Caterpillar Hydraulic Shovel 6040 Service Manual EM028957-0

Description

Contents:
1. General
1.1 Introduction
1.1.1 Service Manual
1.1.2 How To Use The Service Manual
1.1.3 Servicing And Repair
1.1.4 Important Hints
1.2 Safety Instructions
1.2.1 Risks Of Disregarding Safety Instructions
1.2.2 Safety Regulations
1.2.3 Modificaterpillarion Of The Machine
1.2.4 Re- Commissioning
1.3 General
2. Technical Data
2.1 Introduction
2.1.1 Foreword
2.1.2 Safety
2.1.3 General
2.2 Engine – Motor
2.3 Hydraulic System
2.3.1 Main Pump
2.3.2 Swing System
2.3.3 Servo Pump – Gear Oil Pump
2.3.4 Cooling System Hydraulic Oil – Water
2.3.5 Travel Motor
2.3.6 Control Block
2.3.7 Filter Elements For Hydraulic System
2.4 Pressure Setting
2.5 Governing Current For Proportional Valves
2.6 Hydraulic Cylinder
2.6.1 Face Shovel
2.6.2 Backhoe
2.7 Transmission Ratio
2.8 Weights Of Modules And Components
2.8.1 Modules
2.8.2 Components
2.9 Tightening Procedures For Bolts
2.9.1 Tightening Procedures For Module Bolts
2.9.2 Tightening Procedures For Component Bolts
3. Tools, Assembly
3.1 Introduction
3.1.1 Foreword
3.1.2 Safety
3.1.3 General
3.1.4 Corrosion Protection For Pins And Bearings
3.2 Tools
4. Undercarriage
4.1 Introduction
4.1.1 Foreword
4.1.2 Safety
4.1.3 General
4.2 Travel System
4.2.1 General
4.2.2 Components Of Travel System
4.2.3 Wear Limits
4.3 Track Chain
4.3.1 General
4.3.2 Components Of Track Chain
4.3.3 Assembly
4.3.3.1 Opening The Track Chain
4.3.3.2 Closing The Track Chain
4.4 Idler
4.4.1 General
4.4.2 Components Of The Idler
4.4.3 Assembly Of The Idler
4.5 Bottom Roller
4.5.1 General
4.5.2 Components Of The Bottom Roller
4.5.3 Bottom Roller Installation
4.6 Top Roller
4.6.1 General
4.6.2 Components Of The Top Roller
4.6.3 Top Roller Installation
4.7 Sprocket
4.8 Travel Gearbox – Removal And Installation
4.9 Track Pads
4.10 Hydraulic Track Tensioning System
4.10.1 General
4.10.2 Components
4.10.3 Releasing The Track Tension
4.10.4 Checking The Accumulators
4.11 Duo Cone Seals
5. Superstructure
5.1 Introduction
5.1.1 Foreword
5.1.2 Safety
5.1.3 General
5.2 Swing Ring
5.2.1 General
5.2.2 Components Of The Swing Ring
5.2.3 Hardness Gap, Soft Spot
5.2.4 Assembly Swing Ring – Undercarriage
5.2.5 Assembly Swing Ring – Superstructure
5.3 Engine – Motor Installation
5.3.1 Engine Mounting
5.3.2 Radiator Installation
5.4 Engine – Motor Coupling
5.5 Swing Gearbox Installation
5.6 Pump Gearbox Installation
5.7 Hydraulic Pumps Installation
5.8 Oil Cooler Installation
5.9 Rotor Installation
6. Drive Unit
7. Gearboxes
7.1 Introduction
7.1.1 Foreword
7.1.2 Safety Instructions
7.1.3 General
7.1.4 Checking Procedures
7.1.5 Hubs And Bearings
7.1.6 Fitting Of Toroidal Sealing Rings
7.2 Travel Gearbox
7.2.1 General
7.2.2 Dismantling And Installing The Travel Gearbox
7.2.3 Disassembly- And Assembly Instructions
7.3 Swing Gearbox
7.3.1 General
7.3.2 Dismantling And Installing The Swing Gearbox
7.3.3 Disassembly- And Assembly Instructions
7.4 Pump Gearbox
7.4.1 General
7.4.2 Dismantling And Installing The Pump Gearbox
7.4.3 Disassembly- And Assembly Instructions
8. Hydraulic System
8.1 Introduction
8.1.1 Foreword
8.1.2 Safety
8.1.3 General
8.2 Depressurizing, Bleeding, Flushing
8.2.1 Depressurizing Of The Hydraulic System
8.2.2 Bleeding Of The Hydraulic System
8.2.3 Flushing Of The Hydraulic System
8.3 Hydraulic Circuit Diagram
8.3.1 Technical Data
8.3.2 Components Of The Hydraulic Schematic
8.3.3 Components Of The Hydraulic System
8.3.4 Hydraulic Circuit Diagram
8.4 Main Hydraulic Components
8.4.1 Main Pumps
8.4.2 Swing Pump
8.4.3 Rotor
8.4.4 Valve Blocks
8.5 Description Of Hydraulic Circuits
8.5.1 Load Limiting System
8.5.2 Pressure Cut Off System
8.5.3 Servo System
8.5.4 Working Functions
8.5.5 Travel System
8.5.6 Swing System
8.5.7 Track Tensioning System
8.5.8 Cooling System For Hydraulic Oil
8.5.9 Cooling System For Engines
8.5.10 Cooling System For Pump Gearbox
8.6 Pressure Checking And Setting
8.6.1 Introduction
8.6.2 Pressure Settings
8.6.3 Tools
8.6.4 Hydraulic Systems
8.7 Installation Of Hydraulic Pumps
8.8 Hydraulic Cylinders ( Faceshovel)
8.8.1 Boom Cylinder
8.8.1.1 Introduction
8.8.1.2 Safety
8.8.1.3 Design Configuration
8.8.1.4 Assembly
8.8.1.5 Tightening Torques
8.8.2 Arm Cylinder
8.8.2.1 Introduction
8.8.2.2 Safety
8.8.2.3 Design Configuration
8.8.2.4 Assembly
8.8.2.5 Tightening Torques
8.8.3 Bucket Crowd Cylinder
8.8.3.1 Introduction
8.8.3.2 Safety
8.8.3.3 Design Configuration
8.8.3.4 Assembly
8.8.3.5 Tightening Torques
8.8.4 Clam Cylinder
8.8.4.1 Introduction
8.8.4.2 Safety
8.8.4.3 Design Configuration
8.8.4.4 Assembly
8.8.4.5 Tightening Torques
9. Electric System
9.1 Introduction
9.1.1 Foreword
9.1.2 Safety Instructions
9.1.3 General
9.2 Electric System
9.2.1 Overview Of Switch Cabinets
9.2.2 Electrical Documentation
9.2.3 List Of Electrical Components
9.2.4 Circuit Diagram
9.2.5 Connection Tables – Terminal Strips
9.2.6 Connection Tables – Plug Connections
9.2.7 Schematic Symbols
9.3 Control And Monitoring Platform ( Camp)
9.3.1 Introduction To Camp
9.3.2 Overview Of The Individual Control System
9.3.3 Locaterpillarion Of The Main Components
9.3.4 Servo Control System ( Scs)
9.3.5 Auxiliary System ( As)
9.3.6 Drive Controller Left Hand ( Dclh)
9.3.7 Drive Controller Right Hand ( Dcrh)
9.3.8 Board Control System ( Bcs)
9.4 Communicaterpillarion And Control Loops Within Camp
9.4.1 Controller Area Network ( Can)
9.4.2 Electronic Hydraulic Servo Control (Ehsc)
9.4.3 Hand Levers And Pedals
9.4.4 Pump Flow Regulation
9.4.5 Lubricaterpillarion System
9.4.6 Lights
9.5 Electric Components
9.5.1 Locaterpillarion Of Components
9.5.2 List Of Components
9.6 Bcs Software
9.6.1 Overview Of The Menus
9.6.2 Start Screen
9.6.3 Service Menus
9.6.4 Fault Storage Menus
9.6.5 Setup Menus
9.7 Troubleshooting
9.7.1 Safety Instructions
9.7.2 General Troubleshooting
10. Attachment
11. Central Lubricaterpillarion System
11.1 Introduction
11.1.1 Preface
11.1.2 Illustration Conventions
11.1.3 Operator’s Responsibility
11.1.4 Safety Instructions
11.1.5 Operation – Maintenance
11.2 Technical Data ( 1,000 Kg Grease Container – Supply)
11.2 Technical Data ( 280 Kg Round Container – 180 Kg Grease
Drum – Supply)
11.3 Design Of The Central Lubricaterpillarion System
11.3.1 Functional Diagram
11.3.2 Component Arrangement
11.3.3 Distributor Design
11.4 System Function
11.4.1 Central Lubricaterpillarion System
11.4.1.1 Design
11.4.1.2 Operation Sequence
11.4.2 Lubricant Distributor
11.4.3 Control Unit
11.4.3.1 Upper Carriage Control Panel
11.4.3.2 Upper Carriage Control Panel With
Under Carriage Control
11.4.3.3 Operation Sequence
11.4.4 Grease Pump
11.4.4.1 Start- Up
11.4.4.2 Operation Sequence
11.4.5 Electrical Function
11.5 Lubricaterpillarion System Test
11.7 Setting Of The Lubricaterpillarion And Break Time
11.7.1 Duration Of A Lubricaterpillarion Cycle For The Upper Carriage In Normal Operation
11.7.2 Duration Of A Lubricaterpillarion Cycle For The Under Carriage In Normal Operation
11.7.3 Function Of The Reset Button
11.7.4 Greasing Cycle: Greasing Of The Superstructure
11.8 Bleeding Of The Central Lubricaterpillarion System
11.9 Repairing The Lubricaterpillarion Pump
11.9.1 Components Of The Barrel Pump
11.9.2 Disassembly Of The Pump
11.9.3 Assembly Of The Pump
11.9.4 Spare Parts For Hydraulic Pump
11.10 Repair Of The Lubricaterpillarion Distributors
11.11 Renewal Of High Pressure Hose Lines
11.12 Troubleshooting Instructions
12. Options
15. Service Manual For Fundamental Principles Of Electricity
16. Service Manual For Handling Circuit Diagrams
17. Service Manual For General Information, Conversion Cal-Culations And Tihtening Torques
18. Service Manual For Sealing, Protective, Testing And Cleaning Agents
19. Service Manual For Fittings, Tube Assemblies And Hose Assemblies
20. Repair Welding Manual
21. Service Manual For Oil Samples And Oil Analysis