Download Caterpillar Hydraulic Shovel 6040 Service Manual EM028957-0 PDF ( English )

Download the official Caterpillar Hydraulic Shovel 6040 Service Manual EM028957-0 PDF. This comprehensive digital service manual provides detailed diagnostic procedures, repair instructions, and complete technical specifications for all systems. Essential for professional mechanics, technicians, and equipment operators, it equips you with exact guidance to properly troubleshoot, maintain, and repair your hydraulic mining shovel. www.themanualsgroup.com

MODEL COVERED :
Caterpillar 6040 Hydraulic Shovel

CONTENTS INCLUDED:
General
Introduction
Service Manual
How To Use The Service Manual
Servicing And Repair
Important Hints
Safety Instructions
Risks Of Disregarding Safety Instructions
Safety Regulations
Modification Of The Machine
Re- Commissioning
General
Technical Data
Introduction
Foreword
Safety
General
Engine – Motor
Hydraulic System
Main Pump
Swing System
Servo Pump – Gear Oil Pump
Cooling System Hydraulic Oil – Water
Travel Motor
Control Block
Filter Elements For Hydraulic System
Pressure Setting
Governing Current For Proportional Valves
Hydraulic Cylinder
Face Shovel
Backhoe
Transmission Ratio
Weights Of Modules And Components
Modules
Components
Tightening Procedures For Bolts
Tightening Procedures For Module Bolts
Tightening Procedures For Component Bolts
Tools, Assembly
Introduction
Foreword
Safety
General
Corrosion Protection For Pins And Bearings
Tools
Undercarriage
Introduction
Foreword
Safety
General
Travel System
General
Components Of Travel System
Wear Limits
Track Chain
General
Components Of Track Chain
Assembly
Opening The Track Chain
Closing The Track Chain
Idler
General
Components Of The Idler
Assembly Of The Idler
Bottom Roller
General
Components Of The Bottom Roller
Bottom Roller Installation
Top Roller
General
Components Of The Top Roller
Top Roller Installation
Sprocket
Travel Gearbox – Removal And Installation
Track Pads
Hydraulic Track Tensioning System
General
Components
Releasing The Track Tension
Checking The Accumulators
Duo Cone Seals
Superstructure
Introduction
Foreword
Safety
General
Swing Ring
General
Components Of The Swing Ring
Hardness Gap, Soft Spot
Assembly Swing Ring – Undercarriage
Assembly Swing Ring – Superstructure
Engine – Motor Installation
Engine Mounting
Radiator Installation
Engine – Motor Coupling
Swing Gearbox Installation
Pump Gearbox Installation
Hydraulic Pumps Installation
Oil Cooler Installation
Rotor Installation
Drive Unit
Gearboxes
Introduction
Foreword
Safety Instructions
General
Checking Procedures
Hubs And Bearings
Fitting Of Toroidal Sealing Rings
Travel Gearbox
General
Dismantling And Installing The Travel Gearbox
Disassembly- And Assembly Instructions
Swing Gearbox
General
Dismantling And Installing The Swing Gearbox
Disassembly- And Assembly Instructions
Pump Gearbox
General
Dismantling And Installing The Pump Gearbox
Disassembly- And Assembly Instructions
Hydraulic System
Introduction
Foreword
Safety
General
Depressurizing, Bleeding, Flushing
Depressurizing Of The Hydraulic System
Bleeding Of The Hydraulic System
Flushing Of The Hydraulic System
Hydraulic Circuit Diagram
Technical Data
Components Of The Hydraulic Schematic
Components Of The Hydraulic System
Hydraulic Circuit Diagram
Main Hydraulic Components
Main Pumps
Swing Pump
Rotor
Valve Blocks
Description Of Hydraulic Circuits
Load Limiting System
Pressure Cut Off System
Servo System
Working Functions
Travel System
Swing System
Track Tensioning System
Cooling System For Hydraulic Oil
Cooling System For Engines
Cooling System For Pump Gearbox
Pressure Checking And Setting
Introduction
Pressure Settings
Tools
Hydraulic Systems
Installation Of Hydraulic Pumps
Hydraulic Cylinders ( Faceshovel)
Boom Cylinder
Introduction
Safety
Design Configuration
Assembly
Tightening Torques
Arm Cylinder
Introduction
Safety
Design Configuration
Assembly
Tightening Torques
Bucket Crowd Cylinder
Introduction
Safety
Design Configuration
Assembly
Tightening Torques
Clam Cylinder
Introduction
Safety
Design Configuration
Assembly
Tightening Torques
Electric System
Introduction
Foreword
Safety Instructions
General
Electric System
Overview Of Switch Cabinets
Electrical Documentation
List Of Electrical Components
Circuit Diagram
Connection Tables – Terminal Strips
Connection Tables – Plug Connections
Schematic Symbols
Control And Monitoring Platform ( Camp)
Introduction To Camp
Overview Of The Individual Control System
Location Of The Main Components
Servo Control System ( Scs)
Auxiliary System ( As)
Drive Controller Left Hand ( Dclh)
Drive Controller Right Hand ( Dcrh)
Board Control System ( Bcs)
Communication And Control Loops Within Camp
Controller Area Network ( Can)
Electronic Hydraulic Servo Control (Ehsc)
Hand Levers And Pedals
Pump Flow Regulation
Lubrication System
Lights
Electric Components
Location Of Components
List Of Components
Bcs Software
Overview Of The Menus
Start Screen
Service Menus
Fault Storage Menus
Setup Menus
Troubleshooting
Safety Instructions
General Troubleshooting
Attachment
Central Lubrication System
Introduction
Preface
Illustration Conventions
Operator’s Responsibility
Safety Instructions
Operation – Maintenance
Technical Data ( 1,000 Kg Grease Container – Supply)
Technical Data ( 280 Kg Round Container – 180 Kg Grease Drum – Supply)
Design Of The Central Lubrication System
Functional Diagram
Component Arrangement
Distributor Design
System Function
Central Lubrication System
Design
Operation Sequence
Lubricant Distributor
Control Unit
Upper Carriage Control Panel
Upper Carriage Control Panel With Under Carriage Control
Operation Sequence
Grease Pump
Start- Up
Operation Sequence
Electrical Function
Lubrication System Test
Setting Of The Lubrication And Break Time
Duration Of A Lubrication Cycle For The Upper Carriage In Normal Operation
Duration Of A Lubrication Cycle For The Under Carriage In Normal Operation
Function Of The Reset Button
Greasing Cycle: Greasing Of The Superstructure
Bleeding Of The Central Lubrication System
Repairing The Lubrication Pump
Components Of The Barrel Pump
Disassembly Of The Pump
Assembly Of The Pump
Spare Parts For Hydraulic Pump
Repair Of The Lubrication Distributors
Renewal Of High Pressure Hose Lines
Troubleshooting Instructions
Options
Service Manual For Fundamental Principles Of Electricity
Service Manual For Handling Circuit Diagrams
Service Manual For General Information, Conversion Calculations And Tightening Torques
Service Manual For Sealing, Protective, Testing And Cleaning Agents
Service Manual For Fittings, Tube Assemblies And Hose Assemblies
Repair Welding Manual
Service Manual For Oil Samples And Oil Analysis

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