Cat 6040AC, 6040ACFS Hydraulic Excavator Operation and Maintenance Manual BI651376

BA 6040(3 847 027.00)-EN 10 / 2013

Operation and Maintenance Manual 6040AC, 6040ACFS Hydraulic Shovel

No.

BA 6040(3 847 027.00)-EN

Published by:

Caterpillar Global Mining HMS GmbH Dept. Technical Publications D-44149 Dortmund, Karl-Funke-Straße 36 Tel. 49 (0) 231 922-4340 Fax 49 (0) 231 922-5005 E-Mail dokumentation.HEX@cat.com https://mining.cat.com www.bucyrus-hex.de

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2013. 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: Operating instructions

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 PREFACE _______________________________________________________________________ 1-3 Further machine documentation _____________________________________________________ 1-3 WARRANTY______________________________________________________________________ 1-4 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-5 Warnings and symbols ____________________________________________________________ 1-5 DESIGNATED USE ________________________________________________________________ 1-6 ORGANIZATIONAL MEASURES _____________________________________________________ 1-7 Selection and qualification of personnel; basic responsibilities______________________________ 1-8 Safety instructions governing specific operational phases _________________________________ 1-8 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables____________________________ 1-9 Warning of special dangers________________________________________________________ 1-10 Gas, dust, steam and smoke_______________________________________________________ 1-11 Hydraulic / pneumatc equipment____________________________________________________ 1-11 Noise _________________________________________________________________________ 1-11 Oil, grease and other chemical substances ___________________________________________ 1-11 Transporting and recommissioning __________________________________________________ 1-11 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS____ 1-12 Safety instructions for excavators with electric motor ____________________________________ 1-13 FIRE AND EXPLOSION HAZARD____________________________________________________ 1-14 NOTES__________________________________________________________________________ 1-1 2 OPERATION _____________________________________________________________________ 2-1 OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3 Operation and Maintenance Manual, where to store it in the operator’s cab ___________________ 2-4 FIRE AND EXPLOSION HAZARD_____________________________________________________ 2-5 DESCRIPTION OF THE SHOVEL_____________________________________________________ 2-6 Shovel layout____________________________________________________________________ 2-7 Undercarriage ___________________________________________________________________ 2-8 Superstructure___________________________________________________________________ 2-8 Drive __________________________________________________________________________ 2-8 Hydraulic system _________________________________________________________________ 2-8 Control and Monitoring Platform (CAMP) ______________________________________________ 2-8 Demand control / Zero-flow regulation ________________________________________________ 2-9 Automatic reset to idling ___________________________________________________________ 2-9 Board-Control-System (BCS) _______________________________________________________ 2-9 Electrical system _________________________________________________________________ 2-9 Power supply___________________________________________________________________ 2-10 Operation with cable reel (optional)__________________________________________________ 2-11 Signs _________________________________________________________________________ 2-12 Entering and leaving the machine Safety instructions____________________________________ 2-24 Access ladder lighting ____________________________________________________________ 2-24

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TABLE OF CONTENTS Swinging ladder_________________________________________________________________ 2-25 Folding ladder (optional) __________________________________________________________ 2-26 Emergency exit in operator’s cab and escape ladder ____________________________________ 2-27 Switching the cab interior lighting on and off___________________________________________ 2-28 Switching the maintenance lights on and off ___________________________________________ 2-29 EMERGENCY STOP switch _______________________________________________________ 2-30 Servicing switch_________________________________________________________________ 2-31 Windscreen washer______________________________________________________________ 2-31 Operator's seat _________________________________________________________________ 2-32 Fire extinguisher ________________________________________________________________ 2-34 Automatic fire-extinguishing system (optional) _________________________________________ 2-35 Trainer's / instructor's seat ________________________________________________________ 2-35 Emergency escape device (optional) ________________________________________________ 2-36 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-40 PUTTING THE MACHINE INTO OPERATION __________________________________________ 2-58 Service station (tanklift) ___________________________________________________________ 2-58 Battery main switch, switching on and off _____________________________________________ 2-61 Electrical system (24V), switching on and off __________________________________________ 2-61 Switching the electric motor on and off _______________________________________________ 2-62 Time-out before restart ___________________________________________________________ 2-63 Electric motor can not be switched on________________________________________________ 2-64 In case of failure ________________________________________________________________ 2-64 Circuit breaker, switching on and off _________________________________________________ 2-65 Motor protection relay, functions ____________________________________________________ 2-66 Air conditioner (optional) __________________________________________________________ 2-68 Back-up heating operator’s cab (optional)_____________________________________________ 2-68 TRAVELLING, SAFETY INSTRUCTIONS ______________________________________________ 2-69 TRAVELLING____________________________________________________________________ 2-70 Superstructure basic position ______________________________________________________ 2-70 Travelling forwards/backwards _____________________________________________________ 2-70 Superstructure holding brake ______________________________________________________ 2-74 Track parking brake _____________________________________________________________ 2-74 TRANSPORTING THE MACHINE____________________________________________________ 2-75 Transport - Safety instructions _____________________________________________________ 2-75 WORKING OPERATION - SAFETY INSTRUCTIONS ____________________________________ 2-76 WORKING OPERATION ___________________________________________________________ 2-78 Before starting work _____________________________________________________________ 2-78 Activating the electronic servo control________________________________________________ 2-78 Swinging the superstructure _______________________________________________________ 2-79 Braking the superstructure ________________________________________________________ 2-79 Working _______________________________________________________________________ 2-80 Emergency lowering of the working equipment_________________________________________ 2-81 After daily operation _____________________________________________________________ 2-82 ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS ________________________ 2-83 Securing the machine ____________________________________________________________ 2-84

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TABLE OF CONTENTS CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)____________ 2-85 ON-BOARD CRANE (OPTIONAL)____________________________________________________ 2-86 On-board crane, monitoring, warning and control elements _______________________________ 2-86 On-board crane, putting into operation _______________________________________________ 2-87 On-board crane, drive unit_________________________________________________________ 2-87 On-Board crane, – blocking the boom in position of rest _________________________________ 2-88 On-board crane, checking _________________________________________________________ 2-88 Monitoring cameras______________________________________________________________ 2-89 NOTES_________________________________________________________________________ 2-91 3 INSPECTION AND SERVICING ______________________________________________________ 3-1 SAFETY INSTRUCTIONS FOR EXCAVATORS 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 / Greases ___________________________________________________________________ 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 – GREASE___________________________________________________ 3-24 Lubricating chart – Grease (legend) _________________________________________________ 3-25 Filling quantities – Grease_________________________________________________________ 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 greases ____________________________________________ 3-29 Avoid mixing of different hydraulic fluids ______________________________________________ 3-29 LUBRICANTS / CONSUMABLES ____________________________________________________ 3-30 I. Oil for combustion engines (On-Board Crane, option) ________________________________ 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. Grease for bearings, swing rings and track system (Central lubrication system) __________ 3-34 Greases for idlers, track rollers and support 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, cleaning ___________________________________________________________ 3-37 vii

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TABLE OF CONTENTS Electric motor, greasing___________________________________________________________ 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 Xenon floodlight projector (optional), 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 excavator 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 cooling circuit, replace oil filter _________________________________________ 3-74 SWING GEARBOX _______________________________________________________________ 3-75 Swing gearbox - Checking the oil level / Topping up with oil ______________________________ 3-75 Swing gearbox - Changing the gearbox oil ____________________________________________ 3-75 Swing gearbox, venting , __________________________________________________________ 3-76 SWING GEARBOX _______________________________________________________________ 3-77 Swing gearbox - Gearbox - Checking the oil level / Topping up with oil ______________________ 3-77 Swing gearbox - Changing the gearbox oil ____________________________________________ 3-78 Swing gearbox - venting __________________________________________________________ 3-79 TRAVEL GEARBOX ______________________________________________________________ 3-80 Travel gearbox - Checking the oil level / Topping up with oil ______________________________ 3-80 Travel gearbox - Changing oil ______________________________________________________ 3-81

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TABLE OF CONTENTS Travel gearbox - Breather filter _____________________________________________________ 3-82 CRAWLER TRACKS ______________________________________________________________ 3-83 Track rollers ___________________________________________________________________ 3-84 Track tensioner _________________________________________________________________ 3-85 Pressure-accumulator inspection regulations __________________________________________ 3-86 Checking the gas charging pressure in the pressure accumulator __________________________ 3-86 SWING RING ____________________________________________________________________ 3-87 Swing ring - Instructions __________________________________________________________ 3-87 Bearing races __________________________________________________________________ 3-87 CENTRAL LUBRICATING __________________________________________________________ 3-89 Design and function______________________________________________________________ 3-89 Function ______________________________________________________________________ 3-90 Filling up the grease container _____________________________________________________ 3-91 Breather filter___________________________________________________________________ 3-91 Checking the greasing pressure ____________________________________________________ 3-92 Checking the greasing pressure ____________________________________________________ 3-93 Unblocking a grease line. _________________________________________________________ 3-94 Unblocking a grease line. _________________________________________________________ 3-94 Oilfilter (hydraulic circuit grease pump) )______________________________________________ 3-95 Grease filter (Filling the grease container) ____________________________________________ 3-96 Grease filter (Grease lines) ________________________________________________________ 3-97 OTHER MAINTENANCE ___________________________________________________________ 3-98 Heating and air conditioning _______________________________________________________ 3-98 Equipment, check for cracks _______________________________________________________ 3-98 Reservoirs for used grease at the A-frame, emptying____________________________________ 3-99 Hydraulic ladder, pressure accumulator ______________________________________________ 3-99 Pressure-accumulator inspection regulations _________________________________________ 3-100 Extract from the regulations ______________________________________________________ 3-100 Checking the gas charging pressure in the pressure accumulator _________________________ 3-100 ON-BOARD CRANE, DRIVE UNIT __________________________________________________ 3-101 On-board crane, lubricating_______________________________________________________ 3-102 On-Board crane, checking tightness of fastening bolts __________________________________ 3-102 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ______________ 3-103 Putting the excavator out of operation_______________________________________________ 3-103 Battery storage ________________________________________________________________ 3-103 Recommissioning ______________________________________________________________ 3-103 NOTES__________________________________________________________________________ 3-1 4 REPAIR WORK ___________________________________________________________________ 4-1 SAFETY INSTRUCTIONS FOR EXCAVATORS 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

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TABLE OF CONTENTS 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 TROUBLESHOOTING ______________________________________________________________ 5-3 Instructions on troubleshooting ______________________________________________________ 5-3 Layout of the fault table ____________________________________________________________ 5-3 Possible causes _________________________________________________________________ 5-3 Measures ______________________________________________________________________ 5-3 Section ________________________________________________________________________ 5-3 FAULT TABLES ___________________________________________________________________ 5-4 Working hydraulics – Fault table _____________________________________________________ 5-4 Track drive – Fault table ___________________________________________________________ 5-5 Swing mechnism – Fault table ______________________________________________________ 5-6 Central lubricating system – Fault table _______________________________________________ 5-7 HYDRAULIC CIRCUIT DIAGRAM _____________________________________________________ 5-8 ABBREVIATIONS _________________________________________________________________ 5-9 NOISE AND VIBRATION INFORMATION ______________________________________________ 5-11 Noise emission information ________________________________________________________ 5-11 Vibration information _____________________________________________________________ 5-11 PRODUCT SPECIFICATION SHEET _________________________________________________ 5-13 NOTES_________________________________________________________________________ 5-15 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

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

The Operation and Maintenance Manual contain important information on how to operate the machine safely, properly and with maximum efficiency.

Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.

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

The Operation and Maintenance Manual must always be available in the 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 1 observed The Operation and Maintenance Manual are directed to the mining-machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days' instruction by a qualified CGM HMS GmbH (Caterpillar Global Mining Hydraulic Mining Shovels GmbH) mechanic or by attending an CGM HMS GmbH training course for operators or maintenance personnel.

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

All CGM HMS GmbH Operation and Maintenance Manuals are issued in German and then translated.

Even a good translation may give rise to questions which CGM HMS GmbH will be pleased to answer.

The Operation and Maintenance Manual are not work instructions for carrying out major repairs.

Such work is willingly done for you by the CGM HMS GmbH after-sales service.

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:

spare-parts list of the machine,

Volume 3:

crossreference list of spare-parts,

Volume 4:

electrical circuit diagram and key,

Volume 5:

documentation of the engine and of other components,

Volume 6:

Service Manual Part 1

Volume 7:

Service Manual Part 2

Depending on the size of your machine, the documentation can also consist of more volumes.

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

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

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

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Complies with VDMA recommendation "Operation and Maintenance Manual"

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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 CGM HMS 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 CGM HMS GmbH Service.

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

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

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



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



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

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

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

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

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

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

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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.

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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,

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".

 blasted rock,

Lifting eyes on the lower carriage

 ore,

-

are settled for transporting with a crane only.

-

must not be used for towing a machine.

 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 desigated use also involves observing the instructions set out in the Operation and Maintenance Manual and complying with the inspection and maintenance directives.

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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.

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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.

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 sparts 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

Safety instructions governing specific operational phases

Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

Standard operation

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.

Avoid any operational mode that might be prejudicial to safety.

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

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

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

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

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

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.

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

Persons accopanying the operator must be seated on the passenger seat provided for this purpose.

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Introduction 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 engines.

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.

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.

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

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair.

Never use aggressive detergents. Use lint-free cleaning rags.

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

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

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.

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.

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

High-voltage system

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

The high voltage is generated by a ballast unit.

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

Switch off the electrical system of the excavator 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

1-10

BA 6040(3 847 027.00)-EN

Introduction Gas, dust, steam and smoke

Noise

Always start and operate the engine in a wellvented area;

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

If in an enclosed area, vent the exhaust to the outside;

Always wear the prescribed ear protectors.

Do not modify or tamper with the exhaust system

Oil, grease and other chemical substances

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).

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

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

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

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

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

Hydraulic / pneumatc 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 / pneumatic system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Hydraulic- and pneumatic 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.

1-11

BA 6040(3 847 027.00)-EN

Introduction ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS 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)".

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 excavator 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.

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 excavator 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 excavator equipment must never be set down on the power cable.

When the excavator is being moved, the cable must never be pulled or dragged over the ground.

Whenever work is being carried out on electrically powered excavators, 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.

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BA 6040(3 847 027.00)-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 excavator operator and all personnel working on the excavator 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 excavator 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 excavators 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 excavator  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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BA 6040(3 847 027.00)-EN

Introduction FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain informationon 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.

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 excavator before starting a job.

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

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

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

Do not store or handle any flammable substances during operation.

Do not extinguish flammable liquids with water.

Use:  dry-powder, 

carbon-dioxide or



foam extinguishing compounds.

Clean the excavator 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.

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.

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

DANGER TO LIFE

Even battery gases can ignite in open flames or fire.

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

open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator 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 excavator.

1-14

Call the fire brigade.

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

BA 6040(3 847 027.00)-EN

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

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BA 6040(3 847 027.00)-EN

Introduction

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BA 6040(3 847 027.00)-EN

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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BA 6040(3 847 027.00)-EN

OPeration

2-2

BA 6040(3 847 027.00)-EN

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

Safety belt For machines with a safety belt for operating personnel: Check the safety belt attached to the operator's seat. In the event of damage or after an accident, have it replaced immediately.

Apply the safety belt before starting work.

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

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

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

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the 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 Always face the machine when entering or leaving it.

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

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

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

Hazard range 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.

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BA 6040(3 847 027.00)-EN

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

Operation and Maintenance Manual, where to store it in the operator’s cab

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

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.

Marshallers The marshaller must keep outside the hazard zone.

The binder with the Operation and Maintenance Manual can be stored in the tray (Fig. 2-1:).

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.

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.

2-4

Fig. 2-1:

BA 6040(3 847 027.00)-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 excavator.

Clean the excavator 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 excavator in places where – combustible substances such as coal dust or tar are present, – open or smouldering fire may occur.

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

Flying sparks may cause fire on the ground that can spread to the excavator.

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BA 6040(3 847 027.00)-EN

OPeration DESCRIPTION OF THE SHOVEL

Fig. 2-2:

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OPeration Shovel layout Fig. 2-2:

37 - Control-cabinet with CMS

Undercarriage

38 - Control-cabinet (24V) in cab module

1 - Track drive 2 - Idler 3 - Track roller 4 - Support roller 5 - Crawler track 6 - Track tensioner 7 - Swing ring 8 - Escape ladder 9 - Slip ring assembly 10 - Cable guide for drag cable

Superstructure 11 - Electric motor 12 - Switchgear cabinet medium voltage (6.6 kV / 7.2 kV / 7.2 kV); circuit breaker; DER I and II 13 - Switchgear cabinet 14 – Connection box electric motor 15 - Switchgear cabinet 400V, motor protection relay, mains power supply 16 - Switchgear cabinet power factor correction 17 - Hydraulic oil reservoir 18 - Hydraulic oil cooler

with battery main switch 39 - On-board-crane (optional) 40 - Drive unit for on-bord-crane (optional) 41 - Service station (Tanklift) 44 - Grease container of central lubricating system 46 – Hydraulic ramp-type ladder 47 - Ladder 48 - Escape ladder (optional) 50 - Counterweight

Loading bucket 51 - Boom 52 - TriPower linkage 53 - Stick 54 - Bottom-dump bucket 55 - Boom cylinder 56 - Stick cylinder 57 - Tipping cylinder 58 - Bottom-dump cylinder 64 - Control valves working equipment 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 36 – Batteries

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OPeration Undercarriage The undercarriage of the hydraulic excavator 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.

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

Drive 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 excavator.

Four interconnected electronic units ensure optimal use of the installed engine power. Microprocessors are used to adapt the power output of the hydraulic pumps optimally to actual operating conditions. The machine is thus prevented from demanding more hydraulic power than the diesel engines can provide.

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

As soon as movement is detected, the corresponding signals are transmitted to the electronic units. These units activate the drive control in order to provide the hydraulic energy needed for working.

Only then do they activate the electro-hydraulic valves which control the execution of the working movements.

BA 6040(3 847 027.00)-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 excavator operating conditions and to evaluate, store and display these data to the excavator 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 excavator are compared to the predefined reference values. Inadmissible deviations are indicated as fault messages on a display screen. Sensor or transducer defects or defective connecting cables are detected and indicated by plain-text messages.

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

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

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 excavator 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)

7200 V 60 Hz

Control voltage (low voltage)

400 / 230 V

Lighting voltage

24 V

Emergency voltage

24 V

Control voltage

24 V

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

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

Fig. 2-3:

Fig. 2-4:

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BA 6040(3 847 027.00)-EN

OPeration Operation with cable reel (optional) (Fig. 2-5:) 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.

Fig. 2-5:

 Turn rotary switch - cable reel (3, Fig. 2-5:) to automatic operation (Auto).

Manual operation  Turn rotary switch - cable reel (3, Fig. 2-5:) 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. 2-6:) 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. 2-6:

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BA 6040(3 847 027.00)-EN

OPeration Signs Warning and instruction signs Observe the warning and instruction signs attached to the machine.

Keep the signs legible and clean.

Replace signs immediately if they have become illegible.

New warning and instruction signs can be ordered from the CGM HMS GmbH Spare Parts Service.

The ordering spare part numbers are set out in the spare-parts list of the machine.

Fig. 2-7: - Fig. 2-16: 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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OPeration

Fig. 2-7:

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BA 6040(3 847 027.00)-EN

OPeration

Fig. 2-8:

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BA 6040(3 847 027.00)-EN

OPeration

Fig. 2-9:

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OPeration

Fig. 2-10:

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BA 6040(3 847 027.00)-EN

OPeration

Fig. 2-11:

2-17

BA 6040(3 847 027.00)-EN

OPeration

Fig. 2-12:

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OPeration

Fig. 2-13:

2-19

BA 6040(3 847 027.00)-EN

OPeration

Fig. 2-14:

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OPeration

Fig. 2-15:

2-21

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OPeration

Fig. 2-16:

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OPeration Machine number The identification plate (Fig. 2-18:) with the machine number is attached to the front side of the A-frame (arrow, Fig. 2-17:).

Fig. 2-18:

Fig. 2-17:

Motor number The serial number plates (Fig. 2-19:) for the electric motor are located on the electric motor.

Fig. 2-19:

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.

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

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

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

From outside: The pull-switch (2, Fig. 2-21:) of the lighting system is located beneath the superstructure. The lights are switched on from the ground by means of the pull-rope.

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

From the cab: The switch is located besides the door (arrow, Fig. 2-22:).

For entering and leaving use only the ladders, steps, platforms and grab handles provided (see illustration in Fig. 2-20:).

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

Always face the machine when entering or leaving it.

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

Fig. 2-21:

Fig. 2-20:

Fig. 2-22:

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OPeration Swinging ladder

Lowering the swinging ladder (from the upper carriage)

Raising resp. lowering the swinging ladder (Fig. 2-23:).

 Start engine.  Push lever (1, Fig. 2-24:)on control valve (2) downwards to position “ II “.

The swinging ladder is lowered (Fig. 2-23:) The swinging ladder can also be lowered when the engine ist stopped.

Fig. 2-23:

Raising the swinging ladder (from the upper carriage)  Start engine.  Pull lever (1, Fig. 2-24:) on control valve (2) upwards to position “ I “.

The swinging ladder is raised (Fig. 2-25:)

Fig. 2-25:

Lowering the swinging ladder (from the bottom)  Pull down rope (3, Fig. 2-26:).

The swinging ladder is lowered (Fig. 2-23:).

Fig. 2-24:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-25:).

Fig. 2-26:

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OPeration Folding ladder (optional) Raising resp. lowering the folding ladder (Fig. 2-27:).

Lowering the folding ladder (from the upper carriage)  Start electric motor.  Push lever (1, Fig. 2-28:) on control valve (2) downwards to position “ II “.

The folding ladder is lowered (Fig. 2-27:).

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

Fig. 2-27:

Raising the folding ladder (from the upper carriage)  Start electric motor.  Pull lever (1, Fig. 2-28:) on control valve (2) upwards to position “ I “.

The folding ladder is raised (Fig. 2-29:).

Fig. 2-29:

Lowering the folding ladder (from the bottom)  Pull down rope (3, Fig. 2-30:).

The folding ladder is lowered (Fig. 2-27:).

Fig. 2-28:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-29:).

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Fig. 2-30:

BA 6040(3 847 027.00)-EN

OPeration Emergency exit in operator’s cab and escape ladder The sliding window (arrow, Fig. 2-31:) 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. 2-32:) 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. 2-32:

 Kick down locking lever (1, Fig. 2-33:). The escape ladder is now unlocked and moves down quickly to the ground.  Swing barrier (2, Fig. 2-33:) to the right and use the ladder to escape downwards.

Fig. 2-33:

Fig. 2-31:

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OPeration Switching the cab interior lighting on and off The cab interior lighting can be switched on and off with the switches (arrow, Fig. 2-34:), (96, Fig. 2-35:) and (arrow, Fig. 2-36:) 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. 2-34:

Fig. 2-35:

Fig. 2-36:

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OPeration Switching the maintenance lights on and off The maintenance lights in the various modules can be activated from a central point with the switches (arrow, Fig. 2-37:) or (95, Fig. 2-38:).

The invidual modules are also equipped with switches, for example the engine module: Switch at the switchgear cabinet behind the hydraulic oil reservoir (1, Fig. 2-39:).

Fig. 2-37:

Fig. 2-38:

Fig. 2-39:

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

Medium voltage 6.6 kV / 7.2 kV is still alive at the input side of the circuit breaker switch (in control column medium voltage 6.6 kV / 7.2 kV).

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.

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").

Fig. 2-40:

In an emergency, actuate one of the EMERGENCY STOP switches.

The EMERGENCY STOP switches are located  in the control column in the operator's cab (31, Fig. 2-40:), 

in the front of the 400V control cabinet in the counterweight (3, Fig. 2-41:),



near the service lift (6, Fig. 2-42:). The pull switch is is operated by a string (5).

The electrical system can be switched on after the EMERGENCY STOP switches are activated, to do so, pull out switches (Pull switch Fig. 2-42: must be pushed in).

Fig. 2-41:

Fig. 2-42:

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OPeration Servicing switch

Windscreen washer

Before starting live-line servicing work e.g. measuring and testing with voltage applied, press switch (4, Fig. 2-43:) and secure it with a padlock.

The reservoir of the windscreen washing system (1, Fig. 2-44:) is installed in the cab module. For the reservoir capacity refer to the "Refilling quantities Other" table.

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

Fig. 2-44:

Fig. 2-43:

2-31

BA 6040(3 847 027.00)-EN

OPeration Operator's seat The operator's seat (Fig. 2-45: and Fig. 2-46:) can be adjusted in several positions.

Fig. 2-45:

2-32

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"

BA 6040(3 847 027.00)-EN

OPeration

Fig. 2-46:

2-33

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OPeration Fire extinguisher

Handling

The excavator is equipped with two four extinguishers. The conventional one is located near the operators cab (Fig. 2-47:), the carbon dioxide fire extinguishers are located near the electric motor and switching cabinets.

Fig. 2-48:

 Pull out securing pin (2, Fig. 2-48:).  Strike knob (3) hard, then release again.

Fig. 2-47:

 Operate the extinguishing gun.

The excavator operator and the maintenance personnel must informthemselves 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.

After fire-fighting, the extinguisher must be refilled Immediately and prepared ready for use.

Extinguishing agent

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

The conventional fire-extinguisher is filled with 12 kg (26.4lb) Glutex. This extinguishing agent is used for fighting fires of classes A, B and C. Fires are extinguished fast, perfectly and without residues.

The carbon dioxide fire extinguishers are intended for fighting fires of electrical parts.

2-34

Inspection

Have the fire-extinguisher checked at the prescribed intervals by authorized testing agencies.

BA 6040(3 847 027.00)-EN

OPeration Automatic fire-extinguishing system (optional) 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 excavator 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.

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

For the safety of the trainer / instructor during excavator operation the cab is equipped with a second seat. This seat is installed behind the operator's seat (Fig. 2-49:).  Sit down on this seat and do not forget to fasten the seat-belt, if installed (arrow, Fig. 2-49:).  Do not leave this seat during the training / instruction session and /or as long as the machine is in operation.

Individual extinguishing circuits can be activated manually.

Inspection 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.

Fig. 2-49:

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OPeration Emergency escape device (optional) Elements of the harness (Fig. 2-50: - Fig. 2-52:) Pos. Designation Back support 1 Shoulder belt 2 Shoulder belt 3 Loop (chest belt) 4 Loop (chest belt) 5 Loop (back support) 6 11 Holding device 12 Fall arrester 13 Guidance line 14 Hanging up line 15 Handbag with harness 16 Snap hook 17 Hook safety device

Fig. 2-51:

Fig. 2-52:

Fig. 2-50:

Important hints Read and observe the Description of the supplier.

Before using operator shall have received adequate training.

The harness must be used by one person only.

He is responsible for the appropriate use and maintenance.

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

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

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OPeration Taking on harness  Take harness out of handbag (15, Fig. 2-53:).

 Pull loop (6) of the back support (1) between your legs to the front (Fig. 2-55:).  Pull loop (5, Fig. 2-56:) through loop (6).

Fig. 2-53:

 Take on shoulder belts (2 and 3, Fig. 2-54:).

Fig. 2-56:

 Pull loop (4, Fig. 2-56:) through loop (5).  Press the hooking safety device (17, Fig. 2-56:) of the snap hook (16).

Fig. 2-54:

 Pull back support (1, Fig. 2-54:) behind your body (Fig. 2-55:). The loops (4 and 5) are in front of your body.

Fig. 2-57:

Fig. 2-55:

2-37

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OPeration

 Hang up loop (4, Fig. Fig. 2-58:) into snap hook (16).

Fig. 2-58:

 Release hooking safety device (17, Fig. 2-59:).

Fig. 2-59:

2-38

If you have the harness put on in such a way in case of danger you can escape from the excavator (Fig. Fig. 2-60:).

Fig. 2-60:

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OPeration

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2-39

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OPeration MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-61:

2-40

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OPeration (Fig. 2-61:) BCS, Board-Control-System No. 1

2

Element BCS

Monitor

Function Electronic system for measured data acquisition and processing

Board Control System, acquisition and display of important operating data of the hydraulic shovel.

BCS

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

Note:

Symbol

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”.

Do not remove the film visible on the screen surface. This is a polarization film which makes the displayed graphics much better visible.

3

4

Push-button

Push-button

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

2-41

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OPeration

Fig. 2-62

2-42

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OPeration (Fig. 2-62) 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.

2-43

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OPeration

Fig. 2-63:

2-44

BA 6040(3 847 027.00)-EN

OPeration (Fig. 2-63:)

No.

Element

Function

Key-switch

Switches the electrical system on and off.

33

Buzzer (inside the control column)

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

34

Socket connectors

Connection of electronic devices for fault diagnosis purposes.

32

35

Switch

Emergency shut-off

Symbol

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

2-45

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OPeration

Fig. 2-64:

2-46

BA 6040(3 847 027.00)-EN

OPeration (Fig. 2-64:) 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

Lamp is lit up when the circuit breaker is switched on. Medium voltage 6.6 kV / 7.2 kV applied.

50

Indicator lamp

Rotary field monitoring

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

Symbol

2-47

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OPeration

Fig. 2-65:

2-48

BA 6040(3 847 027.00)-EN

OPeration (Fig. 2-65:) 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.

Function Symbol No. Element Push-button Superstructure hold- Blocks the superstructure.

61 ing brake

63

64

Push-button

Push-button

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.

Press the switch face with the symbol: Hydraulic shovel The parking brake is applied permanently. parking brake, for Service and Mainte- The hydraulic shovel cannot be moved. nance purposes only 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.

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”.

2-49

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OPeration

Fig. 2-66:

2-50

BA 6040(3 847 027.00)-EN

OPeration (Fig. 2-66:) 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, only parallel forward travel is possible. in case of backward travel and cornering, the machine switches back automatically into the 1st travelling stage.

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 tanklift.

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 (option)

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

76

81

2-51

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OPeration

Fig. 2-67:

2-52

BA 6040(3 847 027.00)-EN

OPeration (Fig. 2-67:) 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 (optional)

Switches the preheating system on and off.

96

Switch

Cable reel (optional)

Switches the cable reel system on and off.

2-53

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OPeration

Fig. 2-68:

2-54

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OPeration (Fig. 2-68:) 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

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

Electronic hydraulic The electronic hydraulic shovel control (servo-control) is activated when the operashovel control tor sits down on the seat. (servo-control) The electronic hydraulic shovel control (servo-control) is deactivated when he leaves the seat.

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

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

Warning signal

Footrest 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.

Control lever

Control lever

Push-button Thumb wheel

Shovel trap (shovel equipment only)

Push-button

By-pass for the automatically switch off for stickand /or backhoe cylinders (Option)

Thumb wheel

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

Function can be overridden by Pedal 111.

(Thumb wheel is spring centered).

Lower half pushed – automatically stopped stick- and/or backhoe cylinders can be driven slowly to the limit stopps.

Upper half pushed – Each press on the button increments the loaded dumper count for by "1". (Count reset with button (91)).

Not used on this machine.

2-55

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OPeration

Fig. 2-69:

2-56

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OPeration (Fig. 2-69:)

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

2-57

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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 dailiy start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

Otherwise, increased fire and explosion hazard will exist.

Pos. Fluid Fig. 2-70: 5 10 11

Express coupling for

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.

Service station (tanklift)

Lowering the service station

The excavator is equipped with a central service station (Fig. 2-70:). 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).

Draw out control knob (21, Fig. 2-70:) 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. 2-70:).

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.

Fig. 2-70:

2-58

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

BA 6040(3 847 027.00)-EN

OPeration

Assemblies resp. Measuring device reservoirs Pump drive gearDipstick (1, Fig. 2-71:) box Hydraulic oil tank

Remarks 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").

BCS monitor (Fig. 2-74:), Checking the oil level: Inspection glass (1, Fig. Extend the piston rods of stick and bucket cylinders 2-72:), sign (2. Fig. 2-72: halfway and stand working equipment on the ground and Fig. 2-73:) (as shown on sign 2, Fig. 2-73:).

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. 2-71:

Fig. 2-73:

Fig. 2-72:

2-59

BA 6040(3 847 027.00)-EN

OPeration

Assemblies resp. Measuring device reservoirs

Remarks

Grease container BCS display (Fig. 2-74:) – cental lubricating system

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

Fill in grease using express coupling (11, Fig. 2-75:).

Switch on the display system with the toggle switch (23, Fig. 2-75:). Monitoring lamp (22) lits up.

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

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

Monitoring lamp (22) is then off.

Fig. 2-75: Fig. 2-74:

2-60

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OPeration Battery main switch, switching on and off

Electrical system (24V), switching on and off

When the excavator is disconnected from the medium voltage (6.6 kV / 7.2 kV) the electrical system (24V) is supplied with voltage by two batteries.

The electrical system is switched on or off with key-switch (32, Fig. 2-77:).

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

Switching the electrical system (24V) on

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.

Switching the battery main switch on  Turn switching handle of main switch (1, Fig. 2-76:) to position "ON".

Switching the battery main switch off  Turn switching handle of main switch (1. Fig. 2-76:) from position "ON" to position "OFF".

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

 Insert key into key-switch (32) and turn to the right.

Now all electronical assemblies of the excavator 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. 2-76:

Fig. 2-77:

2-61

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OPeration Switching the electric motor 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 excavator itself.

Switch on the electric motor only when all these work on the excavator is finished and all persons leave the danger area.  Switch on battery main switch (see: "Battery main switch, switching on and off").

Fig. 2-78:

 Switch on electrical system (24V) (see: "Electrical system (24V), switching on and off").  Check telltales (49 and 50, Fig. 2-78:), 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.

Switching the electric motor on  Actuate switch-key (41, Fig. 2-79:), 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).

2-62

Fig. 2-79:

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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.

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 timeout circuit (PLC) the electric motor can be switched on only three times a hour (time-out period is 30 minutes).

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

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. 2-80:). The electric motor starts running down.  Turn key in key-switch (32) counter-clockwise and withdraw.

The control voltage is switched off.

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

The BCS monitor (Fig. 2-81:) displayes the remaining time until the time-out period is over.

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. 2-81:

Fig. 2-80:

2-63

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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 "6.6 kV / 7.2 kV 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 6.6kV 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 excavators. Only these have the skills to work in a safe way, for trouble shooting and removing the fault.

2-64

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 

6.6 kV / 7.2 kV/ 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 excavator may be energized.

The operator must notify the electrician in charge from the excavator superstructure.

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

BA 6040(3 847 027.00)-EN

OPeration Circuit breaker, switching on and off By means of the circuit breaker the supplied medium voltage 6.6kV can be connected to the excavators electrical system or can be disconnected from it. The circuit breaker is installed in the control cabinet 6.6 kV / 7.2 kV (outer view, Fig. 2-82:, inside view Fig. 2-83:).

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. 2-83:) light up in green colour.

Switching the circuit breaker  The circuit breaker is switched on and off by means of a actuating lever (Fig. 2-84:).

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.

The circuit breaker is operated with an actuating lever which is stored in a fixture inside the control cabinet 6.6 kV / 7.2 kV.

Fig. 2-84:

Fig. 2-82:

Fig. 2-83:

2-65

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OPeration Motor protection relay, functions The electric motor is equipped with a motor protection relay. The relay is located in the 400 V switch cabinet (Fig. 2-85:).

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:

Fig. 2-85:



protection against overcurrents,



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. 2-86:).

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. 2-86:):

1 2 3 4 5 6

7 8 9

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

Fig. 2-86:

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

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OPeration Air conditioner (optional) 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. 2-87:).

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

Back-up heating operator’s cab (optional) The back-up heating for the operator’s cab is located in the module below the operator’ cab (Fig. 2-88:). 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. 2-89:). 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. 2-87:

Control panel (SIGMA) (see Fig. 2-87:) 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. 2-88:

Fig. 2-89:

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

Close the cab door.

If the machine is fitted with a safety belt for the operator, fasten the belt.

If the superstructure is turned by more than 90° from the BASIC POSITION, the excavator travels in the opposite direction to that selected.

If the position of the superstructure in relation to the undercarriage is not exactly known, touch the accelerator lightly to see which direction the machine takes, before initiating the full travelling movement.

Fig. 2-91:

Warn persons in the immediate vicinity by sounding the horn before setting off.

Running-in specifications for components of the crawler tracks

Never drive across slopes.

Prior to initial commissioning and/or after repair work, run in the idlers, track rollers and support rollers as follow:  Raise the equipment (Fig. 2-90:) or (Fig. 2-91:).

Take the utmost care on slippery, greasy ground.

If the machine is to be driven a longer distance, the superstructure must be secured against turning by means of the superstructure holding brake.

 Drive the excavator in revers approx. 50 m / 164ft.  Drive the excavator in forwards approx. 50 m / 164ft.  Stop the excavator.  Measure the temperature at each dler, track roller and support roller with an infrared thermometer (at a temperature of approx. 100° C / 212°F wait for idlers, track rollers and support rollers to cool down).  Repeat this running-in procedure up to 10x.

Fig. 2-90:

 Check all idlers, track rollers and support rollers for leaks.

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 TRAVELLING Superstructure basic position Travel direction and sense of actuation of pedals (112 and 113, Fig. 2-93:) are identical only when the excavator is in its BASIC POSITION (Fig. 2-92:).

Travelling forwards/backwards  Travelling forwards: depress pedals (112 and 113) forwards, the excavator travels in the direction of the idler (2, Fig. 2-92:).  Travelling backwards: depress pedals (112 and 113, Fig. 2-93:) backwards, the excavator travels in the direction of the drive sprocket (4, Fig. 2-92:).

During travelling an acoustic warning sounds (Travel Alarm).

Fig. 2-92:

If the superstructure is swung out of its basic position by more than 90° (Fig. 2-94:), the excavator moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-93:) are depressed.

Fig. 2-94:

The pedals return automatically to their "0" positions when released.

Reverse the excavator only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

Do not travel across slopes.

When travelling uphill or downhill, the travel drive must always be at the rear.

Travel only in the basic position of the excavator and only forwards.

Be extremely careful on slippery and greasy ground.

Fig. 2-93:

If the operator is not completely sure of the position of the superstructure with regard to the undercarriage, pedals (112 and 113) should be depressed slightly in order to find out which way the excavator moves before initiating the full travelling movement.

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

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OPeration Regulating the travelling speed Travelling on level ground: Regulate the travelling speed with  pedals (112 and 113, Fig. 2-95:)  set the first (slow) range or the second (fast) range with switch (72, Fig. 2-96:).

Change speed range only when the excavator is stationary.

Travelling uphill and downhill Read and observe the "Travelling Safety instructions" chapter.  Depress padals (112 and 113, Fig. 2-95:) fully to the limit stop.

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

The travel retarder valve works correctly if pedals (112 and 113) are fully depressed down to the limit stop.

Should the travelling speed become too high when travelling downhill release pedals (112 and 113) to stop the excavator.

Fig. 2-95:

Fig. 2-96:

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OPeration Cornering Never use the working equipment to raise one side of the undercarriage and then turn the undercarriage by initiating the swing and/or the travelling function.

To take a right-hand corner forwards:  depress only pedal (112, Fig. 2-97:) forwards.

To take a lefthand corner forwards:  depress only pedal (113) forwards.

Turning To turn to the right:  depress pedal (112) forwards and pedal (113) backwards.

To turn to the left:  depress pedal (113) forwards and pedal (112) backwards.

This way of working is contrary to the excavator'sdesignated use.

There is a risk of accident. Moreover, the tracks, swing gear, roller bearing swing ring, backhoe or bucket back-wall and the front part of the bucket are subjected to inadmissibly high stresses.

Fig. 2-98:

Fig. 2-97:

Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-98:).

Cornering to the left: forwards

from pos. 1 to pos. 2

backwards

from pos. 2 to pos. 3

forwards

from pos. 3 to pos. 4

The same procedure should be adopted if the excavator is to be driven out of depressions (Fig. 2-99:): Cornering to the left

from pos. 1 to pos. 2

Cornering to the right

from pos. 2 to pos. 3

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Fig. 2-99:

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OPeration Travelling over long distances Travel only forwards with the excavator in its basic position.

Travelling backwards over longer distances could damage parts of the undercarriage.

Read and observe the "Travelling – Safety instructions" chapter.

Backhoe bucket equipment (Fig. 2-101:)  Fully extend boom cylinder (1),  extend backhoe cylinder (2),  extend stick cylinder (3) to such an extent as to reach the position of the working equipment shown in (Fig. 2-101:).

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

Keep the loading or the backhoe bucket close to the ground. For a more uniform loading of the tracks, the equipment must, however, be kept at a steep angle (Fig. 2-100: / Fig. 2-101:).

Loading bucket equipment (Fig. 2-100:):  Fully extend boom cylinder (1),  retract bucket cylinder (2),  retract stick cylinder (3) to such an extent as to reach the position of the working equipment (Fig. 2-100:).

Fig. 2-101:

Lower the equipment when travelling underneath obstacles.

If the equipment position must be changed:  stop the excavator,  change the position,  continue to travel.

After travelling for 15 minutes without interruption, stop the excavator and check the temperatureof the track rollers.

If the temperature does not exceed ca. 100° C / 212°F, continue travelling.

Fig. 2-100:

In case of higher temperatures:  Stop travelling. Resume travelling only after the track rollers have cooled down to ca. 40° C / 104°F.

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OPeration Superstructure holding brake

Track parking brake

The excavator is equipped with four superstructure holding brakes. The superstructure holding brakes are used to block the superstructure and the undercarriage.

The hydraulic shovel is equipped with four travelling gear brakes which are integrated in the travel drives.

The superstructure holding brakes are parking brakes.

Do not actuate the switch unless the superstructure is stationary. Do not use this switch while the superstructure is still in motion. Risk of damage to the brakes and the slewing gears.  To activate the holding brakes, press switch (61, Fig. 2-102:):  when the excavator is parked, 

when travelling over longer distances.

The travelling gear brakes are parking brakes.

They protect the hydraulic shovel from rolling forwards or backwards. When the machine is parked, travel brakes are activated automatically. The brakes are deactivated during operation of the machine.

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

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

Fig. 2-102:

Fig. 2-103:

For Service and Maintenance purposes the travelling gear brakes can also be applied with switch (63, Fig. 2-103:).

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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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 excavator's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Secure the transport vehicle against rolling away.

Transport The dimensions and the service weight of the fully assembled excavator do not allow the excavator to be transported in an undismantled state on a lowbed 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. 2-104:).

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.

Use only tying equipment of sufficient strength (the weights and dimensions of the excavator are set out in the "Technical specifications").

Fig. 2-104:

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OPeration WORKING OPERATION - SAFETY INSTRUCTIONS Read the sections "Fundamental safety instructions" and "Operation, safety instructions" carefully and observe the instructions given in them.

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

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements.

Sound the horn to warn persons in the immediate vicinity before starting work.

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

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

Ensure that the attachment has adequate clearance below overhead power lines and structures.

Trenches and working faces may give way. Keep well clear of them.

Do not operate the machine, 

when several track rollers or 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 GmbH as "abusive utilization".

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

2-76

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 excavator can operate at a higher engine speed.

BA 6040(3 847 027.00)-EN

OPeration Avoid extreme positions of the attachment Parts of the attachment may damage the machine if they are moved into extreme positions (see illustrations Fig. 2-105: - Fig. 2-109:).

Work carefully, avoiding extreme positions of this kind.

Fig. 2-107:

Fig. 2-105:

Fig. 2-108:

Fig. 2-106:

Fig. 2-109:

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OPeration WORKING OPERATION Before starting work Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded equipment for abt. 5 minutes.

This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts.

Warming up At low outside temperatures it is necessary to run the hydraulic system up to operating temperature.

The temperatures at which warming up is necessary depend on the type of hydraulic oil used; see also "Oils for hydraulic systems".  Switch on the electric motor and start to perform no-load working movements for abt. 10 minutes with the excavator.

Activating the electronic servo control The hydraulic shovel can execute working movements only after the electronic servo control (pilotcontrol) has been activated.

The servo-control block is enabled by switch (71, Fig. 2-110:).

At the beginning of the work, the electronic servo control (pilot-control) is activated by a contact in the operator's seat (105):  Electronic servo control ON The operator is sitting on his seat.  Electronic servo control is OFF The operator's seat is empty.

Note: During operation it is absolutely necessary that the operator keeps sitting on his seat.

Otherwise working movements may be interrupted suddenly: risk of damaging the holding brakes and the gearboxes.

Fig. 2-110:

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OPeration Swinging the superstructure Swinging of the superstructure is possible onlywhen: 

the superstructure 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 superstructure to the right move control lever to the right (115, Fig. 2-111:).  To swing the superstructure to the left move control lever to the left (115).

After releasing, the control lever returns automatically to position “0”.

Releasing the control lever (115) is not sufficient to brake the superstructure automatically. In order to brake the superstructure, the control lever must be moved in the direction opposite the swinging movement (reversing).

Fig. 2-111:

Braking the superstructure The superstructure can only be braked by moving control lever (115) in the direction opposite the swinging movement (reversing).

The superstructure does not stop automatically by simply releasing the swing control lever (115).

To brake the superstructure, the swing control lever (115) must be moved in opposite direction.

In an emergency, activate the holding brake by pressing switch (61, Fig. 2-112:).

Fig. 2-112:

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OPeration Working When released, all control levers for working operation return automatically to position “0”.

Sound the horn to warn persons in the immediate vicinity before starting work.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter).

Level a surface only in the bucket’s digging direction. Never “beat” or “sweep” with the bucket.

Do not level off a surface with the front shell of the bucket open.

Close bucket completely before beginning to dig.

Fig. 2-113:

Extending and retracting the bucket or backhoe bucket stick  To extend the stick: push control lever (115, Fig. 2-113:) forwards.  To retract the stick: pull control lever (115) backwards.  To retract the stick with pressure: (only on bottom-dump bucket equipment) depress button (102) and push control lever (115) backwards.

Opening and closing the bottom-dump bucket  To open the bucket: press pedal (111, Fig. 2-113:) forwards or turn thumb wheel (118) forwards.  To close the bucket: press pedal (111) backwards or turn thumb wheel (118) backwards.

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

Fig. 2-114:

Raising and lowering the boom

Filling and emptying the bucket or the backhoe

 To raise the boom: pull control lever (116, Fig. 2-114:) backwards.

 To fill/tip back the bucket: shift control lever (116, Fig. 2-114:) to the left.

 To lower the boom: push control lever (116) forwards.

 To empty the bucket by dumping/tipping: shift control lever (116) to the right.

 To lower the boom with pressure: depress button (103) and push control lever (116) forwards.

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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. 2-115:) 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. 2-116:) and hold.  Push control lever (116) forwards to lower the working equipment to ground.  Contact the responsible service personnel as soon as possible.

Fig. 2-115:

Fig. 2-116:

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OPeration After daily operation Escaping oil pollutes the environment.

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.

 Repair leaks immediately (or have them repaired).

 Switch off the electric motor.

 Report oil accidents to the responsible person.

 Shift both control levers into all directions todepressurize the hydraulic cylinders.

 Check the superstructure, undercarriage and the working equipment for damage and all steel components for cracks or fractures.

 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.

2-82

 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. .

BA 6040(3 847 027.00)-EN

OPeration ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS

Tools and auxiliaries

Personel

Tools, hoists, slings, trestles and other devices must be in a reliable, safe state.

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 .

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.

The operating manual, and in particular the section headed “Fundamental Safety Instructions”, must have been read and understood.

Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Securing the working equipment

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. 2-117:), 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. 2-117:).

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 Fig. 2-117:

The machine is equipped with an integrated cabprotection roof (FOPS).

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OPeration Securing the machine Risk of injury

Secure the machine as described below:  before carrying out any fitting and modification work on the working equipment,

The machine must not be started by unauthorized persons.



Therefore, secure the machine.

 Park the machine on level and stable ground.

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.

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.

2-84

before carrying out any servicing and repair work on the machine.

 Stand the working equipment on the ground.  Switch off the electric motor.  Depressurize the hydraulic system.  Withdraw the key from the key-switch.

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OPeration CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) Use GLEITMO 815 anti-corrosive agent only.

Other agents are not approved by CGM HMS GmbH. All pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated GLEITMO 815 anti-corrosive agent before fitting.

GLEITMO 815:  permits easy fitting and dismantling, 

protects against rust, oxidation and similar wear,



prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminium and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden.

Application of GLEITMO 815  Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel.

Rust patches must be thoroughly removed, if any.

All parts must present a dry, bright metal surface.  Apply a thin layer of GLEITMO 815 on pins and all bearings using a brush or a spray can.

Pin shafts and bearings must be completely covered by the protective layer.

If the protective layer of a pin already treated with GLEITMO 815 is damaged, these areas must be touched up before fitting the part.  Fitting and securing of pins If the pin is too heavy to be fitted manually, apply GLEITMO 815 at first only on abt. A quarter of the pin’s length Then position pin by means of a lifting gearready for fitting.

Apply GLEITMO 815 on the remaining length of pin shaft, fit pin and secure.

Part number of GLEITMO 815 is 2764305. Available from CGM HMS GmbH Spare-Parts Service.

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OPeration ON-BOARD CRANE (OPTIONAL) The on-board crane is designed for lifting heavy parts only.

On-board crane, monitoring, warning and control elements (Fig. 2-118:)

Do not lift persons.

Observe all national directives as well as specific regulations relevant to crane operation.

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. 2-118:

Pos. Element 1 Monitoring lamp 2 Warning lamp 3 Warning lamp 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

2-86

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

BA 6040(3 847 027.00)-EN

OPeration On-board crane, putting into operation Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

Do not exceed the maximum lifting capacity (observe the lift capacity chart attached to the boom).

On-board crane, drive unit The drive unit (Fig. 2-119:) supplies the crane with hydraulic power. So the on-board crane is functional without the shovel’s engines running.

The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

The drive unit is equipped with an Emergency OFF push switch (arrow, Fig. 2-119:).

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. 2-118:) 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. 2-119:

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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. 2-120:) 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. 2-120:).  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, 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. 2-120:

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OPeration Monitoring cameras This excavator 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. 2-121:).

Fig. 2-121:

Additional information can be found in the manuals of the camera manufacturer (see Volume 5 of the Technical Documentation “Components”).

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OPeration

2-90

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OPeration NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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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 EXCAVATORS 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  Cut out the supply voltage.  Secure against switching on; apply a warning sign.

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 excavator  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).

 Check that the electrical system is off circuit.  Connect to earth and short-circuit.

On the hydraulic excavator

 Protect adjacent and live parts against accidental contact.

 Disconnect the earthing and short-circuiting line.  Withdraw the partition.

On the excavator

 Fasten cover.

 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 Operating manual No inspection and servicing work must be carried out until the operating manual has been read and understood.

Pay special attention to: Fundamental safety instructions” and all warnings and safety instructions attached to the machine.

The operating 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 an CGM HMS GmbH mechanic or by attending an CGM HMS GmbH training course.

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.

Securing the machine Carry out servicing work only if the machine is secured as described in the section “Securing the machine”.

Climbing onto and off the machine Use only the ladders, steps, platforms and handrails provided when climbing onto or off the machine.

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

Always 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 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.

Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

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.

Securing the working equipment

Prevent solvents and cleaning agents from coming into contact with your skin.

Stand working equipment 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

Wear gloves.

Observe the instructions on the packaging.

BA 6040(3 847 027.00)-EN

Inspection and servicing Handling flammable liquids

Visisble oil losses

When handling flammable liquids:  never smoke,

Have any visible leakage repaired immediately.



Soak up any oil that has escaped with a binding agent.

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.

Escaping oil is an environmental hazard.

Sweep up binding agent and dispose of it separately from other waste.

Use:  dry powder,

Relieving residual pressure in the hydraulic system



carbon dioxide or



foam extinguishers.

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.

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.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken

Fastening and securing elements

immediately after stopping, the system must be depressurzized:

Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

(do not leave the operator’s seat)  Stand working equipment on the ground,

Spare parts

 Switch off the electric motor,

Use only the original sparts parts of CGM HMS GmbH .

 Move all control levers and pedals repeatedly into all ndirections.

They are the only ones to fulfill the technical specifications of the machine.

Screwed connections, piping, hydraulic hoses Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Repair any leakage in the piping and hose system immediately.

Never set foot withing reach of the emerging oil jet.

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Avoid contact with the skin. Wear gloves and firm protective clothing.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

Used oil may be harmful to the skin.

If oil has penetrated into the skin, consult a doctor immediately.

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.

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.

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Inspection and servicing Non-polluting disposal

Handling batteries

Dispose of oils, greases, cooling liquids, detergents, solvents and oil-containing components, such as filters, cleaning rags, replaced wearing parts and unusable machine parts, without polluting the environment and separately from other waste.

California Proposition 65 Warning

Do not dispose of these substances together with household wastes.

Battery Posts, terminals and related accessories contain lead and lead compounds, and handling batteries may also exposure you to sulfuric acid mist, chemicals known to the state of California to cause cancer and reproductive harm. Wash hands after handling.

Batteries give off explosive gases.

Fill these substances into the containers provided for such purposes.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Like any other oil, also bio-degradable, “environmental-friendly” hydraulic oil must be disposed of separately.

Battery acid is toxic and corrosive.

Do not allow oils and oily wastes to penetrate into the soil or into water. They are an environmental hazard

Seals Individual spares may contain asbestos. Such spares or their packaging are marked with: Never process spares containing asbestos mechanically. Inhaling asbestos dust is a health hazard.

Clean sealing faces prior to assembly.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Wear gloves, firm protective clothing and goggles when handling batteries.

If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Before working on the electrical system Before performing work on the electrical system where tools, spare parts, etc. can come into contact with electrical conductors or contacts, the battery must be disconnected.

Disconnect first the negative and then the positive terminal.

After the work: Reconnect first the positive and then the negative terminal.

3-6

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Inspection and servicing Selecting oils and greases

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 engine 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 Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

To prevent corrosion, coat all bright metal parts with a grease 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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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 excavator.

Clean the excavator 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 excavator in places where  combustible substances such as coal dust or tar are present. 

open or smouldering fire may occur.

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

Flying sparks may cause fire on the ground that can spread to the excavator.

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 sServicing 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

Oils / Greases For the specification of oils and greases to be used refer to the “Lubricants” section.

The numerals mentioned in the “Oil / Grease” column in the inspection and sServicing plans have the following meaning: Oils for combustion engines and I compressors Oils for hydraulic systems II IIIa, b, c Oils for gearboxes Greases for bearings and swing V 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.

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

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

3-10

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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 bearings (Follow instructions on the information signs / plates on the motor) Check direction of rotation (see electric motor manufacturer´s servicing instructions)

Electrical system Battery Lighting Terminals Slip ring assembly Switchgear cabinets Monitoring, warning and control elements

BCS Slewing system (SIL2 machines only)

Hydraulic system

Hydraulic oil reservoir Hydraulic cylinders Pump drive gearbox and cooling circuit - Expansion reservoir Swing gearbox (PN 3692960) Swing gearbox (PN 3676892) - Expansion reservoirs Travel gearbox - Pre-chamber / Spur gear section - Brake-chambers Swing ring Internal gearing Undercarriage Track roller Support roller Track Idler

Check liquid level (not on sealed batteries) Check operation Check for tightness Visual inspection 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“) Check function of working and travelling movement Check pressure (see Service Manual) Check oil level Vent (see chapter “Venting hydraulic system“) Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level Check grease filling Check for leaks and free movement Check for leaks and free movement Check pressure (see Service Manual) Check for leaks and free movement

Quantity/ No. 2

2

1

3 1

1

3 6 2 2x1 2x2 1 2x7 2x2 2 2

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Inspection and servicing Plan V – Once prior to initial commissioning Page 2 of 2 Location Central lubricating system - Grease container - Greasing and pause cycles Service – Station (tanklift) Air conditioner (optional) - Compressor Hydraulic ladder - Central lubricating point On-board crane (optional) - Fastening bolts - Bearings - Joint (column / boom) - Cylinder bearing - Swing ring Hydraulic oil reservoir

Crane drive engine

- Battery Escape ladder - Locking device - Ladder Harness (optional) - Harness holding device on cab roof All lines, fittings and connections All articutated joints and hinges

3-12

Servicing work

Quantity/ No.

Check filling level Check setting Check operation Check oil level Lubricate Check tightness (see “On-Board Crane“ Operation and Maintenance Manual) Lubricate Lubricate Lubricate Grease Check oil level (see “On-Board Crane“ Operation and Maintenance Manual) Check oil level (see “Crane drive Engine“ Operation and Maintenance Manual) Check liquid level Check function Check function Check free movement Check completeness and condition Check for tightness Inspect visually for leaks, 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

Electrical system Medium-voltage cells - mechanical connections - lines - terminals and plug connections Hydraulic system Oil cooler - Bearing - Fastening bolts Return-flow filter Magnetic rod Pressure accumulator – emergency lowering Pressure accumulator – hydraulic ladder Pressure accumulator – track tension system Pump drive gearbox and cooling circuit - Pre-chambers, expansion reservoir - Gearbox oil filter (cooling circuit) - Fastening bolts Swing gearbox (PN 3692960) - Fastening bolts Swing gearbox (PN 3676892) - Brake chambers - Fastening bolts Travel gearbox - Pre-chamber / Spur gear section - Hydraulic motor chambers - Magnetic plugs - Fastening bolts Swing ring Fastening bolts (swing ring, undercarriage and superstructure)

3

Servicing work

Quantity/ No.

Check for tightness Check for tightness Check for tightness

Check for tightness (for tightening torques see Service Manual) Replace Clean Check function Check function Check function Change oil Check oil level Replace Check for tightness (for tightening torques see Service Manual) Change oil Check for tightness (for tightening torques see Service Manual) Change oil Change oil Check for tightness (for tightening torques see Service Manual) Change oil Change oil Change oil Clean Check for tightness (for tightening torques see Service Manual)

2x7 1 1 1 2 13 1 1 33 33 33 23 2x13 2x23

Check for tightness (for tightening torques see Service Manual)

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 Cable guide for power supply cable - Fastening bolts cable guide / machine Cable reel (optional) - 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 Superstructure Fastening bolts, especially at superstructure / pedestal / operator´s cab All lines, fittings and connections

3-14

Servicing work

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.

BA 6040(3 847 027.00)-EN

Inspection and servicing Plan T and W Plan T – Every 10 OH or every working shift (whichever comes first) Plan W – Every 60 OH or every working week (whichever comes first) Page 1 of 2 Location

Servicing work

Electric motor - Cooling fins

Listen for unusual machine noise Clean

Electrical system Lighting

Quantity/ No. 1

Plan T 

Plan W  

Check operation





Switchgear cabinets

Check for condensation/drain water





- Electrical components

Visual check



Switchgear cabinets - Breather filters - Dust traps - EMERGENCY OFF switches

Remove dust Check function

3 3

 

Button „Servicing works“

Check function

1



Monitoring, warning and control elements BCS

Check function of monitoring, warning and control elements Check function

Hydraulic system

Check function of working and travelling movement Inspect visually for leaks

1











 

Hydraulic oil reservoir Oil cooler

Check oil level Check / clean

1 2



 

Fan wheel

Check condition

2





Pump drive gearbox and cooling circuit - Pre chamber expansion reservoir

Check oil level

1 1 1

- Oil filter (tell-tale) Swing gearbox (PN 3692969)

Check oil level Check for unusual noises or smells, higher teperatures or vibrations. If in doubt, contact your Caterpillar dealer.

Check for excessive dirt and dust, clean to prevent overheating.

Check Check oil level

1 3



 

Swing gearbox (PN 3676892) - Expansion reservoirs

Check oil level

6





- Gearbox housing

Reservoir for used grease at the A-frame Travel gearbox Escape ladder - Locking - Ladder Emergency escape device / seat - Holding device - Harness

Check, depollute used grease Check for leaks Check function Check free movement Visual condition check Check tightness and fixation on cab Connect to the holding device

 



1



2x1 2

 





    

    

3-15

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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

Servicing work

Undercarriage Tracks

Inspect track tension visually

Track roller

Check for leaks and free movement

2x7



Support roller

Check for leaks and free movement

2x2



Idler

Check for leaks and free movement

2



Face shovel

Inspect clam cylinders chambers, remove all accumulated debris, rocks, soil and so on.

2x1





Check filling level Check visually Carry out all service work described in the “Air Conditioning manual“

1 1

  

  

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





 

 





 

  









   

   

Central lubricating system Grease container Lubricating points Air conditioner (optional) On-board crane (optional) 4 Fastening bolts

Crane drive engine

Hydraulic oil reservoir - Reflow filter (contamination indicator) Check condition Fire extinguisher Automatic fire-extinguishing sys- Check control module tem (optional) All lines, fittings and connections Inspect visually for leaks, wearing marks Overall cleaning Hydraulic shovel Visual inspection Cable reel (optional) Check tightness (see Service Manual) - Fastening bolts at reel, cable guide, drive motor, switchg. cabinet - Fastening bolts cable reel / under- Check for tightness (see Service Mancarriage ual) - Cable Visual inspection Operator’s cab - Window panes Clean - ROPS structure Inspect visually for damage - Operator’s seat belt Check condition - Trainer’s seat belt Check condition

4 before each deployment

3-16

Quantity/ No.

Plan T

Plan W

2





1

1 1 4 1

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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

See Electric motor manufacturer´s maintenance instructions for further details

Servicing work

Menge / No.

Plan Plan Plan Plan Plan A B C D E     

Lubricate lightly

2x45







Lubricate lightly

3x25



















Lubricate bearings (Follow instructions on the information signs / plates on the motor as well as the motor manufacturer’s maintenance instructions) Check for vibration

Visual inspect interior of machine for degree of dirt deposits Visual inspect all accessible places of the rotor (inside and outside of machine) for rust Check insulating resistance of stator windings Terminals Check tightness Check for degree of dirt deposits Coupling Check for alignment and record measurements 6 Screwed / bolted connections Check condition and tightness Operator’s cab - Fastening bolts to cab moCheck for tightness (see Serdule vice Manual for tightening torques)

2













 

 

 











5

apply a thin layer of low temperature grease

6

Check for alignment after every 2000 OH (refer to electric motor manufacturers servicing instructions)

3-17

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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 Electrical system Battery cable connections Battery Switchgear cabinets - Filter mats - Medium-voltage cells - Electrical components Slip ring assembly

- Brushes

Mechanical components Switchgear cabinets - Breather filter element Cable reel (optional) 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

Servicing work

Check for tightness Check fluid level (not on sealed batteries) Visual inspection Clean/dry Check for tightness Visual inspection, if neccessary clean inside from wear debris and grease.

(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

Menge / No.

Plan Plan Plan Plan Plan A B C D E

2



Clean Replace Visual inspection Check for wear, replace if excessive worn Replace Check adjustment Check for contamination, clean and regrease 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)



 

 

 

 

   

   

   

   











 











 

 

 



 

 

 

 

  

  

 

 





   





BA 6040(3 847 027.00)-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 Oil cooler - Bearing - Fastening bolts - Rubber bearing Return-flow filter - O-Ring of filter chamber cover - Magnetic rod Bypass valve (working circuit) Filterhousing (cooling circuit) - Return-flow filter - Bypass valve - Magnetic rod High-pressure filter Filter (pump control circuit) Filter (servo circuit) Filter (swing charge pump) Hydraulic oil reservoir - Breather filter Pressure accumulators Cylinder (seals and guide rings)

7

Plan C

Plan D

Plan E

Check pressure (see Service Manual)







Check for tightness Check condition Replace Replace

   

   

   

Check / clean Check / clean filter sieve Replace Check filter sieve / clean Check / clean Replace Replace Replace Replace Carry out oil analysis Change oil Replace Check pressure (see Service Manual) Replace

Menge / No.

Plan A

Plan B

2x7 2x1 2 4



 

 

 

2 2 1 4 2x1 1 2x2 1 178 2 3

 

  





       

 

 

           

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

BA 6040(3 847 027.00)-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

- pre-chamber expansion reservoir - Breather filter Gearbox oil filter (cooling circuit) Swing gearbox - Breather filter - Brake chamber (Gearbox PN 3676892 only) Travel gearbox

- Magnetic plug Pre-chamber / Spur gear section - Magnetic plug Hydraulic motor chambers Breather filter

9

Change oil Check oil level

19 1

 

 

 

Clean / Replace Replace

2 1



 

 

Carry out oil analysis Change oil Replace Change oil

3 39 3 39



   

   

   

Carry out oil analysis Check oil level Change oil Clean Check oil level Change oil Clean Check oil level Change oil Clean / replace

2 2 29 2x6 2x1 2x19 2x1 2x2 2x29 2x3

 

 



 



 

         

         

see “Refilling quantities – Oil“ table

3-20

Quant./ Plan Plan Plan Plan Plan No. A B C D E     1



BA 6040(3 847 027.00)-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 5 of 6 Location

Servicing work

Swing ring Gearing / pinion Fastening bolts (swing ring, undercarriage and superstructure) Undercarriage

Check grease filling Check condition Check for tightness (see Service Manual)

Menge / No. 1

Plan Plan Plan Plan Plan A B C D E           



















- Diaphragm

Check wear (see Service Manual) Check pressure (see Service Manual) Replace

Central lubricating system

Check function

Oilfilter (hydraulic circuit grease pump) Grease filter (filling grease container) Grease filter (grease lines) Breather filter

Replace

1





Replace

1





Replace Check / replace

2 1



 

 



















Diaphragm accumulator

- Filter mats

Carry out all service work described in the “Air Conditioning manual" Clean / replace if damaged

Hydraulic ladder - central greasing point

Lubricate

Air conditioner (optional)

2 2x1 



1





3-21

BA 6040(3 847 027.00)-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 Grease 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

10

Do all servicing jobs at least once a year and when necessary

11

see “Refilling quantities – Oil“ table

12

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

„Structural Inspection Reports“ for inspections every 500 OH can be downloaded from the CGM HMS GmbH website www.bucyrus-HEX.de, section „Support, Warranty“.

3-22

BA 6040(3 847 027.00)-EN

Inspection and servicing

3-23

BA 6040(3 847 027.00)-EN

Inspection and servicing LUBRICATING CHART – GREASE

Fig. 3-1:

3-24

BA 6040(3 847 027.00)-EN

Inspection and servicing Lubricating chart – Grease (legend) No. Greasing point 1 2 3

Central lubricating system – grease container Hydraulic ladder, central greasing point Electric motor, bearings

Number

Lubricant properties

1 1 2x1

V 13 V 13

5

6

On-board crane

V 13

Grease every .... operating hours 10 1000 See plate with lubricating instructions attached to the electric motor for detailed information.

250

- Bearing

4

250

- Joint (column / boom)

2

250

- Cylinder bearing

5

250

- Swing ring Monitoring, warning and control elements

1

- Joystick - Pedal

Graphitespray

250

V 13

1000

2 x 4 14 3x2

14

1000

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities – Grease Greasing point

Lubricant properties

Central lubricating system – grease container (Depending on the ordered system the volume may vary)

Internal gearing – Roller-bearing swing ring

V 13

Idler (permanent grease filling) Track rollers (permanent grease filling) (optional: rollers supported with grease via the central lubrication system for the undercarriage) Support rollers (permanent grease filling)

13

see "LUBRICANTS" section

14

apply a thin layer of low temperature grease

Tribol CGM HMS GMBH part no. 2764564

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

3-25

BA 6040(3 847 027.00)-EN

Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-2:

3-26

BA 6040(3 847 027.00)-EN

Inspection and servicing Inspection plan – Oil (legend) No. Location

Lubricant properties 15

II

1

Hydraulic system

1

2

Pump drive gearbox and cooling circuit Pre-chamber expansion reservoir Swing gearbox (Gearbox PN 3692960) Swing gearbox (Gearbox PN 3676892) - Expansion reservoir

1

2 3 3

- Expansion reservoir brake chamber 4, 6 Travel gearbox - Pre-chamber / spur gear section - Brake-chambers 5

15

Number

1

III.a

Check oil level every ... OH 10

Change oil every ... OH 10000 16

60

1000

10

1000

3

III.b

10

1000

3x2

III.b

10

1000

3x2

10

1000

2

500

5000

500

5000

500

5000

10

250 17

10

1000 18

2x1

III.a

2x2

On-board crane (optional) - Crane drive engine

1

- Hydraulic oil reservoir

1

I II

see "LUBRICANTS" 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

BA 6040(3 847 027.00)-EN

Inspection and servicing Filling quantities - oil Location

Filling quantity

Oil

litres

gal

Hydraulic oil reservoir Hydraulic system Pump drive gearbox - Pre-chamber expansion reservoir Swing gearbox (Gearbox PN 3692960)

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

Swing gearbox (Gearbox PN 3676892) - Brake chambers Travel gearbox - Pre-chamber / Spur gear section - Hydraulic motor chambers On-board crane (optional) - Crane drive engine

3 x appr. 26 3 x appr. 6 2 x appr. 80 2 x appr. 10 4 x appr. 0,3

3 x appr. 6.9 3 x appr. 1.6 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.b III.a I II

Filling quantities - other Location

Filling quantity litres

gal

Fuel tank, crane drive engine (optional)

appr. 20

appr. 5.3

Screen washer

appr. 13

appr. 3.4

3-28

BA 6040(3 847 027.00)-EN

Inspection and servicing LUBRICANTS Notes on the selection of oils and greases Original CGM HMS GmbH oils and greases Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies.

The lubricants tables in the CGM HMS GmbH Operation and Maintenance Manual contain specifications for the oils and greases that are approved for use in CGM HMS GmbH machines. These oils and greases are especially adapted to CGM HMS GmbH machines and their units and assemblies.

Other oils and greases which do not fulfil the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies.

For this reason, CGM HMS GmbH only approves the use of the specified oils and greases.

All other qualities are not approved.

Alternative oils and greases The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the CGM HMS GmbH Operation and Maintenance Manual.

In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with CGM HMS GmbH specifications, CGM HMS GmbH does not assume any responsibility and does not accept any warranty claims.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM 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 BM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-29

BA 6040(3 847 027.00)-EN

Inspection and servicing LUBRICANTS / CONSUMABLES I. Oil for combustion engines (On-Board Crane, option)

Fig. 3-3:

3-30

BA 6040(3 847 027.00)-EN

Inspection and servicing

II.

Oil for hydraulic system (selection)

Fig. 3-4:

3-31

BA 6040(3 847 027.00)-EN

Inspection and servicing III.a Oil for pump gearboxes and travel gearboxes

Fig. 3-5:

3-32

BA 6040(3 847 027.00)-EN

Inspection and servicing III.b Oil for swing gearboxes

Fig. 3-6:

3-33

BA 6040(3 847 027.00)-EN

Inspection and servicing V. Grease for bearings, swing rings and track system (Central lubrication system)

Fig. 3-7:

3-34

BA 6040(3 847 027.00)-EN

Inspection and servicing Greases for idlers, track rollers and support rollers (Lifetime lubrication)

Fig. 3-8:

3-35

BA 6040(3 847 027.00)-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 (tanklift) (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. 3-10:

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.

Fig. 3-9:

3-36

BA 6040(3 847 027.00)-EN

Inspection and servicing ELECTRIC MOTOR Electric motor - Safety instructions

Electric motor, cleaning When cleaning with compressed air deposited dust and loose parts can be whirled up and may cause injuries.

Read and observe: "Inspection and Servicing – Safety Instructions" and the electric motor Operation and Maintenance Manual.

Always wear your personal protection equipment like protective suit, goggles, respiratory protection, gloves etc.

Use a vacuum cleaner to extract dust.

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:).

Clean the electric motor, the cooling fins, bearing shields and ventilators from dust with compressed air, brushes and clothes only.

 Set servicing switch (4, Fig. 3-12:) to locked position and secure in this position with a padlock.

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.

It is not permissible to clean the electric motor or any live excavator 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.

Fig. 3-11:

Fig. 3-12:

3-37

BA 6040(3 847 027.00)-EN

Inspection and servicing Electric motor, greasing Read and observe: "Inspection and Servicing – Safety Instructions" and the electric motor Operation and Maintenance Manual.

Secure the machine as described in the "Securing the machine" section.

Wear protective gloves and firm working clothing.

During greasing the electric motor must be switched on. Be extremely careful to rotating parts.

Grease chambers at the bearings of the electric motor can carry only a limited amount of used grease.

Check grease chambers before pressing in fresh grease and remove used grease if necessary.

Grease the bearings of the electric motor in regular intervals (see plate on the electric motor for more detailed instruction about greasing procedure).  Press in grease into the grease nipples located at the end shields at the electric motor. The grease nipples are located at the motor housing away from the bearings.  When the electric motor is at standstill, remove the old, used grease from the bearing housing.

Additional information on servicing the electric motor is given in the electric motor operating and maintenance instructions given from the motor manufacturer.

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.

Additional servicing work All servicing and maintenance work not described here are carried out by the CGM HMS GmbH after sales service resp. by the Service Dept. of the manufacturer of the electric motor. (see electric motor Operation and Maintenance Manual).

3-38

BA 6040(3 847 027.00)-EN

Inspection and servicing ELECTRICAL SYSTEM Electrical system - Safety instructions

Risk of injury caused by battery acid and gases.

Wear goggles, working gloves and firm working clothing.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

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.

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 excavators with electric motor" at the beginning of this chapter).

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".

Before starting live-line servicing work e.g. measuring and testing with voltage applied, press switch (4, Fig. 3-13:) 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 excavator.

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. 3-13:

Gas-discharge lamps in Xenon working lights are operated with high voltage.

3-39

BA 6040(3 847 027.00)-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. 3-14:).  If checking inserts are provided, the battery acid must reach up to their bottom.  If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm / 0.4".  If the fluid level is too low, top up with distilled water only

Fig. 3-14:

3-40

Checking charge of the battery The acid temperature must be 20 ° C / 68°F.  Unscrew caps of the battery (Fig. 3-14:).  Measure the acid density of the battery using a commercial acid tester (Fig. 3-14:).

The acid density measured is in direct correlation with the battery charge.

Acid density kg / dm3 Charge Normal Tropical conditicondition ons 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 Caterpillar dealer for assistance.

Charging the batteries The batteries are charged by the battery charger only if the electrical system with the circuit breaker is switched on.

The battery main switch must be in position I "ON".

BA 6040(3 847 027.00)-EN

Inspection and servicing Removing and installing the battery Read and observe the "Inspection and servicing – Safety instructions" chapter.

The batteries (1, Fig. 3-15:) 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.

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. 3-15:

 Detach battery holder (3).  Disconnect the cable lug from the negative terminal of the battery.  Disconnect the cable lug from the positive terminal of the battery.  Insulate the cable lugs.  Lift battery out of battery box.

Before installing new batteries, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.  Install the new batteries.  Connect the cable lug to the positive terminal of the battery. Tighten the clamping bolts of the cable lugs. Do not use too much force to avoid deformation.  Connect the cable lug to the negative terminal of the battery.  Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs. Loose or corroded clamping lugs will lead to charger overloading.

3-41

BA 6040(3 847 027.00)-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 6600 V / 7200 V power supply, 

For the 400 V system,



For the 24 V system,

Fig. 3-16:

the air is drawn in and cleaned by a ventilator with filter (Fig. 3-16:).

Emptying the dust trap  Press dust trap (14, Fig. 3-16:) and hold until the dust trap is empty.

Emptying the dust collector  Loosen clips (11, Fig. 3-16:).  Remove dust collector (12) and empty.

Filter element, clean / replace  Remove dust collector (12, Fig. 3-16:).  Withdraw filter element (13, Fig. 3-17:).  Replace or clean filter element (13).  Refit dust collector (12, Fig. 3-16:).

3-42

Fig. 3-17:

BA 6040(3 847 027.00)-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. 3-18:). 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. 3-19:) 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. 3-18:

Never clean filter element by beating it against hard objects.

 Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Fig. 3-19:

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.

Replacing filter mats A filter mat is installed in the control cabinets behind the cover (4, Fig. 3-20:).  Check filter mats visually and replace if necessary.

Fig. 3-20:

3-43

BA 6040(3 847 027.00)-EN

Inspection and servicing Slip ring assembly, servicing work (Fig. 3-21:) High voltage! Danger to life!

Switch off power supply at the transformer station.

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

Check that the slip ring assembly is without tension before opening it.

Fuses and their function are listed on a sheet inside the switch-cabinets in the cab module.

Read and observe the "Inspection and servicing – Safety instructions" chapter as well as the chapter “Electrical system, safety instructions”.

Use only original fuses with the specified current rating.

Replacing lamps and bulbs 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 grease. Remove if necessary.

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”.

 Clean insulators and check for damage.  Check condition of slip ring contact surfaces; remove any sign of oxydation, "splatter" or burn spots.

Then coat with contact grease.  Check carbon brushes for signs of wear.

(See Servicing Instructions of the slip ring manufacturer).

Fig. 3-21:

3-44

Floodlights working with LED-technology do not have replaceable lamps / bulbs. The floodlight must be replaced if defective.

BA 6040(3 847 027.00)-EN

Inspection and servicing Xenon floodlight projector (optional), replacing the lamp Safety instructions The floodlight projectors use xenon technology.

The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector.

When the projector is turned on, the ballast unit generates a high-voltage pulse of more than 25000 volts to start the xenon lamp.

Warning!

This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance,  if the lamp is operated improperly,  

if the projector housing is opened in an inapropriate way or by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp.

Allow the xenon lamp to cool off before removing it from the projector.

Wear googles and safety gloves when replacing the lamp.

Never stick your hand into the lampholder. The contacts may still be live with residual voltage.

Never switch on the projector when the xenon lamp has been removed.

There is a risk of voltage discharge and damage to the lampholder.

The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters) If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector.

If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol.

The replaced Xenon lamp must be disposed of as special waste.

Never switch on projectors when housing or electrical wiring is damaged.

Have damaged projectors be replaced by a qualified electrician as soon as possible.

3-45

BA 6040(3 847 027.00)-EN

Inspection and servicing Replacing a defective Xenon-lamp Read and observe the: „Floodlight projector, replacing the lamp, Safety instructions“.  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.

Fig. 3-22

 Remove four bolts (1, Fig. 3-22) and withdraw the reflector (2) from the projector housing.  Withdraw connector (Fig. 3-23) from Xenon lamp socket.  Unscrew Xenon lamp holding clamp (Fig. 3-24).  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.

Fig. 3-23

Fig. 3-24

3-46

BA 6040(3 847 027.00)-EN

Inspection and servicing Lighting systems in LED technonogy, instructions The lights of the maintenance lighting system (Fig. 3-25) as well as the working floodlights (Fig. 3-26) 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.

Fig. 3-25

For this reason, the housings must not be covered up and cleaning rags or similar things placed over them.

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. 3-26

3-47

BA 6040(3 847 027.00)-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.

Depressurizing the hydraulic system Hydraulic systems may only be opened if they are completely depressurized.

Even when an excavator is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-27: and Fig. 3-28:) 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:

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.

Fig. 3-27:

Fig. 3-28:

 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

BA 6040(3 847 027.00)-EN

Inspection and servicing Examples of system sections:

Checking the hydraulic oil level

1) working hydraulics

 Bring hydraulic oil to operating temperature (abt. 50 °C / 122°F).

2) servo control circuit 3) precharged return-flow line Depressurizing:  Park the excavator on a horizontal surface.  Set the working equipment on the ground.  Switch off the electric motor.

 Park the machine on a horizontal surface.  Stand working equipment on the ground as shown on signs (2, Fig. 3-30: and Fig. 3-32:).

The oil level must be between the “min” and “max” marks of the signs (2, Fig. 3-30:) near the level indicator tube (1).

 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. 3-29:).

Fig. 3-30:

The hydraulic oil level is monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-30:) if the hydraulic oil level is too low or too high. In this case: Switch off the electric motor, locate cause and rectify.

Fig. 3-29:

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. 3-31:

3-49

BA 6040(3 847 027.00)-EN

Inspection and servicing

Fig. 3-34:

Hydraulic oil can also be filled in by means of the service station (Fig. 3-35:).

Fig. 3-32:

Stand working equipment on the ground as shown on the signs (Fig. 3-32:).

The signs (2, Fig. 3-33:) are attached beside the level indicator tube (1).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Unscrew cap of express coupling (10).

Connect filling hose 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. 3-33:) 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. 3-33:

Fill in hydraulic oil through the return-flow filters.  Remove cover (19, Fig. 3-34:).  Fill in hydraulic oil through the opening until the oil level is 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. 3-35:

BA 6040(3 847 027.00)-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.

Shut off the electric motor.

Remove return flow filter elements  Remove covers (3, Fig. 3-38:) 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”).

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. 3-37:). In this case, the filter elements (9, Fig. 3-38:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-37:

Fig. 3-36: Fig. 3-38:

3-51

BA 6040(3 847 027.00)-EN

Inspection and servicing Install return flow filter elements  Insert new filter elements (9, Fig. 3-39:) 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. 3-40:).

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. 3-39:

Remove filter-basket, inspect / clean If you found one of the return flow filter elements (9, Fig. 3-40:) 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. 3-40:

BA 6040(3 847 027.00)-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. 3-43:) 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. 3-42:). In this case, the filter elements (9, Fig. 3-43:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-41:

Fig. 3-42:

Fig. 3-43:

3-53

BA 6040(3 847 027.00)-EN

Inspection and servicing Install return flow filter elements  Insert new filter elements (9, Fig. 3-44:) 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. 3-45:).

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. 3-44:

Remove filter-basket, inspect / clean If you found one of the return flow filter elements (9, Fig. 3-44:) 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. 3-45:

BA 6040(3 847 027.00)-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.

Fig. 3-46:

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.

Cleaning the filter screens  Remove covers (3 and 4, Fig. 3-46:) together with sealing rings.  Unscrew bolts (25, Fig. 3-47:). Withdraw bypass valve. Take off screen (21) together with sealing ring and clean in white spirit or paraffin oil. Replace, if required.

Fig. 3-47:

 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).

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. 3-47:) and a new sealing ring.  Insert bypass valve with new sealing ring (243) and fasten with bolts (25).

3-55

BA 6040(3 847 027.00)-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.

Replacing the filter elements Two breather filters (Fig. 3-48:) 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. 3-48:) and remove holding brackets (22).

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.

 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. 3-48:

3-56

BA 6040(3 847 027.00)-EN

Inspection and servicing Filter (servo control circuit), replace Risk of scalding caused by hot hydraulic oil.

Replacing the filter element To filter the hydraulic oil in the control circuit, the machine is equipped with a high-pressure filter (9, Fig. 3-49:).

Change filter element regulary and when the BCS indicates a contamination.

The filter housings themselves may also be hot.

 Place a suitable collecting recipient under the filter housing (Fig. 3-49:).

Wear protective gloves and firm working clothing.

 Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.

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.

 Unscrew filter housing (5, Fig. 3-50:) 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. 3-49:

Fig. 3-50:

3-57

BA 6040(3 847 027.00)-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 (8, Fig. 3-51:).

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

 Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Unscrew drain plug (11, Fig. 3-52:) by counterclockwise rotation. Pour out the oil.  Unscrew filter housing (9).  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.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

 Check sealing ring (13) and support ring (14) on the filter housing for position and damage.

Replace, if necessary.

 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.

3-58

 Place a suitable collecting recipient under the filter housings (Fig. 3-51:).

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

 Shut off the electric motor.

Fig. 3-51:

Replacing the filter elements

 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. 3-52:

BA 6040(3 847 027.00)-EN

Inspection and servicing Filters for swing charge pump, replace The excavator has three high-pressure filters (9, Fig. 3-53:) for the feeding circuits of the swing pumps. The filters are installed in front of the hydraulic reservoir.

Replacing the filter elements  Place a suitable collecting recipient under the filter housings (Fig. 3-53:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Detach flange (4, Fig. 3-54:).

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.

 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. 3-54:) 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. 3-54:

Fig. 3-53:

3-59

BA 6040(3 847 027.00)-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.

Replacing the filter element  Place a suitable collecting recipient under the filter housings (Fig. 3-55:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Detach flanges (4, Fig. 3-56:).

Risk of scalding caused by hot hydraulic oil.

 Remove filter housings and pour out used oil.

The filter housings themselves may also be hot.

 Withdraw filter element (6) from filter housing (5).

Wear protective gloves and firm working clothing.

 Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

 Install new filter element (6) and re-assemble with a new, lightly oiled sealing ring (7).

Read and observe the "Inspection and servicing – Safety instructions" chapter.

 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. 3-56:

Fig. 3-55:

3-60

BA 6040(3 847 027.00)-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 BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). 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 BM 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 BM 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

BA 6040(3 847 027.00)-EN

Inspection and servicing Draining off hydaulic oil using the Service Station (tanklift)

Cleaning the hydraulic oil reservoir Explosion hazard.

The hydraulic oil can also be drawn off through the service station (Fig. 3-57:).

Do not use white spirit, paraffin oil or other solvents for cleaning.

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

 Bring hydraulic oil to operating temperature (ca. 50° C / 122°F).

Use only diesel fuel or a special flushing oil for cleaning the hydraulic tank.

 Retract hydraulic cylinders as far as possible and stand working equipment on the ground.

Skin contact with hydraulic oil, diesel fuel or special flushing and cleaning fluids may cause skin injury. Avoid skin contact.

 Switch off the electric motor.

Wear protective gloves and firm working clothing.

 Unscrew cap of express coupling (10).

Dispose of contaminated hydraulic oil, diesel fuel or special flushing and cleaning fluids without polluting the environment and separately from other waste.

 Connect hose line of the service vehicle.  Drain oil.  Remove hose line. The coupling closes automatically.  Screw on protective cap.

 Drain off hydraulic oil as described under "Draining off the hydraulic oil using the Service Station".  Remove caps (3,4, and 5, Fig. 3-58:).  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. 3-57:

Fig. 3-58:

3-62

BA 6040(3 847 027.00)-EN

Inspection and servicing Filling in hydraulic oil using the service station  Fill in hydraulic oil by means of the service station (Fig. 3-59:).

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. 3-60:) near the inspection glass (1).

(Oil grade see "LUBRICANTS").  The oil level is also displayed on the BCSscreen (Fig. 3-61:).

Fig. 3-59:

 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:

3-63

BA 6040(3 847 027.00)-EN

Inspection and servicing Filling in hydraulic oil through the return-flow filters.  Remove cap (19, Fig. 3-62:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks on the sign (2, Fig. 3-63:) near the inspection glass (1).

(Oil grade see " LUBRICANTS ").  Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir. Top up with oil, if required.  Refit cap (19, Fig. 3-62:).

Fig. 3-62:

Fig. 3-63:

3-64

BA 6040(3 847 027.00)-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 excavator, 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 

Fig. 3-65:

Hydraulic pumps and hydraulic motors (with electric motors shut off).

Always admit oil first to that side of the cylinder where the piston (2) is. This is

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

 the piston-side port (3) when the piston rod is retracted (1, Fig. 3-64:),  the rod-side port (4) when the piston rod is extended (1, Fig. 3-65:).

Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions. 

If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the piston-side 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.

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. 3-64: and Fig. 3-65:) must be either completely retracted or completely extended.

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. 3-64:

3-65

BA 6040(3 847 027.00)-EN

Inspection and servicing Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

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

Switch off the electric motor.

 Remove any accumulated dirt.

Never start cleaning work until the cooler fan blades have stopped turning.

 Clean the fan blades (2).

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

 Clean the radiators with a jet of water or compressed air from outside to inside.

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.

 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.

The speeds of the fan motors (1, Fig. 3-66:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C / 140°F.

Fig. 3-66:

3-66

BA 6040(3 847 027.00)-EN

Inspection and servicing Electronic excavator control Joystick At regular intervals acc. to the maintenance plans:  Loosen gaiter and move upwards.  Apply a thin layer of low temperature grease on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-67:) to prevent jamming of the joysticks.

Pedal At regular intervals acc. to the maintenance plans:  Remove old grease and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-68:).  Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

 Refit gaiter using a cable strap.

Fig. 3-68:

Fig. 3-67:

3-67

BA 6040(3 847 027.00)-EN

Inspection and servicing Pressure accumulator - Emergency lowering To permit the working equipment to be lowered in an emergency, the machine is equipped with a pressure accumulator (1, Fig. 3-69:).

The pressure accumulator (1) is located in the superstructure 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. 3-69:

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.

BA 6040(3 847 027.00)-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.

Fig. 3-70:

Details for selecting the correct gearbox oil refer to chapter “LUBRICANTS / CONSUMABLES”.

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. 3-70: and 1, Fig. 3-71:).  Insert dipstick (1) again until the thread lies on top of the dipsticks tube (2, Fig. 3-71:).

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.

Fig. 3-71:

 Top up with oil if required through the plug of filler tube (arrows, Fig. 3-72:).

(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.

3-69

BA 6040(3 847 027.00)-EN

Inspection and servicing Topping up with oil  Screw out plug of filler tube (arrows, Fig. 3-72:).  Fill fresh oil through the filler tube.

(Oil grade see: “LUBRICANTS / CONSUMABLES”).  Check oil level.  Fit plug again.

Fig. 3-72:

3-70

BA 6040(3 847 027.00)-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. 3-73:) through express coupling (5).  Unscrew protective cap of express coupling and connect hose line of the service vehicle.

Fig. 3-73:

 Drain gearbox oil.  Remove hose after the oil has been drained.

The coupling closes automatically.  Screw on protective cap.

Filling in gearbox oil (Oil grade see: „“LUBRICANTS / CONSUMABLES”).  Fill in gearbox oil with the service station (Fig. 3-73:).  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).

Fig. 3-74:

 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. 3-72:).

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.

3-71

BA 6040(3 847 027.00)-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. 3-75) 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. 3-76).

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. 3-76

Fig. 3-75

3-72

BA 6040(3 847 027.00)-EN

Inspection and servicing Pre-chambers working pumps, draining oil, changing oil

Pre-chambers swing pumps, draining oil, changing oil

Draining oil:

Draining oil:

 Place a suitable receptacle for used oil under the plugs (13, Fig. 3-77:).

The required receptacle capacity is specified in the „Filling quantities – oil“ table.

 Place a suitable receptacle for used oil under the plugs (23, Fig. 3-78:).

The required receptacle capacity is specified in the „Filling quantities – oil“ table.

 Drain oil from the expansion reservoir.

 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.

 Unscrew plugs (23) and allow oil to drain.

Screw in plugs and fill in oil after repair work has finished.

Changing oil:

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.

 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. 3-77:

Fig. 3-78:

3-73

BA 6040(3 847 027.00)-EN

Inspection and servicing Pump gearbox cooling circuit, replace oil filter Oil for the pump drive gearbox is cleaned in the filter (Fig. 3-79:).

Checking for contamination  Check filter tell-tale (1, Fig. 3-79:) regulary - at operating temperature - for indication of contamination.

If the red sector is visible through transparent cap (2), the filter element must be cleaned or changed.

It is possible that the filter is contaminated with metal particles. Inspect the filter element carefully. Trace any cause and remedy.

Replacing the filter element  Place a suitable collecting recipient under the filter housing (Fig. 3-79:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Unscrew filter housing (42, Fig. 3-80:).  Pour oil out of filter housing (42) and remove filter element (43).

Fig. 3-79:

 Check filter housing as well as used filter surface for debris.  Clean filter housing and the sealing faces at the filter head with white spirit or paraffin oil.  Place new filter element (43) and new sealing (45) into filter housing and re-assemle with new O-ring (46).  Screw in the filter housing (42) 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. 3-80:

3-74

BA 6040(3 847 027.00)-EN

Inspection and servicing SWING GEARBOX (For swing gearboxes P/N 3692960) Read and observe: "Inspection and servicing - Safety instructions.

Swing gearbox - 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.

Shut off the electric motor.

 Prepare a collecting recipient for used oil.

Secure the machine as described in the "Securing the machine" section.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

The gearbox housings may be hot, too.

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”.

Fig. 3-82:

Draining off oil  Attach hose (8, Fig. 3-82:) 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.

Fig. 3-81:

Swing gearbox - Checking the oil level / Topping up with oil

The drain valve (7) is accessible from the undercarriage.  Remove hose. The oil drain valve closes automatically.for oil and cooling liquid change" section.

 Park the machine as described under "Securing the machine".  Screw out dipstick (1, Fig. 3-81:) 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.

3-75

BA 6040(3 847 027.00)-EN

Inspection and servicing Filling in new oil / Topping up

Swing gearbox, venting ,

 Unscrew plug (4, Fig. 3-83:) and fill in new oil.

The gearbox is vented through breather filter (2, Fig. 3-83:).

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.

 Check oil level with dipstick (1).  Screw in plug (4) again.

 Screw breather filter (2) back in place.

Fig. 3-83:

3-76

BA 6040(3 847 027.00)-EN

Inspection and servicing SWING GEARBOX (For swing gearbox P/N 3676892) The gearbox housings may be hot, too.

Read and observe: "Inspection and servicing - Safety instructions.

Swing gearbox - Gearbox Checking the oil level / Topping up with oil  Check the oil level visually at expansion tanks (5 and 6, Fig. 3-84:). The expansion tanks must be filled with gearbox oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).

Shut off the electric motor.

 If necessary, unscrew cap (7) and fill in oil.

Secure the machine as described in the "Securing the machine" section.

The hoses (4, Fig. 3-84: and Fig. 3-85:) connect the gearboxes (1) with the expansion reservoirs (5 and 6).

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

 Check all threaded joints for leaks.

Wear protective gloves and firm working clothing.

Collect escaping oil carefully and dispose of in an environmentally acceptable manner.

Carry out oil change when gearoil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

Oil grade see”LUBRICANTS”.

These swing gearboxes have two seperated oil chambers. Each gearbox is connected to two expansion reservoirs for gearoil: 

Expansion reservoir for oil in the gearbox housing (5).



Expansion reservoir for oil in the brake chamber (6).

Fig. 3-85:

Fig. 3-84:

3-77

BA 6040(3 847 027.00)-EN

Inspection and servicing Swing gearbox - Changing the gearbox oil Gearbox housing, draining off oil  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew caps (7, Fig. 3-88:) from expansion reservoirs (5). Oil will escaping faster then.  Attach hose (3, Fig. 3-86:) to drain valve (2) and drain off oil completely.

The use of the oil draining hose is described in the "Hose line for oil change" chapter.

The drain valve (2, Fig. 3-87:) is accessible from the undercarriage.  Remove oil draining hose. The oil drain valve closes automatically.

Screw on protection cap to the drain valve.

Fig. 3-86:

Gearbox housing, filling in new oil / topping up  Unscrew caps (7, Fig. 3-88:) from expansion reservoirs (5) and fill in new gearbox oil.

The expansion tanks must be filled with oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).  Screw caps (7) back in place.

Fig. 3-87:

Fig. 3-88:

3-78

BA 6040(3 847 027.00)-EN

Inspection and servicing Brake chamber, draining off oil

Swing gearbox - venting

 Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

The gearbox is vented through the caps of the expansion reservoirs (7, Fig. 3-90:).

 Unscrew caps (7, Fig. 3-90:) from expansion reservoirs (6). Oil will escaping faster then.  Unscrew plug at the upper edge of the gearbox housing (arrow, Fig. 3-89:).

Oil escapes.  Screw plug (arrow, Fig. 3-89:) back in place.

Brake chamber, filling in new oil / topping up  Fill in new gearbox oil into expansion reservoirs (6, Fig. 3-90:).

The expansion tanks must be filled with oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).  Screw caps (7) back in place.

Fig. 3-90:

Fig. 3-89:

3-79

BA 6040(3 847 027.00)-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.

Pre-chamber / Spur gear section Checking the oil level / Topping up with oil  Check oil level at the inspection glass (2, Fig. 3-92:).

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”.

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. 3-91:) 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. 3-92:

Hydraulic motor chamber - Checking the oil level / Topping up with oil  Unscrew checking screw (6, Fig. 3-93:).

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. 3-91:

Fig. 3-93:

3-80

BA 6040(3 847 027.00)-EN

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. 3-94:) are in the displayed position.

Pre chamber / Spur gear section Changing the oil / Draining off oil  Place a collecting recipient for used oil under the pre-chamber / spur gear section.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (3, Fig. 3-95:) and drain off the oil completely.

Slackening plug (4) allows the oil to run out more readily.

 Place a collecting recipient for used oil under the travel gearbox.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Clean screw plugs (3 and 4)

 Unscrew drain plug (2) and drain off the oil completely.

Slackening plug (3) allows the oil to run out more readily.

Filling in oil

 Clean screw plugs (2 and 3)  Screw screw plug (2) back in place.

 Screw screw plug (3) back in place.

 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. 3-95:

Fig. 3-94:

3-81

BA 6040(3 847 027.00)-EN

Inspection and servicing Hydraulic motor chamber - Changing oil Draining off oil  Place a collecting recipient for used oil under the hydraulic motor chamber.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Travel gearbox - Breather filter  Unscrew breather filter (1, Fig. 3-97:) and clean in white spirit or parafin.

Replace according to the maintenance plan.

 Unscrew drain plug (7, Fig. 3-96:) and drain off the oil completely.

Slackening plug (5) allows the oil to run out more readily.  Clean screw plug (7).  Screw screw plug (7) back in place.

Filling in oil  Unscrew screw plug (6).  Fill in oil through opening of plug (5) until it flows out of the bore of plug (6).

Oil grade see: „LUBRICANTS / CONSUMABLES“.  Screw plug (6) and plug (5) back in place.

Fig. 3-96:

3-82

Fig. 3-97:

BA 6040(3 847 027.00)-EN

Inspection and servicing CRAWLER TRACKS Cleaning Clean tracks, track and support 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 support rollers, sprockets and idlers



excessive wear



the track from breaking.

To clean the tracks:  Raise one side of the excavator with the working equipment and allow track to turn.  Clean the side member supporting the track.  Clean support and track rollers (1 and 2 ,Fig. 3-98:) thoroughly.  Clean the sliding planes on the idler guides.

Fig. 3-98:

3-83

BA 6040(3 847 027.00)-EN

Inspection and servicing Track rollers

Track roller fastening

(Option)

 Check fastening bolts (4, Fig. 3-100:) regularly for tightness.

The track rollers (2, Fig. 3-99:) have a permanent grease filling (Not when the machine is equipped with a central lubricating system for the undercarriage).

 Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual").

Nevertheless press in grease filling at regular intervals.

It is necessary to be sure that always sufficient grease in the roller bearings.

Fig. 3-100:

Support roller fastening Fig. 3-99:

 Unscrew plug (6, Fig. 3-99:) from breather line.  Remove dust cap (1) from coupling (2).  Remove dust cap (4) from plug (5).  Connect grease hose (3) to couling (2).  Press in grease as long as used grease emerges from breather line.  Screw on plug (6) to breather line.  Disconnect the grease hose (3).  Fix dust caps (1 and 4) back in place.

3-84

 Check fastening bolts (3, Fig. 3-100:) regularly for tightness.  Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual").

BA 6040(3 847 027.00)-EN

Inspection and servicing Track tensioner Design The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-101: and Fig. 3-102: 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. 3-102:) to slacken the tracks.

Fig. 3-101:

1 2 3 4

Pressure accumulator Pressure cylinder Pressure limiting valve Mini- measuring port

 After the work, screw down the pressure limiting valves (3) to the limit stop.

Fig. 3-102:

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.

3-85

BA 6040(3 847 027.00)-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 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:

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".

Tab. 3-1

Group IV p  l bar p·x l  1000

3-86

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

BA 6040(3 847 027.00)-EN

Inspection and servicing SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing (1, Fig. 3-104:) and the pinion (2) are enclosed in a housing (3, Fig. 3-105:). The housing forms a grease-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 grease filling must be replaced:  when repairs have been carried out on the swing ring, the swing ring seals or the swing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the swing ring.

Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-103:). The amount of grease used up during operation is replenished by the central lubricating system.

Bearing races

The housings have a check opening which is closed with a cover (2, Fig. 3-105:). For checking, the cover must be removed.

Fig. 3-104:

The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing .

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-103:).

Fig. 3-105:

Fig. 3-103:

3-87

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Inspection and servicing Swing ring - Checking the grease filling Read and observe: "Inspection and servicing - Safety instructions.

Swing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Add grease when  the housing has been replaced

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



old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never swing the superstructure when refilling grease.

 check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm / 0.78" of grease over its whole circumference (Fig. 3-106:).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued swing movements.

Swing ring - Checking the bolts for tightness The fastening bolts of the swing ring in the superstructure 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. 3-106:

3-88

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Inspection and servicing CENTRAL LUBRICATING Design and function The excavator is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those mentioned in the "Lubricating chart - Grease".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and the electric motor is running. All greasing points connected to the system are greased at regular intervals.

The central lubricating system is controlled electrohydraulically by the programmable SPC contoller.

Fig. 3-108:

If a fault occurs, BCS gives a warning on the screen (Fig. 3-108:).

Actuate the "Reset" button (64, Fig. 3-107:) 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.

Fig. 3-107:

3-89

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Inspection and servicing Function The grease is pumped by the pump (1, Fig. 3-109:) via greasing lines from the grease container to the main distributors on the superstructure and on the undercarriage.

The control elements of the lubricating system are installed on the panels (3).

Fig. 3-111:

As soon as the grease container is empty, the BCS (Fig. 3-112:) gives a warning signal. In the event of a fault, the "dumping" function is switched off automatically after 15 min.

Fig. 3-109:

Work can be continued when the grease container is filled with grease.

For machines with automatic greasing of the track rollers, optional: The grease is pumped by the pumps (1 and 3, Fig. 3-110:) via greasing lines from the grease container to the main distributors on the superstructure and on the undercarriage.

The control elements of the lubricating system are installed on the panels (3 and 21, Fig. 3-111:).

Fig. 3-112:

Fig. 3-110:

3-90

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Inspection and servicing Filling up the grease container

Breather filter

Fill up the grease container through the service station (Fig. 3-113:).

Check/change the breather filter at regular intervals.  Unscrew wing nut (10, Fig. 3-114:).

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. 3-113:).

 Withdraw cover (7, Fig. 3-115:) and filter element (8).

 Unscrew the cap of the express coupling (11).

 Check filter element. Replace if necessary.

 Connect the filling hose of the service vehicle.

 Re-install breather filter.

 When the grease container is full, the indicator lamp (24) lights up.  Remove the flexible hose.

The express coupling closes automatically.  Refit the protective cap.

Fig. 3-114:

Fig. 3-113:

Fig. 3-115:

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Inspection and servicing Checking the greasing pressure Check every week, whether the oil pressure indicated by pressure gauge (4, Fig. 3-116:) 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 superstructure 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 grease.

Higher oil pressure may cause bursting of a greasing line.

Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.

Fig. 3-116:

This oil pressure is reduced so that the pressure indicated by pressure gauge (2) is 47 – 50 bars (681-725psi).

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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. 3-117:) 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 superstructure and 180 bar / 2610psi for the lundercarriage is generated by means of a pressure translator.

The greasing pressure for the superstructure is indicated by pressure gauge (9, Fig. 3-117:) 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 grease.

Higher oil pressure may cause bursting of a greasing line.

Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.

Fig. 3-117:

This oil pressure is reduced so that the pressure indicated by pressure gauge (2, Fig. 3-118:) is 35 – 40 bars (507-580psi) and by pressure gauge (4) is 49 – 51 bar (710-739psi).

Fig. 3-118:

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Inspection and servicing Unblocking a grease line.

Unblocking a grease line.

Put the excavator back into operation only after the lubricating system works properly and after having actuated the unloaded working equipment for abt.

5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

(for machnes with automatic greasing of the track rollers, optional)

Check the grease sieve regularly for contamination and clean, if required. The grease sieve must also be cleaned after an obstruction in one of the grease lines.

Cleaning  Loosen nut (6, Fig. 3-119:).  Withdraw sieve and clean with white spirit or paraffin oil.  Re-insert sieve and fasten with nut (6).

Put the excavator back into operation only after the lubricating system works properly and after having actuated the unloaded working equipment for abt.

5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

Check the grease sieve regularly for contamination and clean, if required. The grease sieve must also be cleaned after an obstruction in one of the grease lines.

Cleaning  Loosen nut (6, Fig. 3-120:).  Withdraw sieve and clean with white spirit or paraffin oil.  Re-insert sieve and fasten with nut (6).

Fig. 3-119: Fig. 3-120:

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Inspection and servicing Oilfilter (hydraulic circuit grease 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. 3-121:).is installed in the pumping line.

Fig. 3-122:

 Unscrew filter housing (5, Fig. 3-122:).  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.

Fig. 3-121:

 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.

3-95

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Inspection and servicing Grease filter (Filling the grease container) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Switch off the electric motor.

Grease filter (13, Fig. 3-123:) is installed in the greasing line to the grease container.

Checking the filter element  Unscrew filter housing (32, Fig. 3-124:).  Withdraw filter element (33) from housing (32).  Remove the grease.  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. 3-123:

Fig. 3-124:

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.

3-96

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Inspection and servicing Grease filter (Grease lines) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Checking the filter element  Unscrew filter housing (42, Fig. 3-126:).  Withdraw filter element (43) from housing (42).  Remove the grease.

Switch off the electric motor.

Grease filter (12, Fig. 3-125:) is installed in the greasing line to the grease container.

 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. 3-125:

Fig. 3-126:

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.

3-97

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Inspection and servicing OTHER MAINTENANCE Heating and air conditioning

Equipment, check for cracks

Check and clean the filter mats in the air suction regulary.

Inspections must be carried out acc. to the "Structural Inspection Reports" every 500 OH and every 5000 OH.

The filter mats are located in the air conditioner housing (Fig. 3-127:) below the cab roof.

Check the welded joins of the working equipment regulary.

"Structural Inspection Report" forms for those inspections can be downloaded from the CGM HMS GmbH website, section "Support, Warranty".

The inside located joins are accessible through the man-holes in stick (arrow, Fig. 3-128:) and boom (arrow, Fig. 3-129:).

Fig. 3-127:

Fig. 3-128:

 Open housing of air conditioner.  Check and clean filter mats or replace if necessary.  Close housing.

Fig. 3-129:

3-98

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Inspection and servicing Reservoirs for used grease at the A-frame, emptying

Hydraulic ladder, pressure accumulator

Remove used grease from the reservoirs (Fig. 3-130:) regularly according to the maintenance plans.

To allow the ladder (Fig. 3-131: and Fig. 3-132:) 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. 3-133:). The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

Do not re-use the grease because it is polluted.

Dispose off used grease as well as cleaning rags without polluting the environment and separately from other waste.

Fig. 3-131:

Fig. 3-130:

Fig. 3-132:

Fig. 3-133:

3-99

BA 6040(3 847 027.00)-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

3-100

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.

BA 6040(3 847 027.00)-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. 3-134:).  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. 3-134:

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. 3-135:); top up with hydraulic oil if necessary.  Check contamination of hydraulic oil filter regularly at contamination indicator (4).

Fig. 3-135:

 Regularly, but at least once a year replace the hydraulic oil filter (3) and the breather filter (2).

3-101

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Inspection and servicing On-board crane, lubricating Servicing work  Lubricate all bearings regularly and as required, and spray swing ring with a graphite spray (Fig. 3-136:) 4 lube points 1 - bearing 2 - joint (column/boom) 2 lube points 3 - cylinder bearing 5 lube points 4 - swing ring Graphite spray

On-Board crane, checking tightness of fastening bolts The hydraulic driven on-board crane (Optional) is fixed on the uppercarriage of the machine by means of 16 fastening bolts. The upper and lower fastening bolts (Fig. 3-137:) 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. 3-136:

Fig. 3-137:

3-102

BA 6040(3 847 027.00)-EN

Inspection and servicing PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING Putting the excavator out of operation

Battery storage

 Park the excavator on firm and level ground.

 Check the acid density and the electrolyte level of the battery every two weeks.

 Set the working equipment 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.

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.

 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.

 Carry out a visual inspection of the excavator.  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.

Recommissioning  Remove the covers.  Degrease / clean all protected components.

 Remove the batteries; see "Battery storage".

 Check track tension (visual inspection)

 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.

 Check grease filling in grease container.

 Cover up all openings

 Check battery acid density and level.

 Oil level

- swing gearboxes - pump drive gearboxes - travel gearboxes

 Check oil level in hydraulic oil reservoir.

 Install batteries and reconnect.  Set battery main switch to ON  Set the main circuit breaker to ON  Function checks:

- superstructure holding brake - track brake - lighting system - signalling equipment

 Vent the hydraulic system.

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Inspection and servicing NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

3-1

BA 6040(3 847 027.00)-EN

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

BA 6040(3 847 027.00)-EN

Repair work

4-2

BA 6040(3 847 027.00)-EN

Repair work SAFETY INSTRUCTIONS FOR EXCAVATORS 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  Cut out the supply voltage.  Secure against switching on; apply a warning sign.

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 excavator  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).

 Check that the electrical system is off circuit.  Connect to earth and short-circuit.  Protect adjacent and live parts against accidental contact.

On the excavator  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

BA 6040(3 847 027.00)-EN

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.

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.

The operating manual must be kept with the machine at all times.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

Repair personnel

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

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

Never remove lead seals.

Never change rated pressure of pressure relief valves without the explicit authorization of CGM HMS GmbH .

Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the 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.

BA 6040(3 847 027.00)-EN

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.

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

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 excavator before starting a job.

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

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 excavator 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 excavator in places where  combustible substances such as coal dust or tar are present. 

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

4-5

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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.

BA 6040(3 847 027.00)-EN

Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So:  Never handle accumulators never weld or solder.

mechanically,

 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

BA 6040(3 847 027.00)-EN

Repair work WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work".

Read these safety instructions before starting any welding or flame-cutting operations.

Welding work by qualified personnel only Carry out welding work only if you have received special training and if you have been ordered to perform such work.

Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country.

Observe all warning and instruction signs attached to the machine.

Wear the prescribed personal protective equipment such as:  protective clothing,  protective gloves,  protective mask and,  a fall-arrest system for persons working at height.

4-8

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.

BA 6040(3 847 027.00)-EN

Repair work Tanks, pressure vessels and pressure accumulators Any work on vessels containing or having contained  combustible or combustion-accelerating substances,  potentially explosive substances or  substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work.

This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease.

Welding work on pressure vessels and pressure accumulators is forbidden.

Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

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).

Protect the vessels against damage and high temperatures.

Lay the welding cables as far away from electric lines as possible.

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.

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.

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.

Never touch the enclosures of electrical and electronic modules with the welding electrode.

Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.

Protect electric lines against the heat emanating from the weld area.

Restore all electrical connections when the welding operations are terminated.

Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

4-9

BA 6040(3 847 027.00)-EN

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.

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.

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.

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

Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

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".

BA 6040(3 847 027.00)-EN

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.

4-11

BA 6040(3 847 027.00)-EN

Repair work Further hazardous substances

Appropriate disposal of batteries



Batteries contain lead and acid.



Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.

The machine is equipped with batteries containing lead and other harmful and polluting substances.



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.

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:

4-12



Crossed-out waste bin= Do not dispose of batteries with normal household waste.



Pb……= Chemical symbol for lead.



Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

BA 6040(3 847 027.00)-EN

Repair work NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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BA 6040(3 847 027.00)-EN

Repair work

4-14

BA 6040(3 847 027.00)-EN

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

5-1

BA 6040(3 847 027.00)-EN

Annex

5-2

BA 6040(3 847 027.00)-EN

Annex TROUBLESHOOTING Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

Fault

For this reason, it is vital to read through the relevant section of the Operation and Maintenance Manual once again before rectifying any faults.

The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

If you are unable to detect the cause of the fault or to rectify it, apply to the CGM HMS GmbH aftersales service.

Study the problem carefully. First think, then act.

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.



What repair and servicing work was carried out previously?



Has this defect already occurred?

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.

Is it one or several simultaneously occurring faults?

Possible causes

Ask yourself the following questions:  Which warning signals preceded the fault?

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

5-3

BA 6040(3 847 027.00)-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 excavator control not activated/defective



Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS GmbH Service Abschnitt Working P





Malfunction of pressure-relief valve

1)





Servo system pump defective

1)

  



5-4

 Malfunction of primary / sencondary pressure-relief valves ECO-power switch in 80%-position Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil lamp lit) oil cooler contaminated cooler cleaning Malfunction of solenoid valves   Malfunction of control spool

1) P P/R

1) 1)

BA 6040(3 847 027.00)-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







 

    

  

Cause Malfunction of pressure-relief valves

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS GmbH Service Chapter ref.

1)

Servo system pump defective Malfunction of travel valve (pedal) Malfunction of control spool ECO-power switch in 80%-position Travelling Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil cator lamp lit) oil cooler contaminated cooler cleaning

1) 1) 1) P P/R

5-5

BA 6040(3 847 027.00)-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 excavator control not activated / defective

    



 

    

5-6

Superstructure holding brake applied Pressure-relief valve adjusted too low level / defective Servo system pump defective Malfunction in feed-pressure circuit of swing pump Malfunction in high-pressure circuit of swing system Malfuction of moment-regulating valve Malfunction in swing pump displacement cylinder Excessive leakage in swing motor

Check Adjust Replace Top up Reduce Clean 1) Contact the CGM HMS GmbH Service Chapter ref.

Working

P E W A S R

P P 1) 1) 1) 1) 1) 1) 1)

BA 6040(3 847 027.00)-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

  



  

    

Lines between timer and hydraulic motor defective Hydraulikmotor defektive Grease pump defective Grease sieve clogged Distributor defective Grease container empty Grease pump does not suck grease Leaky lines Non-return valve defective Pressure switch defective

Check P Adjust E Replace W Top up A Reduce S Clean R Vent L 1) Contact the CGM HMS GmbH Service Chapter ref.

P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

5-7

BA 6040(3 847 027.00)-EN

Annex HYDRAULIC CIRCUIT DIAGRAM Detailled information can be found in the „Service Manual“ chapter 8 or contact CGM HMS GmbH service.

5-8

BA 6040(3 847 027.00)-EN

Annex ABBREVIATIONS

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

A abt. acc.

Ah

Manual 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

CECE

CEN cm cm3/rev CCW CW

dia.

DIN

Decibel (sound intensity according to measuring method A) Diameter German Industrial Standard

EDS eff. e.g. etc.

Electronic diagnostic system effective for example etcetera

dB(A)

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 i.e.

IFN

id est = that is ISO service rating, blocked

Incl.

ISO

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 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 1 Milliampere (= /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

Transmission ratio

5-9

BA 6040(3 847 027.00)-EN

Annex ABBREVIATIONS

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 (excavator) 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

PMS P/No. PS psi

THB TL tm

W

Watt (unit of electric power)

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

5-10

BA 6040(3 847 027.00)-EN

Annex NOISE AND VIBRATION INFORMATION Noise emission information

Vibration information

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

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.

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

The vibrations drivered 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).

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Annex

5-12

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Annex PRODUCT SPECIFICATION SHEET

5-13

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Annex

5-14

6040/6040 FS Hydraulic Shovel Specifications General Data

Operating Weight

Operating weight Face Shovel Backhoe

405 tonnes (446 tons) 407 tonnes (449 tons)

Engine Output SAE J1995 Cat® C32

1516 kW (2,032 hp)

Shovel Standard track pads 1200 mm (3 ft 11 in) Operating weight 404 600 kg (891,980 lb) Ground pressure 24.1 N/cm2 (35.0 psi) • Other track pads available on request

Standard Bucket Capacity Face Shovel (heaped 2:1) Backhoe (heaped 1:1)

22.0 m3 (28.8 yd3) 22.0 m3 (28.8 yd3)

Features • 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

Backhoe Standard track pads 1200 mm (3 ft 11 in) Operating weight 407 300 kg (897,930 lb) Ground pressure 24.3 N/cm2 (35.3 psi) • Other track pads available on request

Hydraulic Shovel—6040/6040 FS Dimensions All dimensions are approximate.

10

8 11

9

14 1 3

2

4 5

6 7

12 13

Dimensions and weights of AC machine differ slightly. Separate drawings, dimensions and weights can be provided upon request.

Diesel Engines Make and model 2 × Cat C32 (Tier 2) Total rated net power ISO 3046/1 1516 kW (2,032 hp) 1,750 min-1 Total rated net power SAE J1349 1516 kW (2,032 hp) 1,750 min-1 Total rated gross power SAE J1995 1516 kW (2,032 hp) 1,750 min-1 No. of cylinders (each engine) 12 Bore 145 mm (5.71 in) Stroke 162 mm (6.38 in) Displacement 32.1 L (1,959 in3) Aspiration Turbocharged and air-to-air aftercooled Max. altitude without deration at 10° C 2500 m (8,200 ft) above sea level Emissions U.S. EPA flex Alternators 2 × 150 A Fuel tank capacity 7800 L (2,060 U.S. gal) • Hydraulically driven radiator fan with electronically controlled fan speed • Microprocessed engine management • Heavy-duty air filters • Two-stage fuel filter including water separator • Additional high-capacity water separator

1 6800 mm (22 ft 4 in) 2 2250 mm (7 ft 5 in) 3 5620 mm (18 ft 5 in) 4 2620 mm (8 ft 7 in) 5 1030 mm (3 ft 5 in) 6 6170 mm (20 ft 3 in) 7 8090 mm (26 ft 7 in) 8 7000 mm (23 ft) 9 6780 mm (22 ft 3 in) 10 8050 mm (26 ft 5 in) 11 6100 mm (20 ft) 12 1200 mm (3 ft 11 in) 13 6600 mm (21 ft 8 in) 14 7920 mm (26 ft)

Electric Motor – 6040 AC/6040 AC FS Type Squirrel cage induction motor Output 1400 kW Voltage 6.6 kV ± 10% (other on request) Rated Current IN 156 A (at 6.6 kV) Frequency 50 Hz (60 Hz on request) Revolutions 1,500 min-1 (1,800 min-1 at 60 Hz) Starting current 350% of IN (197% of IN Optional) • 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 6 × 210 Ah – 12V each in series/parallel installation 630 Ah – 24V in total Working spot lights 8 × high-brightness LED lights • Battery isolation relays and switches • Emergency stop switches accessible from ground level, in engine module and in operator’s cab

2

Hydraulic Shovel—6040/6040 FS Hydraulic System with Pump Managing System Main pumps Diesel version 4 × variable swash plate pumps AC version 4 × variable flow axial piston pumps Max. oil flow Diesel version 4 × 724 L/min (4 × 191 U.S. gal/min) AC version 4 × 746 L/min (4 × 197 U.S. gal/min) Max. pressure, attachment 300 bar (4,350 psi) Max. pressure, travel 350 bar (5,080 psi) Swing pumps Diesel version 4 × reversible swash plate pump AC version 3 × reversible swash plate pump Max. oil flow Diesel version 4 × 321 L/min (4 × 85 U.S. gal/min) AC version 3 × 491 L/min (3 × 130 U.S. gal/min) Max. pressure, swing pumps 350 bar (5,080 psi) Total volume of hydraulic oil Diesel version Approx. 5800 L (1,532 U.S. gal) AC version Approx. 6400 L (1,585 U.S. gal) Hydraulic tank capacity Diesel version Approx. 3400 L (898 U.S. gal) AC version Approx. 4000 L (1,057 U.S. 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 filters (100 μm) for the main pumps, installed directly behind each pump – Full-flow filters (10 μm) for the complete return circuit – Full-flow filters (10 μm) for the cooling return circuit – Pressure filters (6 μm) for servo circuit – Pressure filters (40 μm) for the feed pumps of the closed swing circuit – Transmission oil filters (40 μm)

Hydraulic Oil Cooling Oil flow of cooling pumps Diesel version 2 × 799 L/min (2 × 211 U.S. gal/min) AC version 4 × 379 L/min (4 × 100 U.S. gal/min) Diameter of fans 2 × 1 524 mm (2 × 60 in) • 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 System Swing drives

3 compact planetary transmissions with axial piston motors Parking brake Wet multiple disc brake, springloaded/hydraulically released Max. swing speed Diesel version 4.7 rpm AC version 5.1 rpm Swing ring 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 race ways of swing ring, as well as grease bath for internal gearing, supplied by automatic central lubrication system 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

Hydraulic Shovel—6040/6040 FS Operator’s Cab Operator’s eye level Internal dimensions of cab

Undercarriage (continued) • 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

Approx. 6.8 m (22 ft 4 in) Length: 2200 mm (7 ft 3 in) Width: 1600 mm (5 ft 3 in) Height: 2150 mm (7 ft 1 in) • Pneumatically cushioned and multi-adjustable comfort seat with lumbar support, seat heating, safety belt, headand 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 blind at windshield • 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 Undercarriage Travel speed (2 stages) 1st stage 2nd stage Max. tractive force Gradeability of travel drives Track pads (each side) Bottom rollers (each side) Support rollers (each side) Travel drives (each side) Parking brake

Automatic Lubrication System Capacity of grease container 1000 L (264 U.S. gal) • Dual-circuit system with hydraulically driven heavy-duty pump and electronic time relay control adjust the pause/ lube times • Connected to the lubrication system are the swing roller bearing with internal gearing and all pivot points of attachment, bucket and cylinders • System failures displayed by Board Control System • Grease filters (200 μm) between service station and container, as well as directly behind grease pump Attachments • 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 of BH-attachment • 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

Max. 1.5 km/h (0.93 mph) Max. 2.5 km/h (1.55 mph) 2097 kN (214 t = 471,260 lb) Max. 57% 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

4

Hydraulic Shovel—6040/6040 FS Working Range – TriPower Face Shovel Attachment (FS) All dimensions are approximate. ft 50

m 15

45

14 13

40 35

12 11 10

30 25

9 8 7

20 15 10 5 0 –5 –10

6 5

785D

4 3 2 1 0 –1 –2 –3

17 16 15 14 13 12 11 10

9

8

55

30

25

50

45

40

35

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

7

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

5

Hydraulic Shovel—6040/6040 FS 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 14.0 m3 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 15.3 m3 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 17.2 m3 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

6

3,710 lb/yd3

3,370 lb/yd3

3,030 lb/yd3

Hydraulic Shovel—6040/6040 FS General Packing List 2 crawler side frames (values per each side frame) Gross weight

30 350 kg (66,910 lb)

1 Length

7850 mm (25 ft 9 in)

Width

2100 mm (6 ft 11 in)

2 Height

1900 mm (6 ft 3 in)

2 1

6 tracks consisting of 14 pad links (values per each track) Gross weight 1 Length

6050 mm (19 ft 10 in)

Width

1200 mm (3 ft 11 in)

2 Height

2

1

8050 kg (17,750 lb)

310 mm (1 ft)

Undercarriage center frame with swing roller bearing Gross weight

33 900 kg (74,740 lb)

1 Length

6240 mm (20 ft 6 in)

Width

3800 mm (12 ft 6 in)

2 Height

2120 mm (6 ft 11 in)

2 1

Superstructure center frame Gross weight

50 500 kg (111,330 lb)

1 Length

9500 mm (31 ft 2 in)

Width

3610 mm (11 ft 10 in)

2 Height

3180 mm (10 ft 5 in)

2

1

Engine module with diesel engines Gross weight

31 700 kg (69,890 lb)

1 Length

3850 mm (12 ft 8 in)

Width

6150 mm (20 ft 2 in)

2 Height

3600 mm (11 ft 10 in)

2

1

Oil cooler module Gross weight

7450 kg (16,420 lb)

1 Length

4700 mm (15 ft 5 in)

Width

2000 mm (6 ft 7 in)

2 Height

3150 mm (10 ft 4 in)

2

1 Above values are approximate. Details may vary depending on scope of supply and destination.

Exact data subject to selected machine configuration and final packing list.

7

Hydraulic Shovel—6040/6040 FS General Packing List Cab pedestal module Gross weight

5950 kg (13,120 lb)

1 Length

4350 mm (14 ft 3 in)

Width

2150 mm (7 ft 1 in)

2 Height

3100 mm (10 ft 2 in)

2

1

Crate with cabin and FOPS Gross weight

3960 kg (8,730 lb)

1 Length

3500 mm (11 ft 6 in)

Width

2600 mm (8 ft 6 in)

2 Height

2870 mm (9 ft 5 in)

2

1

Counterweight including radiators Gross weight

38 850 kg (85,650 lb)

1 Length

6100 mm (20 ft)

Width

1300 mm (4 ft 3 in)

2 Height

3300 mm (10 ft 10 in)

2

1

Crates Content

1 Length

2 Width

Height

Gross Weight

Three swing gear

1550 mm (5 ft 1 in)

1350 mm (4 ft 5 in)

2000 mm (6 ft 7 in)

3860 kg (8,510 lb)

Swing ring cover

2200 mm (7 ft 3 in)

1300 mm (4 ft 3 in)

1150 mm (3 ft 9 in)

415 kg (910 lb)

Bolts, tools, platform, etc.

3400 mm (11 ft 2 in)

1250 mm (4 ft 1 in)

1370 mm (4 ft 6 in)

2230 kg (4,920 lb)

Grease container with pump

1700 mm (5 ft 7 in)

1370 mm (4 ft 6 in)

2060 mm (6 ft 9 in)

1205 kg (2,660 lb)

Barrels (hydraulic oil)

1900 mm (6 ft 3 in)

1300 mm (4 ft 3 in)

1250 mm (4 ft 1 in)

1330 kg (2,930 lb)

Barrels (oil; grease; antifreeze)

1900 mm (6 ft 3 in)

1300 mm (4 ft 3 in)

1250 mm (4 ft 1 in)

1450 kg (3,200 lb)

Retractable ladder

6000 mm (19 ft 8 in)

1000 mm (3 ft 3 in)

2550 mm (8 ft 9 in)

1500 kg (3,310 lb)

Emergency ladder

4400 mm (14 ft 5 in)

1000 mm (3 ft 3 in)

2000 mm (6 ft 7 in)

1500 kg (3,310 lb)

Service station, gratings, etc.

3200 mm (10 ft 6 in)

1950 mm (6 ft 5 in)

1070 mm (3 ft 6 in)

1660 kg (3,660 lb)

Air condenser, air filters, etc.

3400 mm (11 ft 2 in)

1700 mm (5 ft 7 in)

1800 mm (5 ft 11 in)

760 kg (1,680 lb)

Above values are approximate. Details may vary depending on scope of supply and destination.

Exact data subject to selected machine configuration and final packing list.

8

2 1

Hydraulic Shovel—6040/6040 FS TriPower Shovel Attachment Boom with main valve block, TriPower linkages and rods Gross weight

35 900 kg (79,150 lb)

1 Length

8100 mm (26 ft 7 in)

Width

2800 mm (9 ft 2 in)

2 Height

3500 mm (11 ft 6 in)

2

1

Stick Gross weight

12 150 kg (26,790 lb)

1 Length

5350 mm (17 ft 7 in)

Width

2050 mm (6 ft 9 in)

2 Height

2100 mm (6 ft 11 in)

2 1

Face shovel including pin for stick Capacity (2:1)

22.0 m3 (28.8 yd3)

Gross weight

38 300 kg (84,440 lb)

2

1 Length

4150 mm (13 ft 7 in)

Width

4700 mm (15 ft 5 in)

2 Height

3400 mm (11 ft 2 in)

1

6100 kg (13,450 lb)

1

Bundle with 2 boom cylinders Gross weight

2

1 Length

4350 mm (14 ft 3 in)

Width

1100 mm (3 ft 7 in)

2 Height

550 mm (1 ft 10 in)

2 Bundles with 2 stick cylinders and 2 bucket cylinders (values per each bundle) Gross weight

2 1

4300 kg (9,480 lb)

1 Length

4200 mm (13 ft 9 in)

Width

1100 mm (3 ft 7 in)

2 Height

550 mm (1 ft 10 in)

Crate with catwalks, railings and other parts Gross weight

3750 kg (8,270 lb)

1 Length

4500 mm (14 ft 9 in)

Width

1900 mm (6 ft 3 in)

2 Height

1800 mm (5 ft 11 in)

2 1

Above values are approximate. Details may vary depending on scope of supply and destination.

Exact data subject to selected machine configuration and final packing list.

9

Hydraulic Shovel—6040/6040 FS Backhoe Attachment Monoboom without main valve block Gross weight

36 200 kg (79,810 lb)

1 Length

10 350 mm (33 ft 11 in)

Width

4500 mm (14 ft 9 in)

2 Height

2850 mm (9 ft 4 in)

2

1

Stick with linkage and bucket cylinders Gross weight

22 200 kg (48,940 lb)

1 Length

6500 mm (21 ft 4 in)

Width

2200 mm (7 ft 3 in)

2 Height

2

1

2750 mm (9 ft)

Backhoe bucket including pin for stick Capacity (1:1)

22.0 m3 (28.8 yd3)

Gross weight

24 800 kg (54,670 lb)

1 Length

3820 mm (12 ft 6 in)

Width

4310 mm (14 ft 2 in)

2 Height

3200 mm (10 ft 6 in)

2

1

Bundle with 2 boom cylinders Gross weight

2

9600 kg (21,160 lb)

1 Length

5700 mm (18 ft 8 in)

Width

1200 mm (3 ft 11 in)

2 Height

750 mm (2 ft 6 in)

1

Bundle with 2 stick cylinders Gross weight

2 1

6400 kg (14,110 lb)

1 Length

4800 mm (15 ft 9 in)

Width

1200 mm (3 ft 11 in)

2 Height

700 mm (2 ft 4 in)

Crates with main valve block, catwalks, railings and other parts Gross weight

5300 kg (27,580 lb)

4120 kg (9,080 lb)

1 Length

4950 mm (16 ft 3 in)

4500 mm (14 ft 9 in)

Width

2100 mm (6 ft 11 in)

1900 mm (6 ft 3 in)

2 Height

1750 mm (5 ft 9 in)

1750 mm (4 ft 9 in)

Above values are approximate. Details may vary depending on scope of supply and destination.

Exact data subject to selected machine configuration and final packing list.

10

2 1

Hydraulic Shovel—6040/6040 FS Component Accessibility on Superstructure 1. Diesel engines 2. Gearboxes with hydraulic pumps 3. Engine radiators with hydraulically driven fan

4. Oil coolers 5. Hydraulic tank 6. Swing drives

7. Rotary distributor 8. Travel values 9. Switch cabinet and battery box

4

4

2

10. Operator’s seat 11. BCS tower 12. Auxiliary seat

1 3

7

8

5

6

9

2

1

3

11

10

12 Anti-slip walking Anti-slip walking areasareas Anti-slip catwalks Anti-slip catwalks

Optional Equipment General • Export crating • Finishing as per end user’s corporate colors

Cab • Various heating and air conditioning systems • Roller blinds at all windows • Outside-mounted sun shields

Superstructure • Hydraulic service crane on superstructure with auxiliary engine • Round container with a standard 200 L (53 gal) grease barrel (instead of 1000 L (264 gal) grease container) • Lubricated pinion for greasing of internal gearing of swing ring • Various cold-weather packages

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) Attachment • LED lighting on boom • Special wear packages Additional optional equipment available on request

11

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 © 2013 Caterpillar Inc. 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

AEHQ6524-02 Replaces AEHQ6524-01 July 2013

BA 6040(3 847 027.00)-EN

Annex NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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5-15

BA 6040(3 847 027.00)-EN

Annex

5-16

BA 6040(3 847 027.00)-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

BA 6040(3 847 027.00)-EN

Index

6-2

BA 6040(3 847 027.00)-EN

Index

A ABBREVIATIONS 5-9 Access ladder lighting 2-24 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS 1-12 Activating the electronic servo control 2-78 After daily operation 2-82 Air conditioner (optional) 2-68 Appropriate disposal of batteries 4-12 ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-83 Automatic fire-extinguishing system (optional 235 Automatic reset to idling 2-9 Avoid mixing of different hydraulic fluids 3-29, 362

B Back-up heating operator’s cab (optional) 2-68 Battery main switch, switching and off 2-61 Battery storage 3-104 Battery, checking state of charge 3-40 Bearing races 3-88 Before starting work 2-78 Board-Control-System (BCS) 2-9 Braking the superstructure 2-79 Breather filter 3-92 Bypass valves, clean / replace 3-56

C CENTRAL LUBRICATING 3-90 Central lubricating system – Fault table 5-7 Changing the hydraulic oil 3-62 Checking the gas charging pressure in the pressure accumulator 3-87, 3-101 Checking the greasing pressure 3-93, 3-94 Checking the hydraulic oil level 3-50 Circuit breaker, switching on and off 2-65 Cleaning jobs 3-9 Cleaning the hydraulic oil cooler 3-67 Components 3-9 Control and Monitoring Platform (CAMP) 2-8 Corrosion protection for pins and bearings (bushings and hubs) 2-85 CRAWLER TRACKS 3-84

D Demand control / Zero-flow regulation 2-9 Depressurizing the hydraulic system 3-49 DESCRIPTION OF THE SHOVEL 2-6 Design and function 3-90 Designated use 1-6

Disposal at the end of the service life 4-11 Drive 2-8

E Electric motor - Safety instructions 3-37 Electric motor can not be switched on 2-64 Electric motor, cleaning 3-37 Electric motor, greasing 3-38 Electrical circuit diagrams 3-45 Electrical system 2-9 ELECTRICAL SYSTEM 3-39 Electrical system - Safety instructions 3-39 Electrical system (24V), switching and off 2-61 Electrical system, control cabinets 3-42 Electronic excavator control 3-68 ELEKTRIc MOTOR 3-37 Emergency escape device (optional) 2-36 Emergency exit in operator’s cab and escape ladder 2-27 Emergency lowering of the working equipmen 281 EMERGENCY STOP switch 2-30 Entering and leaving the machine Safety instructions 2-24 Equipment, check for cracks 3-99 Extract from the regulations 3-101

F FAULT TABLES 5-4 Filling 3-92 Filling quantities - Grease 3-25 Filling quantities - oil 3-28 Filling quantities - other 3-28 Filter (servo control circuit), replace 3-58 Filters for swing charge pump, replace 3-60 Fire and explosion hazard 1-14, 2-5 Fire and Explosion Hazard 3-8, 4-5 Fire extinguisher 2-34 Folding ladder (optional) 2-26 Function 3-91 Further machine documentation 1-3

G Gas, dust, steam and smoke 1-11 Gearbox - Checking the oil level / Topping up with oil 3-76 Grease filter (Filling the grease container) 3-97 Grease filter (Grease lines) 3-98 Grease for bearings, swing rings and track system (Central lubrication system) 3-34 Greases for idlers, track rollers and support rollers (Lifetime lubrication) 3-35

H 6-3

BA 6040(3 847 027.00)-EN

Index Heating and air conditioning 3-99 High-pressure filter for working hydraulics, replace 3-59 High-pressure filters for the servo circuit, replace 3-61 Hose line for oil changes 3-36 Hydraulic / pnaumatic equipment 1-11 HYDRAULIC CIRCUIT DIAGRAM 5-8 Hydraulic hoses – Instructions 4-6 Hydraulic ladder, pressure accumulator 3-100 Hydraulic oil return-flow filters, replace 3-52 Hydraulic oil return-flow filters, replace (from machine no. 170138) 3-54 Hydraulic oil tank breather filters, replace 3-57 Hydraulic system 2-8 HYDRAULIC SYSTEM 3-49 HYDRAULIC SYSTEM 4-6 Hydraulic system - Safety instructions 3-49

I In case of failure 2-64 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 5-3

L Layout of the fault table 5-3 Lighting systems in LED technonogy, instructions 3-48 LUBRICANTS 3-29 LUBRICANTS / Consumables 3-30 LUBRICATING CHART – GREASE 3-24 Lubricating chart – Grease (legend) 3-25

M Measures 5-3 Monitoring cameras 2-89 MONITORING, WARNING AND CONTROL ELEMENTS 2-40 Motor protection relay, functions 2-66

N Noise 1-11 Noise and vibration information 5-11 Noise emission information 5-11 notes 3-1 NOTES 2-91, 4-13, 5-15 NOTES 1-1 Notes on the selection of oils and greases 3-29

O Oil for combustion engines (On-Board Crane, option) 3-30

6-4

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 1-11 Oilfilter (hydraulic circuit grease pump) 3-96 Oils / Greases 3-9 ON-BOARD CRANE (OPTIONAL) 2-86 On-Board crane, – blocking the boom in position of rest 2-88 On-board crane, checking 2-88 On-Board crane, checking tightness of fastening bolts 3-103 On-board crane, drive unit 3-102 On-board crane, drive unit 2-87 On-board crane, lubricating 3-103 On-board crane, monitoring, warning and control elements 2-86 On-board crane, putting into operation 2-87 Operation - Safety instructions 2-3 Operation and Maintenance Manual, where to store it in the operator’s cab 2-4 Operation with cable reel (optional) 2-11 Operator's seat 2-32 Organizational measures 1-7 OTHER MAINTENANCE 3-99

P Plan A - E 3-17 Plan N 3-13 Plan T and W 3-15 Plan V 3-11 Possible causes 5-3 Power supply 2-10 Pre-chambers working pumps, draining oil, changing oil 3-74 Preface 1-3 Pressure accumulator - Emergency lowering 3-69 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS 4-7 Pressure-accumulator inspection regulations 387 Pressure-accumulator inspection regulations 3101 Product specification sheet 5-13 PUMP DRIVE GEARBOX 3-70 Pump drive gearbox, changing oil 3-72 Pump drive gearbox, checking oil level / Topping up with oil 3-70 Pump drive gearbox, pre-chamber 3-73 Pump drive gearbox, venting 3-73 Pump gearbox cooling circuit, replace oil filter 375 Putting the excavator out of operation 3-104 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-104 PUTTING THE MACHINE INTO OPERATION 258

BA 6040(3 847 027.00)-EN

Index R Recommissioning 3-104 Repair 4-6 Repair work - Safety instructions 4-4 Replacing fuses 3-45 Replacing lamps and bulbs 3-45 Reservoirs for used grease at the A-frame, emptying 3-100

S Safety instructions for excavators with electric motor 1-13, 3-3, 4-3 Safety instructions governing specific operational phases 1-8 Section 5-3 Securing the machine 2-84 Selection and qualification of personnel; basic responsibilities 1-8 Service station (tanklift) 2-58 Servicing Intervals 3-9 Servicing switch 2-31 SERVICING WORK 3-36 Shovel layout 2-7 Signs 2-12 SLEWING GEARBOX 3-76 Slewing mechnism – Fault table 5-6 SLEWING RING 3-88 Slewing ring - Instructions 3-88 Slip ring assembly, servicing work 3-45 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables 1-9 Superstructure 2-8 Superstructure basic position 2-70 Superstructure holding brake 2-74 SWING GEARBOX 3-78 Swing gearbox - Changing the gearbox oil 3-76, 3-79 Swing gearbox - Gearbox - Checking the oil level / Topping up with oil 3-78 Swing gearbox - venting 3-80 Swing gearbox, venting 3-77 Swinging ladder 2-25 Swinging the superstructure 2-79 Switching the cab interior lighting on and off 2-28 Switching the electric motor on and off 2-62 Switching the maintenance lights on and off 2-29

T Time-out before restart 2-63 Track drive – Fault table 5-5 Track parking brake 2-74 Track rollers 3-85 Track tensioner 3-86 Trainer's / instructor's seat 2-35 Transport - Safety instructions 2-75 Transporting and recommissioning 1-11 Transporting the machine 2-75 TRAVEL GEARBOX 3-81 Travel gearbox - Breather filter 3-83 Travel gearbox - Changing oil 3-82 Travel gearbox - Checking the oil level / Topping up with oil 3-81 TRAVELLING 2-70 Travelling forwards/backwards 2-70 travellING, SAFETY INSTRUCTIONS 2-69 TROUBLESHOOTING 5-3

U Unblocking a grease line. 3-95 Undercarriage 2-8

V Venting the hydraulic system 3-66 Vibration information 5-11

W Warning of special dangers 1-10 Warnings and symbols 1-5 Warranty 1-4 Welding and flame cutting works - Safety instructions 4-8 Windscreen washer 2-31 Working 2-80 Working hydraulics – Fault table 5-4 WORKING OPERATION 2-78 Working operation - Safety instructions 2-76

X Xenon floodlight projector (optional), replacing the lamp 3-46

6-5

BA 6040(3 847 027.00)-EN

Index

6-6