Caterpillar 6040AC, 6040ACFS Hydraulic Shovel Operation And Maintenance Manual 3847027
Caterpillar 6040AC, 6040ACFS Hydraulic Shovel Operation And Maintenance Manual 3847027 - Image 2
Caterpillar 6040AC, 6040ACFS Hydraulic Shovel Operation And Maintenance Manual 3847027 - Image 3
Caterpillar 6040AC, 6040ACFS Hydraulic Shovel Operation And Maintenance Manual 3847027 - Image 4
Caterpillar 6040AC, 6040ACFS Hydraulic Shovel Operation And Maintenance Manual 3847027 - Image 5

Caterpillar 6040AC, 6040ACFS Hydraulic Shovel Operation And Maintenance Manual 3847027

$30.00

  • Type Of Manual: Operation And Maintenance Manual
  • Manual ID: 3847027
  • Number of Pages: 270
  • Size: 6.2MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 6040AC, 6040ACFS Hydraulic Shovel
  • 1. TITLEPAGE
  • 2. INTRODUCTION
  • 2.1. PREFACE
  • 2.1.1. Further machine documentation
  • 2.2. WARRANTY
  • 2.3. FUNDAMENTAL SAFETY INSTRUCTIONS
  • 2.3.1. Warnings and symbols
  • 2.4. DESIGNATED USE
  • 2.5. ORGANIZATIONAL MEASURES
  • 2.5.1. Personal protective equipment and the working clothing
  • 2.5.2. Selection and qualification of personnel basic responsibilities
  • 2.5.3. Safety instructions governing specific operational phases
  • 2.5.4. Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work disposal of parts and consumables
  • 2.5.5. Warning of special dangers
  • 2.5.6. Gas, dust, steam and smoke
  • 2.5.7. Hydraulic / pneumatc equipment
  • 2.5.8. Oil, grease and other chemical substances
  • 2.5.9. Transporting and recommissioning
  • 2.6. ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS
  • 2.6.1. Safety instructions for excavators with electric motor
  • 2.7. FIRE AND EXPLOSION HAZARD
  • 3. OPERATION
  • 3.1. OPERATION – SAFETY INSTRUCTIONS
  • 3.1.1. Operation and Maintenance Manual
  • 3.1.2. Operating personnel
  • 3.1.3. Personal protective gear and working clothing
  • 3.1.4. Safety belt
  • 3.1.5. State of the machine
  • 3.1.6. Entering and leaving the machine
  • 3.1.7. Hazard range
  • 3.1.8. Persons within the hazard zone
  • 3.1.9. Marshallers
  • 3.1.10. Securing the machine
  • 3.1.11. Operation and Maintenance Manual, where to store it in the operators cab
  • 3.2. FIRE AND EXPLOSION HAZARD
  • 3.3. DESCRIPTION OF THE SHOVEL
  • 3.3.1. Shovel layout
  • 3.3.2. Undercarriage
  • 3.3.3. Superstructure
  • 3.3.4. Hydraulic system
  • 3.3.5. Control and Monitoring Platform (CAMP)
  • 3.3.6. Demand control / Zero-flow regulation
  • 3.3.7. Automatic reset to idling
  • 3.3.8. Board-Control-System (BCS)
  • 3.3.9. Electrical system
  • 3.3.10. Power supply
  • 3.3.11. Operation with cable reel (optional)
  • 3.3.12. Entering and leaving the machine Safety instructions
  • 3.3.13. Access ladder lighting
  • 3.3.14. Swinging ladder
  • 3.3.15. Folding ladder (optional)
  • 3.3.16. Emergency exit in operators cab and escape ladder
  • 3.3.17. Switching the cab interior lighting on and off
  • 3.3.18. Switching the maintenance lights on and off
  • 3.3.19. EMERGENCY STOP switch
  • 3.3.20. Servicing switch
  • 3.3.21. Windscreen washer
  • 3.3.22. Operators seat
  • 3.3.23. Fire extinguisher
  • 3.3.24. Automatic fire-extinguishing system (optional)
  • 3.3.25. Trainers / instructors seat
  • 3.3.26. Emergency escape device (optional)
  • 3.4. MONITORING, WARNING AND CONTROL ELEMENTS
  • 3.4.1. Optional equipment Air conditioning
  • 3.5. PUTTING THE MACHINE INTO OPERATION
  • 3.5.1. Service station (tanklift)
  • 3.5.2. Battery main switch, switching on and off
  • 3.5.3. Electrical system (24V), switching on and off
  • 3.5.4. Switching the electric motor on and off
  • 3.5.5. Time-out before restart
  • 3.5.6. Electric motor can not be switched on
  • 3.5.7. In case of failure
  • 3.5.8. Circuit breaker, switching on and off
  • 3.5.9. Motor protection relay, functions
  • 3.5.10. Air conditioner (optional)
  • 3.5.11. Back-up heating operators cab (optional)
  • 3.6. TRAVELLING, SAFETY INSTRUCTIONS
  • 3.6.1. Trailing cable
  • 3.7. TRAVELLING
  • 3.7.1. Superstructure basic position
  • 3.7.2. Travelling forwards/backwards
  • 3.7.3. Superstructure holding brake
  • 3.7.4. Track parking brake
  • 3.8. TRANSPORTING THE MACHINE
  • 3.8.1. Transport – Safety instructions
  • 3.9. WORKING OPERATION – SAFETY INSTRUCTIONS
  • 3.9.1. Running-in instructions for hydraulic cylinders
  • 3.9.2. Avoid extreme positions of the attachment
  • 3.10. WORKING OPERATION
  • 3.10.1. Before starting work
  • 3.10.2. Activating the electronic servo control
  • 3.10.3. Swinging the superstructure
  • 3.10.4. Braking the superstructure
  • 3.10.5. Working
  • 3.10.6. Emergency lowering of the working equipment
  • 3.10.7. After daily operation
  • 3.11. ASSEMBLING WORKING EQUIPMENT SAFETY INSTRUCTIONS
  • 3.11.1. Personel
  • 3.11.2. Personal protective gear and working clothes
  • 3.11.3. Tools and auxiliaries
  • 3.11.4. Securing the working equipment
  • 3.11.5. Securing the machine
  • 3.11.6. Selecting the attachments
  • 3.11.7. Protective roof against falling objects
  • 3.11.8. Securing the machine
  • 3.12. CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)
  • 3.12.1. Application of GLEITMO 815
  • 3.13. ON-BOARD CRANE (OPTIONAL)
  • 3.13.1. Personel
  • 3.13.2. On-board crane, monitoring, warning and control elements
  • 3.13.3. On-board crane, putting into operation
  • 3.13.4. On-board crane, drive unit
  • 3.13.5. On-Board crane, blocking the boom in position of rest
  • 3.13.6. On-board crane, checking
  • 3.13.7. Monitoring cameras
  • 3.14. NOTES
  • 4. INSPECTION AND SERVICING
  • 4.1. SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR
  • 4.1.1. In the transformer station
  • 4.1.2. On the excavator
  • 4.1.3. In the transformer station
  • 4.1.4. On the hydraulic excavator
  • 4.1.5. On the hydraulic excavator
  • 4.2. INSPECTION AND SERVICING SAFETY INSTRUCTIONS
  • 4.2.1. Operating manual
  • 4.2.2. Inspection and servicing personnel
  • 4.2.3. Personal protective equipment and working clothing
  • 4.2.4. Securing the working equipment
  • 4.2.5. Securing the machine
  • 4.2.6. Climbing onto and off the machine
  • 4.2.7. Checking the state of tools
  • 4.2.8. Cleaning jobs
  • 4.2.9. Handling flammable liquids
  • 4.2.10. Fastening and securing elements
  • 4.2.11. Spare parts
  • 4.2.12. Handling oils and greases
  • 4.2.13. Visisble oil losses
  • 4.2.14. Relieving residual pressure in the hydraulic system
  • 4.2.15. Screwed connections, piping, hydraulic hoses
  • 4.2.16. Non-polluting disposal
  • 4.2.17. Handling batteries
  • 4.2.18. Before working on the electrical system
  • 4.2.19. Selecting oils and greases
  • 4.2.20. Filters
  • 4.2.21. Sealing elements
  • 4.2.22. Oil-level check and oil change
  • 4.2.23. Lubricating
  • 4.2.24. After servicing
  • 4.3. FIRE AND EXPLOSION HAZARD
  • 4.4. INSPECTION AND SERVICING PLANS INSTRUCTIONS
  • 4.4.1. Servicing Intervals
  • 4.4.2. Oils / Greases
  • 4.4.3. Cleaning jobs
  • 4.4.4. Components
  • 4.4.5. Plan V
  • 4.4.6. Plan N
  • 4.4.7. Plan T and W
  • 4.4.8. Plan A E
  • 4.5. LUBRICATING CHART GREASE
  • 4.5.1. Lubricating chart Grease (legend)
  • 4.5.2. Filling quantities Grease
  • 4.6. INSPECTION PLAN – OIL
  • 4.6.1. Inspection plan Oil (legend)
  • 4.6.2. Filling quantities – oil
  • 4.6.3. Filling quantities – other
  • 4.7. LUBRICANTS
  • 4.7.1. Notes on the selection of oils and greases
  • 4.7.2. Avoid mixing of different hydraulic fluids
  • 4.8. LUBRICANTS / CONSUMABLES
  • 4.8.1. Oil for combustion engines (On-Board Crane, option)
  • 4.8.2. II. Oil for hydraulic system (selection)
  • 4.8.3. III.a Oil for pump gearboxes and travel gearboxes
  • 4.8.4. III.b Oil for swing gearboxes
  • 4.8.5. Grease for bearings, swing rings and track system (Central lubrication system)
  • 4.8.6. Greases for idlers, track rollers and support rollers (Lifetime lubrication)
  • 4.9. SERVICING WORK
  • 4.9.1. Hose line for oil changes
  • 4.10. ELECTRIC MOTOR
  • 4.10.1. Electric motor – Safety instructions
  • 4.10.2. Electric motor, cleaning
  • 4.10.3. Electric motor, greasing
  • 4.11. ELECTRICAL SYSTEM
  • 4.11.1. Electrical system – Safety instructions
  • 4.11.2. Battery, checking state of charge
  • 4.11.3. Electrical system, control cabinets
  • 4.11.4. Slip ring assembly, servicing work
  • 4.11.5. Electrical circuit diagrams
  • 4.11.6. Replacing fuses
  • 4.11.7. Replacing lamps and bulbs
  • 4.11.8. Xenon floodlight projector (optional), replacing the lamp
  • 4.11.9. Lighting systems in LED technonogy, instructions
  • 4.12. HYDRAULIC SYSTEM
  • 4.12.1. Hydraulic system – Safety instructions
  • 4.12.2. Depressurizing the hydraulic system
  • 4.12.3. Checking the hydraulic oil level
  • 4.12.4. Hydraulic oil return-flow filters, replace
  • 4.12.5. Hydraulic oil return-flow filters, replace (from machine no. 170138)
  • 4.12.6. Bypass valves, clean / replace
  • 4.12.7. Hydraulic oil tank breather filters, replace
  • 4.12.8. Filter (servo control circuit), replace
  • 4.12.9. High-pressure filter for working hydraulics, replace
  • 4.12.10. Filters for swing charge pump, replace
  • 4.12.11. High-pressure filters for the servo circuit, replace
  • 4.12.12. Changing the hydraulic oil
  • 4.12.13. Avoid mixing of different hydraulic fluids
  • 4.12.14. Venting the hydraulic system
  • 4.12.15. Cleaning the hydraulic oil cooler
  • 4.12.16. Electronic excavator control
  • 4.12.17. Pressure accumulator – Emergency lowering
  • 4.13. PUMP DRIVE GEARBOX
  • 4.13.1. Pump drive gearbox, checking oil level / Topping up with oil
  • 4.13.2. Pump drive gearbox, changing oil
  • 4.13.3. Pump drive gearbox, pre-chamber
  • 4.13.4. Pump drive gearbox, venting
  • 4.13.5. Pre-chambers working pumps, draining oil, changing oil
  • 4.13.6. Pre-chambers swing pumps, draining oil, changing oil
  • 4.13.7. Pump gearbox cooling circuit, replace oil filter
  • 4.14. SWING GEARBOX
  • 4.14.1. (For swing gearboxes P/N 3692960)
  • 4.14.2. Swing gearbox – Checking the oil level / Topping up with oil
  • 4.14.3. Swing gearbox – Changing the gearbox oil
  • 4.14.4. Swing gearbox, venting ,
  • 4.15. SWING GEARBOX
  • 4.15.1. (For swing gearbox P/N 3676892)
  • 4.15.2. Swing gearbox – Gearbox – Checking the oil level / Topping up with oil
  • 4.15.3. Swing gearbox – Changing the gearbox oil
  • 4.15.4. Swing gearbox – venting
  • 4.16. TRAVEL GEARBOX
  • 4.16.1. Travel gearbox – Checking the oil level / Topping up with oil
  • 4.16.2. Travel gearbox – Changing oil
  • 4.16.3. Travel gearbox – Breather filter
  • 4.17. CRAWLER TRACKS
  • 4.17.1. Cleaning
  • 4.17.2. Track rollers
  • 4.17.3. Track tensioner
  • 4.17.4. Pressure-accumulator inspection regulations
  • 4.17.5. Checking the gas charging pressure in the pressure accumulator
  • 4.18. SWING RING
  • 4.18.1. Swing ring – Instructions
  • 4.18.2. Bearing races
  • 4.19. CENTRAL LUBRICATING
  • 4.19.1. Design and function
  • 4.19.2. Function
  • 4.19.3. Filling up the grease container
  • 4.19.4. Breather filter
  • 4.19.5. Checking the greasing pressure
  • 4.19.6. Checking the greasing pressure
  • 4.19.7. Unblocking a grease line.
  • 4.19.8. Unblocking a grease line.
  • 4.19.9. Oilfilter (hydraulic circuit grease pump) )
  • 4.19.10. Grease filter (Filling the grease container)
  • 4.19.11. Grease filter (Grease lines)
  • 4.20. OTHER MAINTENANCE
  • 4.20.1. Heating and air conditioning
  • 4.20.2. Equipment, check for cracks
  • 4.20.3. Reservoirs for used grease at the A-frame, emptying
  • 4.20.4. Hydraulic ladder, pressure accumulator
  • 4.20.5. Pressure-accumulator inspection regulations
  • 4.20.6. Extract from the regulations
  • 4.20.7. Checking the gas charging pressure in the pressure accumulator
  • 4.21. ON-BOARD CRANE, DRIVE UNIT
  • 4.21.1. Crane engine
  • 4.21.2. Hydraulic system
  • 4.21.3. On-board crane, lubricating
  • 4.21.4. On-Board crane, checking tightness of fastening bolts
  • 4.22. PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING
  • 4.22.1. Putting the excavator out of operation
  • 4.22.2. Battery storage
  • 4.22.3. Recommissioning
  • 5. REPAIR WORK
  • 5.1. SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR
  • 5.1.1. In the transformer station
  • 5.1.2. On the excavator
  • 5.1.3. In the transformer station
  • 5.1.4. On the hydraulic excavator
  • 5.2. REPAIR WORK – SAFETY INSTRUCTIONS
  • 5.2.1. Operation and Maintenance Manual
  • 5.2.2. Repair personnel
  • 5.2.3. Working in greater heights
  • 5.2.4. Prestressed units
  • 5.2.5. Dismantling components
  • 5.2.6. Never remove lead seals.
  • 5.2.7. After the repair work
  • 5.3. FIRE AND EXPLOSION HAZARD
  • 5.4. HYDRAULIC SYSTEM
  • 5.4.1. Repair
  • 5.4.2. Hydraulic hoses Instructions
  • 5.5. PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS
  • 5.6. WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS
  • 5.6.1. Welding work by qualified personnel only
  • 5.6.2. Increased risk of fire during welding work
  • 5.6.3. Health hazards
  • 5.6.4. Tanks, pressure vessels and pressure accumulators
  • 5.6.5. Slewing rings and articulated joints
  • 5.6.6. Information relating to the electrical system and to electronic modules
  • 5.6.7. Welding on the counterweight
  • 5.6.8. Welding on components of the working equipment and on other fully or partly closed steel structures
  • 5.6.9. Welding on the cab
  • 5.6.10. Further information
  • 5.7. DISPOSAL AT THE END OF THE SERVICE LIFE
  • 5.7.1. Dismantling and removal instructions
  • 5.7.2. Risk of deflagrations
  • 5.7.3. Risk of fire
  • 5.7.4. Disposing of the machine without polluting the environment
  • 5.7.5. Further hazardous substances
  • 5.7.6. Appropriate disposal of batteries
  • 6. ANNEX
  • 6.1. TROUBLESHOOTING
  • 6.1.1. Instructions on troubleshooting
  • 6.1.2. Layout of the fault table
  • 6.1.3. Possible causes
  • 6.1.4. Measures
  • 6.1.5. Section
  • 6.2. FAULT TABLES
  • 6.2.1. Working hydraulics Fault table
  • 6.2.2. Track drive Fault table
  • 6.2.3. Swing mechnism Fault table
  • 6.2.4. Central lubricating system Fault table
Rate this product

Related products