Cat 6040 ELZ Hydraulic Shovel Schematics, Service Manual (SERV1866)

Cat 6040 ELZ Hydraulic Shovel Schematics, Index:

• 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 Modification 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
    • 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
  • 3.3 Assembling the excavator
    • 3.3.1 Overview
    • 3.3.2 Safety instructions
    • 3.3.3 Personnel
    • 3.3.4 Assembly equipment
    • 3.3.5 Boom installation
    • 3.3.6 Modules on arrival
    • 3.3.7 Assembly site
    • 3.3.8 Preparation of modules for assembly
    • 3.3.9 General assembly procedures
    • 3.3.10 Workflow chart of assembly procedure
    • 3.3.11 Preparation of undercarriage and superstructure modules
    • 3.3.12 Undercarriage assembly
    • 3.3.13 Preparations for superstructure installation
    • 3.3.14 Installation of superstructure frame
    • 3.3.15 Installation of swing gearboxes
    • 3.3.16 Connection of hydraulic lines between undercarriage and superstructure
    • 3.3.17 Installation of modules and components to superstructure frame
    • 3.3.18 Stick installation Boom preparation
    • 3.3.19 Final steps of boom
    • 3.3.20 Top up operating fluids
    • 3.3.21 Electric system
    • 3.3.22 Preparations for machine start-up
    • 3.3.23 Machine start-up
    • 3.3.24 Bucket installation
    • 3.3.25 Final preparations for machine start-up
• 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
    • 4.5.4 Bottom roller assembly
  • 4.6 Top roller
    • 4.6.1 General
    • 4.6.2 Top roller components
    • 4.6.3 Top roller installation
    • 4.6.4 Top roller assembly
  • 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 swing bearing
    • 5.2.3 Hardness gap, “S – point’’
    • 5.2.4 Fitting the swing bearing onto the undercarriage
    • 5.2.5 Fitting the swing bearing onto the undercarriage
  • 5.3 Engine / Motor installation
    • 5.3.1 Engine mounting
    • 5.3.2 Radiator installation
    • 5.3.3 Radiator fan installation
  • 5.4 Engine / Motor coupling
  • 5.5 Swing gearbox – removal and installation
  • 5.6 Pump gearbox – removal and 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 in gearboxes
  • 7.2 Travel gearbox
    • 7.2.1 General
    • 7.2.2 Dismantling and installing the travel gearbox
    • 7.2.3 Disassembly and Assembly Instructions for the gearbox
  • 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
      • 8.2.1.1 Depressurization of the attachment circuits
      • 8.2.1.2 Depressurization of the engine off lowering accumulator
      • 8.2.1.3 Depressurization of track tension circuit
      • 8.2.1.4 Depressurization of swing circuit
      • 8.2.1.5 Depressurization of access ladder circuit
    • 8.2.2 Bleeding of the hydraulic system
      • 8.2.2.1 Bleeding air from hydraulic pumps
      • 8.2.2.2 Bleeding air from the main pumps
      • 8.2.2.3 Bleeding air from the swing pumps
      • 8.2.2.4 Bleeding air from the charge pumps
      • 8.2.2.5 Bleeding air from the hydraulic oil fan pumps
      • 8.2.2.6 Bleeding air from the pilot pumps
      • 8.2.2.7 Bleeding air from the hydraulic oil circulation pumps
      • 8.2.2.8 Bleeding air from hydraulic motors
      • 8.2.2.9 Bleeding air from swing motors
      • 8.2.2.10 Bleeding air from hydraulic cylinders
      • 8.2.2.11 Bleeding air from pilot pressure circuit
    • 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 schematic
  • 8.4 Hydraulic components
    • 8.4.1 Main pumps
    • 8.4.2 Swing pump
    • 8.4.3 Pilot pumps
    • 8.4.4 Charge pumps
    • 8.4.5 Hydraulic oil cooling fanpumps
    • 8.4.6 Engine cooling fan pumps
    • 8.4.7 Circulation pumps
    • 8.4.8 Lubrication (grease) pumps
    • 8.4.9 Rotor
    • 8.4.10 Hydraulic valves
  • 8.5 Description of hydraulic circuits
    • 8.5.1 Main pump flow regulation
    • 8.5.2 Pressure cut-off
    • 8.5.3 Servo system
    • 8.5.4 Attachment functions (BH)
    • 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
      • 8.6.1.1 Foreword
      • 8.6.1.2 Safety
      • 8.6.1.3 General
    • 8.6.2 Pressure settings
    • 8.6.3 Tools
    • 8.6.4 Hydraulic circuits
      • 8.6.4.1 Pilot pressure system
      • 8.6.4.2 Main pump flow control
      • 8.6.4.3 Pressure cut-off system
      • 8.6.4.4 Primary relief system
      • 8.6.4.5 Secondary relief system for attachment
      • 8.6.4.6 Secondary relief system for travel
      • 8.6.4.7 Swing system
      • 8.6.4.8 Track tensioning system
      • 8.6.4.9 Cooling system for hydraulic oil
      • 8.6.4.10 Cooling system for engines
      • 8.6.4.11 Hydraulic accumulators
  • 8.7 Installation of hydraulic pumps
    • 8.7.1 General
    • 8.7.2 Components
    • 8.7.3 Removal and installation of the hydraulic pumps
  • 8.8 Hydraulic cylinders backhoe
    • 8.8.1 Boom cylinder
      • 8.8.1.1 Preface
      • 8.8.1.2 Product Description
      • 8.8.1.3 Safety Instructions
      • 8.8.1.4 Description of Cylinder Type and Components
      • 8.8.1.5 Storage, Start-up and Maintenance
      • 8.8.1.6 Hydraulic Cylinder Spare Parts
      • 8.8.1.7 List of Required Tools
      • 8.8.1.8 Dismantling Instructions
      • 8.8.1.9 Assembly Instructions
    • 8.8.2 Stick cylinder
      • 8.8.2.1 Preface
      • 8.8.2.2 Product Description
      • 8.8.2.3 Safety Instructions
      • 8.8.2.4 Description of Cylinder Type and Components
      • 8.8.2.5 Storage, Start-up and Maintenance
      • 8.8.2.6 Hydraulic Cylinder Spare Parts
      • 8.8.2.7 List of Required Tools
      • 8.8.2.8 Dismantling Instructions
      • 8.8.2.9 Assembly Instructions
    • 8.8.3 Bucket cylinder
      • 8.8.3.1 Preface
      • 8.8.3.2 Product Description
      • 8.8.3.3 Safety Instructions
      • 8.8.3.4 Description of Cylinder Type and Components
      • 8.8.3.5 Storage, Start-up and Maintenance
      • 8.8.3.6 Hydraulic Cylinder Spare Parts
      • 8.8.3.7 List of Required Tools
      • 8.8.3.8 Dismantling Instructions
      • 8.8.3.9 Assembly Instructions
• 9. Electric system
  • 9.1 Introduction
    • 9.1.1 Foreword
    • 9.1.2 Safety instructions
    • 9.1.3 General
  • 9.2 Electric System – 24 Volt
    • 9.2.1 Overview of switch cabinets
    • 9.2.2 Electrical documentation
      • 9.2.2.1 Naming of electrical components
      • 9.2.2.2 Layout drawing
    • 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 systems
    • 9.3.3 Location of the main components
    • 9.3.4 Servo Control System (SCS)
      • 9.3.4.1 Introduction with basic functions
      • 9.3.4.2 Technical data
      • 9.3.4.3 Terminal plan (connectors)
      • 9.3.4.5 Installation and removal
    • 9.3.5 Auxiliary System (AS)
      • 9.3.5.1 Introduction with basic functions
      • 9.3.5.2 Technical data
      • 9.3.5.3 Terminal plan (connectors)
      • 9.3.5.4 Installation and removal
      • 9.3.5.5 Settings and adjustments
    • 9.3.6 Drive Controller Left Hand (DCLH)
      • 9.3.6.1 Introduction with basic functions
      • 9.3.6.2 Technical data
      • 9.3.6.3 Terminal plan (connectors)
      • 9.3.6.4 Data exchange
      • 9.3.6.5 Installation and removal
      • 9.3.6.6 Settings and adjustments
    • 9.3.7 Drive Controller Right Hand (DCRH)
      • 9.3.7.1 Introduction with basic functions
      • 9.3.7.2 Technical data
      • 9.3.7.3 Terminal plan (connectors)
      • 9.3.7.4 Data exchange
      • 9.3.7.5 Installation and removal
      • 9.3.7.6 Settings and adjustments
    • 9.3.8 Board Control System (BCS)
      • 9.3.8.1 Introduction with basic functions
      • 9.3.8.2 Technical data
      • 9.3.8.3 Terminal plan (connectors)
      • 9.3.8.4 Installation and removal
      • 9.3.8.5 Settings and adjustments
      • 9.3.8.6 Changing the program
  • 9.4 Communication and control loops within CAMP
    • 9.4.1 Controller Area Network (CAN)
      • 9.4.1.1 CAN bus systems
      • 9.4.1.2 Technical data of the CAN bus
      • 9.4.1.3 CAN bus troubleshooting
    • 9.4.2 Electronic Hydraulic Servo Control (EHSC)
      • 9.4.2.1 Proportional valve block
    • 9.4.3 Hand Levers and Pedals
      • 9.4.3.1 Installing and removing
      • 9.4.3.2 Settings
    • 9.4.4 Pump flow regulation
      • 9.4.4.1 Overview pump control
      • 9.4.4.2 Data transfer
      • 9.4.4.3 Reducing the Pump Control current / pressure
      • 9.4.4.4 Overview hydraulic oil cooling
      • 9.4.4.5 Overview engine cooling
    • 9.4.5 Lubrication system
      • 9.4.5.1 Lubrication system upper carriage
    • 9.4.6 Lights
  • 9.5 Electric Components
    • 9.5.1 Location of components
      • 9.5.1.1 Left engine
      • 9.5.1.2 Right engine
      • 9.5.1.3 Hydraulic oil tank
      • 9.5.1.4 Swing engine
      • 9.5.1.5 Ladder
      • 9.5.1.6 Tank lift
    • 9.5.2 List of components
      • 9.5.2.1 Relay single contact
      • 9.5.2.2 Relay single contact
      • 9.5.2.3 Relay double contact
      • 9.5.2.4 Contamination switch
      • 9.5.2.5 Contamination switch
      • 9.5.2.6 Cable for controller
      • 9.5.2.7 Controller
      • 9.5.2.8 Pressure sensor (0-400bar)
      • 9.5.2.9 Pressure sensor (0-2,5bar)
      • 9.5.2.10 Pressure sensor (0-100bar)
      • 9.5.2.11 Temperature sensor
      • 9.5.2.12 Proximity switch
      • 9.5.2.13 Switch / Spring loaded one side
      • 9.5.2.14 Switch / Spring loaded two sides
      • 9.5.2.15 Switch one side
      • 9.5.2.16 Switch one side 2pin
      • 9.5.2.17 Switch wiper
      • 9.5.2.18 Slewing gear level sensor
      • 9.5.2.19 Temperature switch swing/main pump
      • 9.5.2.20 Pressure switch 20 bar
      • 9.5.2.21 Float Switch / Bedia Sensor / Gearbox minimum
      • 9.5.2.22 Fuel Level sensor
      • 9.5.2.23 Relay / battery main switch
      • 9.5.2.24 Float switch / Bedia Sensor
      • 9.5.2.25 Float switch / Bedia Sensor water level
      • 9.5.2.26 Pressure switch 0,5 bar
      • 9.5.2.27 Pressure switch air cleaner
      • 9.5.2.28 Relay 24V max 150A
      • 9.5.2.29 Relay 24V max 50A
      • 9.5.2.30 Diode
      • 9.5.2.31 Diode
      • 9.5.2.32 Voltage converter 24V / 12V
      • 9.5.2.33 Initiator cut off system
      • 9.5.2.34 Seat contact switch
      • 9.5.2.35 Servo block proportional valve
      • 9.5.2.36 Seat contact valve servo block
      • 9.5.2.37 Track tensioning valve servo block
      • 9.5.2.38 Plug 64 PIN
      • 9.5.2.39 Plug 40 PIN
      • 9.5.2.40 Plug 6 PIN
      • 9.5.2.41 Proportional valve pump
      • 9.5.2.42 Proportional valve pump regulation
      • 9.5.2.43 Grease container level sensor (empty)
      • 9.5.2.44 Grease container level sensor (full)
      • 9.5.2.45 Initiator grease system
  • 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
      • 9.7.2.1 General troubleshooting procedure
      • 9.7.2.1 General troubleshooting procedure
      • 9.7.2.3 Testing electrical components
      • 9.7.2.4 Actions requiring special tools
      • 9.7.2.5 Individual problems
    • 9.7.3 Specific troubleshooting per error–ID
• 10. Attachment
• 11. Central lubrication 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 lubrication system
    • 11.3.1 Functional diagram
    • 11.3.2 Component arrangement
    • 11.3.3 Distributor design
  • 11.4 System function
    • 11.4.1 Central lubrication system
      • 11.4.1.1 Design
      • 11.4.1.2 Operation sequence
    • 11.4.2 Lubricant distributor
      • 11.4.2.1 Functional sequence distributor type VSL / VSG
      • 11.4.2.2 Functional sequence with progressive distributor type SSVD
    • 11.4.3 Control unit
      • 11.4.3.1 Arrangement of the components for upper carriage lubrication
      • 11.4.3.2 Operating 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 Lubrication system test
  • 11.7 Setting of the lubrication and break times
    • 11.7.1 Duration of a lubrication cycle for the upper carriage in normal operation
    • 11.7.2 The functions of the reset button
    • 11.7.3 Greasing cycle: Greasing of the superstructure
  • 11.8 Bleeding of the central lubrication system
  • 11.9 Repairing the lubrication pump
    • 11.9.1 Components
    • 11.9.2 Disassembly
    • 11.9.3 Assembly
    • 11.9.4 Spare parts
  • 11.10 Repair of the lubrication distributors
  • 11.11 Renewal of high pressure hose lines
  • 11.12 Troubleshooting guideline
• 12. Options
• 15. Service Manual for fundamental principles of electricity (refer to Media No. EM030761)
• 16. Service Manual for handling circuit diagrams (refer to Media No. EM030771)
• 17. Service Manual for general information, conversion calculations and tightening torques (refer to Media No. EM030780)
• 18. Service Manual for sealing, protective, testing and cleaning agents (refer to Media No. EM030782)
• 19. Service Manual for fittings, tube assemblies and hose assemblies (refer to Media No. EM030784)
• 20. Repair welding manual (refer to Media No. EM010641)
• 21. Service Manual for oil samples and oil analysis (refer to Media No. EM030788)

Caterpillar