basic responsibilities _____________________________ 1-10 Safety instructions governing specific operational phases _________________________________ 1-10 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ___________________________ 1-11 Warning of special dangers ________________________________________________________ 1-12 Gas, dust, steam and smoke _______________________________________________________ 1-13 Hydraulic equipment ______________________________________________________________ 1-13 Noise __________________________________________________________________________ 1-13 Oil, grease and other chemical substances ____________________________________________ 1-13 Transporting and recommissioning __________________________________________________ 1-13 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED HYDRAULIC SHOVELS1-14 Safety instructions for hydraulic shovels with electric motor _______________________________ 1-15 FIRE AND EXPLOSION HAZARD ____________________________________________________ 1-16 NOTES _________________________________________________________________________ 1-17 2 OPERATION ______________________________________________________________________ 2-1 OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3 Visibility aids _____________________________________________________________________ 2-4 Operation and Maintenance Manual, where to store it in the operator’s cab ____________________ 2-4

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TABLE OF CONTENTS FIRE AND EXPLOSION HAZARD _____________________________________________________ 2-5 DESCRIPTION OF THE HYDRAULIC SHOVEL __________________________________________ 2-6 Hydraulic shovel layout _____________________________________________________________ 2-7 Undercarriage ____________________________________________________________________ 2-8 Upper structure ___________________________________________________________________ 2-8 Drive unit ________________________________________________________________________ 2-8 Hydraulic system _________________________________________________________________ 2-8 Control and Monitoring Platform (CAMP) _______________________________________________ 2-8 Demand control / Zero-flow regulation _________________________________________________ 2-9 Board-Control-System (BCS) ________________________________________________________ 2-9 Electrical system __________________________________________________________________ 2-9 Power supply ___________________________________________________________________ 2-10 Operation with cable reel (if equipped) ________________________________________________ 2-11 Safety films and warning messages – Overview and Description ___________________________ 2-12 Safety messages (ANSI) – Description _______________________________________________ 2-23 Additional messages (ANSI) – Description_____________________________________________ 2-27 Machine identification plate ________________________________________________________ 2-30 Motor number plate_______________________________________________________________ 2-30 Eurasian Economic Union _________________________________________________________ 2-31 CE-Plate, European Union _________________________________________________________ 2-31 Entering and leaving the machine - Safety instructions ___________________________________ 2-32 Access ladder - Lighting ___________________________________________________________ 2-32 Folding ladder – Function (if equipped) _______________________________________________ 2-33 Swinging ladder - Function (if equipped) ______________________________________________ 2-34 Emergency exit in operator’s cab and escape ladder ____________________________________ 2-35 Cab interior lighting – Switch on and off _______________________________________________ 2-36 Maintenance lights – Switch on and off _______________________________________________ 2-37 Emergency shut off - Function ______________________________________________________ 2-38 Servicing switch – Function ________________________________________________________ 2-39 Windscreen washer – Reservoir _____________________________________________________ 2-39 Reducing operators exposure to vibrations ____________________________________________ 2-39 Trainer's / instructor's seat _________________________________________________________ 2-39 Operator's seat __________________________________________________________________ 2-40 Fire extinguisher _________________________________________________________________ 2-42 Automatic fire-extinguishing system __________________________________________________ 2-42 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-44 PUTTING THE MACHINE INTO OPERATION ___________________________________________ 2-62 Electrical Storm Injury Prevention ___________________________________________________ 2-62 Reducing the operator's exposure to noise ____________________________________________ 2-62 Service station __________________________________________________________________ 2-62 Battery main switch - Switch on and off _______________________________________________ 2-65 Electrical system (24V) - Switch on and off ____________________________________________ 2-65 Electric motor – Switch on and off ___________________________________________________ 2-66 Time-out before restart ____________________________________________________________ 2-67 Electric motor can not be switched on ________________________________________________ 2-68 Circuit breaker - Switch on and off ___________________________________________________ 2-69 Motor protection relay - Function ____________________________________________________ 2-70 Active-power transducer - Function __________________________________________________ 2-72 Preheating system for hydraulic oil reservoir and pump gearbox, switching on and off (if equipped) 2-73 Air conditioner (if equipped) ________________________________________________________ 2-74 vi

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TABLE OF CONTENTS Back-up heating operator’s cab (if equipped) ___________________________________________ 2-74 OPERATIONAL PRACTICES ________________________________________________________ 2-75 Working operation - Safety instructions _______________________________________________ 2-75 Before starting work ______________________________________________________________ 2-76 Machine Operating Temperature Range ______________________________________________ 2-76 Warm-up procedure for electric driven shovel __________________________________________ 2-77 Electronic hydraulic shovel control (pilot control) – activate ________________________________ 2-78 Working operation – basics ________________________________________________________ 2-79 OPERATION TECHNIQUES _________________________________________________________ 2-85 Machine operation with backhoe attachment, Best Practices ________________________________ 85 Loading setups __________________________________________________________________ 2-89 Machine operation with face shovel attachment - Best Practices ___________________________ 2-95 Face Shovel Operation – Restricted Operation ________________________________________ 2-109 TRAVELING ____________________________________________________________________ 2-124 Traveling - Safety Instructions _____________________________________________________ 2-124 Before starting traveling __________________________________________________________ 2-126 Traveling – Basic Movements _____________________________________________________ 2-128 Counter-rotation turns / Turning on the spot___________________________________________ 2-131 Track Parking Brake – set/release __________________________________________________ 2-132 Traveling speed – adjust__________________________________________________________ 2-132 Traveling uphill and downhill on ramps and steep slopes ________________________________ 2-133 Traveling over long distances ______________________________________________________ 2-135 Traveling – Best Practices ________________________________________________________ 2-137 Traveling – Restricted Operation ___________________________________________________ 2-138 Maximum Machine Inclinations ____________________________________________________ 2-141 TRANSPORTING THE MACHINE ___________________________________________________ 2-142 Transport - Safety instructions _____________________________________________________ 2-142 RUNNING-IN INSTRUCTIONS FOR HYDRAULIC CYLINDERS ____________________________ 2-143 EMERGENCY LOWERING OF THE WORKING EQUIPMENT _____________________________ 2-144 AFTER DAILY OPERATION ________________________________________________________ 2-145 ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS _______________________ 2-146 Securing the machine ____________________________________________________________ 2-147 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___________ 2-148 ON-BOARD CRANE (IF EQUIPPED) _________________________________________________ 2-149 On-board crane, monitoring, warning and control elements ______________________________ 2-149 On-board crane, putting into operation _______________________________________________ 2-150 On-board crane, drive unit ________________________________________________________ 2-150 On-Board crane, – blocking the boom in position of rest _________________________________ 2-151 On-board crane, checking ________________________________________________________ 2-151 Monitoring cameras (if equipped) ___________________________________________________ 2-152

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TABLE OF CONTENTS NOTES ________________________________________________________________________ 2-153 3 INSPECTION AND SERVICING _______________________________________________________ 3-1 SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS WITH ELECTRIC MOTOR _____________ 3-3 INSPECTION AND SERVICING – SAFETY INSTRUCTIONS ________________________________ 3-4 FIRE AND EXPLOSION HAZARD _____________________________________________________ 3-8 INSPECTION AND SERVICING PLANS – INSTRUCTIONS _________________________________ 3-9 Servicing Intervals ________________________________________________________________ 3-9 Oils / Lubricants __________________________________________________________________ 3-9 Cleaning jobs ____________________________________________________________________ 3-9 Components _____________________________________________________________________ 3-9 Plan V _________________________________________________________________________ 3-11 Plan N _________________________________________________________________________ 3-13 Plan T and W ___________________________________________________________________ 3-15 Plan A – E ______________________________________________________________________ 3-17 LUBRICATING CHART – LUBRICANT ________________________________________________ 3-24 Lubricating chart – Lubricant (legend) ________________________________________________ 3-25 Filling quantities – Lubricant ________________________________________________________ 3-25 INSPECTION PLAN - OIL ___________________________________________________________ 3-26 Inspection plan – Oil (legend) _______________________________________________________ 3-27 Filling quantities - oil ______________________________________________________________ 3-28 Filling quantities - other____________________________________________________________ 3-28 LUBRICANTS ____________________________________________________________________ 3-29 Notes on the selection of oils and lubricants ___________________________________________ 3-29 LUBRICANTS / CONSUMABLES _____________________________________________________ 3-30 I. Oil for combustion engines (On-Board Crane, if equipped) _____________________________ 3-30 II. Oil for hydraulic system (selection)______________________________________________ 3-31 III.a Oil for pump gearboxes and travel gearboxes _____________________________________ 3-32 III.b Oil for swing gearboxes ______________________________________________________ 3-33 V. Lubricant for bearings, swing rings and track system (Central lubrication system) _________ 3-34 Lubricants for idlers, track rollers and upper rollers (Lifetime lubrication) _____________________ 3-35 SERVICING WORK ________________________________________________________________ 3-36 Hose line for oil changes __________________________________________________________ 3-36 ELECTRIC MOTOR _______________________________________________________________ 3-37 Electric motor - Safety instructions ___________________________________________________ 3-37 Electric motor – Clean ____________________________________________________________ 3-37 Electric motor - Lubricate __________________________________________________________ 3-38 ELECTRICAL SYSTEM _____________________________________________________________ 3-39 Electrical system - Safety instructions ________________________________________________ 3-39 Battery, checking state of charge ____________________________________________________ 3-40 Electrical system, control cabinets ___________________________________________________ 3-42 Slip ring assembly, servicing work ___________________________________________________ 3-44 Electrical circuit diagrams __________________________________________________________ 3-44 Replacing fuses _________________________________________________________________ 3-44 Replacing lamps and bulbs ________________________________________________________ 3-44

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TABLE OF CONTENTS Xenon floodlight projector (if equipped), replacing the lamp _______________________________ 3-45 Lighting systems in LED technonogy, instructions _______________________________________ 3-47 HYDRAULIC SYSTEM _____________________________________________________________ 3-48 Hydraulic system - Safety instructions ________________________________________________ 3-48 Depressurizing the hydraulic system _________________________________________________ 3-48 Checking the hydraulic oil level _____________________________________________________ 3-49 Hydraulic oil return-flow filters, replace ________________________________________________ 3-51 Hydraulic oil return-flow filters, replace (from machine no. 170138) _________________________ 3-53 Bypass valves, clean / replace ______________________________________________________ 3-55 Hydraulic oil tank breather filters, replace _____________________________________________ 3-56 Filter (servo control circuit), replace __________________________________________________ 3-57 High-pressure filter for working hydraulics, replace ______________________________________ 3-58 Filters for swing charge pump, replace________________________________________________ 3-59 High-pressure filters for the servo circuit, replace _______________________________________ 3-60 Changing the hydraulic oil _________________________________________________________ 3-61 Avoid mixing of different hydraulic fluids ______________________________________________ 3-61 Venting the hydraulic system _______________________________________________________ 3-65 Cleaning the hydraulic oil cooler _____________________________________________________ 3-66 Electronic hydraulic shovel control ___________________________________________________ 3-67 Pressure accumulator - Emergency lowering ___________________________________________ 3-68 PUMP DRIVE GEARBOX ___________________________________________________________ 3-69 Pump drive gearbox, checking oil level / Topping up with oil _______________________________ 3-69 Pump drive gearbox, changing oil ___________________________________________________ 3-71 Pump drive gearbox, pre-chamber ___________________________________________________ 3-72 Pump drive gearbox, venting _______________________________________________________ 3-72 Pre-chambers working pumps, draining oil, changing oil __________________________________ 3-73 Pre-chambers swing pumps, draining oil, changing oil ___________________________________ 3-73 Pump gearbox, oil filter ____________________________________________________________ 3-74 SWING GEARBOX ________________________________________________________________ 3-75 Swing gearbox - Checking the oil level / Topping up with oil _______________________________ 3-75 Changing the gearbox oil __________________________________________________________ 3-75 Swing gearbox, venting ___________________________________________________________ 3-76 TRAVEL GEARBOX _______________________________________________________________ 3-77 Travel gearbox - Checking the oil level / Topping up with oil _______________________________ 3-77 Travel gearbox - Changing oil ______________________________________________________ 3-78 Travel gearbox - Breather filter ______________________________________________________ 3-79 Track rollers ____________________________________________________________________ 3-81 Track tensioner __________________________________________________________________ 3-82 Pressure-accumulator inspection regulations___________________________________________ 3-83 Checking the gas charging pressure in the pressure accumulator __________________________ 3-83 SWING RING_____________________________________________________________________ 3-84 Swing ring - Instructions ___________________________________________________________ 3-84 Bearing races ___________________________________________________________________ 3-84 CENTRAL LUBRICATING SYSTEM ___________________________________________________ 3-86 Design and function ______________________________________________________________ 3-86 Function _______________________________________________________________________ 3-87 Filling up the lubricant container _____________________________________________________ 3-88 Breather filter ___________________________________________________________________ 3-88 ix

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TABLE OF CONTENTS Checking the greasing pressure _____________________________________________________ 3-89 Checking the greasing pressure _____________________________________________________ 3-90 Unblocking a lubricating line ________________________________________________________ 3-91 Unblocking a lubricant line _________________________________________________________ 3-91 Oilfilter (hydraulic circuit lubricant pump) ) _____________________________________________ 3-92 Lubricant filter (Filling the lubricant container) __________________________________________ 3-93 Lubricant filter (Lubricating lines) ____________________________________________________ 3-94 OTHER MAINTENANCE ____________________________________________________________ 3-95 Heating and air conditioning ________________________________________________________ 3-95 Attachment - Check for cracks ______________________________________________________ 3-95 Reservoirs for used lubricant at the A-frame - Empty ____________________________________ 3-96 Hydraulic ladder - Pressure accumulator ______________________________________________ 3-96 Pressure-accumulator inspection regulations___________________________________________ 3-97 Extract from the regulations ________________________________________________________ 3-97 Checking the gas charging pressure in the pressure accumulator __________________________ 3-97 ON-BOARD CRANE - DRIVE UNIT ___________________________________________________ 3-98 On-board crane - Lubricate ________________________________________________________ 3-99 On-Board crane - Check tightness of fastening bolts _____________________________________ 3-99 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING _______ 3-100 Putting the hydraulic shovel out of operation __________________________________________ 3-100 Battery storage _________________________________________________________________ 3-100 Recommissioning _______________________________________________________________ 3-100 NOTES ________________________________________________________________________ 3-101 4 REPAIR WORK ____________________________________________________________________ 4-1 SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS WITH ELECTRIC MOTOR _____________ 4-3 REPAIR WORK - SAFETY INSTRUCTIONS _____________________________________________ 4-4 FIRE AND EXPLOSION HAZARD _____________________________________________________ 4-5 HYDRAULIC SYSTEM ______________________________________________________________ 4-6 Repair __________________________________________________________________________ 4-6 Hydraulic hoses – Instructions _______________________________________________________ 4-6 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ________________________________ 4-7 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS _______________________ 4-8 DISPOSAL AT THE END OF THE SERVICE LIFE _______________________________________ 4-11 Appropriate disposal of batteries ____________________________________________________ 4-12 NOTES _________________________________________________________________________ 4-13 5 ANNEX __________________________________________________________________________ 5-1 BOARD-CONTROL-SYSTEM _________________________________________________________ 5-3 BCS3e, what’s that? _______________________________________________________________ 5-3 What it is ________________________________________________________________________ 5-3 What it does _____________________________________________________________________ 5-3 Benefits for the operator ____________________________________________________________ 5-3 Want more information? ____________________________________________________________ 5-3

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TABLE OF CONTENTS The keys on the front side __________________________________________________________ 5-4 Other Elements on the Front Side ____________________________________________________ 5-4 BCS3e, the Start Screen ___________________________________________________________ 5-5 Information Given on the Start Screen - Top Section ______________________________________ 5-6 Information Given on the Start Screen - Central Section ___________________________________ 5-7 Information Given on the Start Screen - Lower Section ____________________________________ 5-8 Emergency Stop - Reset Function ____________________________________________________ 5-9 Swing Circuit Lock-Out Function ____________________________________________________ 5-10 Information Given on the “Service” Screen ____________________________________________ 5-11 Information Given on the “Service” Screen – continued ___________________________________ 5-12 Electric Motor Data Screen _________________________________________________________ 5-13 Electric Motor Data Screen – continued _______________________________________________ 5-14 Hydraulic Data Screen ____________________________________________________________ 5-15 Lubrication Data Screen ___________________________________________________________ 5-16 Controls Adjustment Data Screen ___________________________________________________ 5-17 Slew Brake Test Data Screen ______________________________________________________ 5-18 Signal Table Screen ______________________________________________________________ 5-19 Signal Table Screen - Diagram _____________________________________________________ 5-20 Signal Table Screen - Diagram Configuration __________________________________________ 5-21 Fault Storage / Fault Table - Screen _________________________________________________ 5-22 Fault Storage – Save to USB-Stick __________________________________________________ 5-23 Fault Storage – Fault Detail ________________________________________________________ 5-24 BCS files – Copy to USB-Stick ______________________________________________________ 5-25 BCS3e - Interfaces _______________________________________________________________ 5-26 USB Interface - Data Storage _______________________________________________________ 5-26 Store Screenshot Screen __________________________________________________________ 5-27 BCS3e - Cleaning ________________________________________________________________ 5-28 BCS3e - Disposal ________________________________________________________________ 5-28 TROUBLESHOOTING _____________________________________________________________ 5-29 Instructions on troubleshooting ______________________________________________________ 5-29 Layout of the fault table ___________________________________________________________ 5-29 Possible causes _________________________________________________________________ 5-29 Measures ______________________________________________________________________ 5-29 Section ________________________________________________________________________ 5-29 FAULT TABLES __________________________________________________________________ 5-30 Working hydraulics – Fault table ____________________________________________________ 5-30 Track drive – Fault table ___________________________________________________________ 5-31 Swing mechnism – Fault table ______________________________________________________ 5-32 Central lubricating system – Fault table _______________________________________________ 5-33 HYDRAULIC CIRCUIT DIAGRAM ____________________________________________________ 5-34 ABBREVIATIONS _________________________________________________________________ 5-35 NOISE AND VIBRATION INFORMATION ______________________________________________ 5-37 Noise emission information_________________________________________________________ 5-37 Vibration information ______________________________________________________________ 5-37

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TABLE OF CONTENTS PRODUCT SPECIFICATION SHEET __________________________________________________ 5-38 NOTES _________________________________________________________________________ 5-40 6 INDEX ___________________________________________________________________________ 6-1

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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

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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.

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

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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.

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Introduction CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

WARNING: This product can expose you to chemicals including ethylene glycol, which is known to the state of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

Do not ingest this chemical. Wash hands after handling to avoid incidental ingestion.

WARNING: This product can expose you to chemicals including lead or lead compounds, which is known to the state of California to cause cancer, birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

Wash hands after handling components that may contain lead.

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Introduction PREFACE About this Operation and Maintenance Manual These Operation and Maintenance Manual are 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 operator’s cab of the machine.

The Operation and Maintenance Manual must be read and put into practice by any person in charge of carrying out work with or on the machine, such as  operation, including setting-up, troubleshooting in the course of work, care, evacuation of 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 are directed to the mining-machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days' instruction by a qualified CGM-HMS GmbH (Caterpillar Global Mining Hydraulic Mining Shovels GmbH) mechanic or by attending an CGM-HMS GmbH training course for operators or maintenance personnel.

The CGM-HMS GmbH after-sales service will be pleased to deal with any queries you may have after reading through the Operation and Maintenance Manual.

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Complies with VDMA recommendation "Operation and Maintenance Manual"

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The Operation and Maintenance Manual does not contain work instructions for carrying out major repairs. Such work is willingly done for you by the CGM-HMS GmbH after-sales service.

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 „Service Manuals“ 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 other components, Volume 5: Service Manual Volume 1 Volume 6: Service Manual Volume 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“ Volume 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.

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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: 

in a workshop authorized in writing by CGMHMS GmbH ,

and 



by the CGM-HMS GmbH Service

or 

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

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 CGMHMS GmbH Service.

CGM-HMS GmbH refuses to assume the guarantee 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.

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Introduction FUNDAMENTAL SAFETY INSTRUCTIONS Complies with VDMA recommendation "Operating Instructions"

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 life-threatening danger or injuries and to prevent extensive damage.

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

Sound Level Information for Machines in Eurasian Economic Union Countries The declared dynamic operator sound pressure level is XX dB(A) when “ISO 6396:2008” is used to measure the value for an enclosed cab. The measurement was conducted at 70 % of the maximum 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 XXX dB(A) when the value is measured according to the dynamic test procedures and the conditions that are specified in “ISO 6395:2008”. The measurement was conducted at 70 % of the maximum engine cooling fan speed. The sound level may vary at different engine cooling fan speeds.

Visibility 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 

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.

1-6

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Introduction 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 this Operation and Maintenance Manual, “Visibility Information”.

Fig. 1 and Fig. 2 provide an approximate visual indication of the areas at ground level inside a radius of 24 m (79 ft) from the operator of significant restricted visibility for machines with faceshovel and backhoe attachments. Refer to the correct illustration for your machine configuration.

All restricted visibility areas less than 300 mm wide may not be shown. These illustrations do not indicate areas of restricted visibility for distances outside of the shown radius.

The areas of restricted visibility shown in the illustrations are with the track and work tool of the machine in the “travel position”.

This machine may be equipped with optional visibility aids that may provide visibility to some of the restricted visibility areas. Refer to this Operation and Maintenance Manual, “Mirror – Clean/Adjust” for more information on additional visibility.

If your machine is equipped with cameras, refer to this Operation and Maintenance Manual, “Monitoring Cameras” for more information on additional visibility.

For areas that are not covered by the optional visual aids, 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”.

When equipped with optional visual aids, the machine visibility will meet the technical requirements found in ISO5006:2006.

Fig. 1-1:

Fig. 1-1: shows the machine with faceshovel attachment. Top view of machine, ground level visibility without use of visual aids that are not standard in all markets.

Note: The shaded areas indicate the approximate location of areas with significant restricted visibility.

Fig. 1-2:

Fig. 1-2: shows the machine with backhoe attachment. Top view of machine, ground level visibility without use of visual aids that are not standard in all markets.

Note: The shaded areas indicate the approximate location of areas with significant restricted visibility.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Introduction DESIGNATED 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 safety-conscious 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 equipment, the machine is to be used solely for loosening and loading of:  sand, oil sand,  gravel,  blasted rock,  ore,  coal, and other raw materials.

With attached backhoe equipment, 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 designated 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

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 equipment being approved for this purpose,



for driving in posts, sheetpiles supports, etc. without the equipment 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 lower carriage - are settled for transporting with a crane only.

- must not be used for towing a machine.

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.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 closefitting 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.

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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.

1-10

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

Start the machine from the operator'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 operator 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 operator's seat always secure the machine against inadvertent movement and unauthorized use. Shut off the electric motor.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 shut-down 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. 1-3:).

Fig. 1-3:

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

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.

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 firefighting systems do not come into contact with hot cleaning agents as this might activate the firefighting system.

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.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Introduction Warning of special dangers Electric energy 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 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

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.

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.

Trailing cable

HIGH VOLTAGE! THE MACHINE TRAIL CABLE CARRIES A LETHAL VOLTAGE. Risk of voltage drive, if the trailing cable insulation is defective.

Never touch the trailing cable with bare hands.

Visually inspect the trail cable for cuts, abrasions and other damage before handling the cable.

Handle the cable in an approved manner with appropriate and approved rubber gloves and insulated hooks or tongs.

Note: Prevent trail cable from being dragged on the ground for long distances or at high speeds.

Limit the amount of cable being pulled by the machine. Pulling too much cable will damage both the cable and the machine.

Do not travel over the trail cable.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Introduction Gas, dust, steam and smoke

Noise

Always start and operate the engine in a wellvented area. (On-Board crane, if equipped).

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).

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

Hydraulic equipment 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.

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Introduction ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED HYDRAULIC SHOVELS The safety and accident-prevention regulations valid in the respective country must be observed.

The following requirements are based on extracts from the German accident prevention regulations "Electrical Systems (BGV A3 / DGUV V3)".

The installation, modification and repair of the electromechanical component of electrical systems and components must be delegated only to qualified electricians or firms employing such experts.

A "qualified electrician" in the context of this regulation is a person who, on the basis of specialized training, know-how and experience as well as knowledge of the relevant regulations, is in a position to judge the extent of the work assigned to him and to recognize any potential hazards.

The machine owner/contractor must inform all persons working on electrical installations and components or in the vicinity of components conducting electricity during operation, or who are responsible for the operation of electrical systems, of the potential danger of electricity and must instruct them on the accident prevention regulations relevant to their work. Instruction in safety measures is to be repeated at intervals appropriate to the operating conditions. If necessary, special working regulations must be displayed.

The hydraulic shovel and its electrical systems must be adequately protected against other potential hazards of electricity, e.g. fire and explosion.

Electrical systems and components must be protected against electric shock in the case of a fault, e.g. short circuit to exposed conductive part.

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Any parts of the electrical system conducting current when in operation must be housed in lock-up switchgear cabinets. Hazard warning signs are displayed on these lock-up cabinets.

VOLTAGE HAZARD The switchgear cabinets must be secured against unauthorized opening. The key must be kept by the electrician in charge.

Electrical systems and components must not be used unless they comply with the operational and local safety requirements. They must be in an orderly state and must be kept in such a state.

Any defects or malfunctions occurring in electrical systems or components must be reported to the electrician in charge.

Before switching on any systems, the hydraulic shovel operator must check that no one is working on the machine or its electrical systems.

The heavy-duty power cable must never be driven over, buried or ripped away. The hydraulic shovel equipment must never be set down on the power cable. When the hydraulic shovel is being moved, the cable must never be pulled or dragged over the ground.

Whenever work is being carried out on electrically powered hydraulic shovels, the general rules of engineering - especially those concerning low and medium voltage - must be observed. Regulations such as those issued by the German VDE, e.g. specification VDE 0100, should be observed. Observe all the related laws and rules in your state or country.

Before commencing any work on electrical systems and components, the electrician in charge (or an electrician appointed by him) must switch the power off all circuits and lock them in the OFF state as follows:  Switch voltage OFF all systems.  Check with voltage detectors that all systems are voltage-free.  Lock switches/systems to prevent them from being switched ON. The above procedures must be carried out in the given sequence.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Introduction The machine contractor must provide all the necessary protective equipment and adopt the necessary safety procedures. He must ensure that the safety equipment is used and the safety procedures observed.

The hydraulic shovel operator and all personnel working on the hydraulic shovel must use the protective equipment and carry out the specified safety procedures.

It is absolutely forbidden to work on any systems or components while they are conducting current. Fatal injury can occur.

If work has to be done in special cases on systems or components conducting current, appropriate safety measures must be taken. Work must not be done on "live" systems and components except by the electrician in charge. The machine contractor must also be notified.

The hydraulic shovel and its electrical systems must not be switched on again until the above safety procedures have been cancelled and all working areas are prepared for the resumption of operations. Start-up can be ordered only by the person in charge (qualified electrician). Time-based switch-on agreements are absolutely forbidden.

Safety instructions for hydraulic shovels with electric motor Before carrying out any maintenance and repair work on the electrical system, the following precautions must be taken:

In the transformer station  Switch off the supply voltage  Lock the safety device preventing switch-on; apply a warning sign  Check that the electrical system is off circuit and dead  Connect to earth and short-circuit  Protect adjacent and live parts against accidental contact

On the hydraulic shovel  Switch off the switch-disconnector  Lock the safety device preventing switch-on; apply a warning sign  Remove the cover  Check that the electrical system is off circuit and dead  Connect to earth and short-circuit  Slide the partition into the disconnector housing

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Introduction FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents.

Pay particular attention to hazards caused by combustible and easily flammable substances 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 handle any flammable substances during operation.

Clean the hydraulic shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units or objects such as turbo superchargers.

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.

1-16

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.

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.

DANGER TO LIFE Call the fire brigade.

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

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

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Introduction

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OPeration 2 OPERATION 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

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

2-2

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

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

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 Manual 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

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 equipment and component combinations approved by CGM-HMS GmbH .Clear-cut data are given in the technical specification.

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

Before starting work or travelling 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 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.

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.

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:

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

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OMM 6040AC, 6040ACFS(3 847 037.00)-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 equipment 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 Manual, where to store it in the operator’s cab One copy of the Operation and Maintenance Manual for the machine must be available in the operator’s cab during operation.

Replace Operation and Maintenance Manual if lost, damaged or unreadeable.

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

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration FIRE AND EXPLOSION HAZARD Safety instructions Avoid smoking and open fire on, next to and below the machine.

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

Do not store such substances on the hydraulic shovel.

Clean the hydraulic shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units.

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 may cause fire on the ground that can spread to the hydraulic shovel.

2-5

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration DESCRIPTION OF THE HYDRAULIC SHOVEL

Fig. 2-3:

2-6

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Hydraulic shovel layout Fig. 2-3:

Undercarriage

37 - Control-cabinet with CMS

1 - Track drive

38 - Control-cabinet (24V) with battery main switch

2 - Idler

39 - On-board-crane (optional)

3 - Track roller

40 - Drive unit for on-bord-crane (optional)

4 – Upper roller

41 - Service station

5 - Crawler track

44 - Grease container of central lubricating

6 - Track tensioner

system

7 - Swing ring

46 – Hydraulic ramp type ladder

8 - Escape ladder

47 - Ladder

9 - Slip ring assembly

50 - Counterweight

10 - Cable guide for drag cable

Upperstructure

Face shovel attachment

11 - Electric motor

51 - Boom

12 - Switchgear cabinet medium voltage,

52 - TriPower linkage

circuit breaker

53 - Stick

13 - Switchgear cabinet

54 - Bottom-dump bucket

14 – Connection box electric motor

55 - Boom cylinder

15 - Switchgear cabinet 400V, motor protection

56 - Stick cylinder

relay, mains power supply

57 - Tipping cylinder

16 - Switchgear cabinet power factor correction

58 - Bottom-dump cylinder

17 - Hydraulic oil reservoir

64 - Control valves on attachment

18 - Hydraulic oil cooler

65 - Quick-action valve

20 - Pump drive gearbox 21 - Working pump 22 - Cooling oil pump 23 - Gearbox circulating pump 24 - Servo system pump 27 - Swing pump 29 - Swing gear 30 - Travel block and rotor 31 - Operator's cab 32 - Control stand with BCS 33 – Additional heater (optional) 34 - Air conditioner 35 – Fire extinguisher (if equipped) 36 – Batteries

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EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

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

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

Drive unit The drive unit comprises electric motor, pump drive gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Hydraulic system All working and travelling 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 superstructure to the undercarriage is ensured by the rotor. The hydraulic system is overload-protected by pressurerelief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

2-8

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

Four interconnected electronic units ensure optimal use of the installed electric motor 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 electric motor 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 electro-hydraulic valves which control the execution of the working movements.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration 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:  minimum power losses, 

reduced temperature of the hydraulic oil,



greater service life of hydraulic pumps and electric motor.

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 drive 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 other electronic units 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 Manual or to the brochure "Board-Control-System – Operation and Maintenance Manual"

Electrical system Supply voltage  (medium voltage)

6000 V 7200 V

Control voltage (low voltage)

400 / 230 V

Lighting voltage

24 V

Emergency voltage

24 V

Control voltage

24 V

Supply voltage depends on the individual configuration of the shovel. Please refer to the data plate of the electric motor. 

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EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Power supply The electric power is supplied to the hydraulic shovel through the drag cable (1, Fig. 2-4:) and connection box (3).

The drag cable is guided by a cable guide (2).

The power is then transmitted via the slip ring assembly (4) to the circuit breaker in the switchgear cabinet (Fig. 2-5:).

The drag cable can be wound on a cable reel (optional).

Fig. 2-4:

Fig. 2-5:

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EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Operation with cable reel (if equipped) (Fig. 2-6:) 1

Button

2

Button

3

Rotary switch

Cable reel – wind up manual Cable reel – wind off manual Cable reel – manual resp. automatic operation

Automatic operation During travelling the cable reel automatically winds up or winds off the power cable.  Turn rotary switch - cable reel (3, Fig. 2-6:) to automatic operation (Auto).

Fig. 2-6:

Manual operation  Turn rotary switch - cable reel (3, Fig. 2-6:) to manual operation (Man).  Press in button (1) to wind up the cable reel or  Press in button (2) to wind off the cable reel The BCS (Fig. 2-7:) gives a warning when 

the cable is winded off completely from the cable reel,



the resistance during winding up and off the cable is too high.

Fig. 2-7:

2-11

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Safety films and warning messages – Overview and Description Warning and additional messages Observe the safety films and warning and additional messages 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. 2-8: - Fig. 2-17: show the location of warning and instruction signs on the machine.

The numbers in brackets, for example (23), tell the item number in the resp. spare parts group.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-8:

2-13

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-9:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-10:

2-15

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-11:

2-16

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-12:

2-17

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-13:

2-18

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-14:

2-19

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-15:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-16:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-17:

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EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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. 2-18:

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. 2-19:

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. 2-20:

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. 2-21:

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.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

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

Fig. 2-22:

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.

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.

Fig. 2-23:

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.

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 motor compartment.

CAUTION Head bump hazard because of low clearance.

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

Fig. 2-24:

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 motor compartment.

CAUTION Trip hazard because of obstacles on the floor.

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

Fig. 2-25:

2-24

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

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Hot Surface (6)

Fig. 2-26:

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 motor compartments can be hot while motor is running or immediately after 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. 2-27:

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 motor before servicing.

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

Fig. 2-28:

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EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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. 2-29:

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. 2-30:

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.

Fig. 2-31:

CAUTION Hazardous noise level when motor running. May cause loss or degration of hearing over a period of time. Wear proper personal protective equipment / ear protection beyond this point.

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. 2-32:

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OMM 6040AC, 6040ACFS(3 847 037.00)-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. 2-33:

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. 2-34:

Notes on cleaning electric assemblies (12)

Fig. 2-35:

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 motor compartment,  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.

2-27

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OMM 6040AC, 6040ACFS(3 847 037.00)-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. 2-36:

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. 2-37:

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. 2-38:

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. 2-39:

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OMM 6040AC, 6040ACFS(3 847 037.00)-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. 2-40:

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. 2-41:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Machine identification plate

Motor number plate

The identification plate (Fig. 2-43:) with the machine number is attached to the front side of the A-frame (arrow, Fig. 2-42:).

The serial number plate for the electric motor (Fig. 2-44:) is located on the electric motor.

Fig. 2-42:

Fig. 2-44:

Motor number plate of the SIEMENS electric motor.

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. 2-43:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Eurasian Economic Union

CE-Plate, European Union

For machines compliant to the Eurasian Economic Union requirements, the EAC mark plate (Fig. 2-45:) 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. 2-46:) 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. 2-46:

Fig. 2-45:

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

2-31

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OMM 6040AC, 6040ACFS(3 847 037.00)-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. 2-47:).

Always face the machine when entering or leaving it.

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

Access ladder - Lighting The access ladder of the machine can be illuminated.

From outside: The pull-switch (2, Fig. 2-48:) of the lighting system is located beneath the superstructure. The lights are switched on from the ground by means of the pullrope.

From the cab: The switch is located besides the door (arrow, Fig. 2-49:).

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

Fig. 2-48:

Fig. 2-47:

Fig. 2-49:

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OPeration Folding ladder – Function (if equipped) Raising resp. lowering the folding ladder (Fig. 2-50:).

Lowering the folding ladder from the upper structure (for leaving the machine)  Start electric motor.  Push lever (1, Fig. 2-51:) on control valve (2) downwards to position “ II “.

The folding ladder is lowered (Fig. 2-50:).

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

Fig. 2-50:

Raising the folding ladder from the upper structure (after entering the machine)  Start electric motor.  Pull lever (1, Fig. 2-51:) on control valve (2) upwards to position “ I “ and hold.

The folding ladder is raised (Fig. 2-52:).  Leave the lever on the control valve in position “I” while operating the machine. This keeps the hydraulic ladder in the upper position (fully retracted).

Fig. 2-52:

Lowering the folding ladder from the ground (in case of emergency)  Pull down rope (3, Fig. 2-53:).

The folding ladder is lowered (Fig. 2-50:).

Fig. 2-53:

Fig. 2-51:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-52:).

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Swinging ladder - Function (if equipped) Raising resp. lowering the swinging ladder (Fig. 2-54:).

Lowering the swinging ladder from the upper structure (for leaving the machine)  Start electric motor.  Push lever (1, Fig. 2-55:) on control valve (2) downwards to position “ II “ and hold.

The swinging ladder is lowered (Fig. 2-54:) The swinging ladder can also be lowered when the electric motor is stopped.

Fig. 2-54:

Raising the swinging ladder from the upper structure (after entering the machine)  Start electric motor.  Pull lever (1, Fig. 2-55:) on control valve (2) upwards to position “ I “ and hold.

The swinging ladder is raised (Fig. 2-56:).  Leave the lever on the control valve in position “I” while operating the machine. This keeps the hydraulic ladder in the upper position (fully retracted).

Fig. 2-56:

Lowering the swinging ladder from the ground (in case of emergency)  Pull down rope (3, Fig. 2-57:).

The swinging ladder is lowered (Fig. 2-54:).

Fig. 2-57:

Fig. 2-55:

The upper structure can only be swung when the swinging ladder is raised completely (Fig. 2-56:).

2-34

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Emergency exit in operator’s cab and escape ladder The sliding window (arrow, Fig. 2-58:) 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. 2-59:) 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. 2-59:

 Pull out locking pin (1, Fig. 2-60:). 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 released and moves down quickly to the ground.  Swing barrier (3, Fig. 2-60:) to the right and use the ladder to escape downwards.

Fig. 2-60:

Fig. 2-58:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Cab interior lighting – Switch on and off The cab interior lighting can be switched on and off with the switches (arrow, Fig. 2-61:), (96, Fig. 2-62:) and (arrow, Fig. 2-63:) 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. 2-61:

Fig. 2-62:

Fig. 2-63:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Maintenance lights – Switch on and off The maintenance lights in the various modules can be activated from a central point with the switches (arrow, Fig. 2-64:) or (95, Fig. 2-65:).

The invidual modules are also equipped with switches, for example the motor module: Switch at the switchgear cabinet behind the hydraulic oil reservoir (1, Fig. 2-66:).

Fig. 2-64:

Fig. 2-65:

Fig. 2-66:

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OPeration Emergency shut off - Function The entire electrical system beginning at the output side of the circuit breaker switch is switched off by the Emergency shut off switches. The electric motor wil be shut off.

Medium voltage 7.2kV is still alive at the input side of the circuit breaker switch (in control column medium voltage 7.2kV).

To switch off the whole machine from any electric power, electric power must be switched off at the power supply station where the supply cable is connected.

Supply voltage depends on the individual configuration of the shovel. Please refer to the data plate of the electric motor. 

Fig. 2-67:

The battery voltage of 24V still remain, it can be switched off with the key operated switch in the control column or with the battery main switch (see "Electrical system (24V) switching on / off" and "Battery main switch").

In an emergency, actuate one of the Emergency shut off switches.

The EMERGENCY STOP switches are located  in the control column in the operator's cab (31, Fig. 2-67:), 

in the front of the 400V control cabinet in the counterweight (3, Fig. 2-68:),



near the service lift (6, Fig. 2-69:). The pull switch is is operated by a string (5).

The electrical system can be switched on after the Emergency shut off switches are activated, to do so, pull out switches (Pull switch Fig. 2-69: must be pushed in).

Fig. 2-68:

Fig. 2-69:

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OPeration Servicing switch – Function Before starting live-line servicing work e.g. measuring and testing with voltage applied, press switch (4, Fig. 2-70:) and secure it with a padlock.

Pressing the switch transmits a signal to the PLC. The electric motor can not be switched on.

Reducing 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. 2-73: and Fig. 2-74:):  shock absorption (Absorber),  body weight setting (Weight adjustment),  horizontal movement damping (Fore/aft isolator).

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.

Trainer's / instructor's seat

Fig. 2-70:

Windscreen washer – Reservoir The reservoir of the windscreen washing system (1, Fig. 2-71:) is installed in the cab module. For the reservoir capacity refer to the "Refilling quantities Other" table.

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. 2-72:).

 Sit down on this seat and do not forget to fasten the seat-belt, if installed (arrow, Fig. 2-72:).  Do not leave this seat during the training / instruction session and /or as long as the machine is in operation.

Fig. 2-71: Fig. 2-72:

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OPeration Operator's seat The operator's seat (Fig. 2-73: and Fig. 2-74:) can be adjusted in several positions.

Fig. 2-73:

2-40

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"

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-74:

2-41

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Fire extinguisher The hydraulic shovel can be equipped with fire extinguishers.

Base plates for mounting brackets are located at the rear wall of the operator’s cab and in the pump compartment (arrow, Fig. 2-75:).

Fig. 2-75:

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 extinguishers 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.

2-42

Automatic fire-extinguishing system Please contact your local Cat dealer for more detailed information.

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.

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.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

2-43

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OPeration MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-76:

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OPeration (Fig. 2-76:) BCS, Board-Control-System No. 1

2

3

4

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 Manual, chapter “Board-Control-System”.

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

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.

2-45

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OPeration

Fig. 2-77

2-46

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration (Fig. 2-77) BCS, Board Control System, display screen example (For further information please refer to section 5 of this Operation and Maintenance Manual, chapter “BoardControl-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.

2-47

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OPeration

Fig. 2-78:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration (Fig. 2-78:) 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 electric motor is shut off, all valves are de-energized, working movements are no longer possible.

(See chapter: "Emergency shut-off function").

2-49

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OPeration

Fig. 2-79:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration (Fig. 2-79:) 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

Element Push-button Push-button

Function Electric motor ON

Switches on the electric motor.

Electric motor OFF

Switches off the electric motor.

49

Indicator lamp

Medium voltage (Supply voltage)

Lamp is lit up when the circuit breaker is switched on. Supply voltage applied.

50

Indicator lamp

Rotary field monitoring

Lamp is lit up when the rotary field (phasing) is correct.

Symbol

2-51

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OPeration

Fig. 2-80:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration (Fig. 2-80:) 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 Symbol Push-button Superstructure hold- Blocks the superstructure.

61 ing brake Press this button when the superstructure is stationary.

Do not use this button while the superstructure is still in motion. Risk of damage to the brake and the swing gearboxes.

63

64

Push-button

Hydraulic shovel parking brake, for Service and Maintenance purposes only

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

The hydraulic shovel cannot be moved.

For more information refer to chapter “Track parking brake”.

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.

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 superstructure.

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

65

Push-button

Emergency lowering

Lowering of the working equipment in an emergency situation. For instance, if the electric motor has failed.

For more information refer to chapter “Emergency lowering of the working equipment”.

2-53

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OPeration

Fig. 2-81:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration (Fig. 2-81:) 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

Travelling speed

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

Symbol

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

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 superstructure be swung 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 service station.

Switch

Floodlamps

Switches all floodlamps on and off.

82

Switch

Lighting

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

83

Switch

Lighting

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

84

Switch

Rotary beacon (if equipped)

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

76

81

2-55

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Fig. 2-82:

2-56

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration (Fig. 2-82:) 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

Preheating (if equipped)

Switches the preheating system on and off.

96

Switch

Cable reel (if equipped)

Switches the cable reel system on and off.

2-57

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OPeration

Fig. 2-83:

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OPeration (Fig. 2-83:) No. Element 101 Push-button

(Free for options)

102 Push-button

Stick floating position (shovel equipment only)

Function Symbol 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.

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 Push-button inside the seat

Pedal Pedal Pedal

Warning signal

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

Electronic hydraulic The electronic hydraulic shovel control (sershovel control (ser- vo-control) is activated when the operator vo-control) sits down on the seat.

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

Shovel clam (shovel Forwards – shovel clam is opened; Backwards – shovel clam is closed. equipment only) Travel, left track Forwards – forward travel; Backwards – backward travel.

Travel, right track Forwards – forward travel; Backwards – backward travel.

Footrest Control lever

Control lever

Push-button Thumb wheel

Push-button

Thumb wheel

Forwards – raising the stick Backwards – lowering the stick.

To the left / right – swinging and braking of the superstructure.

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.

Shovel clam (shovel Turn Forwards – shovel clam is opened; equipment only) Turn Backwards – shovel clam is closed.

Function can be overridden by Pedal 111.

(Thumb wheel is spring centered).

By-pass for the au- Lower half pushed – automatically stopped tomatically switch stick- and/or backhoe cylinders can be drivoff for stick- and /or en slowly to the limit stopps. backhoe cylinders Upper half pushed – Each press on the but(Option) ton increments the loaded dumper count for by "1". (Count reset with button (91)).

Not used on this machine.

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OPeration

Fig. 2-84:

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OPeration (Fig. 2-84:)

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

No.

Element

Function

150 Rotary switch

Fan (Air conditioner)

Selects the intensity level of the blower (3 levels).

151 Knob

Thermostat (Air conditioner)

Sets the desired temperature inside the cab.

152 Rotary switch

Mode (Air conditioner)

Selects the desired control function (heating, cooling, ventilation, defrosting).

Symbol

2-61

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration PUTTING THE MACHINE INTO OPERATION Before daily start-up, carry out works in accordance with servicing plan T (see Part 3 "Inspection and servicing") Prior to your daily start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

Otherwise, increased fire and explosion hazard will exist.

Service station The hydraulic shovel is equipped with a central service station (Fig. 2-85:). The service station is attached to the frame and accessible from the ground below the uppercarriage. Express couplings are provided for refilling the following consumables (fluids).

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.

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.

Fig. 2-85:

5

Reducing the operator's exposure to noise 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 cover of the motor compartment must be closed,  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 screwed 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 motor on and running.

2-62

Express coupling for

Pos. Fluid Fig. 2-85:

10 11

Gearbox oil for pump drive gearbox Hydraulic oil

Filling and / or draining

Grease for the central greasing system

Filling

Filling and / or draining

A service vehicle is needed for filling and/or draining of the fluids.

Lowering the service station Draw out control knob (21, Fig. 2-85:) of valve (22) with rope (25). The service station is brought down to the lower position. Turn knob (21) by 90° and engage.

Raising the service station Disengage control knob (21) of valve (22), turn by 90° and press in. The service station is raised to the top position.

Refilling and draining For filling in or for draining fluids, unscrew the cap of the corresponding express coupling (Fig. 2-85:).

Attach express coupling of filling hose from the service vehicle to the corresponding express coupling at the service station. Fill in or drain off fluid.

Take off filling hose and refit cap on the express coupling.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Assemblies resp. Measuring device reservoirs

Remarks

Pump drive gearbox

Dipstick (1, Fig. 2-86:)

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").

Hydraulic oil tank

BCS monitor (Fig. 2-89:), Checking the oil level: Inspection glass (1, Fig. Extend the piston rods of stick and bucket cylinders 2-87:), sign (2. Fig. 2-87: halfway and stand working equipment on the ground and Fig. 2-88:) (as shown on sign 2, Fig. 2-88:).

Check oil level at an oil temperature of ca. 50 °C (122°F), with the electric motor shut off.

Fill in oil when the oil level in the inspection glass hasdropped below the "min" mark. Stop filling if the oil reaches the "max" mark on the inspection glass or the acoustic warning signal "Travel alarm" sounds (see chapter "Hydraulic system - Checking the hydraulic oil level / Refilling hydraulic oil").

Fig. 2-86:

Fig. 2-88:

Fig. 2-87:

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OPeration

Assemblies resp. Measuring device reservoirs

Remarks

Grease container – BCS display (Fig. 2-89:) cental lubricating system

BCS display indicates a warning when the grease container is empty.

Switch on the display system with the toggle switch (23, Fig. 2-90:). Monitoring lamp (22) lights up.

Fill in grease using express coupling (11, Fig. 2-90:).

Stop filling when BCS indicates "Grease container filled". The indicator lamp (24) lights up then.

On completion of filling, switch the display system off with the toggle switch (23).

Monitoring lamp (22) is then off.

Fig. 2-90: Fig. 2-89:

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OPeration Battery main switch - Switch on and off

Electrical system (24V) - Switch on and off

When the hydraulic shovel is disconnected from the medium voltage (6kV - 7.2kV, depends on the configuration of the machine) the electrical system (24V) is supplied with voltage by two batteries.

With the battery main switch, the electrical system (24V) is disconnected from the batteries.

The battery main switch is located at the left side wall of the control cabinet (24V). The control cabinet (24V) is mounted in the operator's cab module beneath the operator's cab.

The electrical system is switched on or off with key-switch (32, Fig. 2-92:).

Switching the battery main switch on  Turn switching handle of main switch (1, Fig. 2-91:) to position "ON".

Switching the battery main switch off  Turn switching handle of main switch (1. Fig. 2-91:) from position "ON" to position "OFF".

The handle can be locked in the "OFF" position by means of a padlock.

Switching the electrical system (24V) on  Insert key into key-switch (32) and turn to the right.

Now all electronical assemblies of the hydraulic shovel are supplied with voltage, computer systems are started. A selftest is carried out.

The Board Control System (BCS) displays current operating data as well as detected faults.

If there are no critical faults detected BCS enables starting the electric motor.

If there are critical faults or failings detected BCS disables starting the electric motor and displays corresponding explanatory text.

For more information see " Operation and Maintenance Manual, Board-Control-System".

Switching the electrical system (24V) off  Turn key in key-switch (32) to the left and withdraw

Fig. 2-91:

Fig. 2-92:

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OPeration Electric motor – Switch on and off Before switching on the electric motor Before switching on the electric motor, check that nobody is working on the electrical system or on the hydraulic shovel itself.

Switch on the electric motor only when all these work on the hydraulic shovel is finished and all persons leave the danger area.  Switch on battery main switch (see: "Battery main switch, switching on and off").  Switch on electrical system (24V) (see: "Electrical system (24V), switching on and off").  Check telltales (49 and 50, Fig. 2-93:), they must lit up in green colour.

If so, electric motor can be switched on (see: "Switching the electric motor on").

If telltales didn`t lit up in green colour, BCS has detected critical operating conditions or faults which prohibit starting the electric motor. BCS indicates this case with telltales as well as by displaying corresponding text.

Fig. 2-93:

Switching the electric motor on  Actuate switch-key (41, Fig. 2-94:), the electric motor is switched on.

During starting period the electric motor heavily warm up. Therefore it is not allowed to switch it on and off at will. By means of an electronical time-out circuit (PLC) the electric motor can be switched on only three times a hour (time-out period is 30 minutes).

Fig. 2-94:

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OPeration Switching the electric motor off

Time-out before restart

During breaks in operation and at the end of each shift, the working equipment must be lowered onto the ground.

The electric motor must NOT be switched off until the equipment is resting on the ground.

During starting period the electric motor heavily warms up. Therefore it is not allowed to switch it on and off at will. By means of an electronical time-out circuit (Programmable Logic Controller, PLC) the electric motor can be switched on only three times a hour (time-out period is 30 minutes).

The 30 minutes period means the time from switching on the electric motor up to the next switching on, e. g.

Electric motor is switched on, runs 20 minutes and then is switched off. Now the time-out period is 10 minutes before restart.

After running more than 30 minutes without interruption the electric motor can be switched on without any time-out period.

The BCS3e system prohibits switching on the electric motor until it is cooled down.

The BCS monitor (Fig. 2-96:) displayes the remaining time until the time-out period is over.

To avoid straining the vacuum contactor, the electric motor should be shut down only when load-free, i.e. without any of the hydraulic units being activated at the same time via the control valve.  Actuate switch-key (42, Fig. 2-95:). The electric motor starts running down.  Turn key in key-switch (32) counter-clockwise and withdraw.

The control voltage is switched off.

The electric motor only can be switched on again, after the time-out period (30 minutes after last switching on) is over (see: "Time-out before restart", "Before switching on the electric motor" and "Switching on the electric motor").

Fig. 2-96:

Fig. 2-95:

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OPeration Electric motor can not be switched on If BCS prohibits switching on the electric motor the operator should check the following:  Time-out before restart period still running? 

EMERGENCY STOP switch in control column unlocked?



EMERGENCY STOP switch in control cabinet (400V) unlocked?



EMERGENCY STOP pullswitch near the service station unlocked?



Servicing switch unlocked?



Monitoring lamps "7.2kV OK" and "PHASE SEQUENCE OK" on the control cabinet (400V) and on the control column lighting?

If not, the circuit breaker is switched off or the 7.2kV voltage supply is missing.



Shut-off flaps at the hydraulik oil reservoir closed?



Check BCS display: Faults or explanatory text displayed? If so, give information to the electric maintenance personnel.

If after all of these checks the electric motor cannot be switched on the operator has to inform the specialist personnel for maintenance and service on electric hydraulic shovels. Only these have the skills to work in a safe way, for trouble shooting and removing the fault.

Supply voltage depends on the individual configuration of the shovel. Please refer to the data plate of the electric motor. 

2-68

In case of failure If failures in the electrical systems occur, BCS displayes warnings and corresponding explanatory text Failures in electrical systems may exclusively be removed by specialist personnel for maintenance and service on electrical systems.

The following faults may be responsible:  Fault in high-voltage transformer 

7.2kV / 400V / 230V transformer overloaded.



Earth fault.

If BCS display shows "Overcurrent", the operator does not know if an "Earth fault" happens. In worst case the hydraulic shovel may be energized.

The operator must notify the electrician in charge from the hydraulic shovel superstructure.

The electrician must then cut off the voltage supply from the transformer station and locate and rectify the fault.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Circuit breaker - Switch on and off By means of the circuit breaker the supplied medium voltage 7.2kV can be connected to the hydraulic shovels electrical system or can be disconnected from it. The circuit breaker is installed in the control cabinet 7.2kV (outer view, Fig. 2-97:, inside view Fig. 2-98:).

Switching the circuit breaker on is possible only when the eCAMP system and the motor protection relay enable this function. In this case, all four monitoring lamps (1, Fig. 2-98:) light up in green colour.

The circuit breaker is operated with an actuating lever which is stored in a fixture inside the control cabinet 7.2kV.

Switching the circuit breaker  The circuit breaker is switched on and off by means of a actuating lever (Fig. 2-99:).

The actuating lever is slipped over the actuating shaft of the circuit breaker.  Detailed information is given in the brochure of the manufacturer “Medium-voltage switching devices”. See volume “Components” of the printed machine documentation.

Fig. 2-99:

Supply voltage depends on the individual configuration of the shovel. Please refer to the data plate of the electric motor. 

Fig. 2-97:

Fig. 2-98:

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OPeration Motor protection relay - Function

The electric motor is equipped with a motor protection relay. The relay is located in the 400 V switch cabinet (Fig. 2-100:).

The relay monitors the operating conditions of the electric motor and protects the motor against faults in the electrical system of the motor Depending on the nature of the fault, the motor protection relay switches off  the power supply of the motor via the vacuum contactor or 

the power supply of the machine via the switch-disconnector.

At the factory, the motor protection relay is programmed for the following functions:  protection against overcurrents,

Fig. 2-100:



protection against overloading,



detection of ground faults,



temperature monitoring,



restart inhibit,



protection against undervoltage,



protection against load unbalance (failure of a phase)



phase sequence monitoring,



change of frequency,



run-up period monitoring.

In case a severe fault of the motor system is detected in operation, the motor protection relay is activated and the electric motor shut off automatically.

If the motor protection relay detects a severe fault before or during the starting sequence of the electric motor, it prevents the motor from being started.

Depending on the type of fault detected, one or more LEDs on the front panel light up (9, Fig. 2-101:).

After rectification of the fault press button (7). The LED is extinguished. The motor protection relay is again operational.

For more information please refer to the the manufacturer's description.

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OPeration Front panel control and monitoring elements (Fig. 2-101:):

1 2 3 4

5 6 7 8

9

Fig. 2-101:

RUN indicator (LED) Display screen (provides information on states of operation) Display screen navigation keys Function key freely programmable (not used for this machine) Control of other equipment (not used for this machine) USB interface for communication with external devices (only for CGM-HMS GmbH Service) Reset for LEDs of item 9.

Cover for keypad of item 4.Functional description of the LEDs of item 9.

LEDs G1 – G8, on after detection of a fault: G1 – Overcurrent G2 – Undervoltage/overvoltage G3 – Load unbalance G4 – Frequency change G5 – Overload G6 – Phase sequence fault, ground fault G7 – Run-up monitoring, restart inhibit G8 – Emergency STOP activated

For more information please refer to the the manufacturer's description.

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OPeration Active-power transducer - Function

Fig. 2-102:

The electrical system of this machine is equipped with an active-power transducer. The transducer is located in the 400 V switch cabinet (arrow, Fig. 2-102:).

The active-power transducer measures permanently the currents, voltages and phase angles in the system and derives the active power (P) the apparent power (S) and the reactive power (Q) from these values. All these measured values can be displayed on the screen.

The active-power value is used to generate an analog signal (4-20 mA). This signal is used to monitor the tilting angle of the hydraulic pumps. In combination with the Pump Management System (PMS), any overloading of the electric motor due to an excessive demand of hydraulic power is thus avoided.

The device is factory-programmed in such a way that all relevant measured values can be displayed in four screens on the monitor (1, Fig. 2-103:). The different screens are selected with the keys (3).

Screen 1 displays the numeric values of:  the voltages of phases L1, L2 and L3 and the total current.

Screen 2 displays the numeric values of:  the active-power (P), the apparent power (S), the reactive power (Q) and the frequency.

Screen 3 displays a current / voltage diagram.

Screen 4 displays the numeric values of:  the currents of phases L1, L2 and L3.

For more information please refer to the the manufacturer's description.

Fig. 2-103:

1

Display screen for measured values and menus.

2

ENTER key, switches display illumination on / off; confirms item selection in menus

3

Keys for display navigation; selects the screens for measured values and menus.

2-72

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Preheating system for hydraulic oil reservoir and pump gearbox, switching on and off (if equipped) Preheating systems are build in at the hydraulic oil reservoir as well as in the pump gearbox.

On low outside temperatures they warm up the hydraulic oil as well as the gear oil so that the operating temperature is reached faster.

Integrated thermostats prevent the heating elements from overheating and damage at continious operation.

The heating elements are connected electrically to a centralized switchbox. The switchbox is fixed at the hydraulic oil reservoir and can be accessed from the pump- or motor compartment (Fig. 2-104:).

After the power supply for the shovel is switched on the preheating system is functional.

(The circuit breaker must be switched on, the indicator lamps "7.2kV OK" and "PHASE SEQUENCE OK" are on at the control cabinet 400V).  Switch on the preheating system before starting work using switches at the switchbox (Fig. 2-104:).

The monitoring lamps near the switches lit up then.

Fig. 2-104:

Supply voltage depends on the individual configuration of the shovel. Please refer to the data plate of the electric motor. 

2-73

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Air conditioner (if equipped) Ventilation / Heating The air needed for ventilation and/or heating is sucked in from outside the cab by a blower and ducted to the air outlets.

If necessary, the air in the cab is sucked in through the air conditioner and recirculated.

The air conditioner control elements are located at the left side of the control column (Fig. 2-105:).

Do not switch the air conditioner to "cooling“ when the back-up heating (optional) is on.

Back-up heating operator’s cab (if equipped) The back-up heating for the operator’s cab is located in the module below the operator’ cab (Fig. 2-106:). The heating consists of one or two heating units (1) and the fuel reservoir (2).  Switch on the back-up heating using switch (142, Fig. 2-107:). 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. 2-105:

Control panel (SIGMA) (see Fig. 2-105:) 1 Rotary switch

Selects the intensity level of the blower (3 levels).

2

Rotary switch

Selects the desired control function (heating, cooling, ventilation, defrosting).

3

Thermostat

Sets the desired temperature inside the cab.

Fig. 2-106:

Fig. 2-107:

2-74

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration OPERATIONAL PRACTICES Working operation - Safety instructions

Personnel Any work with the machine must be executed only by reliable, skilled and well trained personnel in good healthy condition. Statutory minimum age limits must be observed.

Never operate the machine while impared with drugs or alcohol.

Read the sections "Fundamental safety instructions" and "Operation, safety instructions" in this Operation and Maintenance Manual carefully and observe the instructions given in this sections.

Observe all job site safety requirements.

State of the site Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life!

Clear all obstacles from the path of the machine.

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 all persons have left the hazard range before resuming work.

Machine stability Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk.

When working or traveling on a slope is required, do not exceed the maximum machine inclination for working operation and for traveling (refer to Operation and Maintenance Manual section “Maximum machine inclinations”).

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.

As travel brakes are deactivated, the 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.

State of operator’s workplace Inspect and fasten your seat belts.

Adjust the operator’s seat for comfortable reach all controls and pedals. Adjust for operator height and weight.

Keep your workplace clean. Remove all unsecured items like tools and other supplies from the cab.

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.

Clean and secure all windows and doors.

Clean and adjust all mirrors for optimum vision.

Start the electric motor only from the operator’s compartment.

Operate the machine only while sitting on the operator’s seat.

State of the machine 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.

Do not operate the machine,  when several track rollers or upper rollers have been removed;  when one or several swing 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 as "abusive utilization".

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

Trailing cable Never touch the trailing cable.

Risk of voltage drive, if the trailing cable insulation is defective!

Change the position of the trailing cable only by means of a cable hook.

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OPeration Before starting work Perform a machine walk around inspection. Report any obvious damage and defects – including changes in the machine’s working behaviour- to your supervisor. In the event of malfunctions, stop the machine immediately and lock it.

Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded equipment for abt. 5 minutes. This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts.

Prior to each shift perform a complete 360° swing movement of the upper structure. Doing this ensures proper distribution of grease and brings all the bearing rollers inside the swing ring to new positions.

2-76

Machine Operating Temperature Range The machine must function satisfactorily in the anticipated ambient temperature limits that are encountered during operation. The standard machine configuration is intended for use within an ambient temperature range of −20 °C (-4 °F) to 55 °C (131 °F). Special configurations for different ambient temperatures may be available. For use at temperatures below -10 ° C (14 ° F), the machine can be equipped with a cold weather package.

Consult your Caterpillar dealer for additional information on special configurations of your machine.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Warm-up procedure for electric driven shovel Operator procedure during start up in extreme cold weather  After starting the electric motor check for any faults on the BCS display.  Make sure the “Servo” switch (74, Fig. 2-108:) is in the OFF position.  Use the “Boom up” (116, Fig. 2-109: backwards) or “Stick out” function (115, Fig. 2-109: forwards) to engage the hydraulic pumps.

This will engage the pumps without moving the attachment.  Do so until:  - the hydraulic oil temperature reaches 10°C / 50°F on the gauge and  - the PTO temperature has reached 5°C / 41°F.  You can now turn ON the “Servo” switch (74) and move the attachment in a slow function one at a time.

Do not extend the cylinders fully.

Fig. 2-108:

Swing circuit warm-up before you start digging  Make sure the attachment or bucket is on the ground.  Turn “Swing brake” switch OFF (82, Fig. 2-108:).  Turn “Servo” switch ON (74, Fig. 2-108:).  Use “Swing left” or “Swing right” function (115, Fig. 2-110:) slowly. This will heat the swing hydraulic circuit quickly.  Once the swing temperature is warm you can lift the attachment and swing the upperstructure in a slow 360° left then right.

Fig. 2-109:

When working constantly at low outside temperatures activate the “Cold area warm-up mode” of the BCS (At machines with CAMP/SIL electric system).

Refer to the Service Manual Chapter 9, “Cold area warm-up mode – activate”.

Fig. 2-110:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Electronic hydraulic shovel control (pilot control) – activate 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. 2-111:).

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.

2-78

Fig. 2-111:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Working operation – basics

Working on level ground

This section gives you basic information about the functions of the joystick controls. For further detailed information refer to section “Operation Techniques” in this Operation and Maintenance Manual:  “Machine operation with backhoe attachment Best Practices”,  “Machine operation with backhoe attachment – Restricted Operation”,  “Machine operation with face shovel attachment - Best Practices”,  “Machine operation with face shovel attachment – Restricted Operation”.

CGM HMS recommends operating the machine on level and stable ground. Doing so ensures maximum productivity and prevents machine components from premature wear.

Working on slopes or on rough terrain Clean and level rough terrain before moving into the bank. A clean, level pit floor is necessary for safe and stable machine operation and prevents the tracks and other components of the undercarriage from being damaged.

When working or traveling on a slope is required, do not exceed the maximum machine inclination for working operation and for traveling (refer to Operation and Maintenance Manual section “Maximum machine inclinations”).

If the machine begins to sideslip on a slope, immediately lower the attachment and the load to the ground and turn the machine facing downhill.

Operate the machine slowly, accelerate and decelerate attachment movements gently. Sudden movements with full speed and filled bucket are a huge strain for the structure which could tip the machine over.

When working on a slope, always operate the hydraulic shovel with the attachment positioned uphill or downhill, never sideways.

When traveling up and down a slope or when traveling over rough terrain reduce travel speed mode to slow (refer to Operation and Maintenance Manual section “Traveling”).

Operate joystick controls gently Accelerate and decelerate attachment movements gently. Sudden acceleration and abrupt braking with full speed and filled bucket are a huge strain for the structure.

Avoid aggressive operating practices. Do not overload the machine.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Upper structure – swing Swinging of the upper structure is possible only when:  the upper structure holding brake is released and  the hydraulic shovel operator is sitting on his seat and  the hydraulic ladder is raised and  the servicestation (tanklift) is raised and  the BCS swing circuit test was successful.  To swing the upper structure to the right move the left joystick to the right (115, Fig. 2-112: and Fig. 2-113:).  To swing the upper structure to the left move the left joystick to the left (115).

After releasing, the joystick returns automatically to position "0".

Note: Releasing the joystick (115) is not sufficient to brake the swinging upper structure automatically. In order to brake the upper structure, the joystick must be moved in the direction opposite the swinging movement (reversing).

Fig. 2-112:

Upper structure – brake The upper structure can only be braked by moving the joystick (115) in the direction opposite the swinging movement (reversing).

The swinging upper structure does not stop automatically by simply releasing the left joystick (115).

To brake the upper structure, the left joystick (115) must be moved in opposite direction.

In an emergency, push the Emergency-Stop button (35, Fig. 2-113:) or activate the holding brake by pressing switch (61, Fig. 2-113:).

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Fig. 2-113:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Stick in / Stick out control When released, all joysticks for working operation return automatically to position "0".  To extend the stick (Stick out): push joystick (115, Fig. 2-114:) forwards.  To retract the stick (Stick in): pull joystick (115) backwards.  To retract the stick with pressure: depress button (102, Fig. 2-115:) and push joystick (115) backwards.

Note: This function works on face shovel attachment only, here the stick-in-function is normally done by gravity.

Fig. 2-114:

Fig. 2-115:

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OPeration Raising and lowering the boom When released, all joysticks for working operation return automatically to position "0".  To raise the boom: pull joystick (116, Fig. 2-116:) backwards.  To lower the boom: push joystick (116) forwards.  To lower the boom with pressure: depress button (103; Fig. 2-117:) and push joystick (116) forwards.

Note: This function works on face shovel attachment as well as on backhoe attachment.

The boom-down-function is normally done by gravity.

Fig. 2-116:

Fig. 2-117:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Filling and emptying the backhoe bucket When released, all joysticks for working operation return automatically to position "0".  To fill / tip back the backhoe bucket: shift joystick (116, Fig. 2-118:) to the left.  To empty the backhoe bucket by dumping / tipping: shift joystick (116) to the right.

Fig. 2-118:

Filling the face shovel, curl close / curl open When released, all joysticks for working operation return automatically to position "0".  To fill / curl close the face shovel: shift joystick (116, Fig. 2-119:) to the left.  To curl open the face shovel: shift joystick (116) to the right.

Fig. 2-119:

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OPeration Opening and closing the face shovel clam When released, all joysticks for working operation return automatically to position "0".  To open the face shovel clam: press pedal (111, Fig. 2-120: and Fig. 2-121:) forwards or turn thumb wheel (118) forwards.  To close the face shovel clam: press pedal (111) backwards or turn thumb wheel (118) backwards.

Note: Pressing pedal (111) overrides turning the thumb wheel (118).

Fig. 2-120:

Fig. 2-121:

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OPeration OPERATION TECHNIQUES Machine operation with backhoe attachment, Best Practices Machine Stability

When working with the attachment in a cross direction to the tracks, be sure that the track is not raised off the ground. This can cause the track to set-off from the rollers when it is lowered down on the ground.

Also the flanges of the track rollers and the track shoes can be bent by the excessive load.

Refer to Operation and Maintenance Manual, “Restricted Operation” for further detailed information.

Do not overfill / overload the bucket, the machine may tip over.

Fig. 2-122:

When working or traveling on a slope is required (Fig. 2-123:), do not exceed the maximum machine inclination for working operation and for traveling (refer to Operation and Maintenance Manual section “Maximum machine inclinations”).

Do not operate the shovel on rain-slicked, slippery slopes. The shovel may slip.

Clean and level the pit floor before moving into the bank. A clean, level pit floor is necessary for safe and stable machine operation and prevents the tracks and other components of the undercarriage from being damaged.

Position the hydraulic shovel on level, consistent, firm and stable ground.

The hydraulic shovel may gradually sink on soft and yielding ground. Always re-enforce soft and yielding ground with firm material.

Fig. 2-123:

The hydraulic shovel must always be operated in a way, that its stability is always ensured and the danger of tipping over is avoided.

Machine stability is greater when the bucket is parallel with the tracks (Fig. 2-122:).

When working with the bucket parallel to the tracks, the final drives should be in the rear position, for the following reasons:  The travel motors and final drives are protected from falling rocks etc. 

When the hydraulic shovel is operated on muddy ground and the tracks are covered with mud, the sprocket runs on a clean track when backing up.

If it is unavoidable to work on soft and yielding ground, operate the machine at reduced bucket loads to avoid tipping of the machine.

When working on high-density and coarse material, operate the machine at reduced bucket loads to avoid overloading and damaging components of the machine.

Stand attachment down to the ground during breaks in working operation.

Do not operate the hydraulic shovel in water or in mud deeper than the breather valves of the final drives. Refer to section “Restricted Operation”.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Know the situation on site To maximize productivity of the machine, it is important that the operator understand characteristics of the material they are digging and how to adjust their operating style accordingly.

Material penetrability:  Easily penetrable material: All loose, free flowing material and all materials which can be excavated without blasting. 

Difficult to penetrate material: Blasted or unblasted material containing large chunks, wet clayey soil and overburden.

Material flow:  Free flowing / loose. 

Sticky / in situ.

2-86

Conditions favorable to hydraulic backhoes: (Preferred option for overburden and softer material)  Low to moderate bench heights (Refer to section “Bench Heights – Recommendations for BH-machines”) 

Truck spotted either on top of bench or on the floor below the backhoe



Tight load area



Short swing – 60°



Well-shot material

Conditions unfavorable to hydraulic backhoes:  High benches 

Excessive tramming



Multiple benches



Unstable benches



Low angle of repose



No cleanup support

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Bench - Climbing and Leaving Climbing Onto a Bench Do not exceed the maximum machine inclination or working. Refer to Operation and Maintenance Manual section “Maximum machine inclinations”.

Build the ramp.  Travel up the ramp onto a bench with idlers first, keep the bucket close to the ground.

If necessary, engage the bucket into the ground and move working equipment towards the machine. This procedure supports the machine while climbing the steep ramp (Fig. 2-124:).

Fig. 2-124:

Leaving a Bench

 Build the ramp. If the bench is steep, bring the hydraulic shovel down the bench with the final drive first.  Keep the bucket close to the ground (Fig. 2-125:).

Fig. 2-125:

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OPeration Bench Heights – Recommendations for BH-machines Insufficient bench height

A too low bench does not allow good bucket fills and involves the risk to pull material against the tracks (Fig. 2-126:).

Insufficient height increases the danger of collision between excavator and truck under certain circumstances (Fig. 2-126: and Fig. 2-127:).

Fig. 2-126:

Fig. 2-127:

Sufficient bench height

A sufficient bench height is essential for efficient and safe operation.

The ideal bench height is equal to the stick length or equal to the truck body rail height (Fig. 2-128:).

Note: This is a rule of thumb and is valid only if the material allows this bench height and only for standard truck match.

For more information please refer to section “Bench Heights – Recommendations for BHmachines, table”.

Fig. 2-128:

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OPeration Loading setups The following setups are used for digging and loading with the hydraulic shovel:  Hydraulic shovel on top of the bench, and truck below (This is the typical application). 

Hydraulic shovel and truck on the same level.

Working with the hydraulic shovel on a proper bench height and the truck below (Fig. 2-129: and Fig. 2-130: and Fig. 2-131:) offers the following improvements:  15-20% more production.

Fig. 2-129:



Clear separation of loading and hauling equipment.



Less risk of collision.



Excellent operator view into the truck body.



Potential for short swing angles.



Shortest attachment lifting distance possible.



Various options for truck positioning with loading through the body gate or over the side wall.

Productivity increases:  10 – 15% higher productivity when bench is correct height vs. too high or to low.

Fig. 2-130:



15 – 20% higher productivity when trucks are spotted on the floor below the excavator vs. on top of bench.



5% higher productivity when excavator swings 60º vs. 90º.



Higher productivity when positioned as close to edge as safely possible.

Fig. 2-131:

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OPeration Truck on lower level — drive-by loading (Fig. 2-132:): Advantage:  Truck spotting time is eliminated, for the highest productivity, because the next truck does not need to reverse for positioning.

Disadvantages:  More than 90° swing angle. 

Fig. 2-132:

Loading through the gate could be more difficult due to limited space for dumping.

Truck on upper level — top loading (Fig. 2-133:): Working with the hydraulic shovel and the truck on the same level offers the following improvements:  Loading over side walls offers reduced swing angle. 

Loading over tail offers reduced lifting effort for faster cycles.

This working technique is best applied for drop cuts and in difficult to access or wet areas at the pit bottom.

Disadvantages:  Increased lifting effort and larger swing angle requires longer cycle time.

Fig. 2-133:



Productivity is approximately 15 to 20% lower.

Bench Heights – Recommendations for BH-machines, table

2-90

Rule of thumb Model

Stick length

Truck body loading edge @ 4 to 5 pass match

Recommended bench height

6015B

3.6 m / 4.1 m

3.7 m (775G)

~ 3-4 m

6020B

3.9 m

4.4 m (777G)

~ 3.5-4.5 m

6030

4.0 m

4.4 m (777G)

~ 3.5-4.5 m

6040

4.6 m

5.0 m (785C)

~ 4.0-5.0 m

6050

5.5 m

5.6 m (789D)

~ 5.0-6.0 m

6060

5.0 m

5.9 m (793D)

~ 5.0-6.0 m

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Digging and Loading Loading Trucks, do:  Start at "key cut" and work toward the truck. 

Always work over the idler and swing no more than 60° to the truck.



Prepare the next cuts in advance.



General digging advance is backwards.



Maintain a proper bench height.



Position the truck close enough to the machine for effective loading, but not too close so that the machine cannot hit and damage the truck.



Most productive work is performed with the truck on a lower level.



Swing the attachment at a sufficient height over the loading platform.



Distribute material evenly on the truck bed.



Remove sticky material from the bucket.



Always keep the shovel as close as possible to the work area. This minimizes short stick and boom movements - high efficiency.



Correct bucket size and properly adjusted equipment prevents overloading and ensures maximum operating efficiency of the hydraulic shovel.

Loading Trucks, do not:  Do not swing the attachment over unprotected driver cabs. 

Do not overload the truck.



When turning into a pit, the swing motion must not be stopped by the walls of the pit. Doing so can cause structural damage to the attachment.

Use the machine hydraulic system to stop the swing motion.



Only a bucket with a complete set of teeth and cutting edges in good condition ensures efficient performance.



Loosen hard material and rocks with the bucket, not with the stick crowding thrust.



Avoid digging with corner tooth to avoid torsional forces into attachments.



Avoid contacting mechanical stops and cylinders end of stroke.

Refer to Operation and Maintenance Manual chapter “Backhoe Operation - Restricted Operation” for further details.

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OPeration Digging and loading a truck

Fig. 2-134:

Fig. 2-135:

2-92

Use the following guidelines when digging and loading a truck (Fig. 2-134: and Fig. 2-135:):  Position the stick at an angle to the ground as shown in (Fig. 2-135:).  Position the bucket cutting edge at an angle to the ground as shown in (Fig. 2-135:). This allows maximum breakout force to be exerted throughout the dig cycle.  Move the stick towards the cab and keep the bucket parallel to the ground.  If the stick stops due to the load, raise the boom and / or perform a curl in order to adjust the depth of the cut.  To apply the greatest force at the cutting edge, decrease the down pressure as you move the stick toward the cab.  Maintain a bucket attitude that ensures a continuous flow of material into the bucket.  Continue the pass in a horizontal direction so that material peels into the bucket.  Curl in the bucket and raise the boom when the pass has been completed.  Swing the load from the rear of the truck or from the side of the truck. Never swing a load over a truck cab or personnel.  To dump a load, move the stick outward and open the bucket in a smooth motion.  Load trucks evenly. This will help to avoid overloading the rear axle.  When bucket is empty, swing the upper structure back and begin the next loading cycle.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Double Benching Double Benching is an operation method which could be productive but also be very harmful to component life. This method should be used only by well trained and experienced operators in accordance with the following rules.

Fig. 2-136:

Rules for “Double Benching” Material: Loose, well blasted and easy to dig material is absolutely essential for Double Benching.

Boom down function should be used in float position only to pull down material from the wall.

Note: Digging poorly blasted material with great boulders or too tough material is a great stress for the steel structure and could result in serious damages.

Do not use the “Power boom down” - function.

Always maintain a proper distance to the highwall to avoid operating at the limits of the cylinders.

Bench height: A high bench is split up into two segments, 1/3 of the bench is below the excavator and 2/3 is above the excavator (Fig. 2-136:).

The ideal upper bench height is when the bucket could lay flat on the top of the bench (1, Fig. 2-136:).

The ideal lower bench height is equal to the length of the stick or equal to the truck body side wall edge.

Note: Too low lower benches can cause collisions of the counterweight and the truck body.

Working direction: While digging the upper bench, the cab must be on the opposite side of the high wall, swing direction is to the truck / cabin side (Fig. 2-136:). Dig forward (arrow, Fig. 2-136:).

While digging the lower bench, the cab must be on the opposite side of the high wall, swing direction is to the truck / cabin side (Fig. 2-137:). Dig backwards (arrow, Fig. 2-137:).

Fig. 2-137:

Working method: Dig the upper bench first, progressing from right to left, by digging down material from the face (Fig. 2-136:).

Dig the lower bench on the way back in standard setup from left to right (Fig. 2-137:).

Dig a trench in front of the machine and along the high wall (2, Fig. 2-136:).

Leave this trench along the dig face (approx. 1.5 meters / 5 ft. deep) while digging forward.

If any spillage falls out it is collected in the trench and won’t damage the excavator.

The hole in front of the machine also eases bucket fill.

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OPeration Grading the pit floor The described grading function can be performed precisely by simultaneously use of the boom, stick and bucket function.  Position the stick slightly forward of the vertical position with the bucket in the dumped position (Fig. 2-138:).  Operate the stick-retract function while slowly raising the boom. When the stick moves past the vertical position, slowly lower the boom to allow the bucket to maintain a smooth surface.

Fig. 2-138:

Park the Machine

Park the machine in a location that is smooth, stable, level and hard. The location should also be dry and free of debris and not endangered by falling rock. Bring the attachment in a position like shown in (Fig. 2-139:): - Half extend the boom cylinders.

- Bring the stick in a vertical position.

- Lower the boom until the bucket is on the ground.

Note: Other positions of the attachment are not allowed when parking the machine. Refer to section “Backhoe Operation - Restricted Operation”.

Fig. 2-139:

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OPeration Machine operation with face shovel attachment - Best Practices Machine stability When working with the attachment in a cross direction to the tracks, be sure that the track is not raised off the ground. This can cause the track to set-off from the rollers when it is lowered down on the ground.

Also the flanges of the track rollers and the track shoes can be bent by the excessive load.

Refer to Operation and Maintenance Manual, “Restricted Operation” for further detailed information.

Do not overfill / overload the face shovel, the machine may tip over.

Fig. 2-140:

When working or traveling on a slope is required (Fig. 2-141:), do not exceed the maximum machine inclination for working operation and for traveling (refer to Operation and Maintenance Manual section “Maximum machine inclinations”).

Do not operate the shovel on rain-slicked, slippery slopes. The shovel may slip.

Clean and level the pit floor before moving into the bank. A clean, level pit floor is necessary for safe and stable machine operation and prevents the tracks and other components of the undercarriage from being damaged.

Position the hydraulic shovel on level and firm ground. The hydraulic shovel may gradually sink on soft ground. Always re-enforce soft ground with firm material.

Fig. 2-141:

The hydraulic shovel must always be operated in a way, that its stability is always ensured and the danger of tipping over is avoided.

Machine stability is greater when the bucket is parallel with the tracks (Fig. 2-140:).

When working with the bucket parallel to the tracks, the final drives should be in the rear position, for the following reasons:  The travel motors and final drives are protected from falling rocks etc. 

When working on soft ground or on high density material, operate the machine at reduced bucket loads.

Stand attachment down to the ground during breaks in working operation.

Do not operate the hydraulic shovel in water or in mud deeper than the breather valves of the final drives. Refer to section “Restricted Operation”.

When the hydraulic shovel is operated on muddy ground and the tracks are covered with mud, the sprocket runs on a clean track when backing up.

2-95

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OPeration Know the situation on site To maximize productivity of the machine, it is important that the operator understand characteristics of the material they are digging and how to adjust their operating style accordingly.

On the site different bench height characteristics can exist:  A steep slope with an angle > approx. 60° and sticky, in-situ material (Fig. 2-142:). 

Fig. 2-142:

A flat slope with an angle ≤ approx. 60° and free flowing, loose, blasted material (Fig. 2-143:).

Material penetrability:  Easily penetrable material: All loose, free flowing material and all materials which can be excavated without blasting. 

Difficult to penetrate material: Blasted or unblasted material containing large chunks, wet clayey soil and overburden.

Material flow:  Free flowing / loose. 

Fig. 2-143:

2-96

Sticky / in situ.

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OPeration Bench Heights on Steep Slopes

Minimum Bench Height Hydraulic face shovels can work on low faces due to their kinematics.

The working face should be at least as high as the bucket itself for sufficient bucket fill. With the 6030, for example, it is about three meters (Fig. 2-144:).

Continuous high lifting effort and frequent relocation results in unproductive loading cycles.

Fig. 2-144:

Bench Height on Steep Slopes Example situation: The material to dig is e.g. free - dig overburden.

- Material characteristics is – sticky / in situ, - It is a steep slope - angle is approx. 60°.

The optimal bench height is for tough digging (Fig. 2-145:): - Cabin roof height (e.g. for 6030 FS): ~7m

Fig. 2-145:

The maximum bench height is (Fig. 2-146:): - 75% of the maximum vertical reach (e.g. for the 6030 FS): 13.9 m x 0.75 ≈ 10 m (These are rules of thumb, they are a guide only, values depend on the material conditions).

Fig. 2-146:

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OPeration Bench Height on Flat Slopes

Bench Height on Flat Slopes Example situation: The material to load is e.g. well blasted pile.

- Material characteristics is – free flowing / loose, material has the tendency to roll down.

- It is a flat slope – angle is approx. ≤ 60°.

The maximum bench height is (Fig. 2-147: and Fig. 2-148:): - Maximum vertical reach (e.g. for 6030 FS): ~14 m (This is a rule of thumb, a guide only, value depends on the material conditions).

Fig. 2-147:

Fig. 2-148:

Bench Heights – Recommendations for FS - Machines, table Minimum

Steep Slope > ~approx. 60° Sticky / in situ material Tough digging

Rule of thumb Model 6015 FS 6018 FS 6030 FS 6040 FS 6050 FS 6060 FS 6090 FS

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Bucket Height

Cab Roof Height

~2m

~5m

~2m ~3m ~3m

Easy digging 75% of max. vertical reach

Flat Slope ≤ ~ 60° Free flowing / loose material Max. vertical reach

~8m

~ 11 m

~7m

~9m

~ 13 m

~7m

~ 10 m

~ 14 m

~8m

~ 10 m

~ 14 m

~3m

~9m

~ 12 m

~ 15 m

~3m

~9m

~ 12 m

~ 15 m

~4m

~ 10 m

~ 15 m

~ 20 m

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Basic setup at a bench



The undercarriage should be positioned at 45° to the face (Fig. 2-149: and Fig. 2-150:).



Sprocket / final drives shall always point away from the face.



Truck position on the left hand (cab) side of the shovel.



Shovel operator and truck driver have eye contact.



The 45° position towards the digging face allows quick escape in case of a face collapse (Fig. 2-150:).



All rollers are not exposed to damage.



Less dirt on RH from material falling from the face track.



The digging forces are transmitted lengthwise through the track pad grousers into the ground (Fig. 2-151:).



Traction is optimal in this position.



A crosswise position would apply side load to the rollers.

Fig. 2-149:

Fig. 2-150:

Fig. 2-151:

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OPeration Recommended working direction Best practice is: Working from right to left (Fig. 2-152:).

Cleaning of the floor behind and beside the shovel is done by a dozer.

Trucks will drive on levelled and clean ground, this results in less tire / suspension damage.

Doing so is a clear separation of loading action and clean-up support.

The hydraulic shovel shall always return to the right end of the face (end of the cut) and start again.

Fig. 2-152:

Not recommended – Digging advance left to right Loading the truck to the left side means increased swing angle and longer cycle times (Fig. 2-153:) = unproductive.  The operator might try to reduce the swing angle, tails are left behind / no straight face. 

Truck position on rough ground / spillage, results in cleanup delays, dozer standby required, risk of tire damage.

Fig. 2-153:

Not recommended – Digging advance left to right Loading the truck to the right side (Fig. 2-154:) results in loading on the blind side.  Poor visibility of shovel operator to the truck means swing over the blind side. 

Fig. 2-154:

2-100

Poor visibility of truck driver to the shovel means difficult positioning.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Loading setups

Single side loading The hydraulic shovel loads the trucks only on the left hand side (Fig. 2-155:). Truck driver and shovel operator have direct eye contact.

Single side loading with standard truck spotting is the best solution for most applications.

Advantages:  The hydraulic shovel can follow a straight working face without major repositioning effort.

Fig. 2-155:



Good floor conditions that are easy to maintain.



Support equipment can clean the excavated area behind the shovel without interfering with the loading action.

The face should always be mined from right to left, then travel back and continue.

The tracks should be positioned 45º toward the face; travel motors to rear.

Double side loading The hydraulic shovel loads the trucks alternately on left and right hand side (Fig. 2-156:).

Double side loading with self spotting increases productivity only short term and only if perfectly executed. A long-term productivity advantage will not be achieved because of the many disadvantages and requirements.

Disadvantages:  Higher risk of collisions.

Fig. 2-156:



Well-trained operators are required.



While loading to the right side, both shovel operator and truck driver are on the blind side.



Shovel cannot follow straight working face and has higher repositioning effort.



Permanent clean-up support required.

The tracks should be positioned 90º toward the face; travel motors to rear.

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OPeration Digging and Loading

Digging  Maintain a digging face which avoids any major slides which could cause an accident.  Always check the digging face for large boulders, large rocks, or frozen material which could slide and cause damage to the machine.  Always inspect the bank, it could collapse.

Rocks can damage track pads, idler and the track tensioning system.  Building a safety trough in front of the tracks will protect the machine (Fig. 2-157:).  Avoid overhanging material.

Fig. 2-157:

 Always strive to work from top to bottom (Top / Center / Bottom in Fig. 2-158: to Fig. 2-160:).  Penetrate as high as possible to reduce lifting effort and shorten cycle times.  Always use the full cutting surface of the shovel lip to contact the bank on each pass. A full face cut combined with a deep bank penetration will result in a well filled shovel.  Use the float function of the boom while penetrating the material.  Always keep the shovel as close as possible to the work area. Short boom trips - high efficiency.

Digging, do not

Fig. 2-158:

 When swinging towards the bank, the swing motion must not be stopped by the walls of the pit or by the material. Doing so can cause structural damage to the attachment.

Use the machines hydraulic system to stop the swing motion.  Do not work with a bucket with missing teeth, missing shrouds or missing components of the hardfacing.  Loosen hard material and rocks with the bucket, not with the stick crowding thrust.  Do not swing the bucket into the material; penetrate only after swing is complete  Never penetrate the material with an open bucket.

Fig. 2-159:

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OPeration

Loading Trucks  Position the truck as closely as possible to the hydraulic shovel (Fig. 2-162:).  Swing the attachment at a sufficient height over the loading platform.

Do not swing the attachment over unprotected driver cabs.  Distribute material evenly on loading platform.  Do not overload the truck.  Remove sticky material from the bucket.

Fig. 2-160:

 Utilize the time between trucks (during truck spotting) to prepare the 1st pass for the next truck load (Fig. 2-161:).  Use low penetration height to clean up the ground and fill the shovel. There is enough time for a large swing angle until the next truck arrives.  Take the opportunity to check the face for potential rock fall and large and oversize material.

Fig. 2-161:

 For the 2nd and the subsequent passes (the truck is in position) dig again from top to bottom maintain smaller swing angles.

This minimizes truck loading time.

Fig. 2-162:

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OPeration Dumping the load Correct bucket position during dumping will reduce bucket wear.

To center the load, the bucket should be tipped forward as the clam is opened (Fig. 2-163:).

Fig. 2-165:

Closing the bucket clam

Fig. 2-163:

If the bucket is tipped too far forward, the load will fall to the near side of the truck bed (Fig. 2-164:).

 Close the clam using gravity to resist motion as shown in Fig. 2-166:.

Doing this  will improve control when clam and backwall near contact. 

reduces impact forces on clam cylinders, clam and backwall.

 Do not close the clam with gravity assisting motion. This motion can be difficult to control.

The clam can bang against the backwall and applying impact forces to the clam, backwall and cylinders. These impact forces will reduce the durability of the clam, backwall and cylinders.

Fig. 2-164:

If the bucket is fully crowded back, the load will fall to the far side of the truck bed (Fig. 2-165:).

Fig. 2-166:

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OPeration Digging on Ground Level

 When digging at ground level, keep the heel of the bucket off the ground (Fig. 2-167:).  Operate with the ground engaging tools (GET) doing all the work.

Fig. 2-167:

Forcing the heel into the ground causes premature wear on the rear of the bucket (Fig. 2-168:).

Fig. 2-168:

2-105

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OPeration Cleaning up the Pit Floor using the Attachment

As loading continues it will be necessary to remove material from the lower down the face (Fig. 2-169:).

Leave some material between the bucket and the tracks.

Fig. 2-169:

Once all the material has been removed from the shovels reach move back 1 to 2 meters to enable the material in front of the tracks to be cleaned up (Fig. 2-170:).  Move back to cleanup material.  Maintain clearance between the bucket and the tracks.

If possible this should be completed between trucks and loaded directly into a truck to avoid lost production.

Fig. 2-170:

Drop cuts

Fig. 2-171:

2-106

Drop cuts are difficult but possible (Fig. 2-171:).  Drop cuts are uncomfortable for the operator due to working on an inclination.  Slewing uphill puts stress on components.  The operator has to be careful while slewing downhill because of additional acceleration and operate the machine slowly.  The maximum working inclination for CGM HMS Shovels is 8.7%, this is less than the recommended haul road grade of 10%.

Procede as follows: Maintain 8.7% with the CGM HMS Shovel and put to final 10% grade with a track type tractor.  For building of ramps, the values specified may be exceeded. In this case, however, a reduced service life of the components can be expected.

Drop cut = Digging down from current level to the next level down, creating a ramp in the process. 

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Handling Oversized Boulders / Overhangs Note: Make sure that no truck or other machine is close proximity or in the projected slope line of the rock.  Ensure the tracks are 90° to the working face.  Position the hydraulic shovel to one side of the boulder/overhang before attempting to undercut. This ensures, that the hydraulic shovel will not be in its path when the rock falls (Fig. 2-172:).  Position the hydraulic shovel little to the right below the boulder/overhang. This ensures best visibility to the boulder/overhang.  Swing to the right hand side and work with the very left tooth.  Watch the size of the boulder; if it is too big to pass through the clam, it should be returned to the face.

Fig. 2-172:

 Place some material into the truck body first (1, Fig. 2-173:).  Warn the truck driver using the horn.  Tip the rock off the front of the bucket onto the material as shown (2, 3 and 4, Fig. 2-173:).

Do not try to get oversized boulders through the clam.

Fig. 2-173:

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OPeration Park the Machine

Fig. 2-174:

Park the machine in a location that is smooth, stable, level and hard. The location should also be dry and free of debris and not endangered by falling rock.

Lower the bucket to the ground and ensure that the stick is vertical to the ground (Fig. 2-174:).

2-108

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Face Shovel Operation – Restricted Operation

Avoid extreme positions of the attachment. Parts of the attachment may damage the machine e.g. the tracks if they are moved to close to the machine (Fig. 2-175:).

Fig. 2-175:

Do not operate the machine when - one or several teeth - parts of the hardfacing - lip shrouds or side shrouds - or other parts of the bucket are worn or missing (Fig. 2-176:).

Working under these conditions reduces digging performance, results in heavy wear, potentional damage and high repair costs.

Fig. 2-176:

Do not operate the machine on uneven, rough ground (Fig. 2-177:).

Doing so is extremely detrimental to undercarriage component life.

Fig. 2-177:

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OPeration

Do not use the dropping force of the bucket as a hammer, breaker or pile driver (Fig. 2-178:). This will bring excessive force on the machine and possible damage to the machine could result.

Fig. 2-178:

Do not operate the machine with the final drives facing the attachment (Fig. 2-179:).

There is a risk of damaging components of the gearboxes and sprockets and hydraulics.

Fig. 2-179:

Do not operate the cylinders to the end of stroke during operation (Fig. 2-180:), excessive force will occur on the inside of the cylinder. This will reduce the life of the cylinder and the structures.

To avoid this issue, always leave a small margin of play when the cylinder is operated (Fig. 2-181:).

If cylinders must be operated to the end of stroke, extend or retract speed must be reduced to 10%.

Fig. 2-180:

2-110

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OPeration

Do not operate cylinders to the end of stroke during operation, excessive force will occur on the inside of the cylinder.

This will reduce the life of the cylinder and structures.

To avoid this issue, always leave a small margin of play when the cylinder is operated (Fig. 2-181:).

If cylinders must be operated to the end of stroke, extend or retract speed must be reduced to 10%.

Fig. 2-181:

Do not operate the machine in unsuitable material for digging (Fig. 2-182:).

Ensure material is blasted or has appropriate penetrability and material fragmentation.

Operating the machine in inappropriate conditions will reduce durability, productivity and increase cost of ownership.

If material conditions cannot improve, the bucket or working tool may need to be exchanged. Please consult your dealer for machine bucket and/or work tool options and recommended operational/maintenance techniques in severe applications.

Fig. 2-182:

Avoid working in materials having higher density than appropriate for bucket or work tool (Fig. 2-183:).

If unavoidable, operate the machine at reduced bucket loads to avoid overloading, tipping and reducing machine durability.

Fig. 2-183:

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OPeration

Do not operate the clam cylinders to the end of stroke when opening the shovel clam (Fig. 2-184:), excessive force will occur on the inside of the cylinder. This will reduce the life of the cylinder and the structures.

To avoid this issue, always leave a small margin of play when the clam is opened.

If the clam must be operated to the end of stroke, cylinder speed must be reduced to 10%.

Fig. 2-184:

Do not extend the bucket cylinder to cause contact between bucket and stick stops (located on the top of the stick) (Fig. 2-185:).

Curl out the bucket to avoid contact with the stick.

The bucket may contact the stick when the stick is retracted or the boom is lowered.

Curl out the bucket when lowering the boom or retracting the stick to avoid contact.

Fig. 2-185:

The bucket may contact the end of the travel stops located on the top of the stick when the stick is retracted (Fig. 2-186:).

Curl out the bucket when retracting the stick to avoid contact.

Fig. 2-186:

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OPeration

The bucket may contact the end of travel stops located on the top of the stick when the boom is lowered (Fig. 2-187:).

Curl out the bucket when lowering the boom to avoid contact.

Fig. 2-187:

Do not retract the bucket cylinder to cause contact between the travel stops between the stick and bucket (located on bottom of the stick) (Fig. 2-188:).

Curl in the bucket to avoid contact.

Fig. 2-188:

The bucket may contact the end of the travel stops located on the bottom of the stick when the stick is extended (Fig. 2-189:).

Curl in the bucket when extending the stick to avoid contact.

Fig. 2-189:

2-113

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OPeration

The bucket may contact the end of the travel stops located on the bottom of the stick when the boom is raised (Fig. 2-190:).

Curl in the bucket when raising the boom to avoid contact.

Fig. 2-190:

Be aware that no rocks or other material are between the bucket and the stick (Fig. 2-191:).

Crushing rocks or other material between bucket and stick will damage stick and bucket.

Fig. 2-191:

Do not engage the bank or any other material when the clam is not fully closed (Fig. 2-192:).

This will damage the clam and the clam cylinders.

Fig. 2-192:

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OPeration

Do not push down on the attachment with the clam in contact with the ground (Fig. 2-193:).

Do not use the fully curled bucket for tamping the ground.

Doing so will damage the clam, the bucket, the bucket cylinder or other parts of the attachment.

Fig. 2-193:

Do not dig with the bucket cylinder fully retracted and the bucket teeth stuck in the ground (Fig. 2-194:). The attachment will be subjected to excessive force.

Fig. 2-194:

Do not open the clam and use the bucket backwall or rear of clam for grading operations, as this will damage the bucket backwall and the clam (Fig. 2-195:).

Fig. 2-195:

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OPeration

Do not use the bucket clam for loosening or removing anchored rocks or other solid objects, since such operations may result in severe damage to the clam pivot bearings (Fig. 2-196:).

Fig. 2-196:

Do not suspend a loaded bucket for more than 5 minutes (Fig. 2-197:). Ground the bucket.

Fig. 2-197:

Do not swing a load over an unprotected truck cab or over personnel (Fig. 2-198:).

Fig. 2-198:

2-116

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OPeration

Do not overload the attachment and do not allow the rear of tracks to rise off the ground. Do not undercut a bank (Fig. 2-199:), undercutting a bank could result in bank collapsing and material falling onto the attachment.

Fig. 2-199:

Do not use the dropping force weight of the machine to pry material in the bank or for excavation (Fig. 2-200:).

Doing so may damage the machine and the attachment.

Fig. 2-200:

If the tracks rise off the ground while digging, lower the machine back to the ground smoothly (Fig. 2-201:).

Fig. 2-201:

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OPeration

Do not try to move or load oversized material pieces (Fig. 2-202:). Doing so could damage the attachment.

Fig. 2-202:

Machine stability is reduced when the load is swung to the side and when operating the attachment perpendicular to the tracks (Fig. 2-203:).

Sudden stopping of the attachment movement can result in the tipping of the machine, especially when the attachment is perpendicular to the tracks.

Never overload the attachment.

Fig. 2-203:

Machine stability is greater when the load is positioned parallel with the tracks and over the front idlers (Fig. 2-204:).

Fig. 2-204:

2-118

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OPeration

Never try to catch falling / rolling material using the attachment (Fig. 2-205:).

Doing so can extremely overload the structures and can result in severe damage of mechanical and hydraulic components.

Fig. 2-205:

Do not use the clam to grip rocks or other objects (Fig. 2-206:).

Fig. 2-206:

Do not use the clam, the bucket backwall, or the bucket to scrap down rocks or material (Fig. 2-207:).

Fig. 2-207:

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OPeration

Do not raise the bucket to scrape the wall to loosen or remove material (Fig. 2-208:).

This is an extremely damaging practice and will reduce the lifetime of the shovel.

Fig. 2-208:

Do not sweep the pit floor.

Do not swing the machine while the bucket is engaged in the material (Fig. 2-209:).

Do not stop swinging by contacting an object such as a bank or ditch.

Do not start swinging until the bucket is completely removed from the bank.

Do not begin digging before the swing motion is stopped.

Fig. 2-209:

Do not propel the machine while the bucket is engaged in the material (Fig. 2-210:).

This operation will potentially damage components of the attachment.

Fig. 2-210:

2-120

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OPeration

Do not propel the machine longer than 5 minutes with the propel motors to the front (Fig. 2-211:).

Fig. 2-211:

Fig. 2-212:

Do not attempt to travel on slopes with the bucket loaded or any load suspended from the bucket.

Never attempt to ascend or descend steep slopes, refer to the Operation and Maintenance Manual for maximum slope.

Keep the bucket pointed in the direction of travel, approximately 0.5 to 1.0 m above the ground (Fig. 2-212:).

If the machine starts to skid or becomes unstable, lower the bucket to the ground immediately.

Avoid swinging the upper carriage on slopes.

Never attempt to swing the upper carriage downhill. The machine may tip over.

If swinging uphill is unavoidable, carefully operate the upper carriage and boom at slow speed.

If the electric motor stalls on a slope, immediately lower the bucket to the ground. Return joysticks to neutral.

Then, restart electric motor.

Be sure to thoroughly warm-up the machine before ascending steep slopes. If the hydraulic oil has not warmed-up sufficiently, performance may be effected.

Always ascend the slope at a 90 degree angle (Fig. 2-213:).

Fig. 2-213:

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OPeration

Driving across the face of a slope or steering on a slope may cause the machine to slide or tip over (Fig. 2-261:).

If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

Fig. 2-214:

Do not exceed the maximum machine inclination for working operation (Fig. 2-215:).

Refer to section “Maximum Machine Inclinations” for further information.

Fig. 2-215:

Do not use the force of the bucket, the stick or the boom to assist in turning the machine while the machine is propelling (Fig. 2-216:).

This technique is referred to as “jump steering.”

The force applied to the swing motor and swing drive by this method may cause damage to the swing motor and swing drive.

For proper turning procedures refer to section “Traveling”.

Fig. 2-216:

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OPeration

When working in any body of water or mud be careful that the level of water or mud is not higher than the breather valves on top of the final drives (Dimension A, Fig. 2-217:).

Water or mud could enter the gearboxes and cause serious damages.

While you cross any body of water or mud, carefully confirm the depth of the water or mud with the bucket. Do not move the machine into an area that has a water or mud depth that is higher than the breather valves of the final drives (Dimension A, Fig. 2-217:).

Fig. 2-217:

2-123

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OPeration TRAVELING Traveling - Safety Instructions Personnel Any work with the machine must be executed only by reliable, skilled and well trained personnel in good healthy condition. Statutory minimum age limits must be observed.

Avoid aggressive operating practices and never operate the machine while impared with drugs or alcohol.

Do not overload the machine.

State of operator’s workplace Inspect and fasten your seat belts.

Adjust the operator’s seat for comfortable reach all controls and pedals. Adjust for operator height and weight.

Keep your workplace clean. Remove all unsecured items like tools and other supplies from the cab.

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.

Clean and secure all windows and doors.

Clean and adjust all mirrors and cameras (if equipped) for optimum vision.

Travel the machine only while sitting on the operator’s seat.

State of the machine 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.

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, section "Restricted Visibility".

Clear the hazard range of the machine Check the surrounding area around the machine (the hazard range of the machine):  No personnel around the machine.  No personnel on the machine outside the cab.

State of the site and machine stability Before starting traveling, inspect the condition of the ground you want to travel on. The machine may sink on soft ground.

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Do not travel into a water surface without knowing how deep the water is and how stable the underground is. The underground may be sludgy and with insufficient bearing capacity. The machine may sink.

Do not travel through water or mud that is deeper than the breather valves of the final drives, refer to section “Restricted Operation”.

Ground that has been newly filled with earth / gravel may collapse from the weight of the machine.

Rocks and moisture of the surface material may drastically affect the machine's traction and machine's stability. Rocky surfaces may promote side slipping of the machine.

The machine may be less stable when traveling on uneven ground.

Have the attachment raised only so far as to permit the machine to be driven under overhead power lines without any risk.

Do not exceed the maximum machine inclination (refer to Operation and Maintenance Manual, section “Maximum machine inclinations”).

Do not travel across slopes. Always travel 90° to the slope face (upwards and downwards). Place the heaviest end of the machine uphill when you are traveling on an incline.

Do not drive the machine close to an overhang, to the edge of a cliff, or to the edge of an excavation.

Take the utmost care on slippery, greasy ground.

If the upper structure is turned by more than 90° from the basic position (refer to section “Upper structure - 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 travel pedals lightly to see which direction the machine takes, before initiating the full traveling movement.

Safe operation on steep slopes may require special machine configuration. Excellent skill of the operator and proper attachment for specific applications are also required. Consult the Operation and Maintenance Manual sections for the proper fluid level requirements and intended machine use.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Trailing cable

HIGH VOLTAGE! THE MACHINE TRAIL CABLE CARRIES A LETHAL VOLTAGE. Risk of voltage drive, if the trailing cable insulation is defective.

Never touch the trailing cable with bare hands.

Visually inspect the trail cable for cuts, abrasions and other damage before handling the cable.

Handle the cable in an approved manner with appropriate and approved rubber gloves and insulated hooks or tongs.

Note: Prevent trail cable from being dragged on the ground for long distances or at high speeds.

Limit the amount of cable being pulled by the machine. Pulling too much cable will damage both the cable and the machine.

Do not travel over the trail cable.

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OPeration Before starting traveling  Read and observe all notes given in section “Traveling – Safety Instructions”.  You need helpers to move the trail cable so that the machine does not drive over it. Communicate with the helpers about the direction of travel.  For increased safety the machine’s upper structure should be rotated in a position that allows the operator to face the direction of travel.  Lift up the hydraulic access ladder.  Lift attachment up to the traveling position.  Activate the signal horn.  Release the travel brake switch (if applied).  Watch the mirrors and the camera monitor (if equipped).  Start traveling.

Fig. 2-218:

Upper structure - basic position Travel only with the upper structure in its basic position.

The drive sprockets should be at the rear of the machine.

Before moving the machine, check the position of the undercarriage.

Travel direction and sense of actuation of travel pedals (112 and 113, Fig. 2-218:) are identical only when the upper structure is in its BASIC POSITION (Fig. 2-219:).

In this BASIC POSITION (Fig. 2-219:) the counterweight (3) is positioned above the final drives (4).

The operator’s cab (1) is above the left idler (2).

Fig. 2-219:

Forwards means: Machine movement in direction of the idlers.

Backwards means: Machine movement in direction of the final drives.

Note: If the upper structure is swung out of its basic position by more than 90° (Fig. 2-220:), the hydraulic shovel moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-218:) are depressed.

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.

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Fig. 2-220:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Travel Speed – Recommendations Traveling Situation

Travel Speed

Adjusting machine position while loading trucks

Slow

Travelling rearwards

Slow

Traveling long distances on flat or slight ramps and slopes

Slow or fast

Turning

Slow

Traveling uphill / downhill on ramps and steep slopes

Slow

Traveling on soft or inconsistent material

Slow

Traveling on rough terrain

Slow

Loading machine onto a trailer

Slow

For detailed information on Traveling Speed refer to section “Travel Speed – adjust”.

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OPeration Traveling – Basic Movements

Fig. 2-221:

Travel straight forward/backward

Fig. 2-222:

Traveling movement is controlled by means of the travel pedals (112 and 113, Fig. 2-221:). The travel pedals return automatically to their neutral positions when released.

During traveling, an acoustic warning signal sounds (Travel Alarm).

All instructions with regard to travel direction control are applicable only as long as the crawler tracks have sufficient grip and do not slip.

For information regarding traveling speed refer to section “Traveling speed – adjust”.

The information given in this section are applicable when traveling on level ground and also when traveling the machine on moderate inclinations, e. g. on haulroads. For additional information about traveling on steep ramps and steep slopes refer to section “Traveling uphill and downhill on ramps and steep slopes”.

Operate travel pedals gently Accelerate and decelerate travel movements gently. Sudden acceleration and abrupt braking from full speed are a huge strain for the machine.

Avoid aggressive traveling practices.

Traveling straight forward  Move both travel pedals in the direction of the front window. The machine moves in direction of the idlers (Fig. 2-222:). To stop travel movement, release the pedals, they return in neutral position.

Note: Reverse the hydraulic shovel only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

When traveling to the rear is required, make sure the trail cable is clear of the machine and follow the signals given by the helper(s).

Fig. 2-223:

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Traveling straight backward  Move both travel pedals in the direction of the operator’s seat. The machine moves in direction of the final drives (Fig. 2-223:). To stop travel movement, release the pedals, they return in neutral position.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Turning

Note: Traveling through curves in a single sharp turn should be avoided whenever possible.

When traveling through curves it is necessary to divide the curve movement into small gradual turns followed by a short distance of straight travel. Doing so prevents from material build up between rollers and tracks which could lead in excessive wear and damage of undercarriage components.

Turning, make a gradual right turn forward  Move the left travel pedal in the direction of the front window. Leave the right travel pedal in neutral. The machine moves in a gradual right turn forward (Fig. 2-224:). To stop the turn, release the pedal, it returns in neutral position.

Fig. 2-224:

Turning, make a gradual left turn forward  Move the right travel pedal in the direction of the front window. Leave the left travel pedal in neutral. The machine moves in a gradual left turn forward (Fig. 2-225:). To stop the turn, release the pedal, it returns in neutral position.

Fig. 2-225:

Note: Reverse the hydraulic shovel only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

When traveling to the rear is required, make sure the trail cable is clear of the machine and follow the signals given by the helper(s).

Turning, make a gradual right turn backward  Move the left travel pedal in the direction of the operator’s seat. Leave the right travel pedal in neutral. The machine moves in a gradual right turn backward (Fig. 2-226:). To stop the turn, release the pedal, it returns in neutral position.

Fig. 2-226:

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OPeration

Turning, make a gradual left turn backward  Move the right travel pedal in the direction of the operator’s seat. Leave the left travel pedal in neutral. The machine moves in a gradual left turn backward (Fig. 2-227:). To stop the turn, release the pedal, it returns in neutral position.

Fig. 2-227:

Note: Select slow speed level. To do so, switch speed level switch (72, Fig. 2-233:) to the left.  Change the position of the undercarriage only by turning forwards/backwards (Fig. 2-228:).

Turning to the left: Fig. 2-228:



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. 2-229:):  Turning to the left from pos. 1 to pos. 2 

Fig. 2-229:

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Turning to the right from pos. 2 to pos. 3

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Counter-rotation turns / Turning on the spot

Fig. 2-230:

Note: Counter rotational turns/turning on the spot in a single sharp turn should be avoided whenever possible.

When turning in single sharp turns, the machine can bury itself - especially in soft material.

When turning on the spot it is necessary to divide the turn movement into small gradual turns followed by a short distance of straight travel. Doing so prevents from material build up between rollers and tracks which could lead in excessive wear and damage of undercarriage components.

Select slow speed level. To do so, switch speed level switch (72, Fig. 2-233:) to the left. Change speed level only when the hydraulic shovel is stationary.

When using the counter-rotation method for turning, use one or more helper(s) to ensure that the trail cable does not get fouled and/or torn from the machine Counter-rotation turn to the right / Turning on the spot  Move the right travel pedal in the direction of the operator’s seat. Move the left travel pedal in the direction of the front window. The machine moves in a gradual turn to the right (Fig. 2-230:). To stop the turn, release the pedals, they return in neutral position.

Fig. 2-231:

Counter-rotation turn to the left / Turning on the spot  Move the left travel pedal in the direction of the operator’s seat. Move the right travel pedal in the direction of the front window. The machine moves in a gradual turn to the left (Fig. 2-231:).

To stop the turn, release the pedals, they return in neutral position.

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OPeration Track Parking Brake – set/release

Traveling speed – adjust

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 forwards or backwards.

The brakes are deactivated during operation of the machine. When the machine is parked, the machine is braked hydraulically.

Note: As travel brakes are deactivated, machine could slightly move in direction of excavating during operation.

Whenever loading operation is interrupted, rest the attachment on the ground. This avoids slight movement of the machine and possible consequential damage of lowered ladder, in case ignition remains engaged.

All instructions with regard to traveling speed regulation are applicable only as long as the crawler tracks have sufficient grip and do not slip.

Select travel speed level Note: Change speed level only when the hydraulic shovel is stationary.  Switch (72, Fig. 2-233:) to the left = slow gear.

All forward/reverse travel movements are possible with this gear.  Switch (72) to the right = fast gear.

All forward/reverse travel movements are possible with this gear.

Adjust the traveling speed  Depress travel pedals (112 and 113, Fig. 2-233:) fully or partially depending on the travel speed wanted. Releasing the travel pedals brings the shovel to a standstill.

Fig. 2-232:

For Service and Maintenance purposes the traveling gear brakes can also be applied with switch (63, Fig. 2-232:).

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.

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Fig. 2-233:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Traveling uphill and downhill on ramps and steep slopes Note: When traveling uphill or downhill on ramps and steep slopes, the travel drives must always face downhill (1, Fig. 2-234: to Fig. 2-237:).

Otherwise track tension loss may occur.

Do not exceed the maximum machine inclination when traveling uphill or downhill (refer to section “Maximum machine inclinations”).

Read and observe section "Traveling – Safety instructions".

Traveling uphill:

Fig. 2-235:

 Select slow speed level. To do so, switch speed level switch (72, Fig. 2-238:) to the left.

Note: Change speed level only when the hydraulic shovel is stationary.  Bring shovel in a position shown in Fig. 2-234: and Fig. 2-235:. The final drives (1) and the counterweight are facing downhill.  Depress travel pedals (112 and 113, Fig. 2-238:).

Traveling downhill:  Select slow speed level. To do so, switch speed level switch (72, Fig. 2-238:) to the left.

Note: Change speed level only when the hydraulic shovel is stationary.  Bring shovel in a position shown in Fig. 2-236: and Fig. 2-237:. The final drives (1) are facing downhill. The counterweight is facing uphill.  Depress travel pedals (112 and 113, Fig. 2-238:).

Fig. 2-236:

Fig. 2-237: Fig. 2-234:

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OPeration Note: Avoid changing the direction of travel on a slope.

Changing the direction of travel on a slope could result in tipping or side slipping of the machine.

Be extremely careful on slippery and greasy ground. The machine may slip.

Do not travel across slopes.

Keep the working attachment close to the ground.

Be careful to avoid any ground condition which could cause the machine to tip. Tipping can occur when you travel on hills, on banks or on slopes.

If the machine begins to sideslip on a grade, immediately dump the load and turn the machine uphill.

Traveling speed on ramps and slopeschange  Select slow speed level. To do so, switch speed level switch (72, Fig. 2-238:) to the left.

Note: Change speed level only when the hydraulic shovel is stationary.  Depress travel pedals (112 and 113, Fig. 2-238:) fully to the limit stop.

When traveling downhill, the travel retarder valve acts as a speed limiter.

If the traveling speed nevertheless becomes too high when traveling downhill, release travel pedals (112 and 113) to stop the shovel.

Fig. 2-238:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Traveling over long distances Note: Travel only forwards with the hydraulic shovel in its basic position.

Traveling backwards over longer distances could wear out or damage parts of the undercarriage.

Read and observe section "Traveling – Safety instructions".

Do not exceed the maximum machine inclination (refer to section “Maximum machine inclinations”).

When traveling, pay attention to sufficient headroom, e. g. under cable bridges or high-tension cables.

Lower the attachment when traveling underneath obstacles.

Keep the face shovel 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. 2-239: and Fig. 2-240:).

Fig. 2-239:

NOTICE If non-OEM buckets are installed, be careful to avoid contact between bucket and machine (i.e. boom).

Set the upper structure holding brake.

Recommended position of the face shovel attachment (Fig. 2-239:):  Fully extend boom cylinder (1).  Retract bucket cylinder (2).  Retract stick cylinder (3).  Retract bucket cylinder (2) and stick cylinder (3) to such an extent as to reach the position of the attachment shown in (Fig. 2-239:).

Fig. 2-240:

Recommended position of the backhoe bucket attachment (Fig. 2-240:):  Fully extend boom cylinder (1).  Extend backhoe cylinder (2).  Extend 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. 2-240:).

If the attachment position must be changed:  Stop the hydraulic shovel,  Change the position,  Continue to travel.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration Upper structure holding brake – set/release The hydraulic shovel is equipped with four upper structure holding brakes which are integrated in the swing gearboxes. The upper structure holding brakes lock the upper structure with respect to the undercarriage.

The gearbox brakes are holding brakes only.

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. 2-241:).

Track roller temperature – check After traveling for 15 minutes without interruption, stop the hydraulic shovel and check the temperature of the track rollers.

If you use an infrared thermometer, you can measure the temperature from some distance (Fig. 2-242:).

If the temperature is below 70 °C (158 °F):  Continue traveling.

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 spray water on the track rollers from a safe distance. This will rapidly cool down the track rollers.

Fig. 2-241:

Fig. 2-242:

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OPeration Traveling – Best Practices

When traveling down from a steep bench (Fig. 2-243:), lower the bucket so that the distance to ground is about 0.5 m to 1 m (about 2 ft. to 3 ft.).

Travel slowly and in the lower gear mode.

In case the machine tends to tip to the front, lower the attachment to ground and protect the machine from tipping over.

Fig. 2-243:

When crossing the sharp edge of a steep bench upwards or downwards, travel very slowly and let the machine tip over the edge very carefully. Doing so prevents the machine from being damaged when impact on the ground (Fig. 2-244:).

Fig. 2-244:

Traveling in mud and water When traveling through any body of water or mud be careful that the level of water or mud is not higher than the breather valves on top of the final drives (Dimension A, Fig. 2-245:).

Water or mud could enter the gearboxes and cause serious damages.

While you cross any body of water or mud, carefully confirm the depth of the water or mud with the bucket. Do not move the machine into an area that has a water or mud depth that is higher than the breather valves of the final drives (Dimension A, Fig. 2-245:).

Fig. 2-245:

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OPeration Traveling – Restricted Operation

Do not travel the machine longer than 5 minutes with the final drives to the front (Fig. 2-246:).

This will reduce the durability of the undercarriage and the travel system components.

Fig. 2-246:

Do not travel with a filled bucket (Fig. 2-247:).

Fig. 2-247:

Fig. 2-248:

2-138

If traveling down from a steep bench, do not place the bucket on the ground in order to prevent the machine from slipping or tipping (Fig. 2-248:).

The weight of the machine will force the stick cylinders and the bucket curl cylinders over the relief valves causing them to extend into their end stops.

The weight and inertia of the machine pressing on the cylinder – this could lead to overstressing cylinder clevis bolts.

Do not travel too steep ramps. Doing so can exceed the hydraulic capability of the machine. This can cause an uncontrolled state and damage to the machine. Refer to Operation and Maintenance Manual, section “Maximum Machine Inclinations” for information about maximum inclinations.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration

Always ascend the slope at a 90 degree angle (Fig. 2-249:).

Driving across the face of a slope or steering on a slope may cause the machine to slide or tip over.

Fig. 2-249:

Driving across the face of a slope or steering on a slope (Fig. 2-250:) may cause the machine to slide or tip over.

If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

Fig. 2-250:

Do not travel through loose gravel material which could penetrate between rollers and track (Fig. 2-251:). This could result in damaging components of the under carriage.

Tracks may point load on rocks making the machine less stable.

Fig. 2-251:

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OPeration

Do not operate the machine in FAST travel speed unless in appropriate situations (Fig. 2-252:).

Refer to the “Travel Speed – Recommendations – Table“ for further details.

Fig. 2-252:

Do not travel over large rocks or unblasted material. Large rocks can damage components of the under carriage (Fig. 2-253:).

Fig. 2-253:

Do not use the force of the bucket, the stick or the boom to lift and assist in turning the machine while the machine is traveling (Fig. 2-254:).

This technique is referred to as “jump steering”.

Doing so creates the risk of high stress and damage to:  Swing ring and mounting bolts. 

Bucket or shovel front clam and back wall.



Undercarriage components.

For more information about correct turning the machine refer to section “Turning”.

Fig. 2-254:

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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 (next page) are valid for all types of attachment.

If the maximum inclinations are exceeded, there is a risk of severe damage to components due to insufficient lubrication. In the event of extreme inclinations the machine can topple over.

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° / 5.2 %.

Maximum machine inclinations during working operations:

forward inclination

rearward inclination

side inclination

5° / 8.7%

5° / 8.7%

5° / 8.7%

Maximum machine inclinations during traveling: Please contact your Cat dealer.

Maximum machine inclinations during maintenance operations:

forward inclination

rearward inclination

side inclination

0° - 2° / 3.4%

0° - 2° / 3.4%

0° - 2° / 3.4%

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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 "Technical specifications").

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. 2-255:).

Dimensions and weights of the machines modules can be found in the annex, chapter “Product Specification Sheet” as well as in the “„Service Manual“”.

Detailed instructions for disassembling and assembling the machine can be found in the Service Manual.

Fig. 2-255:

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OPeration 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:  Switch on the electric motor.

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 speed.

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OPeration EMERGENCY LOWERING OF THE WORKING EQUIPMENT With the electric-motor not functional, the working equipment can be lowered to the ground as follows:  Sit down on the operator’s seat. Switch inside seat (105, Fig. 2-256:) is activated then.  Switch on the electric system with key-switch (32).  Operate switch (71), hydraulic servo system is activated then.  Operate switch (65, Fig. 2-257:) and hold.  Push control lever (116) forwards to lower the working equipment to ground.  Contact the responsible service personnel as soon as possible.

Fig. 2-256:

Fig. 2-257:

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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.  Stand the working equipment on the ground.  Switch off the electric motor.  Shift both control levers into all directions todepressurize the hydraulic cylinders.  Withdraw the key from the electrical systemkey-switch.  Set the battery main switch to OFF.  Close the cab windows.  Lock the cab doors 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.  Inspect the hydraulic system, the track rollers, support rollers, idlers and gearboxes visually for leaks.

Escaping oil pollutes the environment.

 Repair leaks immediately (or have them repaired).  Report oil accidents to the responsible person.  Check the superstructure, undercarriage and the working equipment for damage and all steel components for cracks or fractures.  Report detected damage immediately to the responsible person.  Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler. .

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OPeration ASSEMBLING WORKING EQUIPMENT – 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 operating 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 gear 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.

When carrying out work on the working equipment, f.ex. on the monobloc boom (Fig. 2-258:), use a fall arrester. Falling down from great hight may cause severe injuries. Connect the fall arrester to the safety line on the boom (arrow, Fig. 2-258:).

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 working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Secure any equipment 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 equipment and component combinations expressly approved by CGM-HMS GmbH for this type of machine.

Never install and commission other equipment 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. 2-258:

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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 equipment must be protected against inadvertent starting by placing chocks under the tracks and by standing the working equipment on the ground.

Secure the machine as described below:  before carrying out any fitting and modification work on the working equipment, 

before carrying out any servicing and repair work on the machine.

    

Park the machine on level and stable ground.

Stand the working equipment on the ground.

Switch off the electric motor.

Depressurize the hydraulic system.

Withdraw the key from the key-switch.

Hydraulic and lubricating systems Close all open bores, pipe and hose connections with pressure-resistant 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.

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OPeration CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) All pins and bearings (bushings and hubs) of the attachment or in attachment components must be treated with "White Assembly Grease" multipur-pose lithium assembly grease before fitting.

Doing so 

permits easy fitting and dismantling,



protects against rust, oxidation and similar wear,



prevents seizing and fretting corrosion in nonmoving parts of bearings.

Part nos: CAT 129-1966 - 14 oz. cartridge CAT 266-9682 - 10 oz. tube CAT 129-1969 - 35 lb. plastic pail

2-148

Application of White Assembly Grease  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 White Assembly Grease 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 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 White Assembly Grease 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 White Assembly Grease on the remaining length of pin shaft, fit pin and secure.

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

OPeration ON-BOARD CRANE (IF EQUIPPED) 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. 2-259:)

Personel 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. 2-259:

Pos. Element 1 Monitoring lamp Warning lamp 2 Warning lamp 3 4 Monitoring lamp 5 Key-switch

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

6 7 8 9

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

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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. 2-260:) supplies the crane with hydraulic power. So the on-board crane is functional without the shovel’s electric motor 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. 2-260:).

In case of emergency push 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. 2-259:) 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 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. 2-260:

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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. 2-261:) 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. 2-261:).  Reinsert and lock the the cotter pin.

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 / DGUV 52), 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.

Fig. 2-261:

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OPeration Monitoring cameras (if equipped) This hydraulic shovel is 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-diplay are operational after the electrical system of the machine has been activated with the key operated switch.

Both cameras transmit their images to the same LCD-display. The display is mounted near the control column.

For toggling between the camera images beeing displayed, press the key in the left joystick (arrow, Fig. 2-262:).

Additional information can be found in the manuals of the camera manufacturer (see Volume 5 of the Technical Documentation “Components”).

2-152

Fig. 2-262:

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OPeration NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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.............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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.............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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OPeration

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Inspection and servicing 3 INSPECTION AND SERVICING 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

3-1

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Inspection and servicing

3-2

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Inspection and servicing SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS WITH ELECTRIC MOTOR Maintenance and inspection work on electrical systems may only be performed by qualified electricians or by workshops employing such personnel.

A qualified electrician for the purpose of this regulation is a person who has the corresponding technical training, know-how and experience as well as knowledge of the pertinent prescriptions and who is therefore in a position to judge the work entrusted to him and the potential dangers in connection therewith.

Before carrying out any maintenance and inspection work on the electrical system, the following precautions must be taken:

In the transformer station

After finishing inspection and maintenance work:

In the transformer station  Disconnect the earthing and short-circuiting line.  Unlock the safety device preventing switch-on; remove the warning sign.  Remove the partitions.  Switch on the supply voltage.

On the hydraulic shovel  Unlock the safety device preventing switch-on; remove the warning sign.  Switch on the circuit breaker, (see the “ Switching on the circuit breaker “ chapter in part 2 of the present Operation and Maintenance Manual).

 Cut out the supply voltage.  Secure against switching on; apply a warning sign.  Check that the electrical system is off circuit.  Connect to earth and short-circuit.  Protect adjacent and live parts against accidental contact.

On the hydraulic shovel  Disconnect the earthing and short-circuiting line.  Withdraw the partition.  Fasten cover.

On the hydraulic shovel  Cut out the circuit breaker (see the “ Switching off the circuit breaker “ chapter in part 2 of the present Operation and Maintenance Manual)  Secure circuit breaker against switching on, apply a warning sign.  Switch off the earthing switch (see manufacturers Operating Instructions).

3-3

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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.

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 a CGM-HMS GmbH mechanic or by attending a CGM-HMS GmbH training course.

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, lubricant, soil, clay, snow, ice and other foreign matter immediately.

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

Always face the machine when climbing on and off.

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 equipment 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.

3-4

Prior to commencing work, clean your working area, if necessary and possible, with a stream jet (rubber parts and electric components with compressed air – refer to information label).

Use only lint-free cleaning rags when working on the hydraulic system.

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.

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OMM 6040AC, 6040ACFS(3 847 037.00)-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,

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 sparts parts of CGM-HMS GmbH .

They are the only ones to fulfill the technical specifications of the machine.

Handling oils and lubricants 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.

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 ist attachments supported on the ground and its electric motor 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,  Switch off the electric motor,  Move all control levers and pedals repeatedly into all directions.

For more detailed information on depressurizing hydraulic sections please refer to the Service Manual, chapter 8.

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 plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

3-5

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Non-polluting disposal

Handling batteries

Dispose of oils, lubricants, 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.

Batteries give off explosive gases.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Do not dispose of these substances together with household wastes.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Fill these substances into the containers provided for such purposes.

Wear gloves, firm protective clothing and goggles when handling batteries.

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

If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor.

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.

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.

3-6

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Selecting oils and lubricants

Oil-level check and oil change

Use the recommended qualities only, matching viscosities with the temperature level.

Position the machine horizontally.

Filters 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 components and the hydraulic units.

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 lubricant film.

On completing work, re-install all protective devices.

Never switch on the electric motor while work is being done on the machine.

Carry out performance tests with the machine.

3-7

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing FIRE AND EXPLOSION HAZARD Safety Instructions Avoid smoking and open fire on, next to and below the machine.

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

Do not store such substances on the hydraulic shovel.

Clean the hydraulic shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air – refer to information label), when, for example, oil, lubricant, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units.

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 may cause fire on the ground that can spread to the hydraulic shovel.

3-8

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Inspection and servicing INSPECTION AND SERVICING PLANS – INSTRUCTIONS Servicing 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 V N

T

Do all jobs …. …once prior to initial commissioning. …after initial commissioning and during the running-in period (after 100 OH). …every 10 OH or every working shift 1)

…every 60 OH or weekly .2 W …after every 500 OH. B …after every 1000 OH. C …after every 5000 OH. D …after every 10000 OH. E OH = Bh = Operating hours

Oils / Lubricants For the specification of oils and lubricants to be used refer to the “LUBRICANTS / CONSUMABLES” section.

The numerals mentioned in the “Oil / Lubricant” column in the inspection and servicing plans have the following meaning: I II IIIa, b V

Oils for combustion engines and compressors Oils for hydraulic systems Oils for gearboxes Lubricants for bearings and swing rings

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

Components The maintenance intervals for components, e.g. electric motor and gearboxes, 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.

2 Whichever comes first.

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Inspection and servicing

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Inspection and servicing Plan V Plan V – Once prior to initial commissioning Page 1 of 2 Location

Servicing work

Electric motor

Lubricate roller bearings (Refer to the information plate mounted at the motor) Check Check Check Check Check Check

-Insulation resistance and polarization index -Fixation -Allignment with coupling and gearbox -Electrical connections -Direction of rotation -Motor controlling and monitoring systems (For more information refer to Electric Motor Manufacturers Operating Instructions) Electrical system Battery

Lighting Terminals Slip ring assembly Switchgear cabinets Monitoring, warning and control elements

Board Control System (BCS) Slewing system (SIL2 machines only) Hydraulic system Pressure accumulators - track tensioning system - hydraulic ladder - pilot system - motor-off attachment lowering - Service Station Hydraulic oil reservoir Hydraulic system Hydraulic cylinders

Pump drive gearbox and cooling circuit - Pre chambers, expansion reservoir Swing gearbox Travel gearbox - Spur gear section - Brake-chambers

Check liquid level (not applicable when maintenance-free batteries build in) Check state of charge Check operation Check for tightness Inspect visually Check for condensation/drain off water 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“)

Quantity/ No.

2

3

Check, fill in the correct nitrogen pressure (see Service Manual, chapter 8)

Check oil level Check pressure (see Service Manual) Vent (see chapter “Hydraulic System - Vent“) Check function of working and traveling movement Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level

1

3 2 2x1 2x2

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Inspection and servicing Plan V – Once prior to initial commissioning Page 2 of 2 Location Swing ring Internal gearing Undercarriage Track roller Upper roller Track tensioning system Idler Central lubricating system Lubricant container Greasing and pause cycles Level control Service – Station (Fast fill arm) -Arm bearing lubricating nipple -Hydr. Cylinder bearing lubricating nipple Air conditioner (if equipped) -Compressor -Refrigerant Hydraulic ladder - Lubricating points On-board crane (if equipped) - Fastening bolts - Bearings - Joint (column / boom) - Cylinder bearing - Swing ring Hydraulic oil reservoir Crane drive engine - Battery

Escape ladder - Locking device - Ladder Fall arrest static line on working attachment (if equipped) All lines, fittings and connections All articutated joints and hinges

3-12

Servicing work

Check lubricant filling Check for leaks and free movement Check for leaks and free movement Check pressure (see Service Manual) Check for leaks and free movement Check filling level Check setting Check function Check operation Lubricate Lubricate

Quantity/ No. 1 2x7 2x2 2 2

1 2

Check oil level Check correct filling (Contact your Cat dealer) Lubricate Check 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 „On-board crane“ documentation in Volume „Components“ Check function Check function Check free movement Check condition Check function Check proper fastening Inspect visually for leaks and wearing marks Lubricate

16 4 2 5 1 1 1 2

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Inspection and servicing Plan N Plan N – After initial commissioning and during the running-in period (after 100 OH) Page 1 of 2 Location Electric motor -Electrical parameters are maintained -Permissible bearing temperatures not exceeded -Smooth running characteristics and machine running noise not deteriorated -Motor foundation (For more information refer to Electric Motor Manufacturers Operating Instructions) Electrical system Medium-voltage cells - mechanical connections - lines - terminals and plug connections Hydraulic system Hydraulic oil cooler - Bearing fastening bolts Return-flow filter Magnetic rod Pressure accumulators -motor-off attachment lowering -hydraulic ladder -track tension system -pilot system -Service Station (Fast fill arm) Pump drive gearbox and cooling circuit - Pre-chambers, expansion reservoir - Gearbox oil filter (cooling circuit) - Fastening bolts Swing gearbox - Fastening bolts

Servicing work

Quantity/ No.

Check BCS monitor Check Check Check for cracks and indentations

Check for tightness Check for tightness Check for tightness

Check for tightness (for tightening torques see “Service Manual”) Replace Clean Check function (see “Service Manual”)

Change oil Change oil Replace Check for tightness (for tightening torques see “Service Manual”) Change oil Check for tightness (for tightening torques see “Service Manual”)

2x7 1

13 1 1

33

3 see “Refilling quantities – Oil“ table

3-13

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Inspection and servicing

Plan N – After initial commissioning and during the running-in period (after 100 OH) Page 2 of 2 Location

Servicing work

Travel gearbox - Spur gear section - Brake-chambers - Magnetic plugs - Fastening bolts

Change oil Change oil Change oil Clean Check for tightness (for tightening torques see “Service Manual”)

Swing ring - Fastening bolts (swing ring, undercarriage and upperstructure) Cable guide for power supply cable - Fastening bolts cable guide / machine Cable reel (if equipped) - Fastening bolts at reel, cable guide, drive motor, switchgear cabinet - Fastening bolts cable reel / undercarriage Undercarriage Fastening bolts - carbody – trackframe, - bottom rollers – trackframe, - top rollers - trackframe Upper structure - Fastening bolts, especially at upper structure / pedestal / operator´s cab All lines, fittings and connections

3-14

Check for tightness (for tightening torques see “Service Manual”) Check for tightness (for tightening torques see “Service Manual”)

Check for tightness (for tightening torques see “Service Manual”) Check for tightness (for tightening torques see “Service Manual”) Check for tightness (see “Service Manual” for tightening torques)

Check for tightness (for tightening torques see “Service Manual”) Inspect visually for leaks, wearing marks

Quantity/ No. 23 2 x 13 2 x 23

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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 2 Location

Servicing work

Quantity/ No.

Plan T

Plan W 

Hydraulic shovel Undercarriage Tracks Track roller Upper roller Idler Cable reel (if equipped) - Fastening bolts at reel, cable guide, drive motor, switchg. cabinet - Fastening bolts cable reel / undercarriage - Cable Service Station (Fast fill arm) Travel gearbox Face shovel -Clam cylinders chambers

Overall cleaning 2 2x7 2x2 2



 

     

Check tightness (see Service Manual)





Visual inspection Inspect visually for leaks and damages Check for leaks

2

  

  

2x1









Inspect track tension visually Check for leaks and free movement Check for leaks and free movement Check for leaks and free movement Visual inspection Check tightness (see Service Manual)

Inspect, remove all accumulated debris, rocks, soil and so on.

Check for wear

-Mechanical stops on face shovels backwall and stick All lines, fittings and connections Inspect visually for leaks and wearing marks Electric motor Listen for unusual machine noise









Hydraulic system





Check function of working and travelling movement Inspect visually for leaks



Hydraulic oil reservoir Oil cooler

Check oil level Check / clean

1 2



 

Fan wheel

Check condition

2





Pump drive gearbox and cooling circuit

Check oil level

1

Oil filter (tell-tale) Swing gearbox

Check for unusual noises or smells, higher teperatures or vibrations. If in doubt, contact your Cat dealer.

Check for excessive dirt and dust, clean to prevent overheating.

Check Check oil level

Central lubricating system Lubricant container Lubricating points

Check filling level Check visually

Gearbox housing

 

 1 4 1



 

 

 

3-15

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 2 Location On-board crane (if equipped)4 Fastening bolts

Crane drive engine

Hydraulic oil reservoir - Reflow filter (contamination indicator) Reservoir for used lubricant at the A-frame Fire extinguisher Escape ladder - Locking - Ladder Operators cab - Window panes - Mirrors - Cameras (if equipped) - ROPS structure - Operators seat belt - Trainers seat belt

Servicing work

Quantity/ No.

Check tightness (see “On-Board Crane“ Operation and Maintenance Manual) Check oil level (see “Crane drive Engine“ Operation and Maintenance Manual) Check oil level Check

16

Check, depollute used lubricant

2x1

Plan T

Plan W 

1

1 1  



Check function Check free movement

 

 

Clean Check / Clean / Adjust Check / Clean / Adjust Inspect visually for damage Check condition Check condition

     

     

Electrical system - Lighting

Check operation





- Electrical components

Visual check

- Switchgear cabinets

Check for condensation/drain water

- Switchgear cabinets breather filters dust traps - Travel Alarm

Remove dust Test





- Horn - CAN-BUS wiring connections - EMERGENCY OFF switches

Test Inspect Check function

 

  

Monitoring, warning and control elements BCS

Check function of monitoring, warning and control elements Check function









Air conditioner (if equipped)

Carry out all service work described in the “Air Conditioning manual“ Check control module









Automatic fire-extinguishing system (if equipped)

4 before each deployment

3-16

Check condition

4

 



3

3



EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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) Page 1 of 6 Location Servicing in acc. with W or T Monitoring, warning and control elements - Joysticks - Control spool, plate, cardan joint - Pedals - Control spool (machine with loading shovel) Electric motor (For more information refer to Electric Motor Manufacturers Operating Instructions)

Terminals Coupling Screwed / bolted connections Operators cab - Fastening bolts to cab module

Servicing work

Menge / No.

Plan Plan Plan Plan Plan A B C D E     

Lubricate lightly

2x45







Lubricate lightly

3x25







 

 

 

Lubricate bearings (Every 12 months at the latest.

See plate with lubricating instructions at the electric motor for detailed information) Check for vibration Visual inspect for degree of dirt deposits and clean.

Visual inspect all accessible places for rust, remove rust.

Check tightness Check for degree of dirt deposits, clean.

Check for alignment and record measurements 6 Check condition and tightness Check for tightness (see Service Manual for tightening torques)

2



 

 



 

 









5 apply a thin layer of low temperature lubricant 6 Check for alignment after every 2000 OH (These are works done by specialists using special tools, please

contact your Cat dealer)

3-17

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 2 of 6 Location

Servicing work

Electrical system Battery cable connections

Check for tightness

Battery

Check fluid level

Menge / No.

Plan Plan Plan Plan Plan A B C D E

2

















Switchgear cabinets - Filter mats

Visual inspection









- Medium-voltage cells

Clean/dry









- Electrical components

Check for tightness









Slip ring assembly

Visual inspection, if neccessary clean inside from wear debris and lubricant.

(See Slip ring manufacturer´s servicing instructions) Check for wear Replace if worn out up to max.

1/3 of the original length Check for tightness



















 

- Brushes

Mechanical components Switchgear cabinets

























 

 

 

 

  

  

 

 





   





- Breather filter - Filter element

Clean Replace

Cable reel (if equipped) Contact rings and brushes of slipring assy.

Brushes of slipring assy.

Position switches - Driving chain pos. switches

Drive motor - Drive motor gearbox Driving chain reel All bolted connections

3-18

Visual inspection Check for wear, replace if excessive worn Replace Check adjustment Check for contamination, clean and re-lubricate if neccessary Check condition Check brake function Change oil Check condition and tension, replace if damaged Check, re-tighten with torque wrench (see also the Technical manual of the supplier)





EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 6 Location

Servicing work

Hydraulic system

Menge / No.

Plan A

Plan B

Plan C

Plan D

Plan E

Check pressure (see Service Manual)







- Fastening bolts

Check for tightness







- Rubber bearing

Check condition







Return-flow filter

Replace













Oil cooler - Bearing

2x7 2



- Magnetic rod

Check / clean

- Bypass valve

Check / clean filter sieve

2x3







- O-Ring of filter chamber cover

Replace

2x1







- Return-flow filter

Replace

2







- Bypass valve

Check / clean filter sieve

2









Filterhousing (cooling circuit)

- Magnetic rod

Check / clean

1





High-pressure filter (working hydraulics)

Replace

4





Filter (pump control circuit)

Replace

2x1





Filter (servo circuit)

Replace

1





Filter (swing charge pump)

Replace

2x2





Hydraulic oil reservoir

Carry out oil analysis

1





Change oil

178







- Breather filter

Replace

2







Pressure accumulator

Check pressure (see Service Manual)

5







Cylinder (seals and guide rings)

Replace



7 see “Refilling quantities – Oil“ table 8 Unless it is regulary analyzed,

the hydraulic oil must be changed every 5000 OH or after 3 years at the

latest

3-19

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 4 of 6 Location

Servicing work

Pump drive gearbox and cooling circuit

Carry out oil analysis

- Expansion reservoir - Breather filter Gearbox oil filter (cooling circuit) Swing gearbox - Breather filter Travel gearbox

- Magnetic plug Spur gear section - Magnetic plug Brake-chambers Breather filter

Change oil Check oil level Clean / Replace Replace Carry out oil analysis Change oil Replace Carry out oil analysis Check oil level Change oil Clean Check oil level Change oil Clean Check oil level Change oil Clean / replace

9 see “Refilling quantities – Oil“ table

3-20

Quant./ Plan Plan Plan Plan Plan No. A B C D E     1   

   

   

 

    



 



 

            

            

19 2 2 1 3 39 4 2 2 29 2x6 2x1 2x19 2x1 2x2 2x29 2x3





EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 lubricant filling Check condition Check for tightness (see Service Manual)

Menge / No. 1

Page 5 of 6 Plan Plan Plan Plan Plan A B C D E          

- Diaphragm

Replace first after 40000 OH, then every 10000 OH (see Service Manual) Check wear (see Service Manual) Check pressure (see Service Manual) Replace

Central lubricating system

Check function

Oilfilter (hydraulic circuit lubricant pump) Lubricant filter (filling lubricant container) Lubricant filter (lubricating lines) Breather filter

Replace

1





Replace

1





Replace

2





Check / replace

1

























Undercarriage Diaphragm accumulator

Air conditioner (if equipped) - Filter mats

Carry out all service work described in the “Air Conditioning manual" Clean / replace if damaged

Hydraulic ladder - Central lubricating point

Lubricate

2





















2x1 



1





3-21

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 6 of 6 Location On-board crane (Option) 10 - 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

Modules – Fastening bolts All articulated joints and hinges

Servicing work

Lubricate Lubricate Lubricate Lubricate Change oil Replace Replace see “On-Board Crane“ Operation and Maintenance Manual Clean Change oil Replace Check for tightness Replace Replace Check for tightness see “Crane Drive Engine“ Operation and Maintenance Manual Visual inspection acc. to “Structural Inspection Report every 500 OH” 12 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.

Check for tightness (see Service Manual) Lubricate

Menge / No.

Plan Plan Plan Plan Plan A B C D E

4 2 5 1 1 11 1 1 















































1 1 11 1 1 1 1 2

10 Do all servicing jobs at least once a year and when necessary 11 see “Refilling quantities – Oil“ table 12 „Structural Inspection Reports“ for inspections every 500 OH can be downloaded from the SISWeb, Me-

dia-Id-No.BI644777.

3-22

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing

3-23

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing LUBRICATING CHART – LUBRICANT

Fig. 3-1:

3-24

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Lubricating chart – Lubricant (legend) No. Greasing point 1 2 3

Central lubricating system – lubricant container Hydraulic ladder, central greasing point Electric motor, bearings

Number

Lubricant properties

1

V 13

1 2x1

1000 See plate with lubricating instructions attached to the electric motor for detailed information.

250

V 13 5

6

On-board crane

Lubricate every .... operating hours 10

V 13

- Bearing

4

250

- Joint (column / boom)

2

250

- Cylinder bearing

5

250

- Swing ring Monitoring, warning and control elements

1

Graphitspray

250

- Joystick

2 x 4 14

V 13

1000

- Pedal

3 x 2 14

1000

All other greasing points are supplied with lubricated by the central lubricating system.

Filling quantities – Lubricant Greasing point

Lubricant properties

Central lubricating system – lubricant container (Depending on the ordered system the volume may vary)

Internal gearing – Roller-bearing swing ring

V 13

Idler (permanent lubricant filling) Track rollers (permanent lubricant filling) (optional: rollers supported with lubricant via the central lubrication system for the undercarriage) Upper rollers (permanent lubricant filling)

Tribol CGM-HMS GMBH part no. 4027185

Filling quant. in kg lb appr. 180 to 1000 litres appr. 300

appr. 47.5 to 264 gal appr. 661

2 x appr. 25

2 x appr. 55

14 x appr. 15

14 x appr. 33

4 x appr. 14

4 x appr. 31

13 see "LUBRICANTS / CONSUMABLES" section 14 apply a thin layer of low temperature lubricant

3-25

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-2:

3-26

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Inspection plan – Oil (legend) No. Location

Number

Lubricant properties 15

II

1

Hydraulic system

1

2

Pump drive gearbox and cooling circuit Pre-chambers, expansion reservoir Swing gearbox

1

2 3

1 3

4, 6 Travel gearbox - Pre-chamber / spur gear section - Brake-chambers 5

III.a III.b

2 2x1

III.a

2x2

Check oil level every ... OH 10

Change oil every ... OH 10000 16

60

1000

10

1000

10

1000

500

5000

500

5000

500

5000

10

250 17

10

1000 18

On-board crane (if equipped) - Crane drive engine

1

- Hydraulic oil reservoir

1

I II

15 see "LUBRICANTS / CONSUMABLES" section 16 Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every

3 years.

17 Change oil at least once a year.

18 Change hydraulic oil at least once a year.

3-27

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Filling quantities - oil Location

Filling quantity

Oil

litres

gal

Hydraulic oil reservoir Hydraulic system Pump drive gearbox - Pre-chambers, expansion reservoirs Swing gearbox

appr. 4000 appr. 6400 appr. 149 1 x appr. 10 3 x appr. 38

appr. 1057 appr. 1690.7 appr. 39.4 1 x appr. 2.6 3 x appr. 10

Travel gearbox - Spur gear section - Pre-chambers On-board crane (if equipped) - Crane drive engine

2 x appr. 80 2 x appr. 10 4 x appr. 0,3

2 x appr. 21.1 2 x appr. 2.6 4 x appr. 0.08

appr. 5.5

appr. 1.45

appr. 50

appr. 13.2

- Hydraulic oil reservoir

II III.a III.b III.a I II

Filling quantities - other Location

Filling quantity litres

gal

Fuel tank, crane drive engine (if equipped)

appr. 20

appr. 5.3

Screen washer

appr. 13

appr. 3.4

3-28

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing LUBRICANTS Notes on the selection of oils and lubricants Original CGM-HMS GmbH oils and lubricants Besides regular and careful maintenance, the quality of the oils and lubricants 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 lubricants that are approved for use in CGM-HMS GmbH machines. These oils and lubricants are especially adapted to CGMHMS GmbH machines and their units and assemblies.

Other oils and lubricants 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 lubricants.

All other qualities are not approved.

CGM-HMS Hydraulic Fluid Caterpillar is not in a position to evaluate the many types of fluids promoted by other manufactures and their effect on Caterpillar products. The use of these products is at the discretion of the customer who assumes all risks for the effects that result from this usage.

The CGM-HMS Hydraulic fluid that is provided as a factory fill for the HMS has been evaluated for fluid compatibility when adding or topping off with the Caterpillar HYDO Advanced product. The 2 fluids are compatible and can be used. Follow the maintenance interval schedule and for fluid sampling that is stated in the Operation and Maintenance Manual for your machine. To have the full benefit of the properties of either fluid the cross contamination should be kept to 10% or less. With a greater cross contamination the full benefit of either of the fluids may not be realized so it is important to monitor the fluid properties regularly. For additional details about Cat HYDO Advanced and Caterpillar’s fluids recommendations, please refer to Special Publication SEBU6250, “Caterpillar Machine Fluids Recommendations” and publication EM027744, “Fluid Specifications HMS” which may be found on the Web at SIS.Cat.com.

Although the lab testing has shown compatibility between the BM Hydraulic fluid and the Cat Hydo Advance, we are not able to test every situation and condition with the fluid mixtures and would recommend that the fluid be changed out to eliminate any fluid incompatibility issues.

Alternative oils and lubricants The oils and lubricants 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 lubricants that are not compatible with CGM-HMS GmbH specifications, CGM-HMS GmbH does not assume any responsibility and does not accept any warranty claims.

3-29

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing LUBRICANTS / CONSUMABLES I. Oil for combustion engines (On-Board Crane, if equipped)

Fig. 3-3:

3-30

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing

II.

Oil for hydraulic system (selection)

Fig. 3-4:

3-31

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing III.a Oil for pump gearboxes and travel gearboxes

Fig. 3-5:

3-32

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing III.b Oil for swing gearboxes

Fig. 3-6:

3-33

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing V. Lubricant for bearings, swing rings and track system (Central lubrication system)

Fig. 3-7:

3-34

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Lubricants for idlers, track rollers and upper rollers (Lifetime lubrication)

Fig. 3-8:

3-35

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing SERVICING WORK Hose line for oil changes Collect escaping oil and cooling liquid and discard without polluting the environment.

The the swing gearboxes are equipped with automatic drain valves (1, Fig. 3-10:) These automatic drain valves permit oil 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 is can be done by means of a hose through the service station (Fig. 3-9:).

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. 3-9:

3-36

Fig. 3-10:

Change oil as follows:  Place a collecting recipient for used oil under the corresponding automatic drain valve. For the recipient capacity refer to the "Re-filling quantities - Oil" table or to the "Refilling quantities - Other" table.  Unscrew protective cap from automatic drain valve.  Screw on hose line (2) to open the valve, so that the oil or the cooling liquid can flow out.  When the oil has drained away, unscrew hose line to allow the valve to close automatically.  Screw protective cap back in place.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing ELECTRIC MOTOR Electric motor - Safety instructions Read and observe: "Inspection and Servicing – Safety Instructions" and the electric motor manufacturers Operation and Maintenance Manual.

Secure the machine as described in the "Securing the machine" section.

Wear protective gloves and firm working clothing.  Switch off electric motor, to do so actuate switch (42, Fig. 3-11:).  Set servicing switch (4, Fig. 3-12:) to locked position and secure in this position with a padlock.

Electric motor – Clean

Fig. 3-11:

When cleaning with compressed air deposited dust and loose parts can be whirled up and may cause injuries.

Always wear your personal protection equipment like protective suit, goggles, respiratory protection, gloves etc.

Use a vacuum cleaner to extract dust.

The cooling ducts must be free of any pollution in order that the machine is adequately cooled.

Regularly clean the grids, ducts, ribs, pipes etc. to remove dust and pollution.

Clean the electric motor, the cooling fins, bearing shields and ventilators from dust with compressed air, brushes and clothes only.

Remove the fan guard before cleaning the ventilator fan. Install it after cleaning.

Don't damage the protective coating while cleaning the electric-motor.

For more information see the manufacturers manual for the electric motor.

Fig. 3-12:

It is not permissible to clean the electric motor or any live hydraulic shovel components with a steam cleaner and steam jet.  After finishing work on the electric motor remove the padlock from servicing switch (4, Fig. 3-12:) and unlock.

3-37

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Electric motor - Lubricate Risk of serious injury or death.

During lubricating the bearings the electric motor must be switched on.

Be extremely careful to all rotating parts.

Secure the machine as described in the "Securing the machine" section.

Wear protective gloves and closefitting, firm work clothes.

Read and observe: "Inspection and Servicing – Safety Instructions" and the electric motor Operation and Maintenance Manual.

Lubricate the bearings of the electric motor in regular intervals (see plates on the electric motor, sample is shown in Fig. 3-13:) but every 12 months at the latest.

In the case of unfavorable operating conditions, the regreasing intervals must be reduced after consultation with the manufacturer.  Clean the grease nipples before lubricating.  Start machine and have motor idling.  Press in the correct quantity of lubricant specified on plate (Fig. 3-13:).  The used grease collects outside each bearing in a spent grease chamber.  When the electric motor is at standstill, remove the old, used lubricant from the grease chamber.

Up to 30 minutes after greasing the temperature of the bearings might heavily increase. Thereafter the temperature decrease to normal. This is normal, the procedure is monitored on the BCS display.

Lubricating roller bearings prior to commissioning (Initial Lubrication) When properly stored prior to commissioning for a longer period of time, normally the grease in the bearings does not deteriorate within two years.

Please note the information regarding long-term storage.

When commissioning, the bearings must be relubricated with twice the amount of lubricating grease. When doing this, the shaft must rotate so that the grease is replaced in the bearings.

3-38

Fig. 3-13:

Removing spent grease If the specifications on the lubricant plate are observed, the spent grease chamber will provide capacity for a calculated service life of at least 40 000 operating hours, approx. five years. When the spent grease chamber is full, the spent grease must be removed prior to relubrication. This is indicated by the fact that during relubrication, oil or grease escapes at the bearing cover.

Note: If the spent grease is not removed, then the roller bearings become too hot and can seize up as the grease distribution mechanism is disturbed.  To remove the spent grease, loosen the outer bearing cap.

Additional servicing work Additional information on servicing the electrical motor is given in the electric motor Operation and Maintenance Manual from the motor manufacturer.

All servicing and maintenance work not described here are carried out by your Cat dealer resp. by the Service Dept. of the manufacturer of the electric motor. (See electric motor Operation and Maintenance Manual).

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing ELECTRICAL SYSTEM Electrical system - Safety instructions Read and observe the "Inspection and servicing – Safety instructions" chapter.

Interrupt electrical circuits with the circuit breaker before start working on the electrical system. All electric lines upwards from the circuit breaker are then without voltage (refer to the "Safety instructions for hydraulic shovels with electric motor" at the beginning of this chapter).

Before starting live-line servicing work e.g. measuring and testing with voltage applied, press switch (4, Fig. 3-14:) and secure it with a padlock.

Now voltage is supplied to the whole system but the electric motor can not be switched on.

This prevents accidents, inadvertent starting of the electric motor, and short circuits.

The 24V circuits are energized by the two batteries when the circuit breaker is switched off. These lines can also be de-energized with the battery main switch. Shut off the electrical system with the battery main switch when carrying out repair work or during prolonged downtimes of the hydraulic shovel.

Gas-discharge lamps in Xenon working lights are operated with high voltage. Refer to chapter: “XENON floodlight projector (If equipped) – Replace the lamp”.

Risk of injury caused by battery acid and gases.

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. The electrical circuit diagrams are annexed to the spare-parts list. Further information can be found in the CGM-HMS GmbH Service Manual "Working with circuit diagrams".

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Fig. 3-14:

3-39

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Battery, checking state of charge Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

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. 3-15:).  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.

Note: If the machine is used in regions with particularly high outside temperatures, the liquid level as well as the charging state of the batteries must be checked at shorter intervals than specified in the maintenance schedule.

Fig. 3-15:

3-40

Checking charge of the battery The acid temperature must be 20 ° C / 68°F.  Unscrew caps of the battery (Fig. 3-15:).  Measure the acid density of the battery using a commercial acid tester (Fig. 3-15:).

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

On closed / sealed (so called „maintenance-free“) batteries, the charging status can be checked using a charge meter. Ask your Cat dealer for assistance.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Charging the batteries The batteries are charged by the battery charger only if the electrical system with the circuit breaker is switched on.

The batteries (1, Fig. 3-16:) are located in the pedestal (cab module). The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

Removing and installing the battery Read and observe the "Inspection and servicing – Safety instructions" chapter.

Wear protective gloves and firm working clothing.

Switch off the electric motor before removing the batteries.

Turn key in key-switch to position "0" and withdraw.

Set battery main switch to “OFF“ position.

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

Fig. 3-16:

 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 lubricant or acid-free vaseline on the battery terminal posts and clamping lugs. Loose or corroded clamping lugs will lead to alternator or regulator overloading.

3-41

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Electrical system, control cabinets The electrical system control cabinets are located in the cab module and in the motor compartment.

The cabinets are described in the spare-parts list (electrical circuit diagram) together with the designation of the electrical components.

Breather filter In the control cabinets  For the 6000 V - 7200 V power supply, 

For the 400 V system,



For the 24 V system,

Fig. 3-17:

the air is drawn in and cleaned by a ventilator with filter.

Emptying the dust trap  Press dust trap (14, Fig. 3-17:) and hold until the dust trap is empty.

Emptying the dust collector  Loosen clips (11, Fig. 3-17:).  Remove dust collector (12) and empty.

Filter element, clean / replace    

Remove dust collector (12, Fig. 3-17:).

Withdraw filter element (13, Fig. 3-18:).

Replace or clean filter element (13).

Refit dust collector (12, Fig. 3-17:).

 Supply voltage depends on the individual configuration of the shovel. Please refer to the data plate of the electric motor.

3-42

Fig. 3-18:

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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. 3-19:). 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. 3-20:) dry with compressed air by moving the compressed-air piston up and down inside it.

The pressure at the nozzle must not exceed 3 bars / 43psi.

Cleaning is completed when no more dust is seen to leave the filter element.

Fig. 3-19:

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.

Replacing filter mats

Fig. 3-20:

A filter mat is installed in the control cabinets behind the cover (4, Fig. 3-21:.  Check filter mats visually and replace if necessary.

Draining water from the switchgear cabinet  Check control cabinets for condensation.  Unscrew drain plugs and drain off water.

The base of the control cabinets must be kept clean.

Fig. 3-21:

3-43

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Slip ring assembly, servicing work (Fig. 3-22:) Danger of electrocution.

Switch off the power supply at the transformer station. Block it to prevent unauthorized reconnection.

Check that the slip ring assembly is without tension before opening it.

Read and observe the "Inspection and servicing – Safety instructions" chapter as well as the chapter “Electrical system, safety instructions”.

Observe the Servicing Instructions of the slip ring manufacturer.  Remove all tracks of dirt.  There is a transparent sideplate at the housing. Check the housing inside for wear debris coming from the brushes and for lubricant.

Remove if necessary.  Clean insulators and check for damage.  Check condition of slip ring contact surfaces; remove any sign of oxydation, "splatter" or burn spots.  Check carbon brushes for signs of wear.

(See Servicing Instructions of the slip ring manufacturer for more detailed information).

Fig. 3-22:

3-44

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 Service Manual "Working with circuit diagrams".

Replacing fuses 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.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Xenon floodlight projector (if equipped), 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 lubricant 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.

3-45

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Replacing a defective Xenon-lamp Read and observe the: „Floodlight projector, replacing the lamp, Safety Instructions“.

Fig. 3-23

Fig. 3-24

Fig. 3-25

3-46

 Switch off the projector, shut off the electric motor 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. 3-23) and withdraw the reflector (2) from the projector housing.  Withdraw connector (Fig. 3-24) from Xenon lamp socket.  Unscrew Xenon lamp holding clamp (Fig. 3-25).  Remove the defective Xenon lamp and replace by a new one. Do not touch the glass bulb of the lamp.  Reinstall the new lamp. Screw lamp holding clamp back in place.  Plug the power supply connector onto the lamp.  Re-assemble the housing.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Lighting systems in LED technonogy, instructions The lights of the maintenance lighting system (Fig. 3-26) as well as the working floodlights (Fig. 3-27) 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. 3-26

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. 3-27

3-47

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing HYDRAULIC SYSTEM Hydraulic system - Safety instructions Read and observe the "Inspection and servicing – Safety instructions" chapter.

Switch off the electric motor.

Secure the machine as described in the "Securing the mmachine section.

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated.

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

Wait until the hydraulic system is cooled down to moderate temperature before starting work.

Contact with hydraulic oil can cause skin injury.

Avoid skin contact with hydraulic oil.

Wear protective gloves and firm working clothing.

Depressurizing the hydraulic system 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. 3-28: and Fig. 3-29:) and with its electric motor switched off, 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:

Fig. 3-28:

Fig. 3-29:

 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.

3-48

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Examples of system sections: 1) working hydraulics 2) servo control circuit 3) precharged return-flow line Depressurizing:  Park the hydraulic shovel on a horizontal surface.  Set the attachment on the ground.  Switch off the electric motor.  Do not switch off the electrical system, sit down on the operator's seat, Sections 1 and 2: servo control and working hydraulics:  Shift both control levers and all pedals repeatedly into all directions (Fig. 3-30:).

Checking the hydraulic oil level  Bring hydraulic oil to operating temperature (abt. 50 °C / 122°F).  Park the machine on a horizontal surface.  Stand attachment on the ground as shown on signs (2, Fig. 3-31: and Fig. 3-33:).

The oil level must be between the “min” and “max” marks of the signs (2, Fig. 3-31:) near the level indicator tube (1).

Fig. 3-31:

Fig. 3-30:

The hydraulic oil level is monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-31:) if the hydraulic oil level is too low or too high. In this case: Switch off the electric motor, locate cause and rectify.

Section 3: return-flow line After switching off the electric motor, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

Fig. 3-32:

3-49

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing

Fig. 3-35:

Hydraulic oil can also be filled in by means of the service station (Fig. 3-36:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station”.

Fig. 3-33:

Stand attachment on the ground as shown on the signs (Fig. 3-33:).

The signs (2, Fig. 3-34:) are attached beside the level indicator tube (1).

 Unscrew cap of express coupling (10).

Connect filling hose of the service vehicle to the express coupling.  Fill in hydraulic oil until the oil level is between the “min” and the “max” marks of the sign (2, Fig. 3-34:) beside the level indicator tube.

(Oil grade see "LUBRICANTS / CONSUMABLES" section).

The acoustic warning signal “Travel Alarm” sounds.  Disconnect the filling hose; the express coupling closes automatically.  Screw protective cap back in place

Fig. 3-34:

Fill in hydraulic oil through the return-flow filters.  Remove cover (19, Fig. 3-35:).  Fill in hydraulic oil through the opening until the oil level lies between the ½ and the ¾ marks of the inspection glass.

(Oil grade see "LUBRICANTS / CONSUMABLES" section).  Before fitting the cover (19), check the sealing ring and replace, if damaged.  Fit cover together with sealing ring.

3-50

Fig. 3-36:

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Hydraulic oil return-flow 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.

Remove return flow filter elements  Remove covers (3, Fig. 3-39:) 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 electric motor.

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 (arrow, Fig. 3-38:). In this case, the filter elements (9, Fig. 3-39:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-38:

Fig. 3-37: Fig. 3-39:

3-51

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Install return flow filter elements  Insert new filter elements (9, Fig. 3-40:) 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. 3-41:).

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).

Fig. 3-40:

Remove filter-basket, inspect / clean If you found one of the return flow filter elements (9, Fig. 3-41:) 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 remove washers (15) 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.  Reinsert the filter-baskets (12).  Place brackets (14) in the correct position and screw in bolts (13) together with washers (15).  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”.

3-52

Fig. 3-41:

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Hydraulic oil return-flow filters, replace (from machine no.

170138) 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. 3-44:) 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 electric motorr 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 (arrow, Fig. 3-43:). In this case, the filter elements (9, Fig. 3-44:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-42:

Fig. 3-43:

Fig. 3-44:

3-53

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Install return flow filter elements  Insert new filter elements (9, Fig. 3-45:) 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. 3-46:).

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).

Fig. 3-45:

Remove filter-basket, inspect / clean If you found one of the return flow filter elements (9, Fig. 3-45:) 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”.

3-54

Fig. 3-46:

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Bypass valves, 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 electric motor.

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.

Fig. 3-47:

Cleaning the filter screens  Remove covers (3 and 4, Fig. 3-47:) together with sealing rings.  Unscrew bolts (25, Fig. 3-48:). Withdraw bypass valve. Take off screen (21) 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 (28) for damage and replace, if required.  Insert bypass valve and fasten with bolts (25).

Fig. 3-48:

Replacing the bypass valves and sealing rings  Remove bypass valve as described under "Cleaning the screens".  Re-assemble the bypass valve with a new screen (21, Fig. 3-48:) and a new sealing ring.  Insert bypass valve with new sealing ring (243) and fasten with bolts (25).

3-55

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 electric motor.

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.

Replacing the filter elements Two breather filters (Fig. 3-49:) 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 (21, Fig. 3-49:) and remove holding brackets (22).  Withdraw filter elements (20).  Check foam rings on top of filter elements, replace if damaged.  Attach new filter elements (20) with foam rings to their cylindrical connections  Install holding brackets (22) using bolts (21).

Fig. 3-49:

3-56

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Filter (servo control circuit), replace 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.  Shut off the electric motor.  Depressurize the hydraulic system.  Clean the filter housings as well as the immediate vicinity carefully.  Dispose of waste oil, used filters and oilstained cleaning rags properly and separated from other waste.

Replacing the filter element To filter the hydraulic oil in the control circuit, the machine is equipped with a high-pressure filter (9, Fig. 3-50:).

Change filter element regulary and when the BCS indicates a contamination.  Place a suitable collecting recipient under the filter housing (Fig. 3-50:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Unscrew filter housing (5, Fig. 3-51:) by counterclockwise rotation. Pour out the oil.  Withdraw filter element (6) from filter housing (5).  Check filter housing (5) as well as used filter surface for debris.  Clean filter housing (5) and the sealing face at the filter head with white spirit or paraffin oil.  Check seals (8) and replace, if required.  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 high-pressure filters for leaks after putting the hydraulic system back into operation.

Fig. 3-50: Fig. 3-51:

3-57

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing High-pressure filter for working hydraulics, replace To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with four high-pressure filters (arrows, Fig. 3-52:).

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.  Shut off the electric motor.  Depressurize the hydraulic system.  Clean the filter block and the filter housings carefully.  Dispose of waste oil, used filters and oilstained cleaning rags properly and separated from other waste.

Replacing the filter elements  Place a suitable collecting recipient under the filter housings (Fig. 3-52:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Unscrew drain plug (11, Fig. 3-53:) by counterclockwise rotation. Pour out the oil.  Disengage filter element (15) with a slight turn from the centering spigot in the filter head.  Check filter housing (9) as well as used filter surface for debris.  Clean filter housing (9) and the sealing faces at the filter head with white spirit or paraffin oil.  Check sealing ring (13) and support ring (14) on the filter housing for position and damage.

Replace, if necessary.  Install the new filter element (15) with a new seal (10) on the spigot again by slightly turning it.  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 filters for leaks after putting the hydraulic system back into operation.

Fig. 3-53:

Fig. 3-52:

3-58

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Filters for swing charge pump, replace The hydraulic shovel has three high-pressure filters (9, Fig. 3-54:) for the feeding circuits of the swing pumps. The filters are installed in front of the hydraulic oil tank.

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.

Replacing the filter elements  Place a suitable collecting recipient under the filter housings (Fig. 3-54:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Detach flange (4, Fig. 3-55:).  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.  Install new filter element (6, Fig. 3-55:) and reassemble with a new, lightly oiled sealing ring (7).  Check the high-pressure filter for leaks after putting it into operation.

 Shut off the electric motor.  Depressurize the hydraulic system.  Clean the filter housings as well as the immediate vicinity carefully.  Dispose of waste oil, used filters and oilstained cleaning rags properly and separated from other waste.

Fig. 3-55:

Fig. 3-54:

3-59

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing High-pressure filters for the servo circuit, replace The servo circuit is equipped with two highpressure filters (9, Fig. 3-55:).

The filters are located at the hydraulic oil reservoir.

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.

Replacing the filter element  Place a suitable collecting recipient under the filter housings (Fig. 3-54:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Detach flange (4, Fig. 3-55:).  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.  Install new filter element (6, Fig. 3-55:) and reassemble with a new, lightly oiled sealing ring (7).  Check the high-pressure filter for leaks after putting it into operation.

 Shut off the electric motor.  Depressurize the hydraulic system.  Clean the filter housings as well as the immediate vicinity carefully.  Dispose of waste oil, used filters and oilstained cleaning rags properly and separated from other waste.

Fig. 3-57: Fig. 3-56:

3-60

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Changing the hydraulic oil Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the electric motor.

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 electric motor 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 (see chapter “Avoid mixing of different hydraulic fluids” for more information).

Oil grade see “LUBRICANTS / CONSUMABLES” section.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with CM Long Term Hydraulic Fluid HSS (Part-No. 4211882). CGM-HMS 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 assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-61

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Draining off hydaulic oil using the Service Station

Cleaning the hydraulic oil reservoir Explosion hazard.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

The hydraulic oil can also be drawn off through the service station (Fig. 3-58:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station”.  Bring hydraulic oil to operating temperature (ca. 50° C / 122°F).  Retract hydraulic cylinders as far as possible and stand attachment on the ground.  Switch off the electric motor.  Unscrew cap of express coupling (10).  Connect hose line of the service vehicle.  Drain oil.  Remove hose line. The coupling closes automatically.  Screw on protective cap.

Use only diesel fuel or a special flushing oil for cleaning the hydraulic tank.

Skin contact with hydraulic oil, diesel fuel or special flushing and cleaning fluids may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Dispose of contaminated hydraulic oil, diesel fuel or special flushing and cleaning fluids without polluting the environment and separately from other waste.  Drain off hydraulic oil as described under "Draining off the hydraulic oil using the Service Station".  Remove caps (3,4, and 5, Fig. 3-59:).  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 caps (3, 4 and 5).

Fig. 3-58:

Fig. 3-59:

3-62

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Filling in hydraulic oil using the service station  Fill in hydraulic oil by means of the service station (Fig. 3-60:).

The use of the hose line is described under "hose line for oil changes".  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 on the sign (2, Fig. 3-61:) near the inspection glass (1).

(Oil grade see "LUBRICANTS / CONSUMABLES" section).  The oil level is also displayed on the BCSscreen (Fig. 3-62:).  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.  Screw protective cap back in place.

Fig. 3-60:

Fig. 3-61:

Fig. 3-62:

3-63

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Filling in hydraulic oil through the return-flow filters.  Remove cap (19, Fig. 3-63:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks on the sign (2, Fig. 3-64:) near the inspection glass (1).

(Oil grade see "LUBRICANTS / CONSUMABLES" section).  Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir.

Top up with oil, if required.  Refit cap (19, Fig. 3-63:).

Fig. 3-63:

Fig. 3-64:

3-64

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Venting the hydraulic system 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.

Venting the hydraulic components 

Hydraulic pumps and hydraulic motors (with electric motors shut off).

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of 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.



Fig. 3-66:

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. 3-65: and Fig. 3-66:) must be either completely retracted or completely extended.

Always admit oil first to that side of the cylinder where the piston (2) is. This is  the piston-side port (3) when the piston rod is retracted (1, Fig. 3-65:),  the rod-side port (4) when the piston rod is extended (1, Fig. 3-66:).

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: Always vent only the system section that has been opened.



the travel brake valve at the venting screw,



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 screw (with drive motors stationary).

Fig. 3-65:

3-65

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

Switch off the electric motor.

Never start cleaning work until the cooler fan blades have stopped turning.

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. 3-67:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C / 140°F.

Cleaning The hydraulic oil coolers are located in the oil cooler module.

Clean the hydraulic oil coolers at regular intervals.  Switch off the electric motor  Remove any accumulated dirt.  Clean the fan blades (2).  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. 3-67:

3-66

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Electronic hydraulic shovel control Joystick At regular intervals acc. to the maintenance plans:  Loosen gaiter and move upwards.  Apply a thin layer of low temperature gre on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-68:) to prevent jamming of the joysticks.  Refit gaiter using a cable strap.

Pedal At regular intervals acc. to the maintenance plans:  Remove old lubricant and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-69:).  Apply a thin layer of low temperature lubricant on the control spools of the pedals to prevent jamming of the control spools.

Fig. 3-69:

Fig. 3-68:

3-67

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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. 3-70:).

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. 3-70:

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

3-68

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.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing PUMP DRIVE GEARBOX Risk of scalding caused by hot gearbox oil. The gearbox housing may be hot too.

Shut off the electric motor.

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.

Read and observe: "Inspection and servicing Safety instructions.

Secure the machine as described in the "Securing the machine" section.

Details for selecting the correct gearbox oil refer to chapter “LUBRICANTS / CONSUMABLES”.

Fig. 3-71:

Pump drive gearbox, checking oil level / Topping up with oil Check oil level only when gearbox is cold. Heated oil may result in inaccurate measurements.

Observe the information decals attached to the gearbox housings near the dipsticks.  Screw out and wipe dipstick (1, Fig. 3-71: and 1, Fig. 3-72:).  Insert dipstick (1) again until the thread lies on top of the dipsticks tube (2, , Fig. 3-72:).

Do not screw in.  Withdraw dipstick again and check oil level.

The level should reach up to between the “min” and “max” markers on the dipstick.  Top up with oil if required through the plug of filler tube (arrows, Fig. 3-73:).

(Oil grade see: “LUBRICANTS / CONSUMABLES”).  Screw in dipstick (1) again.

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.

Fig. 3-72:

3-69

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Topping up with oil  Screw out plug of filler tube (arrows, Fig. 3-73:).  Fill fresh oil through the filler tube.

(Oil grade see: “LUBRICANTS / CONSUMABLES”).  Check oil level.  Fit plug again.

Fig. 3-73:

3-70

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Pump drive gearbox, changing 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.

Recommendation: If the gearbox oil is heavily soiled, the gearbox should be flushed with fresh gearbox oil. In this case contact your Caterpillar dealer.

Drawing off gearbox oil The gearbox oil is drained with the service station (Fig. 3-74:) through express coupling (5).  Unscrew protective cap of express coupling and connect hose line of the service vehicle.  Drain gearbox oil.  Remove hose after the oil has been drained.

The coupling closes automatically.  Screw on protective cap.

Fig. 3-74:

Filling in gearbox oil (Oil grade see: „“LUBRICANTS / CONSUMABLES”).  Fill in gearbox oil with the service station (Fig. 3-74:).  Unscrew cap of express coupling (5).  Connect hose line of service vehicle.  Fill in gear oil until the oil level reaches the „max“ mark on dipstick (1, Fig. 3-68).  Remove filling hose after the oil has been filled in. The express coupling closes automatically.  Screw on protective cap.  Start electric motor and run for maximum two minutes, then shut off motor.

The pump drive 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 (approx. after one hour) Top up with oil if necessary through the plug of filler tube (arrows, Fig. 3-73:).

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 accumulated there to lubricate the slined 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.

Fig. 3-75:

3-71

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Pump drive gearbox, prechamber Checking oil level, topping up with oil The oil level in the pre-chambers is visually at the inspection glas (3, Fig. 3-76) in 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.

Pump drive gearbox, venting The gearbox is vented through the breather valve (arrow, Fig. 3-77).

Clean breather valve in accordance with servicing plan.  Unscrew breather filter, clean with white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter back in place.

Fig. 3-77

Fig. 3-76

3-72

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Pre-chambers working pumps, draining oil, changing oil

Pre-chambers swing pumps, draining oil, changing oil

Draining oil:  Place a suitable receptacle for used oil under the plugs (13, Fig. 3-78:).

The required receptacle capacity is specified in the „Filling quantities – oil“ table.  Drain oil from the expansion reservoir.  Unscrew plugs (13) and allow oil to drain.

Screw in plugs and fill in oil after repair work has finished.

Changing oil:  Oil change is necessary only after repairs or after changing a working pump. In this case drain oil and fill in oil as described above.

Oil quantity see „Filling quantities – oil“ table.

Draining oil:  Place a suitable receptacle for used oil under the plugs (23, Fig. 3-79:).

The required receptacle capacity is specified in the „Filling quantities – oil“ table.  Drain oil from the expansion reservoir.  Unscrew plugs (23) and allow oil to drain.

Screw in plugs and fill in oil after repair work has finished.

Changing oil:  Oil change is necessary only after repairs or after changing a swing pump. In this case drain oil and fill in oil as described above.

Oil quantity see „Filling quantities – oil“ table.

Fig. 3-78:

Fig. 3-79:

3-73

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Pump gearbox, oil filter

Check the gear oil filter

Oil for the pump drive gearbox is cleaned in the filter (Fig. 3-80:).



In accordance with the servicing plan.



If the tell-tale pin (1, Fig. 3-80:) on the underpressure indicator (2) springs out and can not be pressed back in.

Changing filter element  Take filter element (43, Fig. 3-81:) out of housing (42).  Clean filter housing and sealing surface on filter head using white spirits or petroleum.  Fit new filter element into housing (42). Fit new, lightly oiled seal rings (45 and 46) to filter head.  After starting operation again, check filter for leakages.

If the tell-tale pin (1, Fig. 3-80:) appears, it is possible that the filter is contaminated with metal particles. Inspect the filter element carefully. Trace any cause and remedy.

Fig. 3-80:

Fig. 3-81:

3-74

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing SWING GEARBOX Read and observe: "Inspection and servicing - Safety instructions.

Shut off the electric motor.

The gearbox housings may be hot, too.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Details for selecting the correct gear oil refer to chapter “LUBRICANTS / CONSUMABLES”.

Changing the gearbox 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.  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Fig. 3-83:

Draining off oil

Fig. 3-82:

Swing gearbox - Checking the oil level / Topping up with oil  Park the machine as described under "Securing the machine".  Screw out dipstick (1, Fig. 3-82:) 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, if required.  Screw dipstick (1) back in place.

 Attach hose (8, Fig. 3-83:) to drain valve (7) and drain off oil completely.

The use of the oil draining hose is described in the "Draining hose for oil changes" chapter.

The drain valve (7) is accessible from the undercarriage.  Remove hose. The oil drain valve closes automatically.for oil and cooling liquid change" section.

3-75

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Filling in new oil / Topping up

Swing gearbox, venting

 Unscrew plug (4, Fig. 3-84:) and fill in new oil.  Check oil level with dipstick (1).  Screw in plug (4) again.

The gearbox is vented through breather filter (2, Fig. 3-84:).

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.

Fig. 3-84:

3-76

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing TRAVEL GEARBOX Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the electric motor.

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.

Spur gear section - Checking the oil level / Topping up with oil  Check oil level at the inspection glass (2, Fig. 3-86:).

The oil level should reach the center of the inspection glass. Top up with oil if required through the bore of plug (4).

Oil grade see: „LUBRICANTS / CONSUMABLES“.

Park and secure the machine as described in the "Securing the machine" section.

Read and observe: "Inspection and servicing Safety 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 - Checking the oil level / Topping up with oil  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-85:) 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“.  Screw checking plug (1) back in place.

Fig. 3-86:

Brake housing - Checking the oil level / Topping up with oil  Unscrew checking screw (6, Fig. 3-87:).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.  Screw checking plug (6) back in place.

Oil grade see: „LUBRICANTS / CONSUMABLES“.

Fig. 3-85: Fig. 3-87:

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Inspection and servicing Travel gearbox - Changing oil Carry out oil change when oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

Draining off oil  Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-88:) 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 screw plug (2) back in place.

Spur gear section - Changing the oil / 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. 3-89:) and drain off the oil completely.

Slackening plug (4) allows the oil to run out more readily.  Clean screw plugs (3 and 4)  Screw screw plug (3) back in place.

Filling in oil  Unscrew screw plug (4).  Fill in oil through opening of plug (4) until it reaches the center of the inspection glass (2).

Oil grade see: „LUBRICANTS / CONSUMABLES“.  Screw plug (4) back in place.

Filling in oil  Unscrew screw plug (1 and 3).  Fill in oil through opening in plug (3) until it flows out of opening in plug (1).

Oil grade see: „LUBRICANTS / CONSUMABLES“.  Screw plugs (1 and 3) back in place.

Fig. 3-89:

Fig. 3-88:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Brake housing - Changing oil Draining off oil  Place a collecting recipient for used oil under the brake housing.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (7, Fig. 3-90:) and drain off the oil completely.

Slackening breather filter (5) allows the oil to run out more readily.  Clean screw plug (7).  Screw screw plug (7) back in place.

Travel gearbox - Breather filter  Unscrew breather filter (1, Fig. 3-91:) and clean in white spirit or parafin.

Filling in oil  Unscrew screw plug (6).  Fill in oil through opening of breather filter (5) until it flows out of the bore of plug (6).

Oil grade see: „LUBRICANTS / CONSUMABLES“.  Screw plug (6) and breather filter (5) back in place.

Fig. 3-91:

Fig. 3-90:

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Inspection and servicing CRAWLER TRACKS Cleaning 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.

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 upper rollers and track rollers (1 and 2, Fig. 3-92:) thoroughly.  Clean the sliding planes on the idler guides.

Fig. 3-92:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Track rollers (Option) The track rollers (2, Fig. 3-93:) have a permanent lubricant filling (Not when the machine is equipped with a central lubricating system for the undercarriage).

Nevertheless press in lubricant filling at regular intervals.

It is necessary to be sure that always sufficient lubricant in the roller bearings.

Track roller fastening  Check fastening bolts (4, Fig. 3-94:) regularly for tightness.  Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual").

Fig. 3-94:

Upper roller fastening Fig. 3-93:

Unscrew plug (6, Fig. 3-93:) from breather line.

Remove dust cap (1) from coupling (2).

Remove dust cap (4) from plug (5).

Connect lubricating hose (3) to couling (2).

Press in lubricant as long as used lubricant emerges from breather line.  Screw on plug (6) to breather line.  Disconnect the lubricating hose (3).  Fix dust caps (1 and 4) back in place.     

 Check fastening bolts (3, Fig. 3-94:) regularly for tightness.  Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual").

3-81

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Inspection and servicing Track tensioner Design The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-95: and Fig. 3-96: show parts of the tracks and the tensioner:

Techncal data Track tensioning pressure Pressure limiting valve Gas pressure in pressure accumulator (nitrogen filling pressure)

ca. 70 bars/1015psi 330 bars / 4786psi 50 bars / 725psi

Function The tensioning system is under permanent pressure of ca. 70 bars / 1015psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the electric motor is switched on. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so:  Switch off the electric motor  open both pressure limiting valves (3, Fig. 3-96:) to slacken the tracks.  After the work, screw down the pressure limiting valves (3) to the limit stop.

Fig. 3-95:

1 2 3 4

Pressure accumulator Pressure cylinder Pressure limiting valve Mini- measuring port

Fig. 3-96:

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 track tensioners are maintenance-free.

3-82

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Pressure-accumulator inspection regulations

Checking the gas charging pressure in the pressure accumulator

The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

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 under "Function".

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:

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

3-83

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Inspection and servicing SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing (1, Fig. 3-98:) and the pinion (2) are enclosed in a housing (3, Fig. 3-99:). The housing forms a lubricant filled trough in which the pinion of the swing mechanism moves.

Switch off the electric motor Wear protective gloves and firm protective clothing.

Swing ring - Instructions The lubricant 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 lubricant completely before filling in new lubricant.

If greater losses are detected, locate cause immediately to prevent damage to the swing ring.

Lubricants and greasy cleaning rags must not be allowed to pollute the environment. Discard lubricant and greasy cleaning rags separately from other waste without polluting the environment.

Bearing races The central lubricating system supplies lubricant continuously to the two roller bearing races and the internal gearing.

The lubricant is pumped to the lubricating points of the bearing races by a distributor (Fig. 3-97:).

Fig. 3-98:

The lubricant is pumped to the greasing port of the lubricant trough by the distributor (Fig. 3-97:). The amount of lubricant 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. 3-99:). For checking, the cover must be removed.

Fig. 3-99:

Fig. 3-97:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Swing ring - Checking the lubricant filling Read and observe: "Inspection and servicing - Safety instructions.

Switch off the electric motor.

Wear protective gloves and firm protective clothing.

At regular intervals  check internal gearing and teeth of swing mechanism pinion for condition  check that the lubricant filling is sufficient.

The housing must always contain enough lubricant for the gearing - measured from its lower edge - to run in at least 20 mm / 0.78" of lubricant over its whole circumference (Fig. 3-100:).

In the event of greater lubricant losses, eliminate cause immediately and add lubricant to prevent the internal gearing and the pinion from being damaged by continued swing movements.

Swing ring - Filling in lubricant Prior to initial commissioning, the lubricant trough of the internal gearing must be filled with lubricant.

Add lubricant when  the housing has been replaced 

old lubricant has been removed in the course of other work.

Always fill in fresh lubricant by hand.

Risk of accidents. Never swing the upper structure when refilling lubricant.

Swing ring - Checking the bolts for tightness The fastening bolts of the swing ring in the upper structure and the undercarriage are tightened with their respective check torque (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 torque (see "Service Manual").

Fig. 3-100:

3-85

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing CENTRAL LUBRICATING SYSTEM Design and function The hydraulic shovel is equipped with an automatic central lubricating system which provides lubricant regularly to all greasing points except those mentioned in the "Lubricating chart - Lubricant ".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and the electric motor is running. All greasing points connected to the system are lubricanted at regular intervals.

The central lubricating system is controlled electrohydraulically by the programmable SPC contoller.

The SPC is located in a switch box underneath the cab.

Fig. 3-102:

If a fault occurs, BCS gives a warning on the screen (Fig. 3-102:).

Actuate the "Reset" button (64, Fig. 3-101:) to eleminate the fault. Is this is not possible, call in servicing personal.

For further information on the function and setting refer to the SERVICE MANUAL – PLC (Programmable Logic Controller).

Fig. 3-101:

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Function The lubricant is pumped by the pump (1, Fig. 3-103:) via greasing lines from the lubricant container to the main distributors on the upper structure and on the undercarriage.

The control elements of the lubricating system are installed on the panels (3).

Fig. 3-105:

Fig. 3-103:

For machines with automatic greasing of the track rollers, optional: The lubricant is pumped by the pumps (1 and 3, Fig. 3-104:) via greasing lines from the lubricant container to the main distributors on the upper structure and on the undercarriage.

The control elements of the lubricating system are installed on the panels (3 and 21, Fig. 3-105:).

As soon as the lubricant container is empty, the BCS (Fig. 3-106:) gives a warning signal. In the event of a fault, the "dumping" function is switched off automatically after 15 min.

Work can be continued when the lubricant container is filled with lubricant.

Fig. 3-106:

Fig. 3-104:

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Inspection and servicing Filling up the lubricant container

Breather filter

Fill up the lubricant container through the service station (Fig. 3-107:).

The use of the hose is described in the chapter "Flexible hose for the change of oil "  Switch on the indicator system with toggle switch (23, Fig. 3-107:).  Unscrew the cap of the express coupling (11).  Connect the filling hose of the service vehicle.  When the lubricant container is full, the indicator lamp (24) lights up.  Remove the flexible hose.

The express coupling closes automatically.  Refit the protective cap.

Check/change the breather filter at regular intervals.  Unscrew wing nut (10, Fig. 3-108:).  Withdraw cover (7, Fig. 3-109:) and filter element (8).  Check filter element. Replace if necessary.  Re-install breather filter.

Fig. 3-108:

Fig. 3-107:

Fig. 3-109:

3-88

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Checking the greasing pressure Check every week, whether the oil pressure indicated by pressure gauge (4, Fig. 3-110:) is 60 bars / 870psi (the pressure is dependind on temperature and viscosity of the oil and may vary).

The necessary greasing pressure of 320 bar / 4641psi for the upper structure is generated by means of a pressure translator.

The greasing pressure is indicated by pressure gauge (9).

In the event of deviating pressure values, switch off the electric motor and check the central greasing system.

Lower oil pressure means that not all of the greasing points are supplied with lubricant.

Higher oil pressure may cause bursting of a lubricanting line.

Always refill the lubricant container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.

Fig. 3-110:

This oil pressure is reduced so that the pressure indicated by pressure gauge (2) is 47 – 50 bars (681-725psi).

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Checking the greasing pressure (for machines with automatic greasing of the track rollers, optional) Check every week, whether the oil pressure indicated by pressure gauge (4, Fig. 3-111:) is 60 bars / 870psi (the pressure is depending on temperature and viscosity of the oil and may vary).

The necessary greasing pressure of 320 bar / 4641psi for the upper structure and 180 bar / 2610psi for the undercarriage is generated by means of a pressure translator.

The greasing pressure for the upper structure is indicated by pressure gauge (9, Fig. 3-111:) and for the undercarriage by pressure gauge (22).

In the event of deviating pressure values, switch off the electric motor and check the central greasing system.

Lower oil pressure means that not all of the greasing points are supplied with lubricant.

Higher oil pressure may cause bursting of a lubricanting line.

Always refill the lubricant container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.

Fig. 3-111:

This oil pressure is reduced so that the pressure indicated by pressure gauge (2, Fig. 3-112:) is 35 – 40 bars (507-580psi) and by pressure gauge (4) is 49 – 51 bar (710-739psi).

Fig. 3-112:

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EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Unblocking a lubricating line

Unblocking a lubricant line

Put the hydraulic shovel back into operation only after the lubricating system works properly and after having actuated the unloaded attachment for abt. 5 minutes. This is necessary in order to supply sufficient amounts of lubricant to the cylinder bearings.

Check the lubricant sieve regularly for contamination and clean, if required. The lubricant sieve must also be cleaned after an obstruction in one of the lubricant lines.

(for machnes with automatic greasing of the track rollers, optional) Put the hydraulic shovel back into operation only after the lubricating system works properly and after having actuated the unloaded attachment for abt. 5 minutes. This is necessary in order to supply sufficient amounts of lubricant to the cylinder bearings.

Check the lubricant sieve regularly for contamination and clean, if required. The lubricant sieve must also be cleaned after an obstruction in one of the lubricant lines.

Cleaning  Loosen nut (6, Fig. 3-113:).  Withdraw sieve and clean with white spirit or paraffin oil.  Re-insert sieve and fasten with nut (6).

Cleaning  Loosen nut (6, Fig. 3-114:).  Withdraw sieve and clean with white spirit or paraffin oil.  Re-insert sieve and fasten with nut (6).

Fig. 3-113: Fig. 3-114:

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EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Oilfilter (hydraulic circuit lubricant pump) ) Read and observe the "Inspection and servicing - Safety instructions" chapter.

Replacing the filter element Change filter element regulary and when the BCS indicates a contamination.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The filter housings may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

For filtering of the hydraulic oil, high pressure filter (11, Fig. 3-115:).is installed in the pumping line.

Fig. 3-116:

Fig. 3-115:

3-92

 Unscrew filter housing (5, Fig. 3-116:).  Withdraw filter element (6) from filter housing (5).  Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.  Check seals (10 and 14) and replace, if required.  Insert new filter element into filter housing (5) and refit to the filter head with new, lightly oiled sealing ring (8).  Check for leaks after putting the filter into operation.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Lubricant filter (Filling the lubricant container) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Switch off the electric motor.

Lubricant filter (13, Fig. 3-117:) is installed in the greasing line to the lubricant container.

Checking the filter element Unscrew filter housing (32, Fig. 3-118:).

Withdraw filter element (33) from housing (32).

Remove the lubricant.

Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert filter element into housing (32) and attach to the filter head with a new, slightly oiled sealing ring (36).  Check the high-pressure filter for leaks after the system has been put into operation.    

Fig. 3-117:

Fig. 3-118:

Replacing the filter element  Remove filter element as described under "Checking the filter element".  Insert new filter element and reassemble.  Check high-pressure filter for leaks after the system has been put into operation.

3-93

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Lubricant filter (Lubricating lines) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Switch off the electric motor.

Lubricant filter (12, Fig. 3-119:) is installed in the greasing line to the lubricant container.

Checking the filter element Unscrew filter housing (42, Fig. 3-120:).

Withdraw filter element (43) from housing (42).

Remove the lubricant.

Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert filter element into housing (42) and attach to the filter head with a new, slightly oiled sealing ring (46).  Check the high-pressure filter for leaks after the system has been put into operation.    

Fig. 3-119:

Fig. 3-120:

Replacing the filter element  Remove filter element as described under "Checking the filter element".  Insert new filter element and reassemble.  Check high-pressure filter for leaks after the system has been put into operation.

3-94

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing OTHER MAINTENANCE Heating and air conditioning Check and clean the filter mats in the air suction regulary.

The filter mats are located in the air conditioner housing (Fig. 3-121:) below the cab roof.

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 SIS-Web, Media-ID-No. BI644777.

The inside located joins are accessible through the man-holes in stick (arrow, Fig. 3-122:) and boom (arrow, Fig. 3-123:).

Fig. 3-122: Fig. 3-121:

 Open housing of air conditioner.  Check and clean filter mats or replace if necessary.  Close housing.

Fig. 3-123:

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EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Reservoirs for used lubricant at the A-frame - Empty

Hydraulic ladder - Pressure accumulator

Remove used lubricant from the reservoirs (Fig. 3-124:) regularly according to the maintenance plans.

Do not re-use the lubricant because it is polluted.

Dispose off used lubricant as well as cleaning rags without polluting the environment and separately from other waste.

To allow the ladder (Fig. 3-125: and Fig. 3-126:) to be lowered with the electric motors at standstill as well as in an emergency, the ladder mechanism is equipped with a pressure accumulator (1, Fig. 3-127:). The pressure accumulator (1) is located in the upper structure and is accessible from the ground.

Fig. 3-125:

Fig. 3-124:

Fig. 3-126:

Fig. 3-127:

3-96

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing Pressure-accumulator inspection regulations

Checking the gas charging pressure in the pressure accumulator

The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

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 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:

Group

III p  l bar and p·x l  200 bars p·x l  1000 bars

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 Inspection schedule to be drawn up by end user, based on experience with type of operation and operating fluids.

3-97

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing ON-BOARD CRANE - DRIVE UNIT 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. 3-128:).  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.

Fig. 3-128:

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. 3-129:); top up with hydraulic oil if necessary.  Check contamination of hydraulic oil filter regularly at contamination indicator (4).  Regularly, but at least once a year replace the hydraulic oil filter (3) and the breather filter (2).

3-98

Fig. 3-129:

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Inspection and servicing On-board crane - Lubricate Servicing work  Lubricate all bearings regularly and as required, and spray swing ring with a graphite spray (Fig. 3-130:) 1 - bearing 4 lube points 2 - joint (column/boom) 2 lube points 3 - cylinder bearing 5 lube points 4 - swing ring Graphite spray

On-Board crane - Check tightness of fastening bolts The hydraulic driven on-board crane (if equipped) is fixed on the uppercarriage of the machine by means of 16 fastening bolts. The upper and lower fastening bolts (Fig. 3-131:) 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. 3-130:

Fig. 3-131:

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Inspection and servicing PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING Putting the hydraulic shovel out of operation  Park the hydraulic shovel on firm and level ground.  Set the attachment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.  Set all control element to "0".  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.  Protect all bright metal parts (e.g. piston rods) from rust and dirt.  Remove the batteries; see "Battery storage".  Secure the machine against unauthorized starting by: withdrawing the key from the key-switch setting the battery main switch to OFF setting the main circuit breaker to OFF locking the cab door securing all lockable hatches.  Cover up all openings

Battery storage 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.  Check the acid density and the electrolyte level of the battery every two weeks.  Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.  Keep the batteries clean and dry on the outside.

Recommissioning     

     



3-100

Remove the covers.

Degrease / clean all protected components.

Check track tension (visual inspection) Check lubricant filling in lubricant container.

Oil level - swing gearboxes - pump drive gearboxes - travel gearboxes Check oil level in hydraulic oil reservoir.

Check battery acid density and level.

Install batteries and reconnect.

Set battery main switch to ON Set the main circuit breaker to ON Function checks: - upper structure holding brake - track brake - lighting system - signalling equipment Vent the hydraulic system.

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Inspection and servicing NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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Repair work 4 REPAIR WORK 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

4-1

EM029995-0

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Repair work

4-2

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Repair work SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS WITH ELECTRIC MOTOR Maintenance and inspection work on electrical systems may only be performed by qualified electricians or by workshops employing such personnel.

A qualified electrician for the purpose of this regulation is a person who has the corresponding technical training, know-how and experience as well as knowledge of the pertinent prescriptions and who is therefore in a position to judge the work entrusted to him and the potential dangers in connection therewith.

Before carrying out any maintenance and inspection work on the electrical system, the following precautions must be taken:

In the transformer station

After finishing repair work:

In the transformer station  Disconnect the earthing and short-circuiting line.  Unlock the safety device preventing switch-on; remove the warning sign.  Remove the partitions.  Switch on the supply voltage.

On the hydraulic hydraulic shovel  Unlock the safety device preventing switch-on; remove the warning sign.  Switch on the circuit breaker, (see the " Switching on the circuit breaker " chapter in part 2 of the present Operation and Maintenance Manual).

 Cut out the supply voltage.  Secure against switching on; apply a warning sign.  Check that the electrical system is off circuit.  Connect to earth and short-circuit.  Protect adjacent and live parts against accidental contact.

On the hydraulic shovel  Cut out the circuit breaker (see the " Switching off the circuit breaker " chapter in part 2 of the present Operation and Maintenance Manual)  Secure circuit breaker against switching on, apply a warning sign.  Switch off the earthing switch (see manufacturers Operating Instructions).

4-3

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Repair work REPAIR WORK - SAFETY INSTRUCTIONS Operation and Maintenance Manual Never carry out repair work without having read and understood the Operation and Maintenance Manual.

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 operating 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 .

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 operating manual contains no information on this point.

4-4

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 CGMHMS 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 electric motor 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.

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Repair work FIRE AND EXPLOSION HAZARD Safety Instructions Prior to commencing work, inform on the national and corporate rules for prevention of accidents. Pay particular attention to hazards caused by combustible and easily flammable substances. 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 handle any flammable substances during operation.

Clean the hydraulic shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units.

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. 

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

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.

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.

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.

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Repair work HYDRAULIC SYSTEM Repair 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.

4-6

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.

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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

4-7

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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.

4-8

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.

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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.

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Repair work Welding on the counterweight

Welding on the cab

Counterweights may contain a build-up of flammable gases. Before starting to work, counterweights must be flushed for at least 20 minutes with compressed air in order to remove these build-ups of gas. To permit flushing, the counterweight has two bores in its upper part: a threaded bore M18x1.5 for the compressed-air line and another unthreaded bore to let the air out.

Detailed information / instructions on this subject can be found in Service Information 2006-33 which is available on the CGM-HMS GmbH website under Maintenance & Service.

The operator'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.

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.

4-10

Further information More detailed information concerning the state-ofthe-art execution of welding operations can be found in the Service Manual "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".

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Repair work DISPOSAL AT THE END OF THE SERVICE LIFE 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.

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 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 drive 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.

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Repair work Further hazardous substances  





  

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.

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. 4-1:).

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.

Fig. 4-1:

The symbols in Fig. 4-1: have the following meaning:  Crossed-out waste bin= Do not dispose of batteries with normal household waste.

4-12



Pb……= Chemical symbol for lead.



Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

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Repair work NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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Annex 5 ANNEX 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

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

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Annex

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Annex BOARD-CONTROL-SYSTEM BCS3e, what’s that?

What it is The BCS3e 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 shovels from CGM HMS GmbH. The BCS3e communicates with other electronic units in the 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 BCS3e are located in cabinets in the module below the operator’s cab, the pump compartment and the electric motor compartment.

The exchange of data between sensors, controllers, the BCS3e 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 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 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 the electric motor 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 shovel constantly transmit their readings to the controllers of the CAMP system.

All essential pieces of operating data are displayed on the BCS screen in the form of simulated instruments as well as they are archived and can be called up as and when required.

Fig. 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 operator’s cab (Fig. 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.

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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. 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. 2) the key (2) lies directly below the active area "Service". Touching the "Service" area or pressing key "2", will take you to the same screen page.

The keys 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. 2

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Annex BCS3e, the Start Screen The screen displays the graphical user interface of the Board Control System. The basic screen (Fig. 3) appears when all electronic units of the CAMP system have started and when their self-tests 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: Never use pointed objects such as a ball pen, screwdriver, nail or similar to touch the screen.

This could damage the active surface of the touchscreen.

Do not press on the sensitive areas, just slightly touch them with your fingertips!

Fig. 3

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Annex Information Given on the Start Screen - Top Section The symbols shown in the top row of the start screen (Fig. 4) appear in background color if function is not activated, in green color 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.

1

Electric motor monitoring.

2

Not used on this machine.

3

The number of dumpers you loaded is displayed here (if counted with the key in the right joystick).

4

Central lubrication system monitoring.

5

Hydraulic system monitoring.

Fig. 4

5-6

6

Operating hours meter.

7

High voltage supply activated when symbol area is in green color..

8

Fast fill arm, turns to red color if lowered.

Swinging superstructure or travelling the machine is not possible then.

9

Hydraulic ladder, turns to red color if lowered. Swinging superstructure or travelling the machine is not possible then.

10

Track parking brakes monitoring, red when brakes are applied.

11

Superstructure holding brakes monitoring, red when brakes are applied.

12

Servo-switch inside seat monitoring, red when no one is sitting on the operator’s seat.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Information Given on the Start Screen - Central Section 1

System data during operation: Hydr. Oil = Hydraulic oil temperature in degrees Celcius, displayed graphically and numerically. 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 or when touching the arrow pointing downwards.

Ambient = Air temperature around the machine in degrees Celsius.

Battery V = Backup batteries voltage.

Spanner symbol = Operating time until next service is to be due, symbols are red then.

2

System data during operation: Output kW = Output power of the electric motor, displayed graphically and numerically.

High voltage ON = LED symbol is green when supply high voltage is available.

Motor ON = LED symbol is green when electric motor is running.

Button “Arrow up” = Tapping with your fingertip opens a window showing all the prerequisites for motor start.

Lightning symbol = Frequency of the supply high voltage input in Hertz (Hz).

Next possible start = Displays remaining time until the electric motor can be started again.

Fig. 5

5-7

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Information Given on the Start Screen - Lower Section 1

2

3

Fig. 6

5-8

Button “Camera”.

Tapping the button produces a “photo” of the current screen to save current data. The screenshot will be stored on a plugged USBstick. A menu will appear where you can proceed with storing the screenshot graphic file (see “Store Screenshot Screen”).

Button “Service”.

Tapping with your fingertip opens a gate to much more information about the shovels current behavior.

A menu will appear where you can select the section you want information about (see “Service Screen”).

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.

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 BCS Service Level I, II and III is requested. Refer to General Service Information EM028493 for more information.

4

Button “Fault”.

Tapping this button opens a list of failures stored in the failure memory.

(See: “Fault storage / Fault Table Screen”). A detailed description of faults can be found in the Service Manual, volume 1, chapt. 9.

5

The red “failure row”.

Here the system displays detailed information about the failure occurred and gives instructions about what to do. Last error is located at the top of the list. More detailed information is available in the fault storage, see position 4.

6

Symbol only appears in case a USB-stick with security level release is detected: Yellow color = Security Level II Red color = Securiy Level III

7

Clock.

Can be adjusted in the “Setup” section by service personnel.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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. 7). The machine is inactivated then, electric motor cannot be started.

Call the responsible service personnel immediately. The fault has to be located and eliminated.

Before being able to restart the electric motor, 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. 7

5-9

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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. 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.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Information Given on the “Service” Screen 1

Tapping on the button with the flag symbol switches text on the screens to the resp. language.

2

Tapping on the photo of the electric motor opens a screen displaying current data coming from the electric motor (see “Electric Motor Data Screen”).

Same result when tapping on button “Motor” or pressing key “1” on the housing.

3

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.

4

Tapping on this button opens the machine documentation stored on the second Compact Flash Memory Card (CF-card) inside the BCS housing. The machine documentation files are stored there as pdf-files.

They can be selected and displayed on the BCS screen.

If the CF-card is not available, a fault message will appear.

5

Adjusting screen brightness. Tapping the buttons “+” or “-* sets the screen brighter / darker. Tapping on button “Autom.” sets brightness to automatic mode. The green signal lamp lights up then.

Fig. 9

5-11

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Information Given on the “Service” Screen – continued 6

7

Fig. 10

5-12

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.

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

8

Tapping on this button opens the “Signal Table” screen (see: “Signal Table Screen”).

9

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.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Electric Motor Data Screen This page shows a large number of technical values of the electric motor. They are interesting for the electrotechnical specialist. This personnel can find more detailed information in the Service Manual of the machine, chapter 9.

The displays in area 4 are particularly important for the operator: If the lights are grey or green, no action is required. If one or more of the lights turns red, the operator must immediately inform the responsible service technician.

In the head line of this screen the total operating hours of the electric motor is monitored.

1

This section of the screen displays current data for all three phases of the electric motor windings: - Stator temperature in degrees Celsius, - Supply voltage in Volts, - Current in Amperes.

2

This section of the screen displays: - Power factor, - Frequency of the supply high voltage in Hertz.

3

In this section information about the electric motors bearing temperatures are displayed.

Bearing (DE) °C = Temperature of bearing on the Drive-End in degrees Celsius.

Bearing (NDE) °C = Temperature of bearing on the Non-Drive-End in degrees Celsius.

4

Upper area: Data from Drive Controller This section of the screen displays status information from the Drive Controller. Gray or green light on = function is active / switched ON, red light on = Inform the responsible service technician immediately.

Fig. 11

5-13

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Electric Motor Data Screen – continued 4

Fig. 12

5-14

Continued: This section of the screen displays status information. Gray or green light on = function is active / switched ON, red light on = Inform the responsible service technician immediately.

Lower area: Data from the Motor Protection Relais (MPR).

This Status information can also be seen directly on the front panel of the MPR. If an error occurs a light will turn from green to red. In any case this will be shown with a message on the main screen.

5

This section of the screen displays the electric motors output data: - Performance in kW - Reactive Power - Reactive - Apparent - Total consumption

6

All data displayed can be saved to an USB-stick after tapping the camera button (see: “Store Screenshot Screen”).

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Hydraulic Data Screen 1

This screen displays data related to the hydraulic system.

2

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

3

All data displayed can be saved to an USB-stick after tapping the camera button (see: “Store Screenshot Screen”).

Fig. 13

5-15

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Lubrication Data Screen 1

2

Fig. 14

5-16

This screen displays data related to the central lubrication system.

Here are information about the status of the lubricating system of the upper carriage.

Status messages are marked here with green dots.

If the system detects faults or malfunctions in the lubrication system of the upper carriage they are marked here with a red dot. If this is the case, call the responsible service personnel.

Malfunctions must be fixed as soon as possible. Serious damage of bearings and other parts of the equipment may occur whe working without lubrication.

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

4

Here you get information about the status of the lubricating system of the under carriage.

If the system detects faults or malfunctions in the lubrication system of the under carriage they are marked here with a red dot. If this is the case, call the responsible service personnel.

Note: A lubrication system for the under carriage is not implemented on every machine.

5

All data displayed can be saved to an USBstick after tapping the camera button (see: “Store Screenshot Screen”).

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Controls Adjustment Data Screen The characteristic curves (ramps) of control levers (1, Fig. 15) and control pedals (2) are adjustable by service personnel. The adjusted values are shown here graphically and numerically.

The values set have influence on moving speed and smoothness of movements of the working equipment.

If adjustment is needed, call the responsible service personnel.

Adjustment is to be done in the “Setup” section of BCS3e. Access to this area is for service personnel only (password required).

Key switches in control levers can be checked by tapping on the touch sensitive areas below the control lever graphic. The color changes from red to green.

1

Tapping on a joystick symbol displayes the current settings of the left/right control lever.

Function of the key switches in the control levers are displayed as well.

2

Tapping on a pedal symbol displayes the current settings of the pedal.

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

4

Tapping on this button opens the “Slew brake test” screen (see: “Slew Brake Test Data Screen”).

5

All data displayed can be saved to an USBstick after tapping the camera button (see: “Store Screenshot Screen”).

Fig. 15

5-17

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Slew Brake Test Data Screen Coming from the “Controls adjustment data screen”, button “SIL-Check” (Fig. 15): 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 placed on a firm, even and safe workplace where the upper structure can rotate 360° without hitting an obstacle. Lift the bucket from the ground. 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.

1

2 3 4

5 6

Fig. 16

5-18

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.

Hydraulic pressures in the units of the slewing systems, lefthand and righthand.

Instruments displaying hydraulic pressure in lefthand / righthand slewing system.

Indicators showing the progress during testing: - “pending”, color red after starting the test, - “in progress”, color yellow when 300 bar, - “passed”, color green when test OK. Button to start the test. A “Level II” password is needed to get access. Exclusively for service personnel.

Instructions to perform the slew brake test.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Signal Table 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.

Status "--" means: Signal is displayed, but not checked for limit values. I.e. no error is displayed.

In column “Code” you can find the identifier for the sensor or unit (if available). This identifier helps the maintenance personnel to localize the sensor or unit in the electric schematics.

1

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

2

Tapping on button “Diagram” opens a screen showing the data coming from four sensors in a diagram (see Fig. 18).

3

Currently not used on this machine.

4

All data displayed can be saved to an USB-stick after tapping the camera button (see: “Store Screenshot Screen”).

Fig. 17

5-19

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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

Button “Delete” = delete data displayed.

2

Buttons to scroll, scale up, scale down and reset to base setting the diagram window.

3

Select signal source to be displayed (channel 1-4)

4

Diagram window, displays the data from four sources as four lines in different colors.

Fig. 18

5-20

5

Rec = starts recording the data from the selected sources, a “Save file as”-dialog will be displayed; Stop = stops recording data; Rev = scrolls the diagram in reverse; Fwd = scrolls the diagram forwards.

6

Choose the storage device and configurate the log file to be saved on USB-stick.

7

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

8

Tapping on button “Config.” opens a window listing all the signal sources available for BCS and CAMP (Fig. 17).

9

All data displayed can be saved to an USB-stick after tapping the camera button (see: “Store Screenshot Screen”).

10

Listing of the four signal sources selected: ID, Name, actual value and value at cursor in the diagram.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Signal Table Screen - Diagram Configuration Button “Config.” (8, Fig. 18) has been tapped, a window appears displaying all the signal sources available (Fig. 19).

In column “Channel” you can mark four signal sources whose data you want to display in the diagram (4, Fig. 18).

Mark the line with the signal source you want and press the appropriate numeric key on the BCS housing: “1” for channel 1; “2”, “3” and “4” for the other channels.

It is also possible to select up to 16 signals. An ASCII file could be generated from the associated values (space separated) and stored on the USB stick. The file can be displayed then as a diagram via a spreadsheet software. Signals 1-4 are also displayed in the "Signal Table Screen - Diagram".

1

For example: This signal source is selected and marked to be displayed on channel 1.

2

For example: This signal source is selected and marked to be displayed on channel 4.

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

4

Tapping the button will confirm your selection and return to the “Signal Table Screen – Diagram”.

Fig. 19

5-21

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Fault Storage / Fault Table Screen Coming from the “Start screen” after tapping the button “Fault” this screen displays all faults stored in the fault storage of the BCS system. You can choose to display “active” faults, “inactive” faults or “all” faults by tapping the radio buttons.

Faults were displayed in section (2, Fig. 20).

Fig. 20

5-22

1

Choose displayed data: The “Fault table” (as shown) or on the other tab the “Fault Details” (see: “Fault Storage / Fault Detail screen“).

2

This is the list of stored errors. The scope depends on the selected display type "active", "inactive" or "all".

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

4

Tapping the button will open a new window on which you can save the stored faults to disk (see: “Fault Storage – Save to USB Stick”).

5

Tapping the button will refresh the display.

6

Tapping the button will delete the fault storage inside the BCS system. You will be asked to proceed.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Fault Storage – Save to USB-Stick Coming from the “Fault Storage / Fault Table Screen” after tapping the button with the USB-stick icon this screen displays all faults stored in the fault storage of the BCS system with details.

1

Tapping the button “OPEN” opens the USB-stick and shows the folder structure and stored files. If no USB-stick is plugged into the USB jack in the control column (Fig. 24), a fault message will be displayed.

2

Tapping the button “NO” leaves the current screen and opens the previous screen.

3

Tapping the button “YES” stores all data from the fault storage to the USB-stick, leaves the current screen and opens the previous screen.

During the first saving process, the BCS creates a folder on the USB-stick. The folder name will be saved according to the "Machine Model" "serial number" scheme, as stored in the BCS configuration file.

The file containing the faults will be named automatically.

Fig. 21

5-23

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Fault Storage – Fault Detail Coming from the “Fault storage / Fault Table screen” after tapping the “Fault Detail” tab, this screen displays detailed information for each fault stored in the fault storage: - Code number of the fault (More information in the Service Manual of the machine, chapter 9), - Description, - Alarm condition, - Additional (if available), - Start time and date, - Hour at start, - Duration.

1 2 3

4

5 6

Fig. 22

5-24

Detailed information about stored faults.

When tapping on Up / Down arrows you can scroll through the stored faults.

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Tapping the button will open a new window on which you can save the stored log-files to a storage medium (see: “BCS files – Copy to USB Stick”).

Tapping the button will open a new window on which you can save the stored faults to a storage medium (see: “Fault Storage – Save to USB Stick”).

Tapping the button will refresh the display.

Tapping the button will delete the fault storage inside the BCS system. You will be asked to proceed.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex BCS files – Copy to USB-Stick Coming from the “Fault Storage – Fault Detail” screen, on this screen you can copy files from the BCS system to a USB-Stick or vice versa.

Plug in your USB-stick (see “BCS3e – Interfaces”).

1

Select the files to be displayed in the selection window: Database = Fault storage files Datalogging = Log files

2

Selection windows. Select the file(s) you want to copy. Tapping on button “Select all” (4) selects all files in the window. Tapping on the red arrow symbols starts the copy process.

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

4

Tapping this button selects all files in the selection window to be copied.

5

Tapping the button will delete the fault storage inside the BCS system. You will be asked to proceed.

6

Tapping the button will refresh the display.

Fig. 23

5-25

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex BCS3e - 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. 24): 1

USB 2.0, jack type A. This jack accepts, for example, a USBstick 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

Ethernet, jack type RJ45.

For the connection of future extensions.

USB Interface - Data Storage A USB-stick can be connected to the USB plug-in connection of type A (1, Fig. 24).

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 button with the camera graphic symbol, the data visible on this screen page can be saved as a graphics file.

For a detailed description see: “BCS files – Copy to USB-Stick”.

5-26

Fig. 24

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Store Screenshot Screen A screenshot can be made of any screen that contains a camera button in the lower left corner. After touching the camera button, a graphic file of the entire screen content is created. This graphic file is automatically named with a descriptive name in the following systematics: "Name of the window_date_time.png".

In this example (Fig. 25): "BCS_Configuration_22.08.2019_15-53-47.png" The screenshots are stored in a directory of the USB-stick, which is named with machine type and serial number. In this example (Fig. 25): 6060158.

Note: The European format is used for date and time: Day_Month_Year_Hour_Minute_Second.

1

Tapping the button with the camera icon produces a screenshot of the momentary displayed screen. This is a graphic file in png-format.

2

This window will appear automatically after tapping the camera icon (1). Tapping the “YES” button will copy the screenshot file to your USB-stick. Tapping the “NO” button will close the window and return to the screen before. The screenshot is lost.

Fig. 25

5-27

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex BCS3e - Cleaning

BCS3e - 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.

5-28

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.

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex TROUBLESHOOTING Instructions on troubleshooting 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 Operation and Maintenance Manual once again before rectifying any faults.

If you are unable to detect the cause of the fault or to rectify it, apply to the CGM-HMS GmbH aftersales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM-HMS GmbH after-sales 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.

Layout of the fault table 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 Operation and Maintenance Manual. If there is no entry, the CGM-HMS GmbH after-sales service should be consulted

5-29

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex FAULT TABLES 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 Uncontrolled working movements Cause Electronic hydraulic shovel control not activated/defective



Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact Cat dealer

your

Chapter ref.

Working P

  



Malfunction of pressure-relief valve

1)





Servo system pump defective

1)

  

5-30

 Malfunction of primary / sencondary pressure-relief valves ECO-power switch in 80%-position

1) P



Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R lamp lit) oil cooler contaminated cooler cleaning Malfunction of solenoid valves 1) 



 Malfunction of control spool

1)

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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 Chapter ref.

1)







Cause Malfunction of pressure-relief valves







Servo system pump defective

1)







Malfunction of travel valve (pedal)

1)





Malfunction of control spool

1)



ECO-power switch in 80%-position



Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil P/R cator lamp lit) oil cooler contaminated cooler cleaning

Travelling

P

5-31

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OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex Swing mechnism – Fault table Fault

Remedial action

No swing possible No righthand or lefthand swing Swing performance insufficient Uncontrolled swing movement

Cause Electronic hydraulic shovel control not activated / defective

  

P 1)

Servo system pump defective

1)



Malfunction in feed-pressure circuit of swing pump

1)



Malfunction in high-pressure circuit of swing system

1)



Malfuction of moment-regulating valve

1)

Malfunction in swing pump displacement cylinder

1)

Excessive leakage in swing motor

1)



 

5-32

P

Pressure-relief valve adjusted too low level / defective





P E W A S R

Superstructure holding brake applied 



Check Adjust Replace Top up Reduce Clean 1) Contact your Cat dealer Chapter ref.

Working

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-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



Cause Timer defective



 







Check P Adjust E W Replace Top up A Reduce S Clean R Vent L 1) Contact your Cat dealer Chapter ref.

P/W

Lines between timer and hydraulic motor defective

P/W

Hydraulikmotor defektive

P/W



Grease pump defective

P/W



Grease sieve clogged

P/R



Distributor defective

P/W



Grease container empty

P/A



Grease pump does not suck grease

P/L



Leaky lines

P/L



Non-return valve defective Pressure switch defective

P/W E





5-33

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex HYDRAULIC CIRCUIT DIAGRAM Detailled information can be found in the „Service Manual“ chapter 8 or contact CGM-HMS GmbH service.

5-34

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex ABBREVIATIONS A abt. acc.

Ah API approx.

Ampere (SI base unit of electric current) about according to Ampere hours (SI base unit of quantity of electricity) American Petroleum Institute approximately

BA

= OMM = Operation and Maintenance

bar Bh

unit of pressure, 1 bar = 14.5 psi = OH = Operating hour

CE

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

Manual

CECE

CEN cm cm3/rev CCW CW

dia.

DIN EDS eff. e.g. etc.

Electronic diagnostic system effective for example etcetera

Fig. FOPS FS ft

Figure, serial number of illustration Falling objects protective structures Rock shovel (working equipment) foot (unit of distance), 1 ft = 0.30 meter

gal GLR

gallon (unit of volume), 1 gal = 3.78 liters Full-load controller (electronic module for PMS)

HD Hydr.

Heavy duty Hydraulic, Hydraulics

i

Transmission ratio

i.e.

IFN

id est = that is ISO service rating, blocked

including, inclusive of International Standardization Organization

kg kg/dm3

Kilogram (unit of weight), 1 kg = 2.2 lb Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

km/h kNm kW

Decibel (sound intensity according measuring method A) Diameter German Industrial Standard

dB(A)

Incl.

ISO

to

l lb Lb/in² LC LDA LED l/min LpA LS LwA

Liter (unit of volume), 1 liter = 0.26 gal pound (unit of mass), 1 lb = 0.45 kg Pounds per square inch (= psi) Long crawler Charge pressure-dependent full-load limiter Light-emitting diode Liters per minute Sound pressure at workplace Limited slip Sound power level of the machine in stationary operation

m MA mA max. min. min-1 mm

Meter (unit of distance), 1 m = 3.28 ft Tightening torque Milliampere (=1/1000 A) maximal, maximum 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 op.inst.

OW

Operating hour Operating instructions Superstructure

oz

ounce (unit of volume) 1 oz = 0.03 liter

5-35

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex ABBREVIATIONS PMS P/No. PS psi PLC

Pump Managing System Part number (CGM-HMS GmbH ) Metric horsepower (1 PS = 0.74 kW) pund per sqare inch (unit of pressure), 1 psi = 0.069 bar Programmable logic controller

Qty.

Quantity

R, r resp.

RH ROPS rpm

Radius Respectively Crawler hydraulics (hydraulic shovel) Roll-over protective structures Revolutions per minute (= min-1)

SAE sec./s.

SN SW

Society of Aotomotive Engineers (USA) Second CGM-HMS GmbH partnumber Width across flats

t TBG

typ.

Metric ton (= 1000 kg) Civil Engineering Employer's Liability Insurance Association Service Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of swing torque) Typical

U/min UW

Revolutions per minute Undercarriage

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

THB TL tm

W

Watt (unit of electric power)

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

5-36

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex NOISE AND VIBRATION INFORMATION Noise emission information

Vibration information

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 = XX dB.

On the condition that the hydraulic shovel is used within the limits of its designated use, the installation of seats for operators 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 operatored 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 wole body is exposed, does not exceed 0.5 m/s2.

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

5-37

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex PRODUCT SPECIFICATION SHEET

5-38

EM029995-0

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

EM029995-0

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

EM029995-0 6040/6040 FS Hydraulic Shovel Specifi cations

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

EM029995-0

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

EM029995-0 6040/6040 FS Hydraulic Shovel Specifi cations

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

EM029995-0

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

EM029995-0 6040/6040 FS Hydraulic Shovel Specifi cations

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

EM029995-0

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

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex

5-39

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Annex NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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.............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

5-40

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Index 6 INDEX 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

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

6-1

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Index

6-2

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Index

A ABBREVIATIONS 5-35 About this Operation and Maintenance Manual 14 Access ladder - Lighting 2-32 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED HYDRAULIC SHOVELS 1-14 Active-power transducer - Function 2-72 Additional messages (ANSI) – Description 2-27 After daily operation 2-145 Air conditioner (if equipped) 2-74 ALL PRODUCTS FOREWORD 1-2 Appropriate disposal of batteries 4-12 ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-146 Attachment - Check for cracks 3-95 Automatic fire-extinguishing system 2-42 Avoid mixing of different hydraulic fluids 3-61

B Back-up heating operator’s cab (if equipped) 2-74 Basic setup at a bench 2-99 Battery main switch Switch - on and off 2-65 Battery storage 3-100 Battery, checking state of charge 3-40 BCS files – Copy to USB-Stick 5-25 BCS3e - Cleaning 5-28 BCS3e - Disposal 5-28 BCS3e - Interfaces 5-26 BCS3e, the Start Screen 5-5 BCS3e, what’s that? 5-3 Bearing races 3-84 Before starting traveling 2-126 Before starting work 2-76 Bench - Climbing and Leaving 2-87 Bench Height on Flat Slopes 2-98 Bench Heights – Recommendations for BHmachines 2-88 Bench Heights – Recommendations for BHmachines, table 90 Bench Heights – Recommendations for FS Machines, table 98 Bench Heights on Steep Slopes 2-97 Board-Control-System 5-3 Board-Control-System (BCS) 2-9 Breather filter 3-88 Bypass valves, clean / replace 3-55

C Cab interior lighting – Switch on and off 2-36 California Proposition 65 Warning 1-3 CENTRAL LUBRICATING system 3-86 Central lubricating system – Fault table 5-33 CE-Plate, European Union 2-31 Changing the gearbox oil 3-75

Changing the hydraulic oil 3-61 Checking the gas charging pressure in the pressure accumulator 3-83, 3-97 Checking the greasing pressure 3-89, 3-90 Checking the hydraulic oil level 3-49 Circuit breaker - Switch on and off 2-69 Cleaning jobs 3-9 Cleaning the hydraulic oil cooler 3-66 Cleaning up the Pit Floor using the Attachment 2106 Components 3-9 Control and Monitoring Platform (CAMP) 2-8 Controls Adjustment Data Screen 5-17 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-148 Counter-rotation turns / Turning on the spot 2-131 CRAWLER TRACKS 3-80

D Demand control / Zero-flow regulation 2-9 Depressurizing the hydraulic system 3-48 DESCRIPTION OF THE HYDRAULIC SHOVEL 2-6 Design and function 3-86 DESIGNATED USE 1-8 Digging and Loading 2-91, 2-102 Digging and loading a truck 2-92 Digging on Ground Level 2-105 DISPOSAL AT THE END OF THE SERVICE LIFE 4-11 Double Benching 2-93 Drive unit 2-8 Dumping the load 2-104

E Electric motor – Clean 3-37 Electric motor - Lubricate 3-38 Electric motor - Safety instructions 3-37 Electric motor – Switch on and off 2-66 Electric motor can not be switched on 2-68 Electric Motor Data Screen 5-13 Electric Motor Data Screen – continued 5-14 Electrical circuit diagrams 3-44 Electrical Storm Injury Prevention 2-62 Electrical system 2-9 ELECTRICAL SYSTEM 3-39 Electrical system - Safety instructions 3-39 Electrical system (24V) - Switch on and off 2-65 Electrical system, control cabinets 3-42 Electronic hydraulic shovel control 3-67 Electronic hydraulic shovel control (pilot control) – activate 2-78 ELEKTRIC MOTOR 3-37 Emergency exit in operator’s cab and escape ladder 2-35 Emergency lowering of the working equipmen 2144

6-3

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Index Emergency shut off - Function 2-38 Emergency Stop - Reset Function 5-9 Entering and leaving the machine - Safety instructions 2-32 Eurasian Economic Union 2-31 Extract from the regulations 3-97

F Face Shovel Operation – Restricted Operation 2109 Fault Storage – Fault Detail 5-24 Fault Storage – Save to USB-Stick 5-23 Fault Storage / Fault Table - Screen 5-22 FAULT TABLES 5-30 Filling 3-88 Filling quantities - Lubricant 3-25 Filling quantities - oil 3-28 Filling quantities - other 3-28 Filter (servo control circuit), replace 3-57 Filters for swing charge pump, replace 3-59 FIRE AND EXPLOSION HAZARD 3-8, 4-5 FIRE AND EXPLOSION HAZARD 1-16, 2-5 Fire extinguisher 2-42 Folding ladder – Function (if equipped) 2-33 Function 3-87 Further machine documentation 1-4

G Gas, dust, steam and smoke 1-13 Gearbox - Checking the oil level / Topping up with oil 3-75 Grading the pit floor 2-94

H Handling Oversized Boulders / Overhangs 2-107 Heating and air conditioning 3-95 High-pressure filter for working hydraulics, replace 3-58 High-pressure filters for the servo circuit, replace 3-60 Hose line for oil changes 3-36 HYDRAULIC CIRCUIT DIAGRAM 5-34 Hydraulic Data Screen 5-15 Hydraulic equipment 1-13 Hydraulic hoses – Instructions 4-6 Hydraulic ladder - Pressure accumulator 3-96 Hydraulic oil return-flow filters, replace 3-51 Hydraulic oil return-flow filters, replace (from machine no. 170138) 3-53 Hydraulic oil tank breather filters, replace 3-56 Hydraulic shovel layout 2-7 Hydraulic system 2-8 HYDRAULIC SYSTEM 3-48 HYDRAULIC SYSTEM 4-6 Hydraulic system - Safety instructions 3-48

6-4

I Information Given on the 5-11, 5-12 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 3-4 INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9 INSPECTION PLAN - OIL 3-26 Inspection plan – Oil (legend) 3-27 Instructions on troubleshooting 5-29

K Know the situation on site 2-96

L Layout of the fault table 5-29 Lighting systems in LED technonogy, instructions 3-47 Loading setups 2-89, 2-101 Lubricant filter (Filling the lubricant container) 393 Lubricant filter (Lubricating lines) 3-94 Lubricant for bearings, swing rings and track system (Central lubrication system) 3-34 LUBRICANTS 3-29 LUBRICANTS / CONSUMABLES 3-30 Lubricants for idlers, track rollers and upper rollers (Lifetime lubrication) 3-35 LUBRICATING CHART – lubricant 3-24 Lubricating chart – Lubricant (legend) 3-25 Lubrication Data Screen 5-16

M Machine identification plate 2-30 Machine Operating Temperature Range 2-76 Machine operation with backhoe attachment, Best Practices 85 Machine operation with face shovel attachment Best Practices 2-95 Machine stability 2-95 Machine Stability 2-85 Maintenance lights – Switch on and off 2-37 Maximum Machine Inclinations 2-141 Measures 5-29 Monitoring cameras (if equipped) 2-152 MONITORING, WARNING AND CONTROL ELEMENTS 2-44 Motor number plate 2-30 Motor protection relay - Function 2-70

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Index N Noise 1-13 NOISE AND VIBRATION INFORMATION 5-37 Noise emission information 5-37 NOTES 2-153, 3-1, 4-13, 5-40 NOTES 1-1 Notes on the selection of oils and lubricants 3-29

O Oil for combustion engines (On-Board Crane, if equipped) 3-30 Oil for hydraulic system (selection) 3-31 Oil for pump gearboxes and travel gearboxes 332 Oil for swing gearboxes 3-33 Oil, grease and other chemical substances 1-13 Oilfilter (hydraulic circuit lubricant pump) 3-92 Oils / Lubricants 3-9 On-Board crane - Check tightness of fastening bolts 3-99 ON-BOARD CRANE - DRIVE UNIT 3-98 On-board crane - Lubricate 3-99 ON-BOARD CRANE (if equipped) 2-149 On-Board crane, – blocking the boom in position of rest 2-151 On-board crane, checking 2-151 On-board crane, drive unit 2-150 On-board crane, monitoring, warning and control elements 2-149 On-board crane, putting into operation 2-150 OPERATION - SAFETY INSTRUCTIONS 2-3 Operation and Maintenance Manual, where to store it in the operator’s cab 2-4 Operation Techniques 2-85 Operation with cable reel (if equipped) 2-11 OPeraTIONAL practices 2-75 Operator's seat 2-40 ORGANIZATIONAL MEASURES 1-9 Other Elements on the Front Side 5-4 OTHER MAINTENANCE 3-95

P Park the Machine 2-94, 2-108 Plan A - E 3-17 Plan N 3-13 Plan T and W 3-15 Plan V 3-11 Possible causes 5-29 Power supply 2-10 Pre-chambers working pumps, draining oil, changing oil 3-73 PREFACE 1-4 Preheating system for hydraulic oil reservoir and pump gearbox, switching on and off (if equipped) 2-73 Pressure accumulator - Emergency lowering 3-68 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS 4-7

Pressure-accumulator inspection regulations 3-83 Pressure-accumulator inspection regulations 3-97 PRODUCT SPECIFICATION SHEET 5-38 PUMP DRIVE GEARBOX 3-69 Pump drive gearbox, changing oil 3-71 Pump drive gearbox, checking oil level / Topping up with oil 3-69 Pump drive gearbox, pre-chamber 3-72 Pump drive gearbox, venting 3-72 Pump gearbox, oil filter 3-74 Putting the hydraulic shovel out of operation 3100 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3100 PUTTING THE MACHINE INTO OPERATION 262

R Recommended working direction 2-100 Recommissioning 3-100 Reducing operators exposure to vibrations 2-39 Reducing the operator's exposure to noise 2-62 Repair 4-6 REPAIR WORK - SAFETY INSTRUCTIONS 4-4 Replacing fuses 3-44 Replacing lamps and bulbs 3-44 Reservoirs for used lubricant at the A-frame Empty 3-96 Restricted Visibility 1-7, 1-9 Running-in instructions for hydraulic cylinders 2143

S Safety films and warning messages – Overview and Description 2-12 Safety instructions for hydraulic shovels with electric motor 1-15 SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS WITH ELECTRIC MOTOR 3-3, 4-3 Safety instructions governing specific operational phases 1-10 Safety messages (ANSI) – Description 2-23 Section 5-29 Securing the machine 2-147 Selection and qualification of personnel; basic responsibilities 1-10 Service station 2-62 Servicing Intervals 3-9 Servicing switch – Function 2-39 SERVICING WORK 3-36 Signal Table Screen 5-19 Signal Table Screen - Diagram 5-20 Signal Table Screen - Diagram Configuration 521 Slew Brake Test Data Screen 5-18 SLEWING GEARBOX 3-75 Slewing mechnism – Fault table 5-32

6-5

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Index SLEWING RING 3-84 Slewing ring - Instructions 3-84 Slip ring assembly, servicing work 3-44 Sound Level Information for Machines in Eurasian Economic Union Countries 1-6 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 Store Screenshot Screen 5-27 Swing Circuit Lock-Out Function 5-10 Swing gearbox, venting 3-76 Swinging ladder - Function (if equipped) 2-34

T The keys on the front side 5-4 Time-out before restart 2-67 Track drive – Fault table 5-31 Track Parking Brake – set/release 2-132 Track roller temperature – check 2-136 Track rollers 3-81 Track tensioner 3-82 Trainer's / instructor's seat 2-39 Transport - Safety instructions 2-142 Transporting and recommissioning 1-13 TRANSPORTING THE MACHINE 2-142 TRAVEL GEARBOX 3-77 Travel gearbox - Breather filter 3-79 Travel gearbox - Changing oil 3-78 Travel gearbox - Checking the oil level / Topping up with oil 3-77 Travel Speed – Recommendations 2-127 Travel straight forward/backward 2-128 Traveling 2-124 Traveling – Basic Movements 2-128 Traveling – Best Practices 2-137 Traveling – Restricted Operation 2-138 Traveling – Safety Instructions 2-124 Traveling over long distances 2-135 Traveling speed – adjust 2-132 Traveling speed on ramps and slopes- change 2134

6-6

Traveling uphill and downhill on ramps and steep slopes 2-133 TROUBLESHOOTING 5-29 Turning 2-129

U Unblocking a lubricant line 3-91 Unblocking a lubricating line 3-91 Undercarriage 2-8 Upper structure 2-8 Upper structure - basic position 2-126 Upper structure holding brake – set/release 2-136 USB Interface - Data Storage 5-26 Useful Life 1-8

V Venting the hydraulic system 3-65 Vibration information 5-37 Visibility aids 2-4 Visibility Information 1-6

W Warm-up procedure for electric driven shovels 277 Warning of special dangers 1-12 Warnings and symbols 1-6 WARRANTY 1-5 WELDING AND FLAME CUTTING WORKS SAFETY INSTRUCTIONS 4-8 Windscreen washer – Reservoir 2-39 Working hydraulics – Fault table 5-30 Working operation – basics 2-79 Working operation - Safety instructions 2-75

X Xenon floodlight projector (if equipped), replacing the lamp 3-45

EM029995-0

OMM 6040AC, 6040ACFS(3 847 037.00)-EN

Index

6-7

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