01 Oper Instr 6040 AC 3847027 en

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 au-
thorization 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
ii
BA 6040(3 847 027.00)-EN
The Operation and Maintenance Manual is in 6 sections;

the sections are designed for different target groups:
Operating instructions Target group
Part 1 INTRODUCTION Operating personnel

+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.
Part 3 INSPECTION AND Inspection and servicing personnel

The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.
Part 4 REPAIR WORK 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
+
+
Repair personnel
iii
BA 6040(3 847 027.00)-EN
iv
BA 6040(3 847 027.00)-EN
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
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
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BA 6040(3 847 027.00)-EN
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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BA 6040(3 847 027.00)-EN
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
HYDRAULIC SYSTEM______________________________________________________________ 4-6

Repair _________________________________________________________________________ 4-6
Hydraulic hoses – Instructions ______________________________________________________ 4-6
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BA 6040(3 847 027.00)-EN
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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BA 6040(3 847 027.00)-EN
Introduction
1 INTRODUCTION
Operation and Maintenance Manual Target group

+
+
Repair personnel

chines.


+
+
Repair personnel
+
+
Repair personnel
1-1
BA 6040(3 847 027.00)-EN
Introduction
1-2
BA 6040(3 847 027.00)-EN
Introduction
PREFACE
All CGM HMS GmbH Operation and Maintenance
Manuals are issued in German and then translated.
This Operation and Maintenance Manual is de- Even a good translation may give rise to questions
signed to familiarize the operator with the machine which CGM HMS GmbH will be pleased to answer.
and its designated use.
The Operation and Maintenance Manual are not
The Operation and Maintenance Manual contain work instructions for carrying out major repairs.
important information on how to operate the ma- Such work is willingly done for you by the CGM
chine safely, properly and with maximum efficiency. HMS GmbH after-sales service.
Observing these instructions helps to prevent haz-
ardous situations, to reduce repair costs and down-
times and to increase the reliability and service life Further machine documentation
of the machine.
The Operation and Maintenance Manual must be The documentation relating to the machine is listed
supplemented by the respective national rules and according to scope, quantity and language in the
regulations for accident prevention and environ- shipping note of the machine or in the covering
mental protection. letter if supplied separately. The Operation and
Maintenance Manual, the spare-parts list and the
The Operation and Maintenance Manual must al- Service Manuals are marked with the serial number
ways be available in the operator's cab of the ma- of the machine.
chine.
The Operation and Maintenance Manual must be The documentation supplied with your machine is
read and put into practice by any person in charge rather comprehensive. Therefore, it has been split
of carrying out work with or on the machine, such up in several volumes:
as Volume 1: the present Operation and Mainte-
 operation, including setting-up, troubleshooting nance Manual,
in the course of work, care, evacuation of pro- Volume 2: spare-parts list of the machine,
duction waste and disposal of fuels and con- Volume 3: crossreference list of spare-parts,
sumables,
Volume 4: electrical circuit diagram and key,
 maintenance (inspection, servicing, repair) and
/ or Volume 5: documentation of the engine and of
 transport. other components,
In addition to the Operation and Maintenance Man- Volume 6: Service Manual Part 1
ual and the mandatory rules and regulations for Volume 7: Service Manual Part 2
accident prevention and environmental protection in
Depending on the size of your machine, the docu-
the user's country and at the place where the ma-
mentation can also consist of more volumes.
chine is to be used, the generally recognized tech-
nical rules for safe and proper working must be If you cannot find the information you are looking for
1
observed in the present Operation and Maintenance Manual
The Operation and Maintenance Manual are di- please check also the other volumes of the docu-
rected to the mining-machine specialist. They can- mentation.
not provide basic know-how. This can be acquired, The Service Manual Part 1 also provides information
for example, in several days' instruction by a quali- on how to assemble the machine, on functions of
fied CGM HMS GmbH (Caterpillar Global Mining the hydraulic system, on hydraulic circuit diagrams
Hydraulic Mining Shovels GmbH) mechanic or by etc.
attending an CGM HMS GmbH training course for On taking receipt of the consignment, please check
operators or maintenance personnel. that the documentation is complete and in the lan-
The CGM HMS GmbH after-sales service will be guage requested by you.
pleased to deal with any queries you may have after
reading through the Operation and Maintenance
Manual.
1
Complies with VDMA recommendation "Operation and Mainte-
nance Manual"
1-3
BA 6040(3 847 027.00)-EN
Introduction
WARRANTY
Do not operate the machine
The warranty of CGM HMS GmbH presupposes
among other things that the servicing works as de-  when components / assemblies are defec-
scribed in the Operation and Maintenance Manual tive or missing,
have been performed:  if one or several of such components of
 by the CGM HMS GmbH Service which more than one are installed in the
machine have been removed.
or
In cases of doubt seek advice from the CGM
 in a workshop authorized in writing by CGM HMS GmbH Service.
HMS GmbH ,
CGM HMS GmbH refuses to assume the guaran-
and teee for damage and consequential damage
caused by an abusive utilization of the machine.
 by using the original spare parts of CGM HMS
GmbH . Therefore:
Do not operate the machine,
The proper execution of the servicing works must  when several track rollers or support rollers
be documented on the CGM HMS GmbH Service have been removed;
checklists.
 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 back-
hoe 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 conse-
quential damage to the track rollers, but also to
other components of the machine: chassis, travel
gearbox and crawler track.
1-4
BA 6040(3 847 027.00)-EN
Introduction
FUNDAMENTAL SAFETY IN-

STRUCTIONS
Complies with VDMA recommendation "Operating In-
structions"
Warnings and symbols

The following signs are used in the Operation and
Maintenance Manual to designate instructions of
particular importance:
Precautionary rules and measures de-
signed to protect the machine operator
and other persons from life-threatening
danger or injuries and to prevent ex-
tensive damage.
Information and precautionary mea-

sures designed to prevent damage to
the machine or other property.
1-5
BA 6040(3 847 027.00)-EN
Introduction
DESIGNATED USE
Using the hydraulic shovel or its at-
The machine has been built in accordance with tachments for purposes other than or
state-of-art standards and the recognized safety extending beyond those stated above,
rules. Nevertheless, its use may constitute a risk to e.g.:
life and limb for the user or third parties or cause
damage to the machine and to other material prop-  for lifting or transporting persons,
erty (acceptable risk)  as a working platform,
An acceptable risk is present, e.g.: loose material or
material to be loaded may drop out of the bucket or  for lifting crane loads without the
backhoe while the working equipment is being swiv- equipment being approved for this
elled. purpose,
 for driving in posts, sheetpiles sup-
The machine must be used only in technically per- ports, etc. without the equipment
fect condition in accordance with its designated use being approved for this purpose,
and the instructions set out in the Operation and
 for moving material to the side
Maintenance Manual, and only by safety-conscious
(sweeping),
persons who are fully aware of the risks involved in
operating the machine. Any functional disorders,  for breaking down rocks by beating
especially those affecting the safety of the machine, with the shovel or the backhoe,
should therefore be rectified immediately.
With attached shovel equipment, the machine is to  for fitting or reparing of other ma-
be used solely for loosening and loading of: chines
 sand, oil sand, is contrary to its designated use and

considered as "unauthorized use".
 gravel,
 blasted rock, Lifting eyes on the lower carriage
 ore, - are settled for transporting with a
crane only.
 coal,
- must not be used for towing a
and other raw materials. machine.
With attached backhoe equipment, the machine can
additionally also be used for excavating and loading
of excavatable soils and other raw materials. Improper use may involve a life-threatening risk for
operators or other personnel or may cause injury or
Operating the machine within the limits of the desi-
extensive damage.
gated use also involves observing the instructions
set out in the Operation and Maintenance Manual The manufacturer/supplier cannot be held liable for
and complying with the inspection and maintenance any damage resulting from other than the desig-
directives. nated use. The risk involved in such misuse lies
with the user.
1-6
BA 6040(3 847 027.00)-EN
Introduction
ORGANIZATIONAL MEASURES Personal protective equipment and the

working clothing
The Operation and Maintenance Manual must al-
ways be at hand at the place of use of the machine, Depending on the cleaning, servicing and/or repair
e.g. by stowing them in the place provided for such activities to be performed, the personal protective
purpose. equipment and the working clothing may consist of
the following items:
In addition to the Operation and Maintenance Man-
ual, observe and instruct the user in all other gen-  fall arresters
erally applicable legal and other mandatory regula-
 protective suit
tions relevant to accident prevention and
environmental protection.  helmet
 goggles
These compulsory regulations may also deal with
- e. g. for cleaning work
the handling of hazardous substances, issuing
- or for welding work
and/or wearing of personal protective equipment or
traffic regulations.  protective gloves
- e.g. for work on hot units
The Operation and Maintenance Manual must be - for grinding and welding work
supplemented by instructions covering the duties
 protective working gloves
involved in supervising and notifying special organ-
- e.g. for fitting work
izational features, such as job organization, working
- for grinding and welding work
sequences or the personnel entrusted with the
work.  ear protectors
Personnel entrusted with work on the machine must Observe all safety instructions and warnings at-
have read the Operation and Maintenance Manual tached to the machine.
and in particular the chapter on safety before be- See to it that safety instructions and warnings at-
ginning work. Reading the Operation and Mainte- tached to the machine are always complete and
nance Manual after work has begun is too late. This perfectly legible.
applies especially to persons working only occa- In the event of safety-relevant modifications or
sionally on the machine, e.g. during setting up or changes in the behaviour of the machine during
maintenance. operation, stop the machine immediately and report
Check - at least from time to time - whether the the malfunction to the competent authority/person.
personnel is carrying out the work in compliance Never make any modifications, additions or conver-
with the Operation and Maintenance Manual and sions which might affect safety without the sup-
paying attention to risks and safety factors. plier's approval. This also applies to the installation
For reasons of security, long hair must be tied back and adjustment of safety devices and valves as well
or otherwise secured, garments must be close- as to welding work on load-bearing elements.
fitting and no jewellery, such as rings, may be worn. Use only the original sparts parts of CGM HMS
Injury may result from being caught up in the ma-
GmbH .
chinery or from rings catching on moving parts.
Use protective equipment wherever required by the They are the only ones to fulfill the technical specifi-
circumstances or by law. cations of the machine.
Replace hydraulic hoses within stipulated and ap-
propriate intervals, even if no safety-relevant de-
fects 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 pro-
cedures.
1-7
BA 6040(3 847 027.00)-EN
Introduction
Selection and qualification of per- Safety instructions governing

sonnel; basic responsibilities specific operational phases
Any work on and with the machine must be exe- Standard operation
cuted by reliable personnel only. Statutory minimum
age limits must be observed. Avoid any operational mode that might be prejudi-
cial to safety.
Employ only trained or instructed staff and set out
clearly the individual responsibilities of the person- Before beginning work, familiarize yourself with the
nel for operation, set-up, maintenance and repair. surroundings and circumstances of the site, such as
obstacles in the working area and the bearing ca-
Make sure that only authorized personnel works on pacity of the soil.
or with the machine.
Take the necessary precautions to ensure that the
Define the machine operator's responsibilities giving machine is in a safe and reliable state.
the operator the authority to refuse instructions by
third parties that are contrary to safety. Operate the machine only if all protective and
safety-oriented devices, such as removable safety
Do not allow persons to be trained or instructed or devices, emergency shut-off equipment, sound-
persons taking part in a general training course to proofing elements and exhausters, are in place and
work on or with the machine without being perma- fully functional.
nently supervised by an experienced person.
Check the machine at least once per working shift
Work on the electrical system and equipment of the for obvious damage and defects. Report any
machine must be carried out only by a skilled elec- changes (incl. changes in the machine's working
trician or by instructed persons under the supervi- behaviour) to the competent organization/person
sion and guidance of a skilled electrician and in immediately. If necessary, stop the machine imme-
accordance with electrical engineering rules and diately and lock it.
regulations.
In the event of malfunction, stop the machine im-
Work on chassis and brake systems must be per- mediately and lock it. Have any defects rectified
formed by skilled personnel only, which has been immediately.
specially trained for such work.
Start the machine from the operator's seat only.
Work on hydraulic systems must be carried out only
by personnel with special knowledge and experi- During start-up and shut-down procedures always
ence of hydraulic equipment. watch the indicators in accordance with the Opera-
tion 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.
1-8
BA 6040(3 847 027.00)-EN
Introduction
When crossing underpasses and bridges or when Special work in conjunction with
passing under overhead lines always make sure
that there is sufficient clearance. utilization of the machine and
Always keep a distance from the working face and maintenance and repairs as well
from slopes. as troubleshooting during work;
Avoid any operation that might be a risk to machine disposal of parts and consum-
stability.
Never travel across slopes; always keep the work-
ables
ing equipment and the load close to the ground, Observe the adjusting, maintenance and inspection
especially when travelling downhill. activities and intervals set out in the Operation and
Maintenance Manual, including information on the
On sloping terrain always adapt your travelling
replacement of parts and equipment. These activi-
speed to the prevailing ground conditions.
ties may be executed by skilled personnel only.
Before leaving the operator's seat always secure
Brief operating personnel before beginning special
the machine against inadvertent movement and un-
operations and maintenance work, and appoint a
authorized use. Shut off the engines.
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, in-
spection 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 mainte-
nance 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 move-
ments.
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 techni-
cally 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 per-
sons 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 mainte-
nance work at heights above 1 m.
Wear an approved harness equipped with fall ar-
resters and safety lines.
1-9
BA 6040(3 847 027.00)-EN
Introduction
Keep all handles, steps, handrails, platforms, land- Warning of special dangers
ings and ladders free from dirt, snow and ice.
Clean the machine, especially connections and Electric energy
threaded unions, of any traces of oil, fuel or pre- Use only original fuses with the specified current
servatives before carrying out maintenance/repair. rating. Switch off the machine immediately if trouble
Never use aggressive detergents. Use lint-free occurs in the electrical system.
cleaning rags. When working with the machine, maintain a safe
Before cleaning the machine with water, steam jet distance from overhead electric lines. If work is to
(high-pressure cleaning) or detergents, cover or be carried out close to overhead lines, the working
tape up all openings which - for safety and func- equipment must be kept well away from them. Cau-
tional reasons - must be protected against water, tion, danger! Check out the prescribed safety dis-
steam or detergent penetration. Special care must tances.
be taken with electric motors and switch-gear cabi- If your machine comes into contact with a live wire
nets.
 do not leave the machine
Ensure during cleaning of the machine that the tem-
perature sensors of the fire-warning and fire-fighting  drive the machine out of the hazard zone; warn
systems do not come into contact with hot cleaning others against approaching and touching the
agents as this might activate the fire-fighting sys- machine
tem.
 have the live wire de-energized
After cleaning remove all covers and tapes applied
for that purpose.  do not leave the machine until the damaged or
After cleaning, examine all fuel, lubricant, brake and contacted line has been safely de-energized.
hydraulic fluid lines for leaks, loose connections,
chafe marks and damage. Any defect found must The electrical equipment of machines is to be in-
be rectified without delay. spected and checked at regular intervals. Defects
Always tighten any screwed connections that have such as loose connections or scorched cables must
been loosened during maintenance and repair. be rectified immediately.
Any safety devices removed for set-up, main-
tenance or repair purposes must be refitted and High-voltage system
checked immediately upon completion of main-
tenance and repair work. Floodlamps equipped with gaz discharge lamps
require a high-voltage supply (ca. 25 kV).
Ensure that all consumables and replaced parts are
disposed of safely and with minimum environmental The high voltage is generated by a ballast unit.
impact. Switch off the electrical system of the excavator
before touching the lamp or the ballast unit.
Battery
Warning! Battery Posts, terminals and related ac-
cessories 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 well- During operation, all sound baffles of the machine
vented area; must be closed.
If in an enclosed area, vent the exhaust to the out- Always wear the prescribed ear protectors.
side;
Do not modify or tamper with the exhaust system
Oil, grease and other chemical
Diesel engine exhaust and some of its constituents
are known to cause cancer, birth defects, and other substances
reproductive harm When handling oil, grease or other chemical sub-
Operate fuel-operated heating systems only on stances, observe the product-related safety regula-
adequately ventilated premises. Before starting the tions (see safety specifications).
machine on enclosed premises, make sure that Be careful when handling hot consumables (risk of
there is sufficient ventilation. burning or scalding).
Observe the regulations in force at the respective
site.
Transporting and recommission-
Carry out welding, flame-cutting and grinding work
on the machine only if this has been expressly au- ing
thorized, as there may be a risk of explosion and The machine must be loaded and transported only
fire. in accordance with the Operation and Maintenance
Before carrying out welding, flame-cutting and Manual.
grinding operations, clean the machine and its sur- Use only appropriate means of transport and lifting
roundings from dust and other inflammable sub- gear of adequate capacity.
stances and make sure that the premises are ade-
The recommisioning procedure must be strictly in
quately ventilated (risk of explosion).
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 in-
terchanged. The fittings, lengths and quality of the
hoses must comply with the technical requirements.
1-11
BA 6040(3 847 027.00)-EN
Introduction
Any parts of the electrical system conducting cur-

ACCIDENT PREVENTION REGU- rent when in operation must be housed in lock-up
LATIONS FOR ELECTRICALLY switchgear cabinets. Hazard warning signs are
POWERED EXCAVATORS displayed on these lock-up cabinets.
VOLTAGE HAZARD
The safety and accident-prevention
regulations valid in the respective The switchgear cabinets must be secured against
country must be observed. unauthorized opening. The key must be kept by the
electrician in charge.
Electrical systems and components must not be
The following requirements are based on ex- used unless they comply with the operational and
tracts from the German accident prevention local safety requirements. They must be in an or-
regulations "Electrical Systems (BGV A3)". derly state and must be kept in such a state.
The installation, modification and repair of the elec- Any defects or malfunctions occurring in electrical
tromechanical component of electrical systems and systems or components must be reported to the
components must be delegated only to qualified electrician in charge.
electricians or firms employing such experts. Before switching on any systems, the excavator
A "qualified electrician" in the context of this regula- operator must check that no one is working on the
tion is a person who, on the basis of specialized machine or its electrical systems.
training, know-how and experience as well as The heavy-duty power cable must never be driven
knowledge of the relevant regulations, is in a posi- over, buried or ripped away. The excavator equip-
tion to judge the extent of the work assigned to him ment must never be set down on the power cable.
and to recognize any potential hazards. When the excavator is being moved, the cable must
The machine owner/contractor must inform all per- never be pulled or dragged over the ground.
sons working on electrical installations and compo- Whenever work is being carried out on electrically
nents or in the vicinity of components conducting powered excavators, the general rules of engineer-
electricity during operation, or who are responsible ing - especially those concerning low and medium
for the operation of electrical systems, of the poten- voltage - must be observed. Regulations such as
tial danger of electricity and must instruct them on those issued by the German VDE, e.g. specification
the accident prevention regulations relevant to their VDE 0100, should be observed. Observe all the
work. Instruction in safety measures is to be re- related laws and rules in your state or country.
peated at intervals appropriate to the operating
conditions. If necessary, special working regulations Before commencing any work on electrical systems
must be displayed. and components, the electrician in charge (or an
electrician appointed by him) must switch the power
The excavator and its electrical systems must be off all circuits and lock them in the OFF state as
adequately protected against other potential haz- follows:
ards of electricity, e.g. fire and explosion.
 Switch voltage OFF all systems.
Electrical systems and components must be pro-
tected against electric shock in the case of a fault,  Check with voltage detectors that all systems
e.g. short circuit to exposed conductive part. are voltage-free.
 Lock switches/systems to prevent them from

being switched ON.
The above procedures must be carried out in the

given sequence.
1-12
BA 6040(3 847 027.00)-EN
Introduction
The machine contractor must provide all the neces- Safety instructions for excavators
sary protective equipment and adopt the necessary
safety procedures. He must ensure that the safety with electric motor
equipment is used and the safety procedures ob- Before carrying out any maintenance and repair
served. work on the electrical system, the following precau-
The excavator operator and all personnel working tions must be taken:
on the excavator must use the protective equipment In the transformer station
and carry out the specified safety procedures.
 Switch off the supply voltage
It is absolutely forbidden to work on any systems or
components while they are conducting current.  Lock the safety device preventing switch-on;
Fatal injury can occur. apply a warning sign
If work has to be done in special cases on systems
or components conducting current, appropriate  Check that the electrical system is off circuit
safety measures must be taken. Work must not be and dead
done on "live" systems and components except by
 Connect to earth and short-circuit
the electrician in charge. The machine contractor
must also be notified.  Protect adjacent and live parts against acciden-
The excavator and its electrical systems must not tal contact
be switched on again until the above safety proce-
dures have been cancelled and all working areas On the excavator
are prepared for the resumption of operations.
 Switch off the switch-disconnector
Start-up can be ordered only by the person in
charge (qualified electrician). Time-based switch-on  Lock the safety device preventing switch-on;
agreements are absolutely forbidden. 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
1-13
BA 6040(3 847 027.00)-EN
Introduction
Place suitable fire guardings (fire barriers) if open

FIRE AND EXPLOSION HAZARD fire or flying sparks cannot be avoided during repair
Prior to commencing work, obtain in- work.
formationon the national and corporate Apply special protection to cables, cable ducts as
rules for the prevention of accidents. well as to hose and pipe lines.
Pay particular attention to hazards If necessary, also cover the ground with fire-
caused by combustible and easily protective blankets.
flammable substances.on the safe Ensure sufficient ventilation.
handling of the fire extinguishers to be
used. Clean the excavator before starting a job.
Do not keep any fire extinguishers that are not suit-
able or have not been tested.
Avoid smoking and open fire on, next to and below Do not extinguish flammable liquids with water.
the excavator. Use:
Combustible and easily flammable substances or  dry-powder,
liquids increase the fire and explosion hazard.
 carbon-dioxide or
Do not store or handle any flammable substances
during operation.  foam extinguishing compounds.
Clean the excavator thoroughly, if possible, with a When getting into contact with burning substances,
steam jet (rubber parts and electric components the fire-fighting water would abruptly evaporate and
with compressed air - refer to information label), distribute the substance such as oil over a wide
when, for example, oil, grease, fuel or cleaner was area. Water causes short-circuits in the electrical
spilled. system thus possibly entailing new hazards.
Such substances may spontaneously ignite if they DANGER TO LIFE
get into the vicinity of hot units or objects such as
turbo superchargers. Call the fire brigade.
Even battery gases can ignite in open flames or fire. Have all your welding, flame cutting and grinding
work approved.
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
BA 6040(3 847 027.00)-EN
Introduction
NOTES
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1-1
BA 6040(3 847 027.00)-EN
Introduction
1-2
BA 6040(3 847 027.00)-EN
OPeration
2 OPERATION

+
+
Repair personnel

chines.


+
+
Repair personnel
+
+
Repair personnel
2-1
BA 6040(3 847 027.00)-EN
OPeration
2-2
BA 6040(3 847 027.00)-EN
OPeration
OPERATION - SAFETY INSTRUC- Safety belt

TIONS For machines with a safety belt for operating per-
sonnel:
Operation and Maintenance Manual Check the safety belt attached to the operator's
Never operate the machine before hav- seat. In the event of damage or after an accident,
ing read and understood the Operation have it replaced immediately.
and Maintenance Manual.
Apply the safety belt before starting work.
Pay special attention to:
the "Fundamental Safety Instructions" and to all State of the machine
warning and instruction signs attached to the ma-
chine. Operate the machine only in a safe state and only
in accordance with its designated use. Always
Familiarize yourself with the layout, the functioning observe the safety instructions.
and the sense of actuation of the control elements
prior to starting up the machine. Always have inspection and maintenance work
carried out on schedule.
Activate the control elements from the operator's
seat only. Operate the machine only with the equipment and
component combinations approved by CGM HMS
Keep the Operation and Maintenance Manual with GmbH . Clear-cut data are given in the technical
the machine at all times. specification.
Never install and commission other equipment and
Operating personnel component combinations without CGM HMS
GmbH having first inspected and approved the
The operating personnel must be fully informed of project.
the operation and application of this or comparable
machines. Before starting work or travelling with the machine,
check that the braking, signalling and lighting sys-
The necessary know-how can be acquired in sev- tems are fully functional.
eral days' instruction, e.g. by an CGM HMS GmbH
mechanic or by attending an CGM HMS GmbH Poor visibility may result in accidents. Always clean
operator's training course. the windows and the glass covers of all lamps be-
fore starting the machine.
Check that all warning and instruction signs at-
Personal protective gear and working tached to the machine are present and legible.
clothing
Wear a safety helmet and working footwear with
non-slip soles. Smooth soles may slip from steps
Entering and leaving the machine
and pedals resulting in injury or incorrect operation. Always face the machine when entering or leaving
it.
Wear closely fitting working clothing when operating
the machine. Loose, wide garments may result in Use only the ladders, steps, platforms and grab
control levers being inadvertently activated 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 non-
slip, 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 at-
tachments falling as a result of operational move-
ments by the machine, of its equipment and at-
tachments or of swinging loads.
2-3
BA 6040(3 847 027.00)-EN
OPeration
Persons within the hazard zone Operation and Maintenance Man-

Always use the horn to warn persons in the imme- ual, where to store it in the opera-
diate vicinity of the machine before starting up the
machine. tor’s cab
Ensure that no one sets foot in the hazard zone of One copy of the Operation and Maintenance Man-
the machine. Interrupt work until such persons ual for the machine must be available in the opera-
have left the hazard zone. tor’s cab during operation.
Replace Operation and Maintenance Manual if lost,
damaged or unreadeable.
Marshallers The binder with the Operation and Maintenance
The marshaller must keep outside the hazard Manual can be stored in the tray (Fig. 2-1:).
zone.
Have a marshaller to assist you:
 when you have no clear overview over the haz-
ard 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 opera-
tion.
Keep in constant contact with the marshaller.
Stop the machine immediately if you lose contact Fig. 2-1:
with the marshaller.
Securing the machine

Secure the machine as described under "Secur-
ing the machine" before:
 mounting or dismantling the attachment,
 parking the machine after daily operation,
 carrying out any servicing or repair work.
2-4
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

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.
– combustible substances such as coal dust or tar
are present,
– open or smouldering fire may occur.
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.
2-5
BA 6040(3 847 027.00)-EN
OPeration
DESCRIPTION OF THE SHOVEL
Fig. 2-2:
2-6
BA 6040(3 847 027.00)-EN
OPeration
Shovel layout
Fig. 2-2: 37 - Control-cabinet with CMS
38 - Control-cabinet (24V) in cab module
Undercarriage
with battery main switch
1 - Track drive
39 - On-board-crane (optional)
2 - Idler
40 - Drive unit for on-bord-crane (optional)
3 - Track roller
41 - Service station (Tanklift)
4 - Support roller
44 - Grease container of central lubricating
5 - Crawler track
system
6 - Track tensioner
46 – Hydraulic ramp-type ladder
7 - Swing ring
47 - Ladder
8 - Escape ladder
48 - Escape ladder (optional)
9 - Slip ring assembly
50 - Counterweight
10 - Cable guide for drag cable
Superstructure
Loading bucket
11 - Electric motor
51 - Boom
12 - Switchgear cabinet medium voltage
52 - TriPower linkage
(6.6 kV / 7.2 kV / 7.2 kV); circuit breaker; DER I
53 - Stick
and II
54 - Bottom-dump bucket
13 - Switchgear cabinet
55 - Boom cylinder
14 – Connection box electric motor
56 - Stick cylinder
15 - Switchgear cabinet 400V, motor protection
57 - Tipping cylinder
relay, mains power supply
58 - Bottom-dump cylinder
16 - Switchgear cabinet power factor correction
64 - Control valves working equipment
17 - Hydraulic oil reservoir
65 - Quick-action valve
18 - Hydraulic oil cooler
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
2-7
BA 6040(3 847 027.00)-EN
OPeration
Undercarriage Control and Monitoring Platform

The undercarriage of the hydraulic excavator (CAMP)
serves as a stable base and for travelling. The The electronic CAMP system ensures the control
crawler tracks are driven hydraulically with oil mo- and monitoring of all electrical and hydraulical func-
tors and travel gearboxes. Undercarriage and su- tions of the excavator.
perstructure are connected by means of a swing
ring. Four interconnected electronic units ensure optimal
use of the installed engine power. Microprocessors
are used to adapt the power output of the hydraulic
Superstructure pumps optimally to actual operating conditions. The
The superstructure accommodates the drive and machine is thus prevented from demanding more
part of the hydraulic and electrical equipment. hydraulic power than the diesel engines can pro-
vide.
The desired working movements are detected by
Drive microcontrollers which permanently sense the po-
The drive unit comprises electric motor, pump drive sition of hand levers and pedals.
gearboxes, hydraulic pumps, hydraulic cylinders
and hydraulic motors. As soon as movement is detected, the corres-
ponding signals are transmitted to the electronic
units. These units activate the drive control in order
to provide the hydraulic energy needed for working.
Hydraulic system Only then do they activate the electro-hydraulic
All working and travelling movements are per- valves which control the execution of the working
formed hydraulically. The movements are controlled movements.
by servovalves. The working commands are initi-
ated by hand and transmitted to the valves via con-
trol circuits. The oil supply from the superstructure
to the undercarriage is ensured by the rotor. The
hydraulic system is overload-protected by pressure-
relief valves. The hydraulic pumps are supplied with
oil from a hydraulic reservoir.
2-8
BA 6040(3 847 027.00)-EN
OPeration
Demand control / Zero-flow regu- Board-Control-System (BCS)

lation The BCS is a micro-processor-controlled system for
In the fine-control range, swivelling of the hydraulic the acquisition and processing of measuring data.
It's function consists in collecting data of the exca-
pumps, and thus the variation of oil flow, are propor- vator operating conditions and to evaluate, store
tional to control lever and pedal valve travel. This and display these data to the excavator operator.
means that during the work, the pumps supply only For this purpose, the BCS is connected via a bus
as much hydraulic oil as required to perform the system to the Control and Monitoring Platform
working movement. In the neutral position of the (CAMP). An interface with the outside world en-
control levers, the pumps are automatically swiv- sures the drive of stored data and software updat-
elled to zeroflow. ing.
These special features offer the following advan-
tages: The measured values (actual values) from the sen-
 minimum power losses, sors and transducers installed in the excavator are
compared to the predefined reference values. In-
 reduced temperature of the hydraulic oil, admissible deviations are indicated as fault mes-
sages on a display screen. Sensor or transducer
 greater service life of hydraulic pumps and elec-
defects or defective connecting cables are detected
tric motor.
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 Critical states of operation are brought to the opera-
tor's attention by means of optical and acoustic
If no servovalves are actuated by the control pedals warning signals.
or levers for more than 8 seconds (factory-set
value, adjustable), the engine is automatically set The display screen of the BCS is a touch-screen
back to idling speed (factory setting ca. 1000 rpm, with a surface sensitive to the touch. This feature
adjustable). This feature, too, contributes to reduc- supports the excavator operator or the service tech-
ing the fuel consumption. nician 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 7200 V
(medium voltage) 60 Hz
Control voltage 400 / 230 V
(low voltage)
Lighting voltage 24 V
Emergency voltage 24 V
Control voltage 24 V
2-9
BA 6040(3 847 027.00)-EN
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 as-
sembly (4) to the circuit breaker in the switchgear
cabinet (Fig. 2-4:).
The drag cable can be wound on a cable reel (op-
tional).
Fig. 2-3:
Fig. 2-4:
2-10
BA 6040(3 847 027.00)-EN
OPeration
Operation with cable reel (op-

tional)
(Fig. 2-5:)
1 Button Cable reel – wind up man-
ual
2 Button Cable reel – wind off man-
ual
3 Rotary switch 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

Fig. 2-6:
 the cable is winded off completely from the ca-
ble reel,
 the resistance during winding up and off the
cable is too high.
2-11
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.
2-12
BA 6040(3 847 027.00)-EN
OPeration
Fig. 2-7:
2-13
BA 6040(3 847 027.00)-EN
OPeration
Fig. 2-8:
2-14
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Fig. 2-9:
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Fig. 2-10:
2-16
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Fig. 2-11:
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Fig. 2-12:
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Fig. 2-13:
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Fig. 2-14:
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Fig. 2-15:
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Fig. 2-16:
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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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Entering and leaving the machine Access ladder lighting

Safety instructions The access ladder of the machine can be illumi-
nated.
Risk of injury due to slipping.
From outside:
Clean off oil, grease, soil, mud, snow, The pull-switch (2, Fig. 2-21:) of the lighting system
ice and other substances from foot- is located beneath the superstructure. The lights
wear, grab handles, ladders and steps. are switched on from the ground by means of the
pull-rope.
From the cab:
Keep ladders, steps, platforms and grab handles in
a non-slippery condition. 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 The lighting remains on during a presettable ON
illustration in Fig. 2-20:). 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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Lowering the swinging ladder (from the upper

Swinging ladder carriage)
Raising resp. lowering the swinging ladder (Fig.
 Start engine.
2-23:).
 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) Fig. 2-25:
upwards to position “ I “.
Lowering the swinging ladder (from the bottom)
The swinging ladder is raised (Fig. 2-25:)
 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 Fig. 2-26:

when the folding ladder is raised
completely (Fig. 2-25:).
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Folding ladder (optional) Lowering the folding ladder (from the upper
carriage)
Raising resp. lowering the folding ladder (Fig.  Start electric motor.
2-27:).
 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 car-

riage)
 Start electric motor.
 Pull lever (1, Fig. 2-28:) on control valve (2)

Fig. 2-29:
upwards to position “ I “.
The folding ladder is raised (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 Fig. 2-30:
completely (Fig. 2-29:).
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Emergency exit in operator’s cab

and escape ladder
The sliding window (arrow, Fig. 2-31:) on the left-
hand side of the operator’s cab serves as an alter-
native 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
Fig. 2-32:
position the ladder moves to.
 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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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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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 hydrau-
lic oil reservoir (1, Fig. 2-39:).
Fig. 2-37:
Fig. 2-38:
Fig. 2-39:
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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 me-
dium 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 con-
nected.
Fig. 2-40:
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 "Bat-
tery main switch").
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
Fig. 2-41:
pushed in).
Fig. 2-42:
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Servicing switch Windscreen washer

Before starting live-line servicing work e.g. measur- The reservoir of the windscreen washing system (1,
ing and testing with voltage applied, press switch Fig. 2-44:) is installed in the cab module. For the
(4, Fig. 2-43:) and secure it with a padlock. reservoir capacity refer to the "Refilling quantities -
Pressing the switch transmits a signal to the PLC. Other" table.
The electric motor can not be switched on.
Fig. 2-44:
Fig. 2-43:
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Operator's seat Never adjust the seat while driving.

The operator's seat (Fig. 2-45: and Fig. 2-46:) can Concentrate on the road to avoid ac-
be adjusted in several positions. cidents.
Before carrying out any seat adjust-
ments stop the machine and set the
control levers to "0"
Fig. 2-45:
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Fig. 2-46:
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Fire extinguisher Handling

The excavator is equipped with two four extinguish-
ers. The conventional one is located near the op-
erators cab (Fig. 2-47:), the carbon dioxide fire ex-
tinguishers 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.
 Operate the extinguishing gun.

Fig. 2-47:
The excavator operator and the maintenance per- After fire-fighting, the extinguisher must be refilled
sonnel must informthemselves about how to handle Immediately and prepared ready for use.
the fire-extinguisher in order to be able to act fast
and efficiently in case of beginning fires. Such in-
struction should be given by a qualified instructor. Inspection
Extinguishing agent Have the extinguisher inspected at regular intervals
by an expert. This is required by local authorities
The conventional fire-extinguisher is filled with 12
and insurance companies and is in the interest of
kg (26.4lb) Glutex. This extinguishing agent is used
your own safety.
for fighting fires of classes A, B and C. Fires are
extinguished fast, perfectly and without residues. Have the fire-extinguisher checked at
the prescribed intervals by authorized
The carbon dioxide fire extinguishers are intended
testing agencies.
for fighting fires of electrical parts.
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Automatic fire-extinguishing sys- Trainer's / instructor's seat

tem (optional) For operator training / instructing purposes it is of-
ten required that a trainer / instructor accompanies
The automatic fire-extinguishing system prevents the operator in the cab.
fire from spreading.
For the safety of the trainer / instructor during exca-
It is, however, assumed that the machine is thor- vator operation the cab is equipped with a second
oughly cleaned of combustible and easily flamma- seat. This seat is installed behind the operator's
ble substances. seat (Fig. 2-49:).
The excavator operator and the maintenance per-  Sit down on this seat and do not forget to fasten
sonnel must familiarize themselves with the auto- the seat-belt, if installed (arrow, Fig. 2-49:).
matic fire-extinguishing system.
Such instruction should be given by a qualified in-  Do not leave this seat during the training / in-
structor. struction session and /or as long as the ma-
chine is in operation.
The fire-extinguishing system is activated auto-
matically in an emergency.
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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Emergency escape device (op-

tional)
Elements of the harness
(Fig. 2-50: - Fig. 2-52:)
Pos. Designation
1 Back support
2 Shoulder belt
3 Shoulder belt
4 Loop (chest belt)
5 Loop (chest belt)
6 Loop (back support)
11 Holding device
12 Fall arrester
13 Guidance line
Fig. 2-51:
14 Hanging up line
15 Handbag with harness
16 Snap hook
17 Hook safety device
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 main-
tenance.
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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Taking on harness  Pull loop (6) of the back support (1) between
your legs to the front (Fig. 2-55:).
 Take harness out of handbag (15, Fig. 2-53:).
 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:
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 Hang up loop (4, Fig. Fig. 2-58:) into snap hook If you have the harness put on in such a way in
(16). case of danger you can escape from the excavator
(Fig. Fig. 2-60:).
Fig. 2-58:
Fig. 2-60:
 Release hooking safety device (17, Fig. 2-59:).
Fig. 2-59:
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This page intentionally left blank.
2-39
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MONITORING, WARNING AND CONTROL ELEMENTS
Fig. 2-61:
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(Fig. 2-61:)
BCS, Board-Control-System
No. Element Function Symbol

BCS Electronic system Board Control System, acquisition and dis-
1
for measured data play of important operating data of the hy-
acquisition and draulic shovel.
processing
The surface of the monitor is sensitive to the
touch (touch-screen technology). A touch-
screen permits selecting menus and pro-
grams by touching graphic control symbols
and to recall, for instance operating data of
the hydraulic shovel.
For further information please refer to sec-
tion 5 of this Operation and Maintenance
Manual, chapter “Board-Control-System”.
Monitor BCS The monitor displays collected operating
2
data, warning messages and – if needed –
instruction for help.
Note:
Do not remove the film visible on the screen
surface. This is a polarization film which
makes the displayed graphics much better
visible.
Push-button Navigation in menus Control of cursor movements, program se-
3
lection within the BCS, confirmation of inputs
/ displayed values (Enter), quitting of menus
/ sub-menus
Push-button Numeric keypad Input of numeric values.
4
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Fig. 2-62
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(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 “Board-
Control-System”).

Status line Indicates activated functions and operating
1
hours.
The symbols displayed are those of the
switches in the control column
Touch-screen BCS Indicates collected operating data graphi-
2
Monitor cally and / or numerically, displays warning
messages, fault messages and – if needed –
instructions for help.
Pushbutton Navigation Control of cursor movements, program se-
3
in menus lection within the BCS, confirmation of inputs
/ displayed values (Enter), quitting of menus
/ sub-menus
Push-button Numeric keypad Input of numeric values.
4
Touch-screen Examples
5
buttons
Status line Fault messages Displays fault messages as a code number
6
and as plain text. The "Fault" button permits
displaying further fault messages stored in
the system.
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Fig. 2-63:
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(Fig. 2-63:)

Key-switch Switches the electrical system on and off.
32
Buzzer (inside the Gives three acoustic warning signals if a
33
control column) fault is reported. The signals appear every
30 seconds.
Socket connec- Connection of electronic devices for fault
34
tors diagnosis purposes.
Switch Emergency De-energizes the outputs of the electronic
35
shut-off control units:
The engines are shut off, all valves are de-
energized, working movements no longer
possible.
(see: "Emergency shut-off function").
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Fig. 2-64:
2-46
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(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.

Push-button
41 Electric motor ON Switches on the electric motor.
Push-button
42 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 monito- Lamp is lit up when the rotary field (phas-
ring ing) is correct.
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Fig. 2-65:
2-48
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(Fig. 2-65:)
Push-button Superstructure hold- Blocks the superstructure.
61
ing brake
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 gear-
boxes.
Push-button Hydraulic shovel Press the switch face with the symbol:
63
parking brake, for The parking brake is applied permanently.
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 gear-
boxes.
Push-button Central greasing Reset function of the central greasing
64
system reset 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.
Push-button Emergency lowering Lowering of the working equipment in an
65
emergency situation. For instance, if the
electric motor has failed.
For more information refer to chapter
“Emergency lowering of the working
equipment”.
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Fig. 2-66:
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(Fig. 2-66:)

Switch Servo-control Press the switch face with the symbol:
71
The electro-hydraulic servo-control is en-
abled.
Switch Travelling speed Not actuated:
72
1st travelling stage
travelling forwards / backwards is possible
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 Press the switch face with the symbol:
76
has to be manoeu- The machine can be driven and the super-
vered out of dan- structure be swung although these functions
gerous situations are automatically deactivated.
Use this function only in danger-
ous situations to manouever
yourself or the machine out of
hazard zones. Risk of damaging
parts of the machine, e.g. the hy-
draulic ladder or the tanklift.
Switch Floodlamps Switches all floodlamps on and off.
81
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 (op- Press the switch face with the symbol:
tion) Rotary beacon ON.
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Fig. 2-67:
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(Fig. 2-67:)
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.
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 Switches the preheating system on and off.

(optional)
96 Switch Cable reel Switches the cable reel system on and off.
(optional)
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Fig. 2-68:
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(Fig. 2-68:)
Can be used as a push-to-speak button on a
101 Push-button (Free for options)
radio, or to switch over from one camera to
another one.
Button is pressed:
102 Push-button Stick floating posi-
tion (shovel equip- The stick cylinders are pressurized on re-
ment only) tracting.
Press button (102) only in posi-

tion "0" of control lever (115).
Push-button Boom floating posi- Button is pressed:
103
tion The boom cylinders are pressurized on re-
tracting.
Press button (103) only in posi-
tion "0" of control lever (116).
Push-button Warning signal Button is pressed:
104
Acoustic warning signal / horn is activated.
Push-button Electronic hydraulic The electronic hydraulic shovel control
105
inside the seat shovel control (servo-control) is activated when the opera-
(servo-control) tor sits down on the seat.
The electronic hydraulic shovel control
(servo-control) is deactivated when he
leaves the seat.
Pedal Shovel trap (shovel Forwards – shovel trap is opened;
111
equipment only) Backwards – shovel trap is closed.
Pedal Travel, left track Forwards – forward travel;
112
Backwards – backward travel.
Pedal Travel, right track Forwards – forward travel;
113
Backwards – backward travel.
Footrest
114
Control lever Forwards – raising the stick
115
Backwards – lowering the stick.
To the left / right –
swinging and braking of the superstructure.
Control lever Forwards – lowering the boom;
116
Backwards – raising the boom.
To the left – backwards tipping of shovel /
bucket;
To the right – dumping of shovel / bucket.
Push-button Not used on this machine.
117
Thumb wheel Shovel trap (shovel Turn Forwards – shovel trap is opened;
118
equipment only) Turn Backwards – shovel trap is closed.
Function can be overridden by Pedal 111.
(Thumb wheel is spring centered).
Push-button By-pass for the Lower half pushed – automatically stopped
119
automatically stick- and/or backhoe cylinders can be
switch off for stick- driven slowly to the limit stopps.
and /or backhoe Upper half pushed – Each press on the but-
cylinders (Option) ton increments the loaded dumper count for
by "1". (Count reset with button (91)).
Thumb wheel Not used on this machine.
120
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Fig. 2-69:
2-56
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(Fig. 2-69:)
Optional equipment: Air conditioning
(Depending on the options ordered with the machine, the described elements can be found on different posi-
tions on the control column).
150 Rotary switch Fan Selects the intensity level of the blower (3
(Air conditioner) levels).
151 Knob Thermostat Sets the desired temperature inside the cab.
(Air conditioner)
152 Rotary switch Mode Selects the desired control function (heating,
(Air conditioner) cooling, ventilation, defrosting).
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PUTTING THE MACHINE INTO

OPERATION Pos. Fluid Express cou-
Fig. pling for
Before daily start-up, carry out works in accor- 2-70:
dance with servicing plan T (see Part 3 "Inspection
and servicing") 5 Gearbox oil for pump Filling and / or
drive gearbox draining
Prior to your dailiy start-up, make sure Hydraulic oil
10 Filling and / or
the machine has been cleaned of
draining
combustible and easily flammable
substances. 11 Grease for the central Filling
greasing system
Otherwise, increased fire and explo-
sion hazard will exist.
A service vehicle is needed for filling and/or drain-
ing of the fluids.
Service station (tanklift) Lowering the service station
The excavator is equipped with a central service Draw out control knob (21, Fig. 2-70:) of valve (22)
station (Fig. 2-70:). The service station is attached with rope (25). The service station is brought down
to the frame and accessible from the ground below to the lower position. Turn knob (21) by 90° and
the uppercarriage. Express couplings are provided engage.
for refilling the following consumables (fluids).
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 cou-
pling at the service station. Fill in or drain off fluid.
Take off filling hose and refit cap on the express
Fig. 2-70:
coupling.
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Assemblies resp. Measuring device Remarks

reservoirs
Pump drive gear- Dipstick (1, Fig. 2-71:) Stop filling when the oil reaches the "max" mark on the
box dipstick (see Part 3, chapter "Pump drive gearbox -
Checking the gearbox oil level/Filling in oil").
Hydraulic oil tank 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 has-
dropped below the "min" mark. Stop filling if the oil rea-
ches 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:
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Assemblies resp. Measuring device Remarks

reservoirs
Grease container BCS display (Fig. 2-74:) BCS display indicates a warning when the grease con-
– cental lubricating tainer is empty.
system 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:
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Battery main switch, switching on Electrical system (24V), switching

and off on and off
When the excavator is disconnected from the me- The electrical system is switched on or off with
dium voltage (6.6 kV / 7.2 kV) the electrical system key-switch (32, Fig. 2-77:).
(24V) is supplied with voltage by two batteries.
With the battery main switch, the electrical system Switching the electrical system (24V)
(24V) is disconnected from the batteries.
on
The battery main switch is located at the left side
 Insert key into key-switch (32) and turn to the
wall of the control cabinet (24V). The control cabi-
right.
net (24V) is mounted in the operator's cab module
beneath the operator's cab.
Now all electronical assemblies of the excavator
Switching the battery main switch on are supplied with voltage, computer systems are
 Turn switching handle of main switch (1, Fig. started. A selftest is carried out.
2-76:) to position "ON". The Board Control System (BCS) displays current
operating data as well as detected faults.
Switching the battery main switch off If there are no critical faults detected BCS enables
 Turn switching handle of main switch (1. Fig. starting the electric motor.
2-76:) from position "ON" to position "OFF". If there are critical faults or failings detected BCS
The handle can be locked in the "OFF" posi- disables starting the electric motor and displays
tion by means of a padlock. corresponding explanatory text.
For more information see " Operation and Mainte-
nance Manual Board-Control-System".
Switching the electrical system (24V)

off
 Turn key in key-switch (32) to the left and with-
draw
Fig. 2-76:
Fig. 2-77:
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Switching the electric motor on

and off
Before switching on the electric motor
Before switching on the electric mo-
tor, check that nobody is working on
the electrical system or on the excava-
tor 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: "Elec-
trical 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 indi-
cates this case with telltales as well as by display-
ing 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 Fig. 2-79:
circuit (PLC) the electric motor can be switched on
only three times a hour (time-out period is 30 min-
utes).
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Switching the electric motor off Time-out before restart

During breaks in operation and at the end of each During starting period the electric motor heavily
shift, the working equipment must be lowered onto warms up. Therefore it is not allowed to switch it
the ground. on and off at will. By means of an electronical time-
The electric motor must NOT be switched off until out circuit (PLC) the electric motor can be switched
the equipment is resting on the ground. on only three times a hour (time-out period is 30
minutes).
To avoid straining the vacuum contac-
tor, the electric motor should be shut The 30 minutes period means the time from
down only when load-free, i.e. without switching on the electric motor up to the next
any of the hydraulic units being acti- switching on, e. g.
Electric motor is switched on, runs 20 minutes and
vated at the same time via the control
then is switched off. Now the time-out period is 10
valve.
minutes before restart.
After running more than 30 minutes without inter-
 Actuate switch-key (42, Fig. 2-80:). The elec- ruption the electric motor can be switched on with-
tric motor starts running down. out any time-out period.
The eCAMP system prohibits switching on the
 Turn key in key-switch (32) counter-clockwise electric motor until it is cooled down.
and withdraw.
The control voltage is switched off. The BCS monitor (Fig. 2-81:) displayes the remain-
ing 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 re-
start", "Before switching on the electric motor" and
"Switching on the electric motor").
Fig. 2-81:
Fig. 2-80:
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Electric motor can not be In case of failure

switched on If failures in the electrical systems occur, BCS
displayes warnings and corresponding explanatory
If BCS prohibits switching on the electric motor the text
operator should check the following:
 Time-out before restart period still running? Failures in electrical systems may exclusively be
removed by specialist personnel for maintenance
 EMERGENCY STOP switch in control column and service on electrical systems.
unlocked? The following faults may be responsible:
 EMERGENCY STOP switch in control cabinet  fault in high-voltage transformer
(400V) unlocked?
 6.6 kV / 7.2 kV/ 400V/ 230V transformer over-
 EMERGENCY STOP pullswitch near the ser- loaded.
vice station unlocked?
 earth fault.
 Servicing switch unlocked?
If BCS display shows "Overcurrent",
 Monitoring lamps "6.6 kV / 7.2 kV OK" and
the operator does not know if an
"PHASE SEQUENCE OK" on the control
"Earth fault" happens. In worst case
cabinet (400V) and on the control column light-
the excavator may be energized.
ing?
If not, the circuit breaker is switched off or the The operator must notify the electri-
6.6kV voltage supply is missing. cian in charge from the excavator su-
perstructure.
 Shut-off flaps at the hydraulik oil reservoir
closed? The electrician must then cut off the
voltage supply from the transformer
 Check BCS display: Faults or explanatory text
station and locate and rectify the fault.
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 spe-
cialist personnel for maintenance and service on
electric excavators. Only these have the skills to
work in a safe way, for trouble shooting and re-
moving the fault.
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Circuit breaker, switching on and Switching the circuit breaker

off  The circuit breaker is switched on and off by
means of a actuating lever (Fig. 2-84:).
By means of the circuit breaker the supplied me-
The actuating lever is slipped over the actuat-
dium voltage 6.6kV can be connected to the exca-
ing shaft of the circuit breaker.
vators electrical system or can be disconnected
from it. The circuit breaker is installed in the control  Detailed information is given in the brochure of
cabinet 6.6 kV / 7.2 kV (outer view, Fig. 2-82:, in- the manufacturer “Medium-voltage switching
side view Fig. 2-83:). devices”. See volume “Components” of the
Switching the circuit breaker on is possible only printed machine documentation.
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.
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:
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Motor protection relay, functions

The electric motor is equipped with a motor protec-
tion 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 pro-
grammed for the following functions:
 protection against overcurrents,
 protection against overloading,
 detection of ground faults,
Fig. 2-85:
 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 detec-
ted in operation, the motor protection relay is acti-
vated and the electric motor shut off automatically.
If the motor protection relay detects a severe fault
before or during the starting sequence of the elec-
tric 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 manu-
facturer's description.
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Front panel control and monitoring

elements 1 RUN indicator (LED)
2 Display screen (provides information on
(Fig. 2-86:): states of operation)
3 Display screen navigation keys
4 Function key freely programmable
(not used for this machine)
5 Control of other equipment
(not used for this machine)
6 USB interface for communication with ex-
ternal devices (only for CGM HMS GmbH
Service)
7 Reset for LEDs of item 9.
8 Cover for keypad of item 4.Functional de-
scription of the LEDs of item 9.
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 manu-
facturer's description.
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Air conditioner (optional) Back-up heating operator’s cab

Ventilation / Heating (optional)
The air needed for ventilation and/or heating is The back-up heating for the operator’s cab is lo-
sucked in from outside the cab by a blower and cated in the module below the operator’ cab (Fig.
ducted to the air outlets. 2-88:). The heating consists of one or two heating
units (1) and the fuel reservoir (2).
If necessary, the air in the cab is sucked in through
the air conditioner and recirculated.  Switch on the back-up heating using switch
(142, Fig. 2-89:). The pilot lamp above switch
The air conditioner control elements are located at (142) lights up.
the left side of the control column (Fig. 2-87:). The heating system has an automatic regula-
Do not switch the air conditioner to tion.
"cooling“ when the back-up heating
(optional) is on. 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).
Fig. 2-88:
2 Rotary switch Selects the desired control
function (heating, cooling,
ventilation, defrosting).
3 Thermostat Sets the desired tempera-
ture inside the cab.
Fig. 2-89:
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TRAVELLING, SAFETY INSTRUC-

TIONS
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 ma- Fig. 2-91:
chine takes, before initiating the full travelling mo-
vement.
Warn persons in the immediate vicinity by sound- Running-in specifications for components of
ing the horn before setting off. the crawler tracks
Never drive across slopes. Prior to initial commissioning and/or after repair
Take the utmost care on slippery, greasy ground. work, run in the idlers, track rollers and support
rollers as follow:
If the machine is to be driven a longer distance, the  Raise the equipment (Fig. 2-90:) or (Fig.
superstructure must be secured against turning by 2-91:).
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 ther-
mometer (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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TRAVELLING Travelling forwards/backwards

 Travelling forwards:
Superstructure basic position depress pedals (112 and 113) forwards, the
Travel direction and sense of actuation of pedals excavator travels in the direction of the idler (2,
(112 and 113, Fig. 2-93:) are identical only when Fig. 2-92:).
the excavator is in its BASIC POSITION (Fig.
2-92:).  Travelling backwards:
depress pedals (112 and 113, Fig. 2-93:)
backwards, the excavator travels in the direc-
tion 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:) Fig. 2-94:
are depressed. The pedals return automatically to their "0" posi-
tions 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.
All instructions with regard to travelling speed

regulation and travel direction control are applica-
Fig. 2-93: ble only as long as the crawler tracks have suffi-
cient grip and do not slip.
If the operator is not completely sure of the posi-
tion of the superstructure with regard to the under-
carriage, pedals (112 and 113) should be de-
pressed slightly in order to find out which way the
excavator moves before initiating the full travelling
movement.
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Regulating the travelling speed Travelling uphill and downhill

Travelling on level ground: Read and observe the "Travelling -
Regulate the travelling speed with Safety instructions" chapter.
 pedals (112 and 113, Fig. 2-95:)
 set the first (slow) range or the second (fast)  Depress padals (112 and 113, Fig. 2-95:) fully
range with switch (72, Fig. 2-96:). to the limit stop.
Change speed range only when the When travelling downhill, the travel retarder valve
excavator is stationary. 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 re-
lease pedals (112 and 113) to stop the
excavator.
Fig. 2-95:
Fig. 2-96:
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Cornering
To take a right-hand corner forwards: Never use the working equipment to
 depress only pedal (112, Fig. 2-97:) forwards. raise one side of the undercarriage
and then turn the undercarriage by
To take a lefthand corner forwards: initiating the swing and/or the travel-
ling function.
 depress only pedal (113) forwards.
Turning This way of working is contrary to the excavator's-

To turn to the right: designated use.
 depress pedal (112) forwards and pedal (113) There is a risk of accident. Moreover, the tracks,
backwards. swing gear, roller bearing swing ring, backhoe or
bucket back-wall and the front part of the bucket
To turn to the left: are subjected to inadmissibly high stresses.
 depress pedal (113) forwards and pedal (112)
backwards.
Fig. 2-98:
Fig. 2-97:
Note
Change the position of the undercarriage - parallel
or perpendicular to the working face - only by cor-
nering 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 ex- Fig. 2-99:
cavator 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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Travelling over long distances

Backhoe bucket equipment (Fig. 2-101:)
Travel only forwards with the excava-
tor in its basic position.  Fully extend boom cylinder (1),
Travelling backwards over longer dis-  extend backhoe cylinder (2),

tances could damage parts of the un-  extend stick cylinder (3)
dercarriage. to such an extent as to reach the position of
the working equipment shown in (Fig. 2-101:).
Read and observe the "Travelling –
Safety instructions" chapter.
When travelling, pay attention to sufficient head-

room, 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), Fig. 2-101:
 retract stick cylinder (3)
to such an extent as to reach the position of
the working equipment (Fig. 2-100:). 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.
In case of higher temperatures:
Fig. 2-100:  Stop travelling. Resume travelling only after
the track rollers have cooled down to
ca. 40° C / 104°F.
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Superstructure holding brake Track parking brake

The excavator is equipped with four superstructure The hydraulic shovel is equipped with four travel-
holding brakes. The superstructure holding brakes ling gear brakes which are integrated in the travel
are used to block the superstructure and the un- drives.
dercarriage. The travelling gear brakes are parking brakes.
The superstructure holding brakes are parking They protect the hydraulic shovel from rolling for-
brakes. wards or backwards. When the machine is parked,
travel brakes are activated automatically. The
Do not actuate the switch unless the superstruc-
brakes are deactivated during operation of the
ture is stationary. Do not use this switch while the
machine.
superstructure is still in motion. Risk of damage to
the brakes and the slewing gears. Note:
 To activate the holding brakes, press switch As travel brakes are deactivated, machine could
(61, Fig. 2-102:): slightly move in direction of excavating during op-
eration.
 when the excavator is parked,
Whenever loading operation is interrupted, stand
 when travelling over longer distances. working equipment on the ground. This avoids
slight movement of the machine and possible con-
sequential damage of lowered ladder, in case igni-
tion remains engaged.
Fig. 2-102:
Fig. 2-103:
For Service and Maintenance purposes the travel-

ling 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 hy-
draulic 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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TRANSPORTING THE MACHINE Transport

The dimensions and the service weight of the fully
Transport - Safety instructions assembled excavator do not allow the excavator to
The machine must be loaded and transported only be transported in an undismantled state on a low-
after all safety regulations have been observed bed trailer over public roads.
and complied with. Therefore, the following components and modules
Entrust loading and transporting of the machine to must be dismantled beforehand.
a company experienced in the transport of heavy Suspensions points as well as the center of gravity
equipment. are marked on the modules (see example, Fig.
The responsability for loading and transporting lies 2-104:).
with the transport company or their representative. Dimensions and weights of the machines modules
Remove oil, grease, soil, mud, snow, ice and other can be found in the annex, chapter “Product Speci-
materials from the excavator's crawler tracks and fication Sheet” as well as in the “„Service Manual“”.
from ramps and loading platforms of the transport Detailed instructions for disassembling and as-
vehicle to minimize slipping. sembling the machine can be found in the Service
Secure the transport vehicle against rolling away. 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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WORKING OPERATION - SAFETY Running-in instructions for hydraulic

cylinders
INSTRUCTIONS
Compression of an oil/air compound in a hydraulic
Read the sections "Fundamental cylinder may result in detonations which might
safety instructions" and "Operation, damage pistons and sealing rings.
safety instructions" carefully and
Prior to initial commissioning and/or after repairs,
observe the instructions given in
run in the hydraulic cylinders as follows:
them.
 Switch on the electric motor.
The pressure-limiting valve in the hydraulic
system must not respond
Inspect the site for underground gas, power and
water lines before starting work. Any damage to  In the first two working cycles, retract and ex-
such lines is a risk to life! tend the pistons of the hydraulic cylinders to
Clean off any earth, mud, snow, ice, grease and oil max. ½ to ¾ (not to the limit stop).
adhering to your working footwear before operating Never change direction suddenly. The waiting
the machine. There is otherwise a risk of slipping time between changes of direction must be at
off the pedals and initiating inadvertent move- least 4 seconds.
ments.
 In the next eight working cycles, retract and
Sound the horn to warn persons in the immediate
extend the pistons of the hydraulic cylinders to
vicinity before starting work.
the limit stop. The waiting time between chan-
Stop work if anyone is in the hazard range of the ges of direction must be at least 4 seconds.
machine. Make sure they have left the hazard
range before resuming work.  When all hydraulic cylinders have been run in,
Never operate the machine unless it is standing on the excavator can operate at a higher engine
a reasonably horizontal, flat surface. The stability speed.
of the machine is otherwise at risk.
Ensure that the attachment has adequate clear-
ance 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 dam-
age caused by an abusive utilization of the ma-
chine.
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Avoid extreme positions of the attach-

ment
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 posi-
tions of this kind.
Fig. 2-107:
Fig. 2-105:
Fig. 2-108:
Fig. 2-106:
Fig. 2-109:
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WORKING OPERATION Activating the electronic servo

Before starting work control
The hydraulic shovel can execute working move-
Prior to initial commissioning and ments only after the electronic servo control (pilot-
after repairs on the central lubricating control) has been activated.
system or the hydraulic cylinders,
The servo-control block is enabled by switch (71,
move the unloaded equipment for
Fig. 2-110:).
abt. 5 minutes.
At the beginning of the work, the electronic servo
This is required to ensure an ade- control (pilot-control) is activated by a contact in
quate supply of grease to the cylinder the operator's seat (105):
bearings when the work starts.
 Electronic servo control ON -
Warming up The operator is sitting on his seat.
At low outside temperatures it is necessary to run  Electronic servo control is OFF -
the hydraulic system up to operating temperature. The operator's seat is empty.
The temperatures at which warming up is neces-
sary depend on the type of hydraulic oil used; see Note:
also "Oils for hydraulic systems". During operation it is absolutely necessary that the
 Switch on the electric motor and start to per- operator keeps sitting on his seat.
form no-load working movements for abt. 10 Otherwise working movements may be interrupted
minutes with the excavator. suddenly: risk of damaging the holding brakes and
the gearboxes.
Fig. 2-110:
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Swinging the superstructure

Swinging of the superstructure is possible only-
when:
 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 automati-
cally to position “0”.
Fig. 2-111:
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).
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 sw-
ing 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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Working
When released, all control levers for working op-
eration 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 be-
ginning 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. Fig. 2-114:
Pressing pedal (111) overrides turning the
thumb wheel (118).
Filling and emptying the bucket or the
Raising and lowering the boom backhoe
 To raise the boom:  To fill/tip back the bucket:
pull control lever (116, Fig. 2-114:) backwards. shift control lever (116, Fig. 2-114:) to the left.
 To lower the boom:  To empty the bucket by dumping/tipping:
push control lever (116) forwards. shift control lever (116) to the right.
 To lower the boom with pressure:
depress button (103) and
push control lever (116) forwards.
2-80
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OPeration
Emergency lowering of the work-

ing equipment
With the electric-motor not functional, the working
equipment can be lowered to the ground as fol-
lows:
 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:
2-81
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After daily operation

Parking the machine Escaping oil pollutes the environ-
ment.
 Park the machine on level and stable
ground. This is particularly important in winter
to avoid freezing of the tracks.
 Repair leaks immediately (or have them re-
 Stand the working equipment on the ground. paired).
 Switch off the electric motor.  Report oil accidents to the responsible person.
 Shift both control levers into all directions to-  Check the superstructure, undercarriage and
depressurize the hydraulic cylinders. the working equipment for damage and all
steel components for cracks or fractures.
 Withdraw the key from the electrical system-
key-switch.  Report detected damage immediately to the
responsible person.
 Set the battery main switch to OFF.
 Clean off gross dirt, ice and snow from the fins
 Close the cab windows. and the fan wheel of the hydraulic oil cooler.
 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 – re-
fer 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
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OPeration
ASSEMBLING WORKING EQUIP-

MENT – SAFETY INSTRUCTIONS Tools and auxiliaries
Tools, hoists, slings, trestles and other devices
Personel must be in a reliable, safe state.
Assembly work may be carried out only by operat- Metal splinters may cause injury when accessory
ing or maintenance personnel who have the nec- bolts are being driven in or out. A brass or copper
essary know-how at their disposal. mandrel should therefore be used for this purpose,
If such know-how is lacking, meticulous instruction and goggles must be worn.
must be given by experienced personnel, e.g. from Use only the steps, platforms and handrails when
CGM HMS GmbH . climbing onto or off the machine.
The operating manual, and in particular the section Always keep steps and platforms in a non-slip
headed “Fundamental Safety Instructions”, must state. Remove any oil, grease, earth, clay, snow,
have been read and understood. ice and other foreign matter immediately.
Only such persons may start up the machine dur-
ing assembly work in order to adjust the attach-
ments. Securing the working equipment
Incorrect operation of the machine or the attach- Stand working equipment on the ground in such a
ments may give rise to life-threatening situations. way that no movements can be made if mechani-
cal or hydraulic connections become detached.
Secure any equipment or component which is to
Personal protective gear and working be mounted or dismantled, or whose position is to
clothes be changed, with hoists or appropriate sling-
Wear closely fitting working clothing when working ing/supporting devices to prevent them from mov-
on the machine. Loose, wide garments may catch ing, slipping or falling inadvertently.
on machine parts and result in injury.
Wear your personal protective equipment: a safety
helmet, safety goggles, safety footwear and
gloves. Carry out work on the attachment only if the ma-
When carrying out work on the working equipment, chine is secured as described in the “Securing the
f.ex. on the monobloc boom (Fig. 2-117:), use a fall machine” section.
arrester. Falling down from great hight may cause Selecting the attachments
severe injuries. Connect the fall arrester to the
safety line on the boom (arrow, Fig. 2-117:). The machine can be equipped with various at-
tachments. The components of the attachments
are assembled with hydraulic cylinders and con-
nectors. 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

The machine is equipped with an integrated cab-
Fig. 2-117: protection roof (FOPS).
2-83
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Secure the machine as described below:

 before carrying out any fitting and modification
Risk of injury work on the working equipment,
The machine must not be started by unauthorized  before carrying out any servicing and repair
persons. work on the machine.
Therefore, secure the machine.  Park the machine on level and stable ground.
Observe the accident prevention regulations.
 Stand the working equipment on the ground.
Depressurize pipeline systems, on which work is to
be carried out, by appropriate measures.  Switch off the electric motor.
Protective shrouds of moving machine parts may
only be opened or removed when the drive unit is  Depressurize the hydraulic system.
stationary and protected against inadvertent start-
ing.  Withdraw the key from the key-switch.
Before carrying out fitting works, the machine and
the equipment must be protected against inadver-
tent 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 environ-
ment.
All components of CGM HMS GmbH machines
have been carefully purpose-coordinated. Trouble-
free 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 ex-
perts.
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CORROSION PROTECTION FOR Application of GLEITMO 815

PINS AND BEARINGS (BUSHINGS
 Clean off grease, oil, dirt and corrosion protec-
AND HUBS) tion agents from pins and bearings using white
Use GLEITMO 815 anti-corrosive spirit or diesel fuel.
agent only. Rust patches must be thoroughly removed, if
Other agents are not approved by any.
CGM HMS GmbH. All parts must present a dry, bright metal sur-
face.
All pins and bearings (bushings and hubs) of the  Apply a thin layer of GLEITMO 815 on pins
working equipment or in equipment componenents and all bearings using a brush or a spray can.
must be treated GLEITMO 815 anti-corrosive Pin shafts and bearings must be completely
agent before fitting. covered by the protective layer.
GLEITMO 815: If the protective layer of a pin already treated
with GLEITMO 815 is damaged, these areas
 permits easy fitting and dismantling,
must be touched up before fitting the part.
 protects against rust, oxidation and similar
wear,  Fitting and securing of pins
If the pin is too heavy to be fitted manually,
 prevents seizing and fretting corrosion in non- apply GLEITMO 815 at first only on abt. A
moving parts of bearings. quarter of the pin’s length
This is achieved by aluminium and copper particles Then position pin by means of a lifting gear-
forming a protective layer on the metal. This layer ready for fitting.
removes surface irregularities and does not sweat, Apply GLEITMO 815 on the remaining length
seize or harden. of pin shaft, fit pin and secure.
Part number of GLEITMO 815 is 2764305. Avail-
able from CGM HMS GmbH Spare-Parts Service.
2-85
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OPeration
ON-BOARD CRANE (OPTIONAL) On-board crane, monitoring,

The on-board crane is designed for warning and control elements
lifting heavy parts only. (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 per-
mission to operate cranes.
If such know-how or such permission is lacking,
meticulous instruction must be given by experi-
enced personnel, e.g. from CGM HMS.
Incorrect operation of the crane may give rise to
life-threatening situations.
Fig. 2-118:
Pos. Element Function

1 Monitoring Alternator
lamp
2 Warning lamp Engine oil pressure
3 Warning lamp Engine temperature
4 Monitoring Air filter
lamp
5 Key-switch Electrical system
ON/OFF
6 Button Start engine of drive unit
7 Monitoring Preheating system (opti-
lamp on)
8 Knob Engine speed variation
9 Monitoring Crane in operation
lamp
10 Warning lamp Malfunction
11 Button EMERGENCY STOP
12 Button Emergency lowering of
winch
21 Control lever Extending and retracting
of boom extension
22 Control lever Folding the boom
23 Control lever Swinging the boom
24 Control lever Winch up / down
2-86
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On-board crane, putting into op- On-board crane, drive unit

eration The drive unit (Fig. 2-119:) supplies the crane with
hydraulic power. So the on-board crane is func-
Risk of serious injuries due to move- tional without the shovel’s engines running.
ments of the crane.
The drive unit comprises the diesel engine, fuel
Put the crane into operation only after tank, starter batteries and the hydraulic system.
all persons have left the danger area.
The drive unit is equipped with an Emergency OFF
Do not exceed the maximum lifting push switch (arrow, Fig. 2-119:).
capacity (observe the lift capacity In case of emergency push switch, the engine of
chart attached to the boom). 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 Emer-
gency 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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On-Board crane, – blocking the On-board crane, checking

boom in position of rest Extract from the inspection and testing
regulations
Movements and accelerations produced by work-
ing operations of the machine can cause damage The on-board crane is approved in
to the swing drive of the on-board crane, if the accordance with the Accident Preven-
crane is not blocked. tion Regulations for Cranes (BGV D6,
The hydraulic on-board crane must therefore be applicable only in Germany).
blocked in its position of rest.
Risk of serious injuries due to move- The on-board crane must be inspected regularly in
ments of the crane. accordance with the regulations in force in the
country of use.
Put the crane into operation only after
all persons have left the danger area. 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 dis-
To block the boom: cretion.
 Retract the boom completely. The user must ensure, however, that the appointed
person meets the requirements.
 Swing the boom in the direction of the blocking
device (Fig. 2-120:) and lower it. The user is obliged to make available all docu-
ments required for the inspection and to ensure the
 Withdraw the cotter pin at the tip of the boom. smooth running of the inspection. He is further-
 Extend the boom carefully until the tip engages more obliged to provide, if required, crane opera-
the blocking device (arrow, Fig. 2-120:). tors and auxiliary personnel and the required test
loads.
 Reinsert and lock the the cotter pin. 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 per-
formance of further regular inspections.
Fig. 2-120:
2-88
BA 6040(3 847 027.00)-EN
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 mod-
ule, 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 con-
trol 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”).
2-89
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OPeration
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NOTES
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2-91
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2-92
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Inspection and servicing
3 INSPECTION AND SERVICING

+
+
Repair personnel

chines.


+
+
Repair personnel
+
+
Repair personnel
3-1
BA 6040(3 847 027.00)-EN
3-2
BA 6040(3 847 027.00)-EN
SAFETY INSTRUCTIONS FOR

EXCAVATORS WITH ELECTRIC After finishing inspection and maintenance work:
MOTOR
Maintenance and inspection work on electrical In the transformer station
systems may only be performed by qualified elec-  Disconnect the earthing and short-circuiting
tricians or by workshops employing such person- line.
nel.
 Unlock the safety device preventing switch-on;
A qualified electrician for the purpose of this regu- remove the warning sign.
lation is a person who has the corresponding tech-
nical training, know-how and experience as well as  Remove the partitions.
knowledge of the pertinent prescriptions and who
is therefore in a position to judge the work en-  Switch on the supply voltage.
trusted to him and the potential dangers in connec-
tion therewith.
Before carrying out any maintenance and inspec-
tion work on the electrical system, the following
On the hydraulic excavator
precautions must be taken:  Unlock the safety device preventing switch-on;
remove the warning sign.
In the transformer station  Switch on the circuit breaker,

(see the “ Switching on the circuit breaker “
 Cut out the supply voltage. chapter in part 2 of the present Operation and
 Secure against switching on; apply a warning Maintenance Manual).
sign.
 Check that the electrical system is off circuit.
 Connect to earth and short-circuit. On the hydraulic excavator
 Protect adjacent and live parts against acci-  Disconnect the earthing and short-circuiting
dental contact. 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 manufac-
turers Operating Instructions).
3-3
BA 6040(3 847 027.00)-EN
INSPECTION AND SERVICING – Securing the machine

SAFETY INSTRUCTIONS Carry out servicing work only if the machine is
secured as described in the section “Securing the
Operating manual machine”.
No inspection and servicing work must be carried
out until the operating manual has been read and
understood.
Climbing onto and off the machine
Use only the ladders, steps, platforms and hand-
Pay special attention to:
rails provided when climbing onto or off the ma-
Fundamental safety instructions” and all warnings chine.
and safety instructions attached to the machine.
Always keep ladders, steps, platforms and hand-
The operating manual lists all jobs to be done. The rails in a non-slip, safe state and remove any oil,
descriptions of job sequences, however, provide grease, soil, clay, snow, ice and other foreign mat-
only experienced personnel with the necessary ter immediately.
instructions.
Always face the machine when climbing on and
The Operation and Maintenance Manual must be off.
kept with the machine at all times.
Checking the state of tools

Use only fully functional, reliable tools.
Inspection and servicing personnel must have the
Select the right tool for the job.
necessary know-how on the inspection and servic-
ing of this or comparable machines. Wrenches of the wrong size, for example, may slip
and cause injury.
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
Cleaning jobs
GmbH training course.
Prior to commencing work, clean your working
area, if necessary and possible, with a stream jet
Personal protective equipment and (rubber parts and electric components with com-
working clothing pressed air – refer to information label).
Wear closely fitting working clothing when working Use only lint-free cleaning rags when working on
on the machine. Loose, wide garments may catch the hydraulic system.
on machine parts and result in injury. Cleaning agents and solvents may give off harm-
Wear a safety helmet, safety footwear, gloves and, ful, readily flammable vapours. Never work with
in the event of high noise levels, ear protectors. such agents except on well ventilated premises;
never inhale the vapours and never smoke.
Prevent solvents and cleaning agents from coming
Securing the working equipment into contact with your skin.
Stand working equipment on the ground in such a Wear gloves.
way that no movements can be made if mechani-
Observe the instructions on the packaging.
cal 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
BA 6040(3 847 027.00)-EN
Handling flammable liquids Visisble oil losses

When handling flammable liquids: Have any visible leakage repaired immediately.
 never smoke, Escaping oil is an environmental hazard.
 keep away from unshielded light sources and Soak up any oil that has escaped with a binding
naked flames, agent.
Sweep up binding agent and dispose of it sepa-
Consumables often have low flash points and are
rately from other waste.
readily ignited. Never attempt to extinguish burning
liquids with water.
Use: Relieving residual pressure in the hy-
 dry powder, draulic system
 carbon dioxide or Only unpressurized hydraulic systems may be
opened. Even when a machine is parked on a
 foam extinguishers. horizontal surface with ist attachments supported
Water used for extinguishing purposes would va- on the ground and its electric motor switched off,
pourize instantaneously on contact with burning there may still be substantial residual pressure in
substances and spread burning oil, for example, parts of the hydraulic system, e.g. primary pres-
over a wide area. Water generates short circuits in sure from the last hydraulic movements prior to
the electrical system, possibly producing hazards. stopping the machine.
Notify the fire brigade. Residual pressure is reduced only gradually. If an
intervention into the hydraulic system is to be un-
dertaken
Fastening and securing elements immediately after stopping, the system must be
Check fastening and securing elements, e.g. bolts, depressurzized:
nuts, washers, before using them again. (do not leave the operator’s seat)
Replace any damaged parts.  Stand working equipment on the
ground,
Spare parts  Switch off the electric motor,

Use only the original sparts parts of CGM HMS
 Move all control levers and pedals repeatedly
GmbH .
into all ndirections.
They are the only ones to fulfill the technical speci-
fications of the machine.
Screwed connections, piping, hydraulic
hoses
Handling oils and greases Repair any leakage in the piping and hose system
Hot lubricant or hydraulic oil emerging uncontrolled immediately.
from the system may result in severe burns. A fine, highly pressurized jet of hydraulic oil can
Never set foot withing reach of the emerging oil jet. penetrate the skin.
Avoid contact with the skin. Wear gloves and firm Never search for leakages with the fingers, but use
protective clothing. 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
Clean soiled skin thoroughly with warm soapy wa- immediately.
ter and apply a barrier cream. Never use fuels or Never repair damaged piping; always replace
solvents for cleaning the skin. them.
If you have swallowed any oil, avoid vomiting but Replace hydraulic hoses immediately on detecting
consult a doctor immediately. any damage or moist areas.
Tighten leaking screw plugs only when the system
is depressurized.
Escaping oil is an environmental hazard.
3-5
BA 6040(3 847 027.00)-EN
Non-polluting disposal Handling batteries

Dispose of oils, greases, cooling liquids, deter- California Proposition 65 Warning
gents, solvents and oil-containing components, Battery Posts, terminals and related accessories
such as filters, cleaning rags, replaced wearing contain lead and lead compounds, and handling
parts and unusable machine parts, without pollut- batteries may also exposure you to sulfuric acid
ing the environment and separately from other mist, chemicals known to the state of California to
waste. cause cancer and reproductive harm. Wash hands
after handling.
Do not dispose of these substances together with
household wastes. Batteries give off explosive gases.
Fill these substances into the containers provided Never handle batteries close to naked flames and
for such purposes. unshielded light sources, never smoke.
Like any other oil, also bio-degradable, “environ- Battery acid is toxic and corrosive.
mental-friendly” hydraulic oil must be disposed of
separately. Avoid any contact with the skin, mouth, eyes and
clothing. Avoid spilling battery acid or inhaling the
Do not allow oils and oily wastes to penetrate into vapours.
the soil or into water. They are an environmental
hazard Wear gloves, firm protective clothing and goggles
when handling batteries.
Seals If the skin is splashed with acid, rinse thoroughly

with running water and consult a doctor.
Individual spares may contain asbestos. Such
If the eyes are splashed with acid, rinse thor-
spares or their packaging are marked with: oughly with running water and consult a doctor
Never process spares containing asbestos me- immediately.
chanically. Inhaling asbestos dust is a health haz- Never set tools down on the battery. They may
ard. induce a short circuit, causing irreparable damage
Clean sealing faces prior to assembly. to the battery and injuring persons.
Never wear metal necklaces, bracelets or watch-
straps 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 sys-

tem
Before performing work on the electrical system
where tools, spare parts, etc. can come into con-
tact 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
BA 6040(3 847 027.00)-EN
Selecting oils and greases Oil-level check and oil change

Use the recommended qualities only, matching Position the machine horizontally.
viscosities with the temperature level.
Change the oil when the machine is at operating
temperature. Warm oil flows better and carries
suspended particles (carbon or abraded matter)
Filters better.
Replace / clean all filter elements or filter car-
tridges within the specified periods.
Lubricating
All filters are coordinated carefully with the equip-
ment. Original CGM HMS GmbH parts must be Clean the lubricating nipple, then lubricate as
used to ensure smooth running and a long ser- scheduled.
vice life of the engine and the hydraulic units.
After servicing
Sealing elements
To prevent corrosion, coat all bright metal parts
When dismantling parts, watch for sealing ele- with a grease film.
ments.
On completing work, re-install all protective de-
Check sealing elements prior to installation and vices.
replace any that are even slightly damaged.
Never switch on the electric motor while work is
When assembling, ensure a perfect fit. being done on the machine.
Carry out performance tests with the machine.
3-7
BA 6040(3 847 027.00)-EN
FIRE AND EXPLOSION HAZARD

Safety Instructions
Avoid smoking and open fire on, next to and be-
low the machine.
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.
fire.
 combustible substances such as coal dust or
tar are present.
combustible or easily flammable liquids have spil-
led from the excavator onto the ground.
Flying sparks may cause fire on the ground that
can spread to the excavator.
3-8
BA 6040(3 847 027.00)-EN
INSPECTION AND SERVICING Oils / Greases

PLANS – INSTRUCTIONS For the specification of oils and greases to be used
refer to the “Lubricants” section.
Servicing Intervals The numerals mentioned in the “Oil / Grease” col-
The inspection and Servicing plan lists all jobs umn in the inspection and sServicing plans have
which have to be done on the machine at regular the following meaning:
intervals. I Oils for combustion engines and
The individual inspection and Servicing plans are compressors
marked with letters providing a link between the II Oils for hydraulic systems
operating hours (OH) recorded by the hours-run IIIa, b, c Oils for gearboxes
meter of the machine and the inspection and sSer- V Greases for bearings and swing
vicing plans. rings
Plan Do all jobs ….

V …once prior to initial commissioning.
Cleaning jobs
N …after initial commissioning and du- Cleaning jobs, especially on cooling systems, must
ring the running-in period be done at shorter intervals if the machine is ex-
(after 100 OH). posed to severe dust build-up.
T …every 10 OH or every working shift
1)
W …every 60 OH or weekly . 2 Components

B …after every 500 OH. The maintenance intervals for components, e.g.
C …after every 1000 OH. electric motor and gearboxes, are listed in the fol-
D …after every 5000 OH. lowing CGM HMS GmbH maintenance schedules.
E …after every 10000 OH. It is possible that the manufacturer’s documenta-
OH = Bh = Operating hours tion for these components states intervals deviat-
ing from the above-mentioned intervals.
In such case, only the maintenance intervals speci-
fied by CGM HMS GmbH shall apply.
2
Whichever comes first.
3-9
BA 6040(3 847 027.00)-EN
3-10
BA 6040(3 847 027.00)-EN
Plan V
Plan V – Once prior to initial commissioning
Page 1 of 2
Location Servicing work Quantity/
No.
Electric motor Lubricate bearings (Follow instructions on the 2
information signs / plates on the motor)
Check direction of rotation (see electric motor
manufacturer´s servicing instructions)
Electrical system
Battery Check liquid level (not on sealed batteries) 2
Lighting Check operation
Terminals Check for tightness
Slip ring assembly Visual inspection 1
Switchgear cabinets Check for condensation/drain off water
Monitoring, warning and control elements Check function of monitoring, warning and
control elements
Check emergency OFF function 3
BCS Check function 1
Slewing system (SIL2 machines only) Perform „Slew brake test“
(see chapter „Service – Slew Brake Test
Screen“)
Hydraulic system Check function of working and travelling mo-
vement
Check pressure (see Service Manual)
Hydraulic oil reservoir Check oil level 1
Hydraulic cylinders Vent (see chapter “Venting hydraulic system“)
Pump drive gearbox and cooling circuit Check oil level
- Expansion reservoir Check oil level
Swing gearbox (PN 3692960) Check oil level 3
Swing gearbox (PN 3676892)
- Expansion reservoirs Check oil level 6
Travel gearbox Check oil level 2
- Pre-chamber / Spur gear section Check oil level 2x1
- Brake-chambers Check oil level 2x2
Swing ring
Internal gearing Check grease filling 1
Undercarriage
Track roller Check for leaks and free movement 2x7
Support roller Check for leaks and free movement 2x2
Track Check pressure (see Service Manual) 2
Idler Check for leaks and free movement 2
3-11
BA 6040(3 847 027.00)-EN
Plan V – Once prior to initial commissioning

Page 2 of 2
No.
Central lubricating system
- Grease container Check filling level
- Greasing and pause cycles Check setting
Service – Station (tanklift) Check operation
Air conditioner (optional)
- Compressor Check oil level
Hydraulic ladder
- Central lubricating point Lubricate
On-board crane (optional)
- Fastening bolts Check tightness (see “On-Board Crane“ Op- 16
eration and Maintenance Manual)
- Bearings Lubricate 4
- Joint (column / boom) Lubricate 2
- Cylinder bearing Lubricate 5
- Swing ring Grease 1
(see “On-Board Crane“ Operation and Main-
tenance Manual)
Crane drive engine Check oil level 1
(see “Crane drive Engine“ Operation and
Maintenance Manual)
- Battery Check liquid level 2
Escape ladder Check function
- Locking device Check function
- Ladder Check free movement
Harness (optional) Check completeness and condition
- Harness holding device on cab roof Check for tightness
All lines, fittings and connections Inspect visually for leaks, wearing marks
All articutated joints and hinges Lubricate
3-12
BA 6040(3 847 027.00)-EN
Plan N
Plan N – After initial commissioning and during the running-in period (after 100 OH)
Page 1 of 2
No.
Electrical system
Medium-voltage cells
- mechanical connections Check for tightness
- lines Check for tightness
- terminals and plug connections Check for tightness
Hydraulic system
Oil cooler
- Bearing
- Fastening bolts Check for tightness (for tightening torques see
Service Manual)
Return-flow filter Replace 2x7
Magnetic rod Clean 1
Pressure accumulator – emergency lowering Check function 1
Pressure accumulator – hydraulic ladder Check function 1
Pressure accumulator – track tension system Check function 2
Pump drive gearbox and cooling circuit Change oil 13
- Pre-chambers, expansion reservoir Check oil level 1
- Gearbox oil filter (cooling circuit) Replace 1
Service Manual)
Swing gearbox (PN 3692960) Change oil 33
Service Manual)
Swing gearbox (PN 3676892) Change oil 33
- Brake chambers Change oil 33
Service Manual)
Travel gearbox Change oil 23
- Pre-chamber / Spur gear section Change oil 2x13
- Hydraulic motor chambers Change oil 2x23
- Magnetic plugs Clean
Service Manual)
Swing ring
Fastening bolts (swing ring, undercarriage Check for tightness (for tightening torques see
and superstructure) Service Manual)
3
see “Refilling quantities – Oil“ table
3-13
BA 6040(3 847 027.00)-EN
Plan N – After initial commissioning and during the running-in period (after 100 OH)
Page 2 of 2
No.
Cable guide for power supply cable
- Fastening bolts cable guide / machine Check for tightness (for tightening torques see
Service Manual)
Cable reel (optional)
- Fastening bolts at
reel, cable guide, drive motor, switchgear Check for tightness (for tightening torques see
cabinet Service Manual)
- Fastening bolts cable reel / undercarriage Check for tightness (for tightening torques see
Service Manual)
Undercarriage
Fastening bolts Check for tightness (see Service Manual for
- carbody – trackframe, tightening torques)
- bottom rollers – trackframe,
- top rollers – trackframe
Superstructure
Fastening bolts, especially at superstructure / Check for tightness (for tightening torques see
pedestal / operator´s cab Service Manual)
All lines, fittings and connections Inspect visually for leaks, wearing marks
3-14
BA 6040(3 847 027.00)-EN
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 Quantity/ Plan Plan
No. T W
Electric motor Listen for unusual machine noise 1 
- Cooling fins Clean  
Electrical system
Lighting Check operation  
Switchgear cabinets Check for condensation/drain water  
- Electrical components Visual check 
Switchgear cabinets
- Breather filters
- Dust traps Remove dust 3 
- EMERGENCY OFF switches Check function 3 
Button „Servicing works“ Check function 1 
Monitoring, warning and control Check function of monitoring, warning  
elements and control elements
BCS Check function 1  
Hydraulic system Check function of working and travel-  
ling movement
Inspect visually for leaks 
Hydraulic oil reservoir Check oil level 1  
Oil cooler Check / clean 2 
Fan wheel Check condition 2  
Pump drive gearbox and cooling Check oil level 1 
circuit
- Pre chamber expansion reservoir Check oil level 1  
Check for unusual noises or smells, 1 
higher teperatures or vibrations. If in
doubt, contact your Caterpillar dealer.
- Gearbox housing Check for excessive dirt and dust, cle- 1 
an to prevent overheating.
- Oil filter (tell-tale) Check 1 
Swing gearbox (PN 3692969) Check oil level 3  
Swing gearbox (PN 3676892)
- Expansion reservoirs Check oil level 6  
Reservoir for used grease at the Check, depollute used grease 2x1 
A-frame
Travel gearbox Check for leaks 2  
Escape ladder
- Locking Check function  
- Ladder Check free movement  
Emergency escape device / seat Visual condition check  
- Holding device Check tightness and fixation on cab  
- Harness Connect to the holding device  
3-15
BA 6040(3 847 027.00)-EN
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 Quantity/ Plan Plan
No. T W
Undercarriage
Tracks Inspect track tension visually 2  
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, re- 2x1  
move all accumulated debris, rocks,
soil and so on.
Central lubricating system
Grease container Check filling level 1  
Lubricating points Check visually  
Air conditioner (optional) Carry out all service work described in 1  
the “Air Conditioning manual“
On-board crane (optional) 4
Fastening bolts Check tightness (see “On-Board Cra- 16  
ne“ Operation and Maintenance Man-
ual)
Crane drive engine Check oil level 1
(see “Crane drive Engine“ Operation
and Maintenance Manual)
- Reflow filter (contamination indi- Check 1
cator)
Fire extinguisher Check condition 4  
Automatic fire-extinguishing sys- Check control module 1  
tem (optional)
All lines, fittings and connections Inspect visually for leaks, wearing  
marks
Hydraulic shovel Overall cleaning 
Cable reel (optional) Visual inspection  
- Fastening bolts at reel, cable Check tightness (see Service Manual)  
guide, drive motor, switchg. cabinet
- Fastening bolts cable reel / under- Check for tightness (see Service Man-  
carriage 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
BA 6040(3 847 027.00)-EN
Plan A – E
Plan A - after every 250 OH Plan B - after every 500 OH

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH
(at 10000, 20000, 30000, ... OH)
Page 1 of 6
Location Servicing work Menge / Plan Plan Plan Plan Plan
No. A B C D E
Servicing in acc.     
with W or T
Monitoring, warning and
control elements
- Joysticks
5
- Control spool, Lubricate lightly 2x4   
plate, cardan joint
- Pedals
- Control spool Lubricate lightly 3x25   
(machine with loading
shovel)
Electric motor Lubricate bearings 2
(Follow instructions on the
information signs / plates on
the motor as well as the motor
manufacturer’s maintenance
instructions)
See Electric motor manufac- Check for vibration    
turer´s maintenance instruc-
tions for further details
Visual inspect interior of ma-   
chine for degree of dirt depos-
its
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 de-   
posits
Coupling Check for alignment and re-
cord measurements 6
Screwed / bolted connections Check condition and tightness  
Operator’s cab
- Fastening bolts to cab mo- Check for tightness (see Ser-   
dule vice Manual for tightening
torques)
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
BA 6040(3 847 027.00)-EN

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
(at 10000, 20000, 30000, ... OH)
Page 2 of 6
No. A B C D E
Electrical system
Battery cable connections Check for tightness    
Battery Check fluid level (not on sea- 2    
led batteries)
Switchgear cabinets
- Filter mats Visual inspection    
- Medium-voltage cells Clean/dry    
- Electrical components Check for tightness    
Slip ring assembly Visual inspection, if necces-     
sary clean inside from wear
debris and grease.
(See Slip ring manufacturer´s    
servicing instructions)
- Brushes Check for wear  
Replace if worn out up to max. 
1/3 of the original length
Mechanical components Check for tightness    
Switchgear cabinets
- Breather filter element Clean    
Replace   
Cable reel (optional) Visual inspection     
Contact rings and brushes of Check for wear, replace if   
slipring assy. excessive worn
Brushes of slipring assy. Replace  
Position switches Check adjustment   
- Driving chain pos. switches Check for contamination,   
clean and regrease if necces-
sary
Drive motor Check condition   
Check brake function   
- Drive motor gearbox Change oil 
Driving chain reel Check condition and tension,   
replace if damaged
All bolted connections Check, re-tighten with torque  
wrench
(see also the Technical man-
ual of the supplier)
3-18
BA 6040(3 847 027.00)-EN
Plan A – after every 250 OH Plan B – after every 500 OH

(at 250, 750, 1250 … OH) (at 500, 1500, 2500 … OH)
Plan C – after every 1000 OH Plan D – after every 5000 OH
(at 1000, 2000, 3000, 4000 … OH) (at 5000, 15000, 25000 … OH)
Plan E – after every 10000 OH
(at 10000, 20000, 30000, … OH)
Page 3 of 6
No. A B C D E
Hydraulic system Check pressure (see Service   
Manual)
Oil cooler
- Bearing
- Fastening bolts Check for tightness   
- Rubber bearing Check condition   
Return-flow filter Replace 2x7   
- O-Ring of filter chamber Replace 2x1   
cover
- Magnetic rod Check / clean 2    
Bypass valve (working circuit) Check / clean filter sieve 4   
Filterhousing (cooling circuit)
- Return-flow filter Replace 2    
- Bypass valve Check filter sieve / clean 2   
- Magnetic rod Check / clean 1    
High-pressure filter Replace 4  
Filter (pump control circuit) Replace 2x1  
Filter (servo circuit) Replace 1  
Filter (swing charge pump) Replace 2x2  
Hydraulic oil reservoir Carry out oil analysis 1    
Change oil 178 
- Breather filter Replace 2   
Pressure accumulators Check pressure (see Service 3   
Manual)
Cylinder (seals and guide Replace 
rings)
7
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

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
(at 10000, 20000, 30000, ... OH)
Page 4 of 6
Location Servicing work Quant./ Plan Plan Plan Plan Plan
No. A B C D E
Pump drive gearbox and coo- Carry out oil analysis 1    
ling circuit
Change oil 19   
- pre-chamber expansion reser- Check oil level 1   
voir
- Breather filter Clean / Replace 2   
Gearbox oil filter (cooling circuit) Replace 1  
Swing gearbox Carry out oil analysis 3    

Change oil 39   
- Breather filter Replace 3   
- Brake chamber Change oil 39   
(Gearbox PN 3676892 only)
Travel gearbox Carry out oil analysis 2    
Check oil level 2    
Change oil 29  
- Magnetic plug Clean 2x6   
Pre-chamber / Spur gear section Check oil level 2x1    
Change oil 2x19  
- Magnetic plug Clean 2x1   
Hydraulic motor chambers Check oil level 2x2    
Change oil 2x29  
Breather filter Clean / replace 2x3   
9
3-20
BA 6040(3 847 027.00)-EN
Plan A – after every 250 OH Plan B – after every 500 OH

(at 250, 750, 1250 … OH) (at 500, 1500, 2500 … OH)
Plan C – after every 1000 OH Plan D – after every 5000 OH
(at 1000, 2000, 3000, 4000 … OH) (at 5000, 15000, 25000 … OH)
Plan E – after every 10000 OH
(at 10000, 20000, 30000, … OH)
Page 5 of 6
No. A B C D E
Swing ring Check grease filling 1    
Gearing / pinion Check condition    
Fastening bolts (swing ring, Check for tightness (see Ser-  
undercarriage and super- vice Manual)
structure)
Undercarriage Check wear (see Service   
Manual)
Diaphragm accumulator Check pressure (see Service 2   
Manual)
- Diaphragm Replace 2x1  
Central lubricating system Check function    
Oilfilter (hydraulic circuit grea- Replace 1  
se pump)
Grease filter (filling grease Replace 1  
container)
Grease filter (grease lines) Replace 2  
Breather filter Check / replace 1   
Air conditioner (optional) Carry out all service work     
described in the “Air Condi-
tioning manual"
- Filter mats Clean / replace if damaged   
Hydraulic ladder
- central greasing point Lubricate 1
  
3-21
BA 6040(3 847 027.00)-EN

(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
(at 10000, 20000, 30000, ... OH)
Page 6 of 6
No. A B C D E
On-board crane (Option) 10
- Bearing Lubricate 4
- Joint (column / boom) Lubricate 2
– Cylinder bearing Lubricate 5
– Swing ring Grease 1
Hydraulic system Change oil 1 11
– Return-flow filter Replace 1
– Breather filter Replace 1
see “On-Board Crane“ Opera-     
tion and Maintenance Manual
Crane drive engine Clean 1
Change oil 1 11
- Oil filter Replace 1
– Fastening bolts Check for tightness 1
– Fuel filter Replace 1
– Air filter Replace 1
– Battery cable connection Check for tightness 2
see “Crane Drive Engine“     
Operation and Maintenance
Manual
Steel components 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 pene-
trant, magnetic powder or
ultrasonic test.
Modules Check for tightness (see Ser-   
– Fastening bolts vice Manual)
All articulated joints and Lubricate   
hinges
10
Do all servicing jobs at least once a year and when necessary
11
12
„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
3-23
BA 6040(3 847 027.00)-EN
LUBRICATING CHART – GREASE
Fig. 3-1:
3-24
BA 6040(3 847 027.00)-EN
Lubricating chart – Grease (legend)
No. Greasing point Number Lubricant Grease every

properties .... operating hours
1 Central lubricating system – grease container 1 V 13 10
2 Hydraulic ladder, central greasing point 1 1000
3 Electric motor, bearings 2x1 See plate with lubri-
cating instructions
V 13 attached to the elec-
tric motor for detailed
information.
5 On-board crane V 13 250
- Bearing 4 250
- Joint (column / boom) 2 250
- Cylinder bearing 5 250
- Swing ring 1 Graphitespray 250
6 Monitoring, warning and control elements
14
- Joystick 2x4 V 13 1000
14
- Pedal 3x2 1000
All other greasing points are supplied with grease by the central lubricating system.
Filling quantities – Grease

Greasing point Lubricant Filling quant. in
properties kg lb
Central lubricating system – grease container appr. 180 to appr. 47.5 to
(Depending on the ordered system the volume may vary) 1000 litres 264 gal
Internal gearing – Roller-bearing swing ring V 13 appr. 300 appr. 661
Idler (permanent grease filling) 2 x appr. 25 2 x appr. 55
Track rollers (permanent grease filling) Tribol 14 x appr. 15 14 x appr. 33
(optional: rollers supported with grease via the cen- CGM HMS GMBH
tral lubrication system for the undercarriage) part no. 2764564
Support rollers (permanent grease filling) 4 x appr. 14 4 x appr. 31
13
see "LUBRICANTS" section
14
apply a thin layer of low temperature grease
3-25
BA 6040(3 847 027.00)-EN
INSPECTION PLAN - OIL
Fig. 3-2:
3-26
BA 6040(3 847 027.00)-EN
Inspection plan – Oil (legend)
No. Location Number Lubricant Check oil level Change oil

properties 15 every ... OH every ... OH
1 Hydraulic system 1 10 10000 16
II
2 Pump drive gearbox and cooling 1 60 1000
2
circuit
Pre-chamber expansion reser- 1
III.a 10 1000
voir
3 Swing gearbox 3 10 1000
(Gearbox PN 3692960)
III.b
3 Swing gearbox
(Gearbox PN 3676892)
- Expansion reservoir 3x2 10 1000
III.b
- Expansion reservoir brake 3x2 10 1000
chamber
4, 6 Travel gearbox 2 500 5000
- Pre-chamber / spur gear sec- 2x1 500 5000
tion
III.a
- Brake-chambers 2x2 500 5000
5 On-board crane (optional)
- Crane drive engine 1 10 250 17
I
- Hydraulic oil reservoir 1 10 1000 18
II
15
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
Filling quantities - oil
Location Filling quantity Oil

litres gal
Hydraulic oil reservoir appr. 4000 appr. 1057
Hydraulic system appr. 6400 appr. 1690.7 II
Pump drive gearbox appr. 149 appr. 39.4
- Pre-chamber expansion reservoir 1 x appr. 10 1 x appr. 2.6 III.a
Swing gearbox (Gearbox PN 3692960) 3 x appr. 38 3 x appr. 10
III.b
Swing gearbox (Gearbox PN 3676892) 3 x appr. 26 3 x appr. 6.9
- Brake chambers 3 x appr. 6 3 x appr. 1.6
III.b
Travel gearbox 2 x appr. 80 2 x appr. 21.1
- Pre-chamber / Spur gear section 2 x appr. 10 2 x appr. 2.6 III.a
- Hydraulic motor chambers 4 x appr. 0,3 4 x appr. 0.08
On-board crane (optional)
- Crane drive engine appr. 5.5 appr. 1.45
I
- Hydraulic oil reservoir appr. 50 appr. 13.2
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
LUBRICANTS Avoid mixing of different hydrau-

Notes on the selection of oils and lic fluids
The machine has been run in at the factory with
greases BM Long Term Hydraulic Fluid HSS (Part-No.
2482971). CGM HMS GmbH recommends using
this high-grade hydraulic fluid also in operation as
Original CGM HMS GmbH oils and
it has been made especially for use in these ma-
greases chines to which it is also perfectly adapted.
Besides regular and careful maintenance, the If oil analyses are performed regularly and with
quality of the oils and greases used in the machine positive results, the BM Long Term Hydraulic Fluid
has a decisive influence on high performance, can remain in the machine for up to 10 000 operat-
reliability and long service life of a machine and of ing hours.
its units and assemblies.
If an alternative hydraulic fluid is to be used, it
The lubricants tables in the CGM HMS GmbH must fulfil the same specifications. Please note
Operation and Maintenance Manual contain speci- that the change interval for alternative fluids is
fications for the oils and greases that are approved fixed at 5 000 operating hours.
for use in CGM HMS GmbH machines. These oils
and greases are especially adapted to CGM HMS There is an increased risk of damage to hydraulic
GmbH machines and their units and assemblies. components, if different hydraulic fluids are mixed
during topping up as well as when changing over
Other oils and greases which do not fulfil the re- to a fluid of a different type or from another manu-
quirements of the specifications can be the cause facturer.
of premature wear or of damage to and failures of
machine units and assemblies. For topping up, it is therefore necessary to use only
same hydraulic fluid as the one that is already in
For this reason, CGM HMS GmbH only approves the hydraulic system.
the use of the specified oils and greases.
When changing over to an alternative hydraulic
All other qualities are not approved. fluid, please observe that there is always a small
amount of old fluid remaining in the hydraulic sys-
tem even after the system has been emptied. The
Alternative oils and greases mixing of this residual amount of old fluid with the
The oils and greases filled into the machine must new alternative fluid reduces the properties of the
meet at least the specifications mentioned in the fluid dramatically and can cause damage to com-
lubricants tables of the CGM HMS GmbH Operati- ponents of the hydraulic system in operation.
on and Maintenance Manual. To avoid this result, the change-over to the alterna-
In the event of damage to the machine or to its tive fluid must be performed in strict compliance
units and assemblies caused by the use of alterna- with the manufacturer's prescriptions. The manu-
tive oils and greases that are not compatible with facturer must confirm that his hydraulic fluid is
CGM HMS GmbH specifications, CGM HMS compatible with the BM Long Term Hydraulic Fluid.
GmbH does not assume any responsibility and The remaining amount of old fluid must not exceed
does not accept any warranty claims. 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 speci-
fication or with mixed fluids.
3-29
BA 6040(3 847 027.00)-EN
LUBRICANTS / CONSUMABLES
I. Oil for combustion engines (On-Board Crane, option)
Fig. 3-3:
3-30
BA 6040(3 847 027.00)-EN
II. Oil for hydraulic system (selection)
Fig. 3-4:
3-31
BA 6040(3 847 027.00)-EN
III.a Oil for pump gearboxes and travel gearboxes
Fig. 3-5:
3-32
BA 6040(3 847 027.00)-EN
III.b Oil for swing gearboxes
Fig. 3-6:
3-33
BA 6040(3 847 027.00)-EN
V. Grease for bearings, swing rings and track system (Central lubri-
cation system)
Fig. 3-7:
3-34
BA 6040(3 847 027.00)-EN
Greases for idlers, track rollers and support rollers (Lifetime lubrication)
Fig. 3-8:
3-35
BA 6040(3 847 027.00)-EN
The the swing gearboxes are equipped with auto-

SERVICING WORK matic drain valves (1, Fig. 3-10:)
Hose line for oil changes These automatic drain valves permit oil changes
without polluting the environment.
Collect escaping oil and cooling liq-
uid and discard without polluting the
environment.
Carry out oil changes when the ma-

chine 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 con-
nected to the express coupling on the service sta-
tion and to the service vehicle at the other end. Fig. 3-10:
The filling operations require an overpressure,
whereas the draining operations require low pres- Change oil as follows:
sure.  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 quanti-
ties - 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
ELECTRIC MOTOR Electric motor, cleaning

Electric motor - Safety instruc- When cleaning with compressed air
deposited dust and loose parts can
tions be whirled up and may cause inju-
Read and observe: "Inspection and ries.
Servicing – Safety Instructions" and Always wear your personal protec-
the electric motor Operation and tion equipment like protective suit,
Maintenance Manual. goggles, respiratory protection, glo-
ves etc.
Secure the machine as described in the "Securing Use a vacuum cleaner to extract dust.
the machine" section.
Wear protective gloves and firm working clothing. Clean the electric motor, the cooling fins, bearing
 Switch off electric motor, to do so actuate shields and ventilators from dust with compressed
switch (42, Fig. 3-11:). air, brushes and clothes only.
 Set servicing switch (4, Fig. 3-12:) to locked Remove the fan guard before cleaning the ventila-
position and secure in this position with a pad- tor fan. Install it after cleaning.
lock. Don't damage the protective coating while cleaning
the electric-motor.
For more information see the manufacturers man-
ual for the electric motor.
It is not permissible to clean the elec-
tric motor or any live excavator com-
ponents with a steam cleaner and
steam jet.
 After finishing work on the electric motor re-

move 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
Electric motor, greasing

Grease chambers at the bearings of the electric
Read and observe: "Inspection and motor can carry only a limited amount of used
Servicing – Safety Instructions" and grease.
the electric motor Operation and
Maintenance Manual. Check grease chambers before pressing in fresh
grease and remove used grease if necessary.
Secure the machine as described in
Grease the bearings of the electric motor in regular
the "Securing the machine" section. intervals (see plate on the electric motor for more
Wear protective gloves and firm detailed instruction about greasing procedure).
working clothing.  Press in grease into the grease nipples located
During greasing the electric motor at the end shields at the electric motor. The
must be switched on. Be extremely grease nipples are located at the motor hous-
careful to rotating parts. ing 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
ELECTRICAL SYSTEM Risk of injury caused by battery acid and gases.

Electrical system - Safety instruc- Wear goggles, working gloves and firm working
tions clothing.
Read and observe the "Inspection Carry out voltage and continuity checks only by
and servicing – Safety instructions" means of a test lamp or a measuring instrument.
chapter. 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 The electrical circuit diagrams are annexed to the
circuit breaker before start working on spare-parts list. Further information can be found
the electrical system. All electric lines in the CGM HMS GmbH Service Manual "Working
with circuit diagrams".
upwards from the circuit breaker are
then without voltage (refer to the Cables and cable lugs must not get in contact with
"Safety instructions for excavators other metal parts. Replace broken or damaged
with electric motor" at the beginning cables and the respective cable lugs.
of this chapter). If a bulb does not work after replacement, the per-
Before starting live-line servicing taining fuses, connection cables and contacts must
work e.g. measuring and testing with be checked.
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 excava-
tor. Fig. 3-13:
Gas-discharge lamps in Xenon work-

ing lights are operated with high volt-
age.
3-39
BA 6040(3 847 027.00)-EN
Battery, checking state of charge Checking charge of the battery

The acid temperature must be 20 ° C / 68°F.
Warning! Battery Posts, terminals and
 Unscrew caps of the battery (Fig. 3-14:).
related accessories contain lead and
lead compounds, chemicals known to  Measure the acid density of the battery using a
cause cancer and reproductive harm. commercial acid tester (Fig. 3-14:).
Risk of injury caused by battery acid The acid density measured is in direct correla-
and gases. tion with the battery charge.
Wear goggles, working gloves and Acid density
firm working clothing. kg / dm3 Charge
Do not eat, drink or smoke when han- Normal Tropical
dling batteries. conditi- conditi-
on ons
Wash hands after handling. 1,28 1,23 fully charged
Read and observe the "Inspection and 1,20 1,12 half charged, recharge
servicing – Safety instructions" chap- 1,12 1,08 discharged, recharge
ter. immediately
On closed / sealed (so called „maintenance-free“)

Checking the battery fluid level batteries, the charging status can be checked us-
(Not applicable in case of maintenance-free batter- ing a charge meter. Ask your Caterpillar dealer for
ies) assistance.
 Unscrew caps (Fig. 3-14:).
 If checking inserts are provided, the battery Charging the batteries

acid must reach up to their bottom. The batteries are charged by the battery charger
only if the electrical system with the circuit breaker
 If no checking inserts are provided, insert a
is switched on.
clean wooden rod into the battery until it con-
tacts the upper edge of the cell plates. The rod The battery main switch must be in position I
must be moistened over at least 10 mm / 0.4". "ON".
 If the fluid level is too low, top up with distilled

water only
Fig. 3-14:
3-40
BA 6040(3 847 027.00)-EN
Removing and installing the battery The batteries (1, Fig. 3-15:) are located in the ped-
estal (cab module). The 12-volt batteries are con-
Read and observe the "Inspection and nected in series and in parallel, so that the system
servicing – Safety instructions" chap- voltage is 24 volts.
ter.
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 with-
draw.
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
Electrical system, control cabi-

nets
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 desig-
nation of the electrical components.
Breather filter
In the control cabinets
 For the 6600 V / 7200 V power supply,
 For the 400 V system, Fig. 3-16:
 For the 24 V system,
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. Fig. 3-17:
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
BA 6040(3 847 027.00)-EN
Checking and cleaning the filter ele-

ment
 Check the filter paper of the element by insert-
ing a lamp into the element (Fig. 3-18:). Any
damage can then be seen.
Replace damaged or distorted ele-

ment immediately.
 Check element seal. If damaged, replace filter

element too.
Cleaning with compressed air allows the filter ele-

ment to be re-used immediately.
Fig. 3-18:
 Blow filter element (Fig. 3-19:) dry with com-
pressed air by moving the compressed-air pis-
ton 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.
Never clean filter element by beating

it against hard objects.
 Replace main filter element after 1000 operat-

ing hours or 3 cleaning cycles, but not later
than after one year of operation.
Fig. 3-19:
Draining water from the switchgear

cabinet Replacing filter mats
 Check control cabinets for condensation. A filter mat is installed in the control cabinets be-
hind the cover (4, Fig. 3-20:).
 Unscrew drain plugs and drain off water.
 Check filter mats visually and replace if neces-
sary.
The base of the control cabinets must
be kept clean.
Fig. 3-20:
3-43
BA 6040(3 847 027.00)-EN
Slip ring assembly, servicing Electrical circuit diagrams

work The electrical circuit diagrams and wiring diagrams
(Fig. 3-21:) are annexed to the spare-parts list. Further infor-
mation can be found in the CGM HMS Service
High voltage! Danger to life! Manual "Working with circuit diagrams".
Switch off power supply at the trans-
former station.
Replacing fuses
Check that the slip ring assembly is Fuses and their function are listed on a sheet in-
without tension before opening it. side the switch-cabinets in the cab module.
Read and observe the "Inspection and Use only original fuses with the specified current
servicing – Safety instructions" chap- rating.
ter as well as the chapter “Electrical
system, safety instructions”.
Replacing lamps and bulbs
Observe the Servicing Instructions of the slip ring If a bulb does not work after replacement, the per-
manufacturer. taining fuses, connection cables and contacts must
be checked.
 Remove all tracks of dirt.
Xenon-working floodlights are oper-
 There is a transparent sideplate at the hous- ated with high voltage.
ing. Check the housing inside for wear debris
Read and observe the chapter:
coming from the brushes and for grease. Re-
“Floodlight projector, replacing the
move if necessary.
lamp”.
 Clean insulators and check for damage.
 Check condition of slip ring contact surfaces; Floodlights working with LED-technology do not
remove any sign of oxydation, "splatter" or have replaceable lamps / bulbs. The floodlight
burn spots. must be replaced if defective.
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
BA 6040(3 847 027.00)-EN
Xenon floodlight projector (op-

tional), replacing the lamp
Always switch off the projector and
Safety instructions
disconnect it from its power supply
The floodlight projectors use xenon technology. before replacing the Xenon lamp.
The lamp is not a usual incandescent lamp, but a
gas discharge lamp which is operated with a bal- Allow the xenon lamp to cool off be-
last unit. The ballast unit is integrated in the flood- fore removing it from the projector.
light projector. Wear googles and safety gloves
When the projector is turned on, the ballast unit when replacing the lamp.
generates a high-voltage pulse of more than 25000
Never stick your hand into the lam-
volts to start the xenon lamp.
pholder. The contacts may still be
Warning! live with residual voltage.
This high-voltage pulse can be a life- Never switch on the projector when
threatening risk, if a person comes the xenon lamp has been removed.
into contact with any of the live com- There is a risk of voltage discharge
ponents. This can be the case, for and damage to the lampholder.
instance,
The glass body of the xenon lamp is
 if the lamp is operated improp- filled with different gases and metal
erly, gases and is under gauge pressure
 if the projector housing is opened (risk of injury from splinters)
in an inapropriate way or If the xenon lamp breaks apart in
 by sticking one's hand into an closed room (workshop), all persons
opened or damaged projector. must leave the room and the room
must be ventilated for at least 20 min-
Protect yourself from potential risks utes to exclude any health risks
by reading and by observing the fol- caused by gases.
lowing safety instructions.
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 opera-
tion and obscure the reflector.
If the fingers have nevertheless come into contact
with the glass bulb, the fingerprints must be re-
moved 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 elec-
trical wiring is damaged.
Have damaged projectors be replaced by a quali-
fied electrician as soon as possible.
3-45
BA 6040(3 847 027.00)-EN
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.
 Remove four bolts (1, Fig. 3-22) and withdraw

the reflector (2) from the projector housing.
Fig. 3-22
 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
Lighting systems in LED tech-

nonogy, 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 (light-
emitting 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 re-
placed. 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
HYDRAULIC SYSTEM Depressurizing the hydraulic sys-

Hydraulic system - Safety instruc- tem
Hydraulic systems may only be opened if they are
tions completely depressurized.
Read and observe the "Inspection Even when an excavator is parked on a horizontal
and servicing – Safety instructions" surface with the working equipment resting on the
chapter. ground (Fig. 3-27: and Fig. 3-28:) and with its elec-
tric motor switched off, there may still be a consid-
erable amount of residual pressure in parts of the
Switch off the electric motor. hydraulic system, as e.g. the primary pressure
resulting from the last hydraulic movements before
Secure the machine as described in the "Securing
the immobilization.
the mmachine section.
Residual pressures disappear only gradually. If
Before working on the hydraulic system, make work is to be carried out on the hydraulic system
sure that the system is without pressure and that immediately after the immobilization, the system
the residual pressures have also been eliminated. must be freed from pressure, i.e. depressurized:
Risk of burning caused by hot hydraulic compo-
nents (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.
Fig. 3-27:
Fig. 3-28:
 Locate the system section to be opened.

 Depressurize the section to be opened. If re-
quired, the necessary measures described
must be combined
 Open the depressurized system section with
caution.
3-48
BA 6040(3 847 027.00)-EN
Examples of system sections: Checking the hydraulic oil level

1) working hydraulics  Bring hydraulic oil to operating temperature
2) servo control circuit (abt. 50 °C / 122°F).
3) precharged return-flow line
 Park the machine on a horizontal surface.
 Stand working equipment on the ground as

Depressurizing: shown on signs (2, Fig. 3-30: and Fig. 3-32:).
 Park the excavator on a horizontal surface.
The oil level must be between the “min” and “max”
 Set the working equipment on the ground. marks of the signs (2, Fig. 3-30:) near the level
indicator tube (1).
 Switch off the electric motor.
 Do not switch off the electrical system, sit

down on the operator's seat,
Sections 1 and 2: servo control and working hy-

draulics:
 Shift both control levers and all pedals repeat-
edly 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 precharg-
ing pressure decreases rapidly through the pre-
charging valve. No measures are required before
opening the return-flow line.
Fig. 3-31:
3-49
BA 6040(3 847 027.00)-EN
Fig. 3-34:
Hydraulic oil can also be filled in by means of the

service station (Fig. 3-35:).
A description of the Service Station can be found
in Part 2 of this manual, chapter “Service Station
Fig. 3-32: (tanklift)”.
Stand working equipment on the ground as shown
on the signs (Fig. 3-32:).  Unscrew cap of express coupling (10).
The signs (2, Fig. 3-33:) are attached beside the Connect filling hose of the service vehicle to
level indicator tube (1). 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 / CONSUM-
ABLES" section).
The acoustic warning signal “Travel Alarm”
sounds.
 Disconnect the filling hose; the express cou-
pling 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 / CONSUM-
ABLES" section).
 Before fitting the cover (19), check the sealing

ring and replace, if damaged.
Fig. 3-35:
 Fit cover together with sealing ring.
3-50
BA 6040(3 847 027.00)-EN
Hydraulic oil return-flow filters, Remove return flow filter elements

replace  Remove covers (3, Fig. 3-38:) together with
sealing rings (5).
Risk of scalding caused by hot hy-  Unscrew ring nuts (6) and remove retaining
draulic oil. disk (7).
 Remove press parts (8) with o-rings (10).
The hydraulic oil reservoir itself may
also be hot.  Withdraw filter elements (9) with o-rings (11)
from filter-baskets (12).
Wait until the hydraulic oil has cooled  Inspect filter elements for damage.
down before starting work on the If no damages are visible, insert new filter ele-
filters. ments (9) with new o-rings (11) into filter-
Read and observe the "Inspection basket (12), (see: “Install return flow filter ele-
and servicing – Safety instructions" ments”).
chapter. If a filter element (9) is damaged, remove filter-
basket (12) and inspect / clean, (see: “Remove
filter-basket, inspect / clean”).
Shut off the electric motor.
Skin contact with hydraulic oil may cause skin in-
jury. Avoid skin contact.
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 fil-
ter elements (9, Fig. 3-38:) are heavily con- Fig. 3-37:
taminated;
 after repairs on the hydraulic system;
 in case of damage.
Fig. 3-36:
Fig. 3-38:
3-51
BA 6040(3 847 027.00)-EN
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 fil-
ings 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 Fig. 3-39:
torque wrench (torque = 79 Nm / 58.3 lbf ft).
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 contamina-
tion and foreign objects and eliminate the fail- Fig. 3-40:
ure. Otherwise there is a risk of serious dam-
age 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
BA 6040(3 847 027.00)-EN
Hydraulic oil return-flow filters, Remove return flow filter elements

 Remove covers (3, Fig. 3-43:) together with
replace (from machine no. sealing rings (5).
170138)  Unscrew ring nuts (6) and remove retaining
disk (7).
Risk of scalding caused by hot hy-  Remove press parts (8) with o-rings (10).
draulic oil.  Withdraw filter elements (9) with o-rings (11)
The hydraulic oil reservoir itself may from filter-baskets (12).
also be hot.  Inspect filter elements for damage.
If no damages are visible, insert new filter ele-
Wait until the hydraulic oil has cooled
ments (9) with new o-rings (11) into filter-
down before starting work on the basket (12), (see: “Install return flow filter ele-
filters. ments”).
Read and observe the "Inspection If a filter element (9) is damaged, remove filter-
and servicing – Safety instructions" basket (12) and inspect / clean, (see: “Remove
chapter. filter-basket, inspect / clean”).
Shut off the electric motorr

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
Fig. 3-42:
screen (arrow, Fig. 3-42:). In this case, the fil-
ter elements (9, Fig. 3-43:) are heavily con-
taminated;
 after repairs on the hydraulic system;
 in case of damage.
Fig. 3-41:
Fig. 3-43:
3-53
BA 6040(3 847 027.00)-EN
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 fil-
ings 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 Fig. 3-44:
(5). Tighten bolts (18) crosswise using a
torque wrench (torque = 79 Nm / 58.3 lbf ft).
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 contamina-
tion and foreign objects and eliminate the fail-
Fig. 3-45:
ure. Otherwise there is a risk of serious dam-
age in the hydraulic system.
 Replace o-ring (15) located in the filter brack-
ets 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
BA 6040(3 847 027.00)-EN
Bypass valves, clean / replace

Risk of scalding caused by hot hy-
draulic oil.
also be hot.
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:

Cleaning the filter screens

 Remove covers (3 and 4, Fig. 3-46:) together
with sealing rings.
 Unscrew bolts (25, Fig. 3-47:). Withdraw by-
pass 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 re-
place, if required.
 Insert bypass valve and fasten with bolts (25).
Replacing the bypass valves and seal-

ing 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
Hydraulic oil tank breather filters, Replacing the filter elements

replace Two breather filters (Fig. 3-48:) on top of the hy-
draulic tank ensure venting of the hydraulic oil tank
Risk of scalding caused by hot hy- at varying hydraulic oil levels.
draulic oil. Inspect and replace the filter elements according to
The hydraulic oil reservoir itself may the maintenance plans.
also be hot. In case the machine is working in very dusty condi-
tions or in an environment with high air humidity,
the filter elements must be inspected and replaced
down before starting work on the
in shorter intervals.
filters.
This protects the hydraulic tank from beeing con-
Read and observe the "Inspection taminated.
chapter. To replace the filter elements:
 Unscrew bolts (21, Fig. 3-48:) and remove
holding brackets (22).
 Withdraw filter elements (20).
jury. Avoid skin contact.  Check foam rings on top of filter elements,
replace if damaged.
Collect escaping hydraulic oil and discard without  Attach new filter elements (20) with foam rings
polluting the environment. to their cylindrical connections
Dispose of used filter elements accordding to the  Install holding brackets (22) using bolts (21).
Fig. 3-48:
3-56
BA 6040(3 847 027.00)-EN
Filter (servo control circuit), Replacing the filter element

replace To filter the hydraulic oil in the control circuit, the
machine is equipped with a high-pressure filter (9,
Fig. 3-49:).
draulic oil. Change filter element regulary and when the BCS
indicates a contamination.
The filter housings themselves may
 Place a suitable collecting recipient under the
also be hot.
filter housing (Fig. 3-49:).
Wear protective gloves and firm
 Collect escaping hydraulic oil and used filter
working clothing.
elements. Discard without polluting the envi-
Skin contact with hydraulic oil may ronment.
cause skin injury. Avoid skin contact.
 Unscrew filter housing (5, Fig. 3-50:) by coun-
Read and observe the "Inspection terclockwise rotation. Pour out the oil.
 Withdraw filter element (6) from filter housing
chapter.
(5).
 Check filter housing (5) as well as used filter
 Shut off the electric motor. surface for debris.
 Depressurize the hydraulic system.  Clean filter housing (5) and the sealing face at
the filter head with white spirit or paraffin oil.
 Clean the filter housings as well as the imme-
diate vicinity carefully.  Check seals (8) and replace, if required.
 Dispose of waste oil, used filters and oil-  Screw in the filter housing (5) to stop. Then
stained cleaning rags properly and separated turn out the filter housing by an 1/8 turn so that
from other waste. 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 put-
ting the hydraulic system back into operation.
Fig. 3-49:
Fig. 3-50:
3-57
BA 6040(3 847 027.00)-EN
High-pressure filter for working Replacing the filter elements

hydraulics, replace  Place a suitable collecting recipient under the
filter housings (Fig. 3-51:).
To filter the hydraulic oil on the high-pressure side
of the working hydraulic system, the machine is  Collect escaping hydraulic oil and used filter
equipped with four high-pressure filters (8, Fig. elements. Discard without polluting the envi-
3-51:). ronment.
 Unscrew drain plug (11, Fig. 3-52:) by coun-
Risk of scalding caused by hot hy- terclockwise rotation. Pour out the oil.
draulic oil.
 Unscrew filter housing (9).
The filter housings themselves may
also be hot.  Disengage filter element (15) with a slight turn
from the centering spigot in the filter head.
Wear protective gloves and firm
working clothing.  Check filter housing (9) as well as used filter
surface for debris.
Skin contact with hydraulic oil may
 Clean filter housing (9) and the sealing faces
cause skin injury. Avoid skin contact.
at the filter head with white spirit or paraffin oil.
Read and observe the "Inspection
 Check sealing ring (13) and support ring (14)
on the filter housing for position and damage.
chapter.
Replace, if necessary.
 Install the new filter element (15) with a new
 Shut off the electric motor. seal (10) on the spigot again by slightly turning
it.
 Depressurize the hydraulic system.
 Screw in the filter housing (9) to stop. Then
 Clean the filter block and the filter housings
turn out the filter housing by an 1/8 turn so that
carefully.
the filter housing is not stuck due to pressure
 Dispose of waste oil, used filters and oil- pulsation and can be easily loosened in case
stained cleaning rags properly and separated of maintenance works.
from other waste.
Fig. 3-52:
Fig. 3-51:
3-58
BA 6040(3 847 027.00)-EN
Filters for swing charge pump, Replacing the filter elements

replace  Place a suitable collecting recipient under the
The excavator has three high-pressure filters (9,
Fig. 3-53:) for the feeding circuits of the swing  Collect escaping hydraulic oil and used filter
pumps. The filters are installed in front of the hy- elements. Discard without polluting the envi-
draulic reservoir. ronment.
 Detach flange (4, Fig. 3-54:).
Risk of scalding caused by hot hy-  Remove filter housings and pour out used oil.
draulic oil.  Withdraw filter element (6) from filter housing
The filter housings themselves may (5).
also be hot.  Clean filter housings and sealing faces at filter
Wear protective gloves and firm head with white spirit or paraffin oil.
working clothing.  Install new filter element (6, Fig. 3-54:) and re-
Skin contact with hydraulic oil may assemble with a new, lightly oiled sealing ring
cause skin injury. Avoid skin contact. (7).
Read and observe the "Inspection  Check the high-pressure filter for leaks after
and servicing – Safety instructions" putting it into operation.
chapter.
 Shut off the electric motor.

diate vicinity carefully.
 Dispose of waste oil, used filters and oil-
stained cleaning rags properly and separated
from other waste.
Fig. 3-54:
Fig. 3-53:
3-59
BA 6040(3 847 027.00)-EN
High-pressure filters for the servo Replacing the filter element

circuit, replace  Place a suitable collecting recipient under the
The servo circuit is equipped with two high-
pressure filters (9, Fig. 3-55:).  Collect escaping hydraulic oil and used filter
The filters are located at the hydraulic oil reservoir. elements. Discard without polluting the envi-
ronment.
 Detach flanges (4, Fig. 3-56:).
draulic oil.  Remove filter housings and pour out used oil.
The filter housings themselves may  Withdraw filter element (6) from filter housing
also be hot. (5).
Wear protective gloves and firm  Clean filter housings and sealing faces at filter
working clothing. head with white spirit or paraffin oil.
Skin contact with hydraulic oil may  Install new filter element (6) and re-assemble
cause skin injury. Avoid skin contact. with a new, lightly oiled sealing ring (7).
Read and observe the "Inspection  Check the high-pressure filter for leaks after
and servicing – Safety instructions" putting it into operation.
chapter.
 Shut off the electric motor.

diate vicinity carefully.
 Dispose of waste oil, used filters and oil-
stained cleaning rags properly and separated
from other waste.
Fig. 3-56:
Fig. 3-55:
3-60
BA 6040(3 847 027.00)-EN
Changing the hydraulic oil Avoid mixing of different hydrau-

Risk of scalding caused by hot hy- lic fluids
draulic oil. The machine has been run in at the factory with
BM Long Term Hydraulic Fluid HSS (Part-No.
2482971). CGM HMS recommends using this
also be hot.
high-grade hydraulic fluid also in operation as it
Read and observe the "Inspection and has been made especially for use in these ma-
servicing – Safety instructions" chap- chines to which it is also perfectly adapted.
ter. 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 operat-
Shut off the electric motor. ing hours.
Skin contact with hydraulic oil may cause skin in- If an alternative hydraulic fluid is to be used, it
jury. Avoid skin contact. must fulfil the same specifications. Please note
Wear protective gloves and firm working clothing. that the change interval for alternative fluids is
Collect escaping oil and discard without polluting fixed at 5 000 operating hours.
the environment. There is an increased risk of damage to hydraulic
components, if different hydraulic fluids are mixed
Do not start up the electric motor during topping up as well as when changing over
when the hydraulic oil reservoir is to a fluid of a different type or from another manu-
empty. The hydraulic pumps may be facturer.
destroyed if they are allowed to run
dry. For topping up, it is therefore necessary to use only
same hydraulic fluid as the one that is already in
Avoid mixing of different hydraulic the hydraulic system.
fluids (see chapter “Avoid mixing of
When changing over to an alternative hydraulic
different hydraulic fluids” for more
fluid, please observe that there is always a small
information).
amount of old fluid remaining in the hydraulic sys-
tem even after the system has been emptied. The
mixing of this residual amount of old fluid with the
Oil grade see “LUBRICANTS / CONSUMABLES”
new alternative fluid reduces the properties of the
section.
fluid dramatically and can cause damage to com-
Change the oil when the machine is at operating ponents of the hydraulic system in operation.
temperature. Warm oil flows better and carries
To avoid this result, the change-over to the alterna-
suspended particles (carbon or abraded matter)
tive fluid must be performed in strict compliance
better.
with the manufacturer's prescriptions. The manu-
facturer 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 speci-
fication or with mixed fluids.
3-61
BA 6040(3 847 027.00)-EN
Draining off hydaulic oil using the Ser- Cleaning the hydraulic oil reservoir
vice Station (tanklift) Explosion hazard.
The hydraulic oil can also be drawn off through the Do not use white spirit, paraffin oil or
service station (Fig. 3-57:). other solvents for cleaning.
A description of the Service Station can be found
in Part 2 of this manual, chapter “Service Station Read and observe the "Inspection
(tanklift)”. and servicing - Safety instructions"
chapter.
 Bring hydraulic oil to operating temperature Use only diesel fuel or a special flushing oil for
(ca. 50° C / 122°F). cleaning the hydraulic tank.
 Retract hydraulic cylinders as far as possible Skin contact with hydraulic oil, diesel fuel or spe-
and stand working equipment on the ground. cial 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 pol-
 Connect hose line of the service vehicle. luting the environment and separately from other
waste.
 Drain oil.
 Remove hose line. The coupling closes auto-  Drain off hydraulic oil as described under
matically. "Draining off the hydraulic oil using the Service
Station".
 Screw on protective cap.
 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
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 in-
spection glass (1).
(Oil grade see "LUBRICANTS").
 The oil level is also displayed on the BCS- Fig. 3-59:

screen (Fig. 3-61:).
 Vent the hydraulic system.
 Check the oil level in the hydraulic oil reser-

voir. 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
Filling in hydraulic oil through the re-

turn-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 in-
spection glass (1).
(Oil grade see " LUBRICANTS ").
 Check the oil level in the hydraulic oil reser-

voir. 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
Venting the hydraulic system

Hydraulic pumps, hydraulic motors, hydraulic cyl-
inders, travel brake valves, suction lines of hydrau-
lic pumps, oil cooler manifolds and the servo con-
trol system must be vented
 after assembly on site and prior to initial com-
missioning,
 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:),
Check the hydraulic system under load. Pay  the rod-side port (4) when the piston rod is
attention to noises produced by the hydraulic extended (1, Fig. 3-65:).
pump or the hydraulic motors. Abrupt move- If, for assembly reasons, the piston rod is in-
ments of the working equipment are a sign of middle position, admit oil first to the piston-side
entrapped air in the system. Remaining air port (4).
pockets can be eliminated by actuating all hy-
draulic functions. When oil is admitted for the first time to the cyl-
inder, the oil flow must be reduced. Therefore
 Hydraulic cylinder extend or retract the piston rod as slowly as
possible.
Before the initial admission of the cylinder with
The bolts/nozzles of the following components
oil, the piston must be in either of the two ex-
must be opened until oil emerges bubble-free from
treme piston positions. In other words, the pis-
the opening:
ton rod (1, Fig. 3-64: and Fig. 3-65:) must be
either completely retracted or completely ex- Always vent only the system section
tended. 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
Cleaning the hydraulic oil cooler Cleaning

Risk of injury from rotating cooler fan The hydraulic oil coolers are located in the oil coo-
blades. ler 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 tempera-  Clean the radiators with a jet of water or com-
ture as the hydraulic oil. Risk of burning. pressed air from outside to inside.
Allow the hydraulic oil cooler to cool down.
 Leave hydraulic oil coolers to dry.
Wear protective gloves and firm protective cloth-
ing.  Check the hydraulic motors (1) for free move-
If the machine is used in places with heavily con- ment.
taminated ambient air, the hydraulic oil coolers
must be cleaned more often than specified in the In winter-time, check that the fans (2)
servicing plan. 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 maxi-
mum speed when the hydraulic oil temperature
reaches ca. 60°C / 140°F.
Fig. 3-66:
3-66
BA 6040(3 847 027.00)-EN
Electronic excavator control Pedal

At regular intervals acc. to the maintenance plans:
Joystick
 Remove old grease and dirt from the control
At regular intervals acc. to the maintenance plans:
spools and the actuator plate of the pedals (ar-
 Loosen gaiter and move upwards. rows, Fig. 3-68:).
 Apply a thin layer of low temperature grease  Apply a thin layer of low temperature grease
on the control spools, the actuator plate above on the control spools of the pedals to prevent
and the cardan joint of the joysticks (arrows, jamming of the control spools.
Fig. 3-67:) to prevent jamming of the joysticks.
 Refit gaiter using a cable strap.
Fig. 3-68:
Fig. 3-67:
3-67
BA 6040(3 847 027.00)-EN
Pressure accumulator - Emer- Extract from the German regulations

gency lowering The accumulator vessel must not be subjected to
welding, soldering or any other mechanical work.
To permit the working equipment to be lowered in Work on systems containing accumulators (re-
an emergency, the machine is equipped with a pairs, connection of pressure gauges or similar
pressure accumulator (1, Fig. 3-69:). work) may be carried out only when the fluid pres-
The pressure accumulator (1) is located in the sure has been released
superstructure and is accessible from the ground.
Extract from the German acceptance
regulations
Hydraulic accumulators are pressure vessels and
are therefore subject to the "Druckbehälterverord-
nung (DruckbehV)" [Pressure Vessel Regulations].
Their installation, equipment and operation are
governed by the "Technische Regeln Druckbe-
hälter (TRB)" [Technical Rules for Pressure Ves-
sels]. The pressure vessels of hydraulic accumula-
tors 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:
Checking the gas charging pressure in the pres-
sure accumulator
Pressure-accumulator inspection regu- After commissioning (new installation or repair),
lations the gas charging pressure in the pressure vessel
The following regulations are applica- must be checked at least once during the first
ble only in Germany. Please observe week. If no pressure loss is detected, the second
the relevant regulations in force in pressure test must be performed after ca. 3
months. If no pressure loss is detected in this test
your own country.
either, the testing interval can be fixed at once
pressure test each year.
Group Inspections prior to commissioning Regular

at the factory at the place of use inspections
II Pressure testing Inspection certificate Inspection schedule to be
p  l bar Prototype and pressure test (Check of correctness and drawn up by end user, based
and certified by the manufacturer correct installation) on experience with type of
p·x l  200 issued by an expert operation and fluid.
3-68
BA 6040(3 847 027.00)-EN
PUMP DRIVE GEARBOX
Risk of scalding caused by hot gear-

box oil. The gearbox housing may be
hot too.
Skin contact with gearbox oil is a po-
tential 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.
Fig. 3-70:
Secure the machine as described in the "Securing
the machine" section.
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
Fig. 3-71:
“min” and “max” markers on the dipstick.
 Top up with oil if required through the plug of
filler tube (arrows, Fig. 3-72:).
(Oil grade see: “LUBRICANTS / CONSUM-
ABLES”).
 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
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 / CONSUM-
ABLES”).
 Check oil level.
 Fit plug again.
Fig. 3-72:
3-70
BA 6040(3 847 027.00)-EN
Pump drive gearbox, changing oil

Carry out oil change when gearoil is nearly at op-
erating 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 Fig. 3-73:
and connect hose line of the service vehicle.
 Drain gearbox oil.
 Remove hose after the oil has been drained.
The coupling closes automatically.
Filling in gearbox oil

(Oil grade see: „“LUBRICANTS / CONSUM-
ABLES”).
 Fill in gearbox oil with the service station (Fig.
3-73:).
 Unscrew cap of express coupling (5).
 Connect hose line of service vehicle.
Fig. 3-74:
 Fill in gear oil until the oil level reaches the
„max“ mark on dipstick (1, Fig. 3-68).
 Remove filling hose after the oil has been filled
in. The express coupling closes automatically.
 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 cor-
rect 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 lubri-
cate the slined hollow shafts. The gearbox oil cool-
ing 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
Pump drive gearbox, pre- Pump drive gearbox, venting

chamber The gearbox is vented through the breather valve
(arrow, Fig. 3-76).
Clean breather valve in accordance with servicing
Checking oil level, topping up with oil plan.
The oil level in the pre-chambers is visually at the  Unscrew breather filter, clean with white spirit
inspection glas (3, Fig. 3-75) in expansion reser- or paraffin oil and blow dry with compressed
voir (1). air.
The oil level should reach up at least to the middle
of the inspection glas (3). Top up with gearbox oil,  Screw breather filter back in place.
if required.
Fig. 3-76
Fig. 3-75
3-72
BA 6040(3 847 027.00)-EN
Pre-chambers working pumps, Pre-chambers swing pumps,

draining oil, changing oil draining oil, changing oil
Draining oil: Draining oil:
 Place a suitable receptacle for used oil under  Place a suitable receptacle for used oil under
the plugs (13, Fig. 3-77:). the plugs (23, Fig. 3-78:).
The required receptacle capacity is specified in The required receptacle capacity is specified in
the „Filling quantities – oil“ table. 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.  Unscrew plugs (23) and allow oil to drain.
Screw in plugs and fill in oil after repair work Screw in plugs and fill in oil after repair work
has finished. has finished.
Changing oil: Changing oil:

 Oil change is necessary only after repairs or  Oil change is necessary only after repairs or
after changing a working pump. In this case after changing a swing pump. In this case
drain oil and fill in oil as described above. drain oil and fill in oil as described above.
Oil quantity see „Filling quantities – oil“ table. Oil quantity see „Filling quantities – oil“ table.
Fig. 3-77: Fig. 3-78:
3-73
BA 6040(3 847 027.00)-EN
Pump gearbox cooling circuit, re- Checking for contamination

place oil filter  Check filter tell-tale (1, Fig. 3-79:) regulary - at
operating temperature - for indication of con-
Oil for the pump drive gearbox is cleaned in the tamination.
filter (Fig. 3-79:). 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 care-
fully. 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 envi-
ronment.
 Unscrew filter housing (42, Fig. 3-80:).
 Pour oil out of filter housing (42) and remove
filter element (43).
 Check filter housing as well as used filter sur-
Fig. 3-79: face 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.
Fig. 3-80:
3-74
BA 6040(3 847 027.00)-EN
SWING GEARBOX Swing gearbox - Changing the

(For swing gearboxes P/N 3692960) gearbox oil
Read and observe: "Inspection and
servicing - Safety instructions. 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 Choose the required capacity in accordance with
the machine" section. 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.
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: The drain valve (7) is accessible from the under-
carriage.
 Remove hose. The oil drain valve closes au-
Swing gearbox - Checking the oil tomatically.for oil and cooling liquid change"
section.
 Park the machine as described under "Secur-
ing 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 gear-
box oil, if required.
 Screw dipstick (1) back in place.
3-75
BA 6040(3 847 027.00)-EN
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:).
 Check oil level with dipstick (1). Clean breather filter in accordance with the servic-
ing plan.
 Screw in plug (4) again.
 Unscrew breather filter (2), clean in white spirit
or paraffin oil and blow dry with compressed
air.
 Screw breather filter (2) back in place.
Fig. 3-83:
3-76
BA 6040(3 847 027.00)-EN
SWING GEARBOX Swing gearbox - Gearbox -

(For swing gearbox P/N 3676892) Checking the oil level / Topping
The gearbox housings may be hot,
up with oil
too.  Check the oil level visually at expansion tanks
(5 and 6, Fig. 3-84:). The expansion tanks
Read and observe: "Inspection and must be filled with gearbox oil up to abt. 1/3.
servicing - Safety instructions. 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 hoses (4, Fig. 3-84: and Fig. 3-85:) connect
the machine" section. the gearboxes (1) with the expansion reservoirs (5
Protect the skin from contact with gearbox oil. and 6).
Skin contact with cooling liquid is a potential health  Check all threaded joints for leaks.
hazard.
Collect escaping oil carefully and dispose of in an
environmentally acceptable manner.
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 ex-
pansion reservoirs for gearoil:
 Expansion reservoir for oil in the gearbox
housing (5).
 Expansion reservoir for oil in the brake cham-
ber (6).
Fig. 3-85:
Fig. 3-84:
3-77
BA 6040(3 847 027.00)-EN
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
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
Brake chamber, draining off oil Swing gearbox - venting

 Prepare a collecting recipient for used oil. The gearbox is vented through the caps of the
Choose the required capacity in accordance expansion reservoirs (7, Fig. 3-90:).
reservoirs (6). Oil will escaping faster then.
 Unscrew plug at the upper edge of the gear-
box housing (arrow, Fig. 3-89:).
Oil escapes.
 Screw plug (arrow, Fig. 3-89:) back in place.
Brake chamber, filling in new oil / top-

ping up
 Fill in new gearbox oil into expansion reser-
voirs (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
TRAVEL GEARBOX Pre-chamber / Spur gear section -

Checking the oil level / Topping up with
Risk of scalding caused by hot gearoil
box oil. The gearbox housings may be
 Check oil level at the inspection glass (2, Fig.
hot too.
3-92:).
Shut off the electric motor. The oil level should reach the center of the in-
Skin contact with gearbox oil is a po- spection glass. Top up with oil if required
tential health hazard. Protect the skin through the bore of plug (4).
from contact with gearbox oil. Wear Oil grade see: „LUBRICANTS / CONSU-
protective gloves and firm working MABLES“.
clothing.
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 / CONSUM-
ABLES”.
Travel gearbox - Checking the oil

 Move the hydraulic shovel into such a position Fig. 3-92:
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 Hydraulic motor chamber - Checking
of the opening. Top up with oil, if required. the oil level / Topping up with oil
Oil grade see: „LUBRICANTS / CONSUM-
ABLES“.  Unscrew checking screw (6, Fig. 3-93:).
The oil level should reach up to the lower edge
 Screw checking plug (1) back in place.
of the opening. Top up with oil, if required.
 Screw checking plug (6) back in place.
Oil grade see: „LUBRICANTS / CONSUM-
ABLES“.
Fig. 3-91:
Fig. 3-93:
3-80
BA 6040(3 847 027.00)-EN
Travel gearbox - Changing oil Pre chamber / Spur gear section -

Changing the oil / Draining off oil
Carry out oil change when oil is nearly at operating
temperature. All suspended particles and contami-  Place a collecting recipient for used oil under
nations will be rinsed out with the old oil. the pre-chamber / spur gear section.
Draining off oil
 Unscrew drain plug (3, Fig. 3-95:) and drain off
 Move the hydraulic shovel into such a position the oil completely.
that the screw plugs (1, 2 and 3, Fig. 3-94:) are Slackening plug (4) allows the oil to run out
in the displayed position. more readily.
 Place a collecting recipient for used oil under  Clean screw plugs (3 and 4)
the travel gearbox.
Choose the required capacity in accordance  Screw screw plug (3) back in place.
 Unscrew drain plug (2) and drain off the oil Filling in oil
completely.
Slackening plug (3) allows the oil to run out  Unscrew screw plug (4).
more readily.  Fill in oil through opening of plug (4) until it
 Clean screw plugs (2 and 3) reaches the center of the inspection glass (2).
Oil grade see: „LUBRICANTS / CONSU-
 Screw screw plug (2) back in place. MABLES“.
 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).
MABLES“.
 Screw plugs (1 and 3) back in place.
Fig. 3-95:
Fig. 3-94:
3-81
BA 6040(3 847 027.00)-EN
Hydraulic motor chamber - Changing Travel gearbox - Breather filter

oil  Unscrew breather filter (1, Fig. 3-97:) and
Draining off oil clean in white spirit or parafin.
Replace according to the maintenance plan.
 Place a collecting recipient for used oil under
the hydraulic motor chamber.
 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).
Fig. 3-97:
 Fill in oil through opening of plug (5) until it
flows out of the bore of plug (6).
MABLES“.
 Screw plug (6) and plug (5) back in place.
Fig. 3-96:
3-82
BA 6040(3 847 027.00)-EN
To clean the tracks:

CRAWLER TRACKS
 Raise one side of the excavator with the work-
Cleaning ing equipment and allow track to turn.
Clean tracks, track and support rollers, sprockets
 Clean the side member supporting the track.
and idlers regularly and whenever required. Clean-
ing is especially important in winter to prevent  Clean support and track rollers (1 and 2 ,Fig.
 the tracks from being thrown off 3-98:) thoroughly.
 oil from leaking out of track and support rollers,
sprockets and idlers  Clean the sliding planes on the idler guides.
 excessive wear
 the track from breaking.
Fig. 3-98:
3-83
BA 6040(3 847 027.00)-EN
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  Tighten bolts with a torque wrench to the pre-
with a central lubricating system for the undercar- scribed tightening torque (see "Service Man-
riage). ual").
Nevertheless press in grease filling at regular in-
tervals.
It is necessary to be sure that always sufficient
grease in the roller bearings.
Fig. 3-100:
Support roller fastening

Fig. 3-99:  Check fastening bolts (3, Fig. 3-100:) regularly
for tightness.
 Unscrew plug (6, Fig. 3-99:) from breather line.
 Tighten bolts with a torque wrench to the pre-
 Remove dust cap (1) from coupling (2). scribed tightening torque (see "Service Man-
ual").
 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
BA 6040(3 847 027.00)-EN
Track tensioner Techncal data

Track tensioning pressure ca. 70 bars/1015psi
Design Pressure limiting valve 330 bars / 4786psi
The tracks are tensioned with the help of the hy- Gas pressure in pressure
draulic pressure created during travelling. Fig. accumulator (nitrogen 50 bars / 725psi
3-101: and Fig. 3-102: show parts of the tracks and filling pressure)
the tensioner:
Function
The tensioning system is under permanent pres-
sure 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:  After the work, screw down the pressure limit-
1 Pressure accumulator ing valves (3) to the limit stop.
2 Pressure cylinder
3 Pressure limiting valve
4 Mini- measuring port
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
Pressure-accumulator inspection Checking the gas charging pres-

regulations sure in the pressure accumulator
The following regulations are applica- After commissioning (new installation or repair),
ble only in Germany. Please observe the gas charging pressure in the pressure vessel
the relevant regulations in force in must be checked at least once during the first
your own country. week. If no pressure loss is detected, the second
pressure test must be performed after ca. 3
Extract from the German regulations either, the testing interval can be fixed at once
The accumulator vessel must not be subjected to pressure test each year.
welding, soldering or any other mechanical work. The above-mentioned pressure tests are required
Work on systems containing accumulators (re- to ensure the functioning of the track tensioner.
pairs, connection of pressure gauges or similar They are no substitute for the inspections as re-
work) may be carried out only when the fluid pres- quired by the "Pressure Vessel Regulations".
sure has been relieved. Before checking the gas charging pressure (nitro-
Extract from the German acceptance gen filling pressure) in the pressure accumulator,
regulations the track must first be slackened, i.e. the hydraulic
part of the tensioning system must be depressur-
Hydraulic accumulators are pressure vessels and ized. See under "Function".
Tab. 3-1

IV Preliminary inspection by an Acceptance inspection by an Internal inspection:
p  l bar expert expert every 10 years for non-
p·x l  1000 Prototype and pressure test corrosive fluids; otherwise
certified by the manufacturer pressure testing every 5
(type approval) or the expert years:
every 10 years by an expert
3-86
BA 6040(3 847 027.00)-EN
SWING RING Internal gearing

Read and observe: "Inspection and The internal gearing (1, Fig. 3-104:) and the pinion
servicing - Safety instructions. (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 cloth-
ing.
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 im- Fig. 3-104:
mediately to prevent damage to the swing ring.
Greases and greasy cleaning rags must not be The grease is pumped to the greasing port of the
allowed to pollute the environment. Discard grea- grease trough by the distributor (Fig. 3-103:). The
se and greasy cleaning rags separately from other amount of grease used up during operation is re-
waste without polluting the environment. plenished by the central lubricating system.
The housings have a check opening which is clo-
sed with a cover (2, Fig. 3-105:). For checking, the
Bearing races cover must be removed.
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
BA 6040(3 847 027.00)-EN
Swing ring - Checking the grease filling Swing ring - Filling in grease
Read and observe: "Inspection and Prior to initial commissioning, the grease trough of
servicing - Safety instructions. the internal gearing must be filled with grease.
Add grease when
 the housing has been replaced
Switch off the electric motor  old grease has been removed in the course of
Wear protective gloves and firm protective cloth- other work.
ing.
Always fill in fresh grease by hand.
At regular intervals
Risk of accidents. Never swing the
 check internal gearing and teeth of swing me- superstructure when refilling grease.
chanism pinion for condition
 check that the grease filling is sufficient.

Swing ring - Checking the bolts for
The housing must always contain enough grease
tightness
for the gearing - measured from its lower edge - to
run in at least 20 mm / 0.78" of grease over its The fastening bolts of the swing ring in the super-
whole circumference (Fig. 3-106:). structure and the undercarriage are tightened with
their respective check torque (see "Service Man-
In the event of greater grease losses, eliminate
ual").
cause immediately and add grease to prevent the
internal gearing and the pinion from being dam- When these values are reached, the fastening
aged by continued swing movements. bolts are perfectly tight.
Loosen slack bolts before tightening them with a
torque wrench to the prescribed torque (see "Ser-
vice Manual").
Fig. 3-106:
3-88
BA 6040(3 847 027.00)-EN
CENTRAL LUBRICATING
Design and function
The excavator is equipped with an automatic cen-
tral lubricating system which provides grease regu-
larly 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 key-
switch and the electric motor is running. All greas-
ing points connected to the system are greased at
regular intervals.
The central lubricating system is controlled electro-
hydraulically 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 el-
eminate 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
BA 6040(3 847 027.00)-EN
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.
Work can be continued when the grease container
Fig. 3-109: 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 con-
tainer 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
BA 6040(3 847 027.00)-EN
Filling up the grease container Breather filter

Fill up the grease container through the service Check/change the breather filter at regular inter-
station (Fig. 3-113:). vals.
The use of the hose is described in the chapter  Unscrew wing nut (10, Fig. 3-114:).
"Flexible hose for the change of oil "
 Switch on the indicator system with toggle  Withdraw cover (7, Fig. 3-115:) and filter ele-
switch (23, Fig. 3-113:). ment (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:
3-91
BA 6040(3 847 027.00)-EN
Checking the greasing pressure The necessary greasing pressure of 320 bar /
4641psi for the superstructure is generated by
Check every week, whether the oil pressure indi- means of a pressure translator.
cated by pressure gauge (4, Fig. 3-116:) is 60 bars
/ 870psi (the pressure is dependind on tempera- The greasing pressure is indicated by pressure
ture and viscosity of the oil and may vary). gauge (9).
In the event of deviating pressure values, switch
off the electric motor and check the central greas-
ing system.
Lower oil pressure means that not all of the greas-
ing 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).
3-92
BA 6040(3 847 027.00)-EN
Checking the greasing pressure The necessary greasing pressure of 320 bar /
4641psi for the superstructure and 180 bar /
(for machines with automatic greasing of the track 2610psi for the lundercarriage is generated by
rollers, optional) means of a pressure translator.
Check every week, whether the oil pressure indi- The greasing pressure for the superstructure is
cated by pressure gauge (4, Fig. 3-117:) is 60 bars indicated by pressure gauge (9, Fig. 3-117:) and
/ 870psi (the pressure is depending on tempera- for the undercarriage by pressure gauge (22).
ture and viscosity of the oil and may vary).
In the event of deviating pressure values, switch
off the electric motor and check the central greas-
ing system.
Lower oil pressure means that not all of the greas-
ing points are supplied with grease.
Higher oil pressure may cause burst-
ing 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:
3-93
BA 6040(3 847 027.00)-EN
Unblocking a grease line. Unblocking a grease line.

Put the excavator back into operation only after the (for machnes with automatic greasing of the track
lubricating system works properly and after having rollers, optional)
actuated the unloaded working equipment for abt. Put the excavator back into operation only after the
5 minutes. This is necessary in order to supply lubricating system works properly and after having
sufficient amounts of grease to the cylinder bear- actuated the unloaded working equipment for abt.
ings. 5 minutes. This is necessary in order to supply
Check the grease sieve regularly for contamination sufficient amounts of grease to the cylinder bear-
and clean, if required. The grease sieve must also ings.
be cleaned after an obstruction in one of the Check the grease sieve regularly for contamination
grease lines. and clean, if required. The grease sieve must also
Cleaning be cleaned after an obstruction in one of the
 Loosen nut (6, Fig. 3-119:). grease lines.
Cleaning
 Withdraw sieve and clean with white spirit or
 Loosen nut (6, Fig. 3-120:).
paraffin oil.
 Withdraw sieve and clean with white spirit or
 Re-insert sieve and fasten with nut (6).
paraffin oil.
 Re-insert sieve and fasten with nut (6).
Fig. 3-119:
Fig. 3-120:
3-94
BA 6040(3 847 027.00)-EN
Oilfilter (hydraulic circuit grease Replacing the filter element

pump) ) Change filter element regulary and when the BCS
indicates a contamination.
Read and observe the "Inspection and
servicing - Safety instructions" chap-
ter.

Risk of scalding caused by hot hydraulic oil.
The filter housings may also be hot.
Avoid skin contact.
jury.
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 re-

quired.
 Insert new filter element into filter housing (5)

and refit to the filter head with new, lightly oiled
Fig. 3-121: sealing ring (8).
 Check for leaks after putting the filter into op-

eration.
3-95
BA 6040(3 847 027.00)-EN
Grease filter (Filling the grease Checking the filter element

container)  Unscrew filter housing (32, Fig. 3-124:).
Read and observe the "Inspection and  Withdraw filter element (33) from housing (32).
servicing –Safety instructions" chap-
ter.  Remove the grease.
 Clean filter housing and contact faces at the

Switch off the electric motor. filter head with white spirit or paraffin oil.
Grease filter (13, Fig. 3-123:) is installed in the
greasing line to the grease container.  Insert filter element into housing (32) and at-
tach 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:

 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
BA 6040(3 847 027.00)-EN
Grease filter (Grease lines) Checking the filter element

Read and observe the "Inspection and  Unscrew filter housing (42, Fig. 3-126:).
servicing –Safety instructions" chap-
 Withdraw filter element (43) from housing (42).
ter.
 Remove the grease.
 Clean filter housing and contact faces at the
Grease filter (12, Fig. 3-125:) is installed in the filter head with white spirit or paraffin oil.
greasing line to the grease container.
 Insert filter element into housing (42) and at-
tach 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:

 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
BA 6040(3 847 027.00)-EN
OTHER MAINTENANCE Equipment, check for cracks

Check the welded joins of the working equipment
Heating and air conditioning regulary.
Check and clean the filter mats in the air suction Inspections must be carried out acc. to the "Struc-
regulary. tural Inspection Reports" every 500 OH and every
The filter mats are located in the air conditioner 5000 OH.
housing (Fig. 3-127:) below the cab roof. "Structural Inspection Report" forms for those in-
spections 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 nec-
essary.
 Close housing.
Fig. 3-129:
3-98
BA 6040(3 847 027.00)-EN
Reservoirs for used grease at the Hydraulic ladder, pressure accu-

A-frame, emptying mulator
Remove used grease from the reservoirs (Fig. To allow the ladder (Fig. 3-131: and Fig. 3-132:) to
3-130:) regularly according to the maintenance be lowered with the electric motors at standstill as
plans. well as in an emergency, the ladder mechanism is
equipped with a pressure accumulator (1, Fig.
Do not re-use the grease because it is polluted. 3-133:). The pressure accumulator (1) is located in
Dispose off used grease as well as cleaning rags the superstructure and is accessible from the
without polluting the environment and separately ground.
from other waste.
Fig. 3-131:
Fig. 3-130:
Fig. 3-132:
Fig. 3-133:
3-99
BA 6040(3 847 027.00)-EN
Pressure-accumulator inspection Checking the gas charging pres-

regulations sure in the pressure accumulator
The following regulations are applica- After commissioning (new installation or repair),
ble only in Germany. Please observe the gas charging pressure in the pressure vessel
the relevant regulations in force in must be checked at least once during the first
your own country. week. If no pressure loss is detected, the second
pressure test must be performed after ca. 3
either, the testing interval can be fixed at once
Extract from the regulations pressure test each year.
The accumulator vessel must not be subjected to
welding, soldering or any other mechanical work.
Work on systems containing accumulators (re-
pairs, connection of pressure gauges or similar
work) may be carried out only when the fluid pres-
sure has been relieved.
Extract from the German acceptance
regulations
Hydraulic accumulators are pressure vessels and

III Preliminary inspection by an Acceptance inspection by an Inspection schedule to be
p  l bar expert expert drawn up by end user, based
and Prototype and pressure test on experience with type of
p·x l  200 certified by the manufacturer operation and operating flu-
bars (type approval) or the expert ids.
p·x l  1000
bars
3-100
BA 6040(3 847 027.00)-EN
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 sys-
tem.
Crane engine
More and detailed information about the diesel
engine can be found in the Operating and Mainte-
nance Manual for the crane engine.
 Before each shift check engine oil level. If nec-
essary 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 con-
Fig. 3-134:
nections.
 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.
Hydraulic system
For more and detailed information, see crane op-
erating 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.
Fig. 3-135:
 Check contamination of hydraulic oil filter regu-
larly at contamination indicator (4).
 Regularly, but at least once a year replace the
hydraulic oil filter (3) and the breather filter (2).
3-101
BA 6040(3 847 027.00)-EN
On-board crane, lubricating On-Board crane, checking tight-

Servicing work ness of fastening bolts
 Lubricate all bearings regularly and as re- The hydraulic driven on-board crane (Optional) is
quired, and spray swing ring with a graphite fixed on the uppercarriage of the machine by
spray (Fig. 3-136:) means of 16 fastening bolts. The upper and lower
1 - bearing 4 lube points fastening bolts (Fig. 3-137:) are important and
2 - joint (column/boom) 2 lube points safety relevant components, they carry all loads
3 - cylinder bearing 5 lube points and forces of the crane.
4 - swing ring Graphite spray Check tightness of all fastening bolts:
 in regular intervals according to the mainte-
nance 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 fasten-
ing 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
PUTTING THE EXCAVATOR OUT Battery storage

OF OPERATION AND RECOM- During prolonged machine downtimes, remove the
batteries and store in a dry room at an ambient
MISSIONING temperature of ca. 20°C / 68°F. Observe the fol-
Putting the excavator out of op- lowing points with regard to maintenance:
 Clean the batteries.
eration
 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 hy-  Recharge the batteries at the latest, when the
draulic cylinders as far as possible. acid density has dropped to 1.23 kg/dm³.
 Set all control element to "0".  Keep the batteries clean and dry on the out-
side.
 Clean the machine.
 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. Recommissioning
 Remove the covers.
 Protect all bright metal parts (e.g. piston rods)
from rust and dirt.  Degrease / clean all protected components.
 Remove the batteries; see "Battery storage".  Check track tension (visual inspection)
 Secure the machine against unauthorized  Check grease filling in grease container.
starting by:
withdrawing the key from the key-switch  Oil level - swing gearboxes
setting the battery main switch to OFF - pump drive gearboxes
setting the main circuit breaker to OFF - travel gearboxes
locking the cab door
securing all lockable hatches.  Check oil level in hydraulic oil reservoir.
 Cover up all openings  Check battery acid density and level.
 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
3-103
BA 6040(3 847 027.00)-EN
NOTES
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3-1
BA 6040(3 847 027.00)-EN
Repair work
4 REPAIR WORK

+
+
Repair personnel

chines.


+
+
Repair 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 After finishing repair work:
MOTOR
Maintenance and inspection work on electrical In the transformer station
systems may only be performed by qualified elec-  Disconnect the earthing and short-circuiting
tricians or by workshops employing such person- line.
nel.
 Unlock the safety device preventing switch-on;
A qualified electrician for the purpose of this regu- remove the warning sign.
lation is a person who has the corresponding tech-
nical training, know-how and experience as well as  Remove the partitions.
knowledge of the pertinent prescriptions and who
is therefore in a position to judge the work en-  Switch on the supply voltage.
trusted to him and the potential dangers in connec-
tion therewith.
Before carrying out any maintenance and inspec-
tion work on the electrical system, the following
On the hydraulic excavator
precautions must be taken:  Unlock the safety device preventing switch-on;
remove the warning sign.
In the transformer station  Switch on the circuit breaker,

(see the " Switching on the circuit breaker "
 Cut out the supply voltage. chapter in part 2 of the present Operation and
 Secure against switching on; apply a warning Maintenance Manual).
sign.
 Check that the electrical system is off circuit.
 Connect to earth and short-circuit.
 Protect adjacent and live parts against acci-
dental 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 manufac-
turers Operating Instructions).
4-3
BA 6040(3 847 027.00)-EN
Repair work
REPAIR WORK - SAFETY IN- Dismantling components

STRUCTIONS Never do dismantling while the machine is at op-
erating temperature.
Operation and Maintenance Manual Oils, greases, or coolants may have a high tem-
Never carry out repair work without having read perature and result in burning or scalding.
and understood the Operation and Maintenance
Leave time for the machine to cool down.
Manual.
Before starting work, depressurize piping and
Pay special attention to: "Fundamental Safety
hoses, cylinders, radiator, hydraulic tank and
Instructions", "Inspection and servicing - safety
other systems or units.
instructions" and all warnings and safety instruc-
tions attached to the machine. Replace defective components in good time to
prevent major damage.
The descriptions of job sequences provide only
experienced personnel with the necessary instruc- Clean the defective component carefully before
tions. dismantling it.
The operating manual must be kept with the ma- Mark the dismantled parts in the correct sequence
chine at all times. to faciliate re-assembly.
When dismantling the component, close off ex-
posed hose and piping connections, exposed drill
Repair personnel holes and housings carefully to prevent any dirt
Repair personnel must have know-how and ex- from penetrating.
perience relevant to repairing this or comparable
machines.
Never remove lead seals.
In the absence of such know-how, meticulous
training must be given by experienced repair per- Never change rated pressure of pressure relief
sonnel, e.g. from CGM HMS GmbH . valves without the explicit authorization of CGM
HMS GmbH .
Never remove lead seals from pressure relief
Working in greater heights valves and accumulators.
Always wear safety harnesses when working at
greater heights.
After the repair work
Wear an approved safety harness; it must be
equipped with fall arresters and safety cables. To prevent corrosion, coat all bright metal ma-
chine parts with a grease film.
On completing the work, re-assemble all protec-
Prestressed units tive devices, covers and noise- and vibration-
Never open defective prestressed units but re- insulation material.
place them as an entirety.
Never start up the electric motor while work is
In exceptional cases, open only when the system being done on the machine.
and the operating sequence are precisely known
Check the repaired components and all machine
and any special tools required are available.
functions in a trial run.
The operating manual contains no information on
Never release the machine for recommissioning
this point.
until it is fully functioning.
4-4
BA 6040(3 847 027.00)-EN
Repair work
Flying sparks (caused by welding, flame cutting,

FIRE AND EXPLOSION HAZARD grinding, electrical short-circuit) may cause fire on
Safety Instructions the ground that can spread to the excavator.
Prior to commencing work, inform Place suitable fire guardings (fire barriers) if open
fire or flying sparks cannot be avoided during re-
on the national and corporate rules for
pair work. Apply special protection to cables, ca-
prevention of accidents. Pay particular ble ducts as well as to hose and pipe lines.
attention to hazards caused by com-
bustible and easily flammable sub- If necessary, also cover the ground with fire-
stances. protective blankets.
on the safe handling of the fire Ensure sufficient ventilation.
extinguishers to be used.
Clean the excavator before starting a job.
Avoid smoking and open fire on, next to and be-
low the excavator. Do not keep any fire extinguishers that are not
suitable or have not been tested.
liquids increase the fire and explosion hazard. Do not extinguish flammable liquids with water.
Do not store or handle any flammable substances Use:
during operation.  dry-powder,
Clean the excavator thoroughly, if possible, with a  carbon-dioxide or

steam jet (rubber parts and electric components  foam extinguishing compounds.
with compressed air - refer to information label),
when, for example, oil, grease, fuel or cleaner was When getting into contact with burning sub-
spilled. stances, 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.
fire.
Avoid parking the excavator in places where Call the fire brigade.
 combustible substances such as coal dust or Have all your welding, flame cutting and grinding
tar are present. work approved.
combustible or easily flammable liquids have spil-
led from the excavator onto the ground.
4-5
BA 6040(3 847 027.00)-EN
Repair work
HYDRAULIC SYSTEM Hydraulic hoses – Instructions

Repair Even hoses that have been properly stored or
used are subject to natural ageing. Their useful
Always depressurize the hydraulic life is therefore limited.
system before disconnecting any hy-
draulic hoses or pipes. Hydraulic hoses must replaced after a service life
of six years (including a storage time of 2 years).
Read and observe also the chapters Check the date of manufacture on the hose or on
"Inspection and servicing - Safety in- the hose fitting regularly.
structions" and "Repair - Safety in- The recommended interval after which hydraulic
structions". hoses - and especially those used in harsh condi-
tions - must be replaced depends on the number of
operating hours and on pressure loading.
Replace damaged and leaking hydraulic hoses The use of hoses close to their recommended load
and pipes as soon as possible by new ones. limit shortens the replacement interval (e.g. high
temperatures, frequent working cycles, extremely
Use original spare parts from CGM HMS GmbH.
high pulse frequencies as well as multi-shift opera-
They are adapted to the respective function.
tion and round-the-clock work).
Do not re-use old hoses.
Hydraulic hoses must be replaced, if one of the
Never repair damaged hoses. following defects is detected during a visual in-
spection:
Discard escaped oil and oily wastes without pol-
luting the environment. These substances must  Damage to the outer fibre reinforcement layer
not be allowed to penetrate into the soil. 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 un-
der 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.
4-6
BA 6040(3 847 027.00)-EN
Repair work
PRESSURE ACCUMULATORS -
SAFETY INSTRUCTIONS
The hydraulic system is equipped
with pressure accumulators contain-
ing nitrogen under high initial pres-
sure.
Even when the hydraulic pressure in the system is

reduced, the nitrogen in the accumulator will re-
main under pressure.
The accumulators are completely safe in opera-
tion. If incorrectly handled, however, there is a risk
of explosion.
So:
 Never handle accumulators mechanically,
never weld or solder.
 Testing and servicing work must be carried out

by experts only.
 Prior to any testing and servicing work, de-

pressurize 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 accumu-
lator was damaged or if the admissible operat-
ing temperature or operating pressure was ex-
ceeded.
Never remove or paint over warning and informa-

tion 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 Increased risk of fire during welding

work
WORKS - SAFETY INSTRUC-
Always bear in mind that the heat, the sparks or
TIONS dripping red-hot metal or slag produced in the
The present safety instructions are valid for both process constitute a considerable risk of fire.
types of work. For easier reading, the text only The present safety instructions provide information
uses the terms "welding work", "welding" or simply on how to minimize the risk of fire.
"work". These terms do however always refer to
both types of work, i.e. "welding and flame-cutting Remove all combustible materials close to the
work". welding location or cover them up with non-
combustible materials.
Read these safety instructions before starting any
welding or flame-cutting operations. If works in the vicinity of combustible materials
cannot be avoided, further persons with fire-
fighting equipment must be present on site as fire-
Welding work by qualified personnel guards.
only Observe the instructions of the machine owner and
of the mine.
Carry out welding work only if you have received
special training and if you have been ordered to
perform such work. Health hazards
Always bear in mind that you are performing weld-
Welding operations produce harmful gases. Do not
ing work on heavily loaded components. The qual-
inhale the fumes and gases and make sure the
ity of your welding work can be decisive for the
surroundings of the welding location are well venti-
operational capability of the machine and also for
lated or equipped with an exhaust system.
the health and life of persons.
Remove all kinds of paint and all coatings as well
Observe the health protection and accident pre-
as all residues of oils and greases from the weld
vention laws and regulations as well as the fire
area.
protection regulations in force in your country.
Do not wind the welding cables round your body or
Observe all warning and instruction signs attached
parts of your body. The electromagnetic fields pro-
to the machine.
duced may damage your health.
Wear the prescribed personal protective equip-
ment such as:
 protective clothing,
 protective gloves,
 protective mask and,
 a fall-arrest system for persons working at
height.
4-8
BA 6040(3 847 027.00)-EN
Repair work
Tanks, pressure vessels and pressure Slewing rings and articulated joints
accumulators The welding current must not flow through ball-
Any work on vessels containing or having con- bearing or roller-bearing slewings rings, through
tained bolted connections or articulated joints or through
 combustible or combustion-accelerating sub- hydraulic cylinders.
stances, An electric current flowing through an air gap (e.g.
in the bearing or in the articulation) produces a
 potentially explosive substances or spark which damages the metallic surface.
 substances susceptible to develop harmful The welding clamps must therefore always be
gases, fumes, mists or dusts during welding connected very close to the weld area (max. 2 - 3
m away (6.6-9.8 ft)).
may only be carried out under expert supervision
and only by experienced personnel especially as-
signed to such work.
Information relating to the electrical
This prescription applies, for instance, to all tanks system and to electronic modules
and reservoirs for hydraulic fluid, engine oil, diesel
fuel or lubricating grease. Electric arc welding produces electromagnetic
fields, electrostatic charges and voltage spikes
Welding work on pressure vessels and pressure which can cause damage to electronic modules.
accumulators is forbidden. Although the electronic modules of the machine
Pressure vessels containing cold-starting fluid are carefully protected against these influences, it
(ether) may be installed in or near the engine com- is nevertheless necessary to take additional pre-
partment. cautions in order to prevent such damage to the
Ether is toxic and highly flammable; the vessels greatest possible extent.
are under pressure. These pressure vessels can Switch off the electrical system ("ignition OFF").
explode if exposed to high temperatures (above Open the battery main switch (or disconnect the
49°C / 120°F) or in the event of damage. starter batteries from the machine).
Protect the vessels against damage and high tem- Lay the welding cables as far away from electric
peratures. lines as possible.
Do not perform welding work in the vicinity of these If it is not possible to implement all of the above-
pressure vessels before they have been covered mentioned precautions, all connectors must be
up safely against accidental contact or flying removed from the electronic modules before be-
sparks. Have the pressure vessels removed from ginning any welding work.
the machine, if safe protection cannot be ensured.
Protect withdrawn terminals and connectors from
Inform yourself about the locations in the machine short circuits and soiling. Cover up terminals and
where the pressure accumulators of the hydraulic connectors with foils or adhesive tape.
system are installed. Do not perform welding work
in the vicinity of these pressure accumulators be- Never touch the enclosures of electrical and elec-
fore they have been covered up safely against tronic modules with the welding electrode.
accidental contact or flying sparks. Have the pres- Protect electric lines against the heat emanating
sure accumulators removed from the machine, if from the weld area.
safe protection cannot be ensured. Restore all electrical connections when the weld-
ing 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 flamma- The operator's cab is designed in such a way that
ble gases. Before starting to work, counterweights it meets the FOPS (Falling Objects Protective
must be flushed for at least 20 minutes with com- Structure) requirements in accordance with DIN
pressed air in order to remove these build-ups of EN ISO 3449.
gas. To permit flushing, the counterweight has two Welding and other mechanical work is forbidden
bores in its upper part: a threaded bore M18x1.5 as there is a risk of reducing the structural stability
for the compressed-air line and another un- of the cab.
threaded bore to let the air out.
Detailed information / instructions on this subject
can be found in Service Information 2006-33 which Further information
is available on the CGM HMS GmbH website un- More detailed information concerning the state-of-
der Maintenance & Service. the-art execution of welding operations can be
found in the Service Manual "Welding for mainte-
nance and repair".
Welding on components of the working
For problems or queries please contact the com-
equipment and on other fully or partly petent service personnel.
closed steel structures
If parts of the machine have to be removed or dis-
Components may be equipped with pipelines mantled, please read and observe the chapters:
routed inside. These lines can contain combustible "Assembly of working equipment, safety instruc-
substances such as hydraulic oil or lubricating tions",
grease which may be set on fire by welding opera- "Inspection and servicing, safety instructions",
tions. "Repair, safety instructions".
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 start-
ing the welding operations.
4-10
BA 6040(3 847 027.00)-EN
Repair work
DISPOSAL AT THE END OF THE Disposing of the machine without pol-

luting the environment
SERVICE LIFE
Before stripping down the machine at the end of its
Dismantling and removal instructions service life observe the following instructions:
Before beginning work, think about the risks in- The assemblies of the machine contain various
volved, e.g.: operating fluids or lubricants. These substances
 Most of the machine components have con- may pollute the environment (so-called hazardous
siderable mass. Therefore use only lifting gear substances) and must therefore be disposed of
and slings of sufficient bearing capacity. properly.
Observe the national laws and regulations govern-
 Risk of residual pressures still in the hydraulic
ing the non-polluting disposal of these substances.
system. Be very careful when opening hydrau-
lic lines. Remove all operating fluids from the systems, re-
move all lubricants and dispose of these sub-
Read the following text attentively and observe the stances properly.
instructions given. Respecting the instructions will
 Fuel system:
help you to protect yourself against health hazards
fuel tanks, fuel filters, fuel lines, filling station.
and injuries and to prevent avoidable environment
Auxiliary attachment and units, such as an on-
pollution.
board crane or an auxiliary heater have their
own fuel tanks with the corresponding line sys-
Risk of deflagrations tems.
In the course of time, flammable gases may have  Hydraulic oil:

formed or accumulated in the hollow spaces of hydraulic oil reservoir, hydraulic cylinders, hy-
welded constructions, e.g. the counterweight. To re- draulic motors, hosepipes, piping, hydraulic
move these flammable gases, the hollow spaces pumps, hydraulic valves, hydraulic oil filter, fill-
must be purged carefully with compressed air being station.
fore work with hand grinders, flame cutters or other  Engine coolant:
sparking tools is being undertaken. engine, radiator, expansion reservoir, piping
and hosepipes, filling station.
 Gearbox oil in slewing, travelling and drive
Risk of fire gearbox systems, expansion tanks, piping and
Remainders of fuel or oils may lead to the forma- hospipes, filling station; idlers, support and
tion of flammable gases in tanks or other hollow track rollers.
spaces. When these tanks or hollow bodies are cut  Have the refrigerant (R134A) sucked out of the
into pieces, the gases may ignite or even explode. air conditioner system.
For this reason, remove all fuel or oil remainders  Grease from the central lubricating system,
from these components and purge them carefully grease drum, piping and hosepipes, distribu-
with compressed air in order to eliminate flammable tors, filling station; grease accumulations in
gases (other efficient methods of removing flam- bearings of the working equipment, grease fill-
mable gases can also be applied) before work with ing in the slewing ring, grease filling in track
hand grinders, flame cutters or other sparking tools and support rollers as well as in idlers.
is being undertaken.
4-11
BA 6040(3 847 027.00)-EN
Repair work
Further hazardous substances Appropriate disposal of batteries

 Batteries contain lead and acid. The machine is equipped with batteries containing
 Electronic modules are located in switch cabi- lead and other harmful and polluting substances.
nets of the cab module, the engine module, the Damaged or used batteries must therefore not be
control column. disposed of in the environment. They must be dis-
 Pressure accumulators contain nitrogen under posed of properly and separately from other waste.
high pressure and possibly remainders of hy- The batteries are marked with the corresponding
draulic oil. symbols (Fig. 4-1:).
 Lamps of Xenon working lights contain mer- Since batteries contain also reusable materials,
cury. they are taken back free of charge by the manufac-
The required electronic control circuits are in- turer, dealer or by other specialized companies.
tegrated in the housings of the working lights.
In the European Community, the final consumer is
 The fluorescent lamps of the maintenance obliged by law to to dispose of used batteries in
lighting (discharge types) contain mercury. designated waste collections centers.
 Insulating material of cables can contain PVC. Observe the current regulations and laws of your
 The fire extinguishing system (if installed) con- country with regard to the handling of damaged or
tains trigger charges (ATTENTION, explosion used batteries.
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.
Fig. 4-1:
The symbols in Fig. 4-1: have the following mean-

ing:
 Crossed-out waste bin=
Do not dispose of batteries with normal house-
hold waste.
 Pb……=
Chemical symbol for lead.
 Circle of bent arrows=
Recycling symbol, ingredients of the battery
can be reused.
4-12
BA 6040(3 847 027.00)-EN
Repair work
NOTES
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4-13
BA 6040(3 847 027.00)-EN
Repair work
4-14
BA 6040(3 847 027.00)-EN
Annex
5 ANNEX

+
+
Repair personnel

chines.


+
+
Repair 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 cor- Fault
rectly operated or serviced.
The fault is described here as the outcome of an
For this reason, it is vital to read through the rele- observation or a previous activity.
vant section of the Operation and Maintenance
Manual once again before rectifying any faults. Therefore make careful observations.
If you are unable to detect the cause of the fault or Study the problem carefully. First think, then act.
to rectify it, apply to the CGM HMS GmbH after- Ask yourself the following questions:
sales service.  Which warning signals preceded the fault?
Describe the fault and all accompanying cir-  What repair and servicing work was carried out
cumstances as precisely as possible when calling previously?
on the CGM HMS GmbH after-sales service. Ex-
act data allow for fast troubleshooting.  Has this defect already occurred?
Never do any jobs for which you are not qualified.  Is it one or several simultaneously occurring
The fault table lists all faults which have been re- faults?
ported to date and outlines their possible causes
and rectifying measures. In exceptional cases, a Possible causes
described fault may also have a different cause. The possible causes of the observed fault are out-
lined 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 trouble-
shooting is given in the Operation and Mainte-
nance 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

Check P
No boom function Adjust E
Replace W
No bucket function Top up A
Reduce S
No backhoe function Clean R
No stick function
Working movements too slow
Power loss in working hydraulics 1) Contact the
CGM HMS
GmbH
Uncontrolled working movements Service
Cause Abschnitt
 Electronic excavator control not activated/defective Working P
  Malfunction of pressure-relief valve 1)
  Servo system pump defective 1)
  Malfunction of primary / sencondary pressure-relief valves 1)
 ECO-power switch in 80%-position P
 Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R
lamp lit) oil cooler contaminated cooler clea-
ning
 Malfunction of solenoid valves 1)
  Malfunction of control spool 1)
5-4
BA 6040(3 847 027.00)-EN
Annex
Track drive – Fault table
No forward travel and no reversing travel

Check P
Maximum travel speed cannot be reached Adjust E
Replace W
Insufficient traction power Top up A
Reduce S
Clean R
1) Contact the
CGM HMS GmbH
Service
Cause Chapter ref.
   Malfunction of pressure-relief valves 1)
   Servo system pump defective 1)
   Malfunction of travel valve (pedal) 1)
  Malfunction of control spool 1)
 ECO-power switch in 80%-position Travelling P
 Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil P/R
cator lamp lit) oil cooler contaminated cooler clea-
ning
5-5
BA 6040(3 847 027.00)-EN
Annex
Swing mechnism – Fault table
No swing possible
Check P
No righthand or lefthand swing Adjust E
Replace W
Swing performance insufficient Top up A
Reduce S
Uncontrolled swing movement Clean R
1) Contact the
CGM HMS
GmbH
Service
Cause Chapter ref.
 Electronic excavator control not activated / defective Working P
 Superstructure holding brake applied P
  Pressure-relief valve adjusted too low level / defective 1)
 Servo system pump defective 1)
  Malfunction in feed-pressure circuit of swing pump 1)
 Malfunction in high-pressure circuit of swing system 1)
  Malfuction of moment-regulating valve 1)
  Malfunction in swing pump displacement cylinder 1)
 Excessive leakage in swing motor 1)
5-6
BA 6040(3 847 027.00)-EN
Annex
Central lubricating system – Fault table
Grease pump not working, the BCS does not indicate a warning
Automatic circuit breaker on
Check P
Grease pump not working, pilot lamp lit Adjust E
Replace W
Grease pump working, no grease delivered Top up A
Reduce S
Greasing pressure too high or too low Clean R
Vent L
1) Contact the
CGM HMS
GmbH
Service
Cause Chapter ref.
  Timer defective P/W
 Lines between timer and hydraulic motor defective P/W
  Hydraulikmotor defektive P/W
    Grease pump defective P/W
 Grease sieve clogged P/R
 Distributor defective P/W
 Grease container empty P/A
 Grease pump does not suck grease P/L
 Leaky lines P/L
 Non-return valve defective P/W
 Pressure switch defective 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
A Ampere (SI base unit of electric current)
abt. about Incl. including, inclusive of
acc. according to ISO International Standardization Organization
Ah Ampere hours (SI base unit of quantity of
electricity)
kg Kilogram (unit of weight), 1 kg = 2.2 lb
API American Petroleum Institute
kg/dm3 Kilograms per cubic decimeter (= unit of
approx. approximately
specific density)
km/h Kilometers per hour
BA = OMM = Operation and Maintenance kNm KiloNewtons per meter (1 kNm = 1000 Nm)
Manual = unit of torque
bar unit of pressure, 1 bar = 14.5 psi kW Kilowatt (1 kW = 1.36 hp)
Bh = OH = Operating hour
l Liter (unit of volume), 1 liter = 0.26 gal
CE Communauté Européenne = European lb pound (unit of mass), 1 lb = 0.45 kg
community Lb/in² Pounds per square inch (= psi)
CECE Committee for european Construction LC Long crawler
Equipment (Defines a measure for bucket,
grab or scoop filling) LDA Charge pressure-dependent full-load limiter
CEN European Standardization Committee LED Light-emitting diode
cm centimeter (= 1/100 m) l/min Liters per minute
cm3/rev Cubic centimeters per revolution LpA Sound pressure at workplace
CCW counterclockwise LS Limited slip
CW clockwise LwA Sound power level of the machine in sta-
tionary operation
dB(A) Decibel (sound intensity according to mea-

suring method A) m Meter (unit of distance), 1 m = 3.28 ft
dia. Diameter MA Tightening torque
1
DIN German Industrial Standard mA Milliampere (= /1000 A)
max. maximal, maximum
EDS Electronic diagnostic system min. minimal, minimum
eff. effective min-1 Revolutions per minute
e.g. for example mm Millimeter (=1/1000 m)
etc. etcetera
N Normal, standard version
Fig. Figure, serial number of illustration N, kN Newton, kiloNewton (unit of force)
FOPS Falling objects protective structures NLGI National Lubricating Grease Institute (USA)
FS Rock shovel (working equipment) NLGI-- Consistency - lubricant classification acc. to
Klasse DIN 51 818
ft foot (unit of distance), 1 ft = 0.30 meter
Nm Newtonmeter (unit of torque)
No. Number
gal gallon (unit of volume), 1 gal = 3.78 liters
GLR Full-load controller (electronic module for
PMS) OH Operating hour
op.inst. Operating instructions
HD Heavy duty OW Superstructure
Hydr. Hydraulic, Hydraulics oz ounce (unit of volume) 1 oz = 0.03 liter
i Transmission ratio
i.e. id est = that is
IFN ISO service rating, blocked
5-9
BA 6040(3 847 027.00)-EN
Annex
ABBREVIATIONS
PMS Pump Managing System

P/No. Part number (CGM HMS GmbH )
PS Metric horsepower (1 PS = 0.74 kW)
psi pund per sqare inch (unit of pressure),
1 psi = 0.069 bar
PLC Programmable logic controller
Qty. Quantity
R, r Radius
resp. Respectively
RH Crawler hydraulics (excavator)
ROPS Roll-over protective structures
rpm Revolutions per minute (= min-1)
SAE Society of Aotomotive Engineers (USA)

sec./s. Second
SN CGM HMS GmbH partnumber
SW Width across flats
t Metric ton (= 1000 kg)

TBG Civil Engineering Employer's Liability Insur-
ance Association
THB Service Manual
TL Backhoe dipper (attachment)
tm Tons by meters (obsolescent unit of swing
torque)
typ. Typical
U/min Revolutions per minute

UW Undercarriage
V Volt (unit of electric voltage)

VDMA Association of German Machinery and
Systems Manufacturers
W Watt (unit of electric power)
°C Degrees Celsius (temperature)

°F 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 On the condition that the hydraulic shovel is used
ISO 6394. within the limits of its designated use, the installa-
Time-averaged A-weighted emission sound pres- tion of seats for operators in conformity with ISO
sure level at operator’s position with the machine 7096 ensures that the weighted vibration accelera-
running at high idle: LAeq = XX dB. tions 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.
The vibrations drivered are indicated in acc. with
EC Machine Directive 2006/42/EG, Annex I; Sec-
tion 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).
5-11
BA 6040(3 847 027.00)-EN
Annex
5-12
BA 6040(3 847 027.00)-EN
Annex
PRODUCT SPECIFICATION
SHEET
5-13
BA 6040(3 847 027.00)-EN
Annex
5-14
6040/6040 FS
Hydraulic Shovel
Specifications
General Data Operating Weight

Operating weight Shovel
Face Shovel 405 tonnes (446 tons) Standard track pads 1200 mm (3 ft 11 in)
Backhoe 407 tonnes (449 tons) Operating weight 404 600 kg (891,980 lb)
Engine Output SAE J1995 Ground pressure 24.1 N/cm2 (35.0 psi)
Cat® C32 1516 kW (2,032 hp) • Other track pads available on request
Standard Bucket Capacity Backhoe

Face Shovel (heaped 2:1) 22.0 m3 (28.8 yd3) Standard track pads 1200 mm (3 ft 11 in)
Backhoe (heaped 1:1) 22.0 m3 (28.8 yd3) Operating weight 407 300 kg (897,930 lb)
Ground pressure 24.3 N/cm2 (35.3 psi)
Features • Other track pads available on request
• 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
Hydraulic Shovel—6040/6040 FS
Dimensions
All dimensions are approximate.
8 10 1 6800 mm (22 ft 4 in)

9 11
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)
14 7 8090 mm (26 ft 7 in)
1
8 7000 mm (23 ft)
3
9 6780 mm (22 ft 3 in)
4
10 8050 mm (26 ft 5 in)
2
11 6100 mm (20 ft)
5
12 1200 mm (3 ft 11 in)
6 12
7 13 13 6600 mm (21 ft 8 in)
14 7920 mm (26 ft)
Dimensions and weights of AC machine differ slightly. Separate drawings, dimensions and weights can be provided upon request.
Diesel Engines Electric Motor – 6040 AC/6040 AC FS

Make and model 2 × Cat C32 (Tier 2) Type Squirrel cage induction motor
Total rated net power ISO 3046/1 1516 kW (2,032 hp) Output 1400 kW
1,750 min-1 Voltage 6.6 kV ± 10%
Total rated net power SAE J1349 1516 kW (2,032 hp) (other on request)
1,750 min-1 Rated Current IN 156 A (at 6.6 kV)
Total rated gross power SAE J1995 1516 kW (2,032 hp) Frequency 50 Hz (60 Hz on request)
1,750 min-1
Revolutions 1,500 min-1
No. of cylinders (each engine) 12 (1,800 min-1 at 60 Hz)
Bore 145 mm (5.71 in) Starting current 350% of IN (197% of IN Optional)
Stroke 162 mm (6.38 in) • Custom-made electric motor with increased gap between
Displacement 32.1 L (1,959 in3) rotor and stator to withstand severe mining conditions
Aspiration Turbocharged and • Power limit control by Pump Managing System
air-to-air aftercooled
Max. altitude without deration at 10° C 2500 m
(8,200 ft) above sea level Electrical System (diesel drive)
Emissions U.S. EPA flex System voltage 24V
Alternators 2 × 150 A Batteries 6 × 210 Ah – 12V each
in series/parallel
Fuel tank capacity 7800 L (2,060 U.S. gal) installation 630 Ah – 24V in total
• Hydraulically driven radiator fan with electronically Working spot lights 8 × high-brightness LED lights
controlled fan speed
• Battery isolation relays and switches
• Microprocessed engine management
• Emergency stop switches accessible from ground level,
• Heavy-duty air filters in engine module and in operator’s cab
• Two-stage fuel filter including water separator
• Additional high-capacity water separator
2
Hydraulic System with Pump Managing System Hydraulic Oil Cooling
Main pumps Oil flow of cooling pumps
Diesel version 4 × variable swash plate pumps Diesel version 2 × 799 L/min (2 × 211 U.S. gal/min)
AC version 4 × variable flow axial piston AC version 4 × 379 L/min (4 × 100 U.S. gal/min)
pumps Diameter of fans 2 × 1 524 mm (2 × 60 in)
Max. oil flow • Cooling system is fully independent of all main circuits,
Diesel version 4 × 724 L/min i.e. controlled cooling capacity is available whenever engine
(4 × 191 U.S. gal/min) is running
AC version 4 × 746 L/min
(4 × 197 U.S. gal/min) • Gear type cooling pumps supplying high-volume,
low-pressure oil to aluminum coolers
Max. pressure, attachment 300 bar (4,350 psi)
• Variable axial piston pumps supplying low-volume,
Max. pressure, travel 350 bar (5,080 psi) high-pressure oil to fans
Swing pumps • Fan speed is thermostatically controlled
Diesel version 4 × reversible swash plate pump
AC version 3 × reversible swash plate pump • Extremely high cooling efficiency to ensure optimum
oil temperature
Max. oil flow
Diesel version 4 × 321 L/min
(4 × 85 U.S. gal/min)
AC version 3 × 491 L/min Swing System
(3 × 130 U.S. gal/min) Swing drives 3 compact planetary transmissions
Max. pressure, with axial piston motors
swing pumps 350 bar (5,080 psi) Parking brake Wet multiple disc brake, spring-
Total volume of hydraulic oil loaded/hydraulically released
Diesel version Approx. 5800 L (1,532 U.S. gal) Max. swing speed Diesel version 4.7 rpm
AC version Approx. 6400 L (1,585 U.S. gal) AC version 5.1 rpm
Hydraulic tank capacity Swing ring Triple-race roller bearing with
Diesel version Approx. 3400 L (898 U.S. gal) sealed internal gearing
AC version Approx. 4000 L (1,057 U.S. gal)
• Closed-loop swing circuit with torque control
• Pump Managing System contains:
• Hydraulic braking of the swing motion by
– Electronic load limit control counteracting control
– Flow on demand from main pumps depending • All race ways of swing ring, as well as grease bath
on joystick position for internal gearing, supplied by automatic central
– Automatic regulation of main pumps to zero flow lubrication system
without demand
– Automatic rpm reduction of engine speed during
working breaks Retractable Service Station
– Reduced oil flow of main pumps at high hydraulic oil Retractable service station installed underneath the engine
temperature or at high engine temperature module and easily accessible from ground
• Pressure cut-off for main pumps Equipped with:
• Cooling of pump transmission gear oil • Quick couplings for:
– Diesel fuel
• Filters: – Engine coolant – left/right
– Full-flow high-pressure filters (100 μm) for the main – Pump transmission gear oil – left/right
pumps, installed directly behind each pump – Engine oil – left/right
– Hydraulic oil tank
– Full-flow filters (10 μm) for the complete return circuit – Grease container
– Full-flow filters (10 μm) for the cooling return circuit • Cat jump-start socket
– Pressure filters (6 μm) for servo circuit • Indicator lights for fuel tanks left/right full and grease
– Pressure filters (40 μm) for the feed pumps of the closed container full
swing circuit
– Transmission oil filters (40 μm)
3
Operator’s Cab Undercarriage (continued)
Operator’s eye level Approx. 6.8 m (22 ft 4 in) • Cast double-grouser combined pad-links with bushings
Internal dimensions of cab Length: 2200 mm (7 ft 3 in) connected by hardened full floating pins
Width: 1600 mm (5 ft 3 in) • All running surfaces of sprockets, idlers, rollers and track
Height: 2150 mm (7 ft 1 in) links, as well as teeth contact areas of sprocket and pad
• Pneumatically cushioned and multi-adjustable comfort links, are hardened
seat with lumbar support, seat heating, safety belt, head- • Fully hydraulic self-adjusting track tensioning system with
and armrests membrane accumulator
• Switch in seat cushion to automatically neutralize the • Automatic hydraulic retarder valve to prevent over-speed
hydraulic controls when operator leaves the seat on downhill travel
• Joystick controls integrated in independently adjustable • Acoustic travel alarm
seat consoles
• Fold-away auxiliary seat with safety belt
Automatic Lubrication System
• FOPS (rock guard; approved according to DIN ISO 3449)
integrated into cab structure Capacity of grease container 1000 L (264 U.S. gal)
• All-round safety glass, armored windshield and sliding • Dual-circuit system with hydraulically driven heavy-duty
side window pump and electronic time relay control adjust the pause/
lube times
• Windshield with parallel intermittent wiper/washer
• Connected to the lubrication system are the swing roller
• Roller blind at windshield bearing with internal gearing and all pivot points of
• Robust instrument panel including large colored BCS attachment, bucket and cylinders
screen with transflective technology • System failures displayed by Board Control System
• Board Control System (BCS III); electronic monitoring, • Grease filters (200 μm) between service station and
data logging and diagnostic system for vital signs and container, as well as directly behind grease pump
service data of engines, hydraulic system and lubrication
system, featuring:
– Robust instrument panel including large (12 in) colored Attachments
touch screen for intuitive handling
• Boom and sticks are torsion-resistant, welded box design of
– On-screen PDF documentation (e.g. operating high-tensile steel with massive steel casting at pivot areas
instructions, technical handbook, spare parts catalog,
electric circuit diagram) • Welding procedures allow for internal counter-welding
(double prep weld) wherever possible
– On-screen troubleshooting assistance
• Boom and sticks are stress-relieved after welding
– Graphic charts of logged data
• Inspection hole in monoboom of BH-attachment
– Fault memory with storage of related conditions
• Catwalks with rails at boom (FS and BH)
– USB, Lan (TCP/IP) and CAN BUS interfaces for
data export • Pressure-free lowering of boom (FS and BH) and stick
(FS) by means of a float valve
• Machine access via retractable access stairway, stairway
angle approximately 45°, hydraulically operated • Shovel attachment with unique TriPower kinematics
ensuring the following main features:
• Sliding emergency ladder (kick-down type) with ladder cage
– Horizontal automatic constant-angle bucket guidance
– Vertical automatic constant-angle bucket guidance
Undercarriage – Automatic roll-back limiter to prevent material spillage
Travel speed (2 stages) – Kinematic assistance to hydraulic forces
1st stage Max. 1.5 km/h (0.93 mph)
2nd stage Max. 2.5 km/h (1.55 mph) – Constant boom momentum throughout the whole lift arc
Max. tractive force 2097 kN (214 t = 471,260 lb) – Crowd force assistance
Gradeability of travel drives Max. 57% • All buckets (FS and BH) are equipped with a wear package
consisting of:
Track pads (each side) 42
– Special liner material covering main wear areas inside
Bottom rollers (each side) 7 and outside of bucket
Support rollers (each side) 2 plus a skid plate in between – Lip shrouds between teeth
Travel drives (each side) 1 planetary transmission with – Wing shrouds on side walls
2 two-stage axial piston motors
– Heel shrouds at bottom edges
Parking brake Wet multiple disc brake,
spring applied/hydraulically • Special wear packages for highly abrasive materials on request
released
4
Working Range – TriPower Face Shovel Attachment (FS)
ft m
50 15
45 14
13
40 12
11
35
10
30 9
8
25
7
20 6
5 785D
15
4
10 3
2
5
1
0 0
–1
–5
–2
–10 –3
17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 m
55 50 45 40 35 30 25 20 15 10 5 0 ft
Boom 7.3 m 23 ft 11 in Working Range

Stick 4.6 m 15 ft 1 in Maximum digging height 14.4 m 47 ft 3 in
Digging Forces Maximum digging reach 15.4 m 50 ft 6 in
Maximum crowd force 1730 kN 388,780 lbf Maximum digging depth 2.6 m 8 ft 6 in
Maximum crowd force at ground level 1200 kN 269,680 lbf Maximum dumping height 10.9 m 35 ft 9 in
Maximum breakout force 1200 kN 269,680 lbf Crowd distance on level 5.1 m 16 ft 9 in
Face Shovels
Type Iron Ore Shovel Heavy Rock Shovel Heavy Rock Shovel Standard Rock Shovel Light Rock Shovel
Capacity heaped 1:1 17.1 m3 22.4 yd3 20.6 m3 26.9 yd3 23.2 m3 30.3 yd3 25.3 m3 33.1 yd3 27.5 m3 36.0 yd3
Capacity heaped 2:1 15.0 m3 19.6 yd3 18.0 m3 23.5 yd3 20.0 m3 26.2 yd3 22.0 m3 28.8 yd3 24.0 m3 31.4 yd3
Total width 4220 mm 13 ft 4 in 4220 mm 13 ft 4 in 4680 mm 15 ft 4 in 4680 mm 15 ft 4 in 5020 mm 16 ft 6 in
Inner width 3840 mm 12 ft 7 in 3840 mm 12 ft 7 in 4300 mm 14 ft 1 in 4300 mm 14 ft 1 in 4640 mm 15 ft 3 in
Opening width 1940 mm 6 ft 4 in 1940 mm 6 ft 4 in 2010 mm 6 ft 7 in 2010 mm 6 ft 7 in 2010 mm 6 ft 7 in
Number of teeth 5 5 6 6 6
Weight including 34 000 kg 74,960 lb 34 500 kg 76,060 lb 36 400 kg 80,250 lb 37 300 kg 82,230 lb 37 600 kg 82,890 lb
wear package
Maximum material 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
density (loose)
5
Working Range – Backhoe Attachment (BH)
ft m
60 18
55 17
16
50 15
45 14
13
40 12
11
35
10
30 9
8
25
7
20 6
5
15
4
10 3
2
5
1
0 0
–1
–5
–2
–10 –3
–4
–15
–5
–20 –6
–7
–25
–8
–30 –9
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 m
65 60 55 50 45 40 35 30 25 20 15 10 5 0 ft
Boom 9.5 m 31 ft 2 in Working Range

Stick 4.6 m 15 ft 1 in Maximum digging depth 7.0 m 23 ft
Digging Forces Maximum digging reach 17.7 m 58 ft 1 in
Maximum tearout force 1020 kN 229,220 lbf Maximum digging height 16.8 m 55 ft 1 in
Maximum breakout force 1120 kN 251,700 lbf
Backhoes
Type Heavy Rock Bucket Heavy Rock Bucket Standard Rock Bucket
Capacity heaped 1:1 18.0 m3 23.5 yd3 20.0 m3 26.2 yd3 22.0 m3 28.8 yd3
3
Capacity heaped 2:1 16.1 m 21.1 yd3 17.7 m 3
23.2 yd3 19.5 m 3
25.5 yd3
Capacity struck 14.0 m3 18.3 yd3 15.3 m3 20.0 yd3 17.2 m3 22.5 yd3
Total width 4150 mm 13 ft 7 in 4150 mm 13 ft 7 in 4150 mm 13 ft 7 in
Inner width 3800 mm 12 ft 6 in 3800 mm 12 ft 6 in 3800 mm 12 ft 6 in
Number of teeth 6 6 6
Weight including wear package 21 000 kg 46,300 lb 22 900 kg 50,490 lb 23 800 kg 52,470 lb
Maximum material density (loose) 2.2 t/m3 3,710 lb/yd3 2.0 t/m3 3,370 lb/yd3 1.8 t/m3 3,030 lb/yd3
6
General Packing List
2 crawler side frames (values per each side frame)

Gross weight 30 350 kg (66,910 lb) 2
1 Length 7850 mm (25 ft 9 in)
1
Width 2100 mm (6 ft 11 in)
2 Height 1900 mm (6 ft 3 in)
6 tracks consisting of 14 pad links (values per each track) 2

Gross weight 8050 kg (17,750 lb) 1

2 Height 310 mm (1 ft)
Undercarriage center frame with swing roller bearing

Width 3800 mm (12 ft 6 in) 1
Superstructure center frame

Gross weight 50 500 kg (111,330 lb)
1 Length 9500 mm (31 ft 2 in) 2
1
Engine module with diesel engines

2
Oil cooler module

Gross weight 7450 kg (16,420 lb)
1 Length 4700 mm (15 ft 5 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
General Packing List
Cab pedestal module

2
2 Height 3100 mm (10 ft 2 in) 1
Crate with cabin and FOPS

1 Length 3500 mm (11 ft 6 in) 2

1
Counterweight including radiators

1 Length 6100 mm (20 ft) 2
1
Crates
Content 1 2
Length 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)
2
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) 1
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)
8
TriPower Shovel Attachment
Boom with main valve block, TriPower linkages and rods

1 Length 8100 mm (26 ft 7 in) 2
1
Stick
Width 2050 mm (6 ft 9 in) 1
Face shovel including pin for stick

Capacity (2:1) 22.0 m3 (28.8 yd3)
2 Height 3400 mm (11 ft 2 in) 1
Bundle with 2 boom cylinders 2

2 Bundles with 2 stick cylinders and 2 bucket cylinders 2

(values per each bundle)
1
Crate with catwalks, railings and other parts

Width 1900 mm (6 ft 3 in) 1
9
Backhoe Attachment
Monoboom without main valve block

2
1 Length 10 350 mm (33 ft 11 in)
2 Height 2850 mm (9 ft 4 in) 1
Stick with linkage and bucket cylinders

2
2 Height 2750 mm (9 ft) 1
Backhoe bucket including pin for stick

Capacity (1:1) 22.0 m3 (28.8 yd3)
1
Bundle with 2 boom cylinders 2

Bundle with 2 stick cylinders 2

Crates with main valve block, catwalks, railings and other parts
Gross weight 5300 kg (27,580 lb) 4120 kg (9,080 lb) 2
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) 1
2 Height 1750 mm (5 ft 9 in) 1750 mm (4 ft 9 in)
10
Component Accessibility on Superstructure
1. Diesel engines 4. Oil coolers 7. Rotary distributor 10. Operator’s seat

2. Gearboxes with hydraulic pumps 5. Hydraulic tank 8. Travel values 11. BCS tower
3. Engine radiators with hydraulically driven fan 6. Swing drives 9. Switch cabinet and battery box 12. Auxiliary seat
4 4 2 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 Cab
• Export crating • Various heating and air conditioning systems
• Finishing as per end user’s corporate colors • Roller blinds at all windows
Superstructure • Outside-mounted sun shields
• Hydraulic service crane on superstructure with Undercarriage
auxiliary engine • Track pad width 1400 mm (4 ft 7 in) or 1600 mm (5 ft 3 in)
• Round container with a standard 200 L (53 gal) grease barrel • Automatic lubrication of rollers by central lube system
(instead of 1000 L (264 gal) grease container)
• Cover plate under carbody (belly plate)
• Lubricated pinion for greasing of internal gearing of
swing ring Attachment
• Various cold-weather packages • LED lighting on boom
• Special wear packages
Additional optional equipment available on request
11
Materials and specifications are subject to change without notice. AEHQ6524-02
Replaces AEHQ6524-01
Featured machines in photos may include additional equipment.
July 2013
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
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

+
+
Repair personnel

chines.


+
+
Repair personnel
+
+
Repair personnel
6-1
BA 6040(3 847 027.00)-EN
Index
6-2
BA 6040(3 847 027.00)-EN
Index
Disposal at the end of the service life 4-11

A Drive 2-8
ABBREVIATIONS 5-9 E
Access ladder lighting 2-24
ACCIDENT PREVENTION REGULATIONS FOR Electric motor - Safety instructions 3-37
ELECTRICALLY POWERED EXCAVATORS Electric motor can not be switched on 2-64
1-12 Electric motor, cleaning 3-37
Activating the electronic servo control 2-78 Electric motor, greasing 3-38
After daily operation 2-82 Electrical circuit diagrams 3-45
Air conditioner (optional) 2-68 Electrical system 2-9
Appropriate disposal of batteries 4-12 ELECTRICAL SYSTEM 3-39
ASSEMBLING WORKING EQUIPMENT – Electrical system - Safety instructions 3-39
SAFETY INSTRUCTIONS 2-83 Electrical system (24V), switching and off 2-61
Automatic fire-extinguishing system (optional 2- Electrical system, control cabinets 3-42
35 Electronic excavator control 3-68
Automatic reset to idling 2-9 ELEKTRIc MOTOR 3-37
Avoid mixing of different hydraulic fluids 3-29, 3- Emergency escape device (optional) 2-36
62 Emergency exit in operator’s cab and escape
ladder 2-27
B Emergency lowering of the working equipmen 2-
81
Back-up heating operator’s cab (optional) 2-68 EMERGENCY STOP switch 2-30
Battery main switch, switching and off 2-61 Entering and leaving the machine Safety instruc-
Battery storage 3-104 tions 2-24
Battery, checking state of charge 3-40 Equipment, check for cracks 3-99
Bearing races 3-88 Extract from the regulations 3-101
Before starting work 2-78
Board-Control-System (BCS) 2-9 F
Braking the superstructure 2-79
Breather filter 3-92 FAULT TABLES 5-4
Bypass valves, clean / replace 3-56 Filling 3-92
Filling quantities - Grease 3-25
C Filling quantities - oil 3-28
Filling quantities - other 3-28
CENTRAL LUBRICATING 3-90 Filter (servo control circuit), replace 3-58
Central lubricating system – Fault table 5-7 Filters for swing charge pump, replace 3-60
Changing the hydraulic oil 3-62 Fire and explosion hazard 1-14, 2-5
Checking the gas charging pressure in the pres- Fire and Explosion Hazard 3-8, 4-5
sure accumulator 3-87, 3-101 Fire extinguisher 2-34
Checking the greasing pressure 3-93, 3-94 Folding ladder (optional) 2-26
Checking the hydraulic oil level 3-50 Function 3-91
Circuit breaker, switching on and off 2-65 Further machine documentation 1-3
Cleaning jobs 3-9
Cleaning the hydraulic oil cooler 3-67 G
Components 3-9
Control and Monitoring Platform (CAMP) 2-8 Gas, dust, steam and smoke 1-11
Corrosion protection for pins and bearings (bush- Gearbox - Checking the oil level / Topping up with
ings and hubs) 2-85 oil 3-76
CRAWLER TRACKS 3-84 Grease filter (Filling the grease container) 3-97
Grease filter (Grease lines) 3-98
D Grease for bearings, swing rings and track system
(Central lubrication system) 3-34
Demand control / Zero-flow regulation 2-9 Greases for idlers, track rollers and support rollers
Depressurizing the hydraulic system 3-49 (Lifetime lubrication) 3-35
DESCRIPTION OF THE SHOVEL 2-6
Design and function 3-90 H
Designated use 1-6
6-3
BA 6040(3 847 027.00)-EN
Index
Heating and air conditioning 3-99 Oil for hydraulic system (selection) 3-31
High-pressure filter for working hydraulics, re- Oil for pump gearboxes and travel gearboxes 3-
place 3-59 32
High-pressure filters for the servo circuit, replace Oil for swing gearboxes 3-33
3-61 Oil, grease and other chemical substances 1-11
Hose line for oil changes 3-36 Oilfilter (hydraulic circuit grease pump) 3-96
Hydraulic / pnaumatic equipment 1-11 Oils / Greases 3-9
HYDRAULIC CIRCUIT DIAGRAM 5-8 ON-BOARD CRANE (OPTIONAL) 2-86
Hydraulic hoses – Instructions 4-6 On-Board crane, – blocking the boom in position
Hydraulic ladder, pressure accumulator 3-100 of rest 2-88
Hydraulic oil return-flow filters, replace 3-52 On-board crane, checking 2-88
Hydraulic oil return-flow filters, replace (from ma- On-Board crane, checking tightness of fastening
chine no. 170138) 3-54 bolts 3-103
Hydraulic oil tank breather filters, replace 3-57 On-board crane, drive unit 3-102
Hydraulic system 2-8 On-board crane, drive unit 2-87
HYDRAULIC SYSTEM 3-49 On-board crane, lubricating 3-103
HYDRAULIC SYSTEM 4-6 On-board crane, monitoring, warning and control
Hydraulic system - Safety instructions 3-49 elements 2-86
On-board crane, putting into operation 2-87
I Operation - Safety instructions 2-3
Operation and Maintenance Manual, where to
In case of failure 2-64 store it in the operator’s cab 2-4
Inspection and servicing – Safety instructions 3-4 Operation with cable reel (optional) 2-11
Inspection and Servicing plans – Instructions 3-9 Operator's seat 2-32
INSPECTION PLAN - OIL 3-26 Organizational measures 1-7
Inspection plan – Oil (legend) 3-27 OTHER MAINTENANCE 3-99
Instructions on troubleshooting 5-3
P
L Plan A - E 3-17
Layout of the fault table 5-3 Plan N 3-13
Lighting systems in LED technonogy, instructions Plan T and W 3-15
3-48 Plan V 3-11
LUBRICANTS 3-29 Possible causes 5-3
LUBRICANTS / Consumables 3-30 Power supply 2-10
LUBRICATING CHART – GREASE 3-24 Pre-chambers working pumps, draining oil,
Lubricating chart – Grease (legend) 3-25 changing oil 3-74
Preface 1-3
M Pressure accumulator - Emergency lowering 3-69
PRESSURE ACCUMULATORS - SAFETY IN-
Measures 5-3 STRUCTIONS 4-7
Monitoring cameras 2-89 Pressure-accumulator inspection regulations 3-
MONITORING, WARNING AND CONTROL 87
ELEMENTS 2-40 Pressure-accumulator inspection regulations 3-
Motor protection relay, functions 2-66 101
Product specification sheet 5-13
N PUMP DRIVE GEARBOX 3-70
Pump drive gearbox, changing oil 3-72
Noise 1-11 Pump drive gearbox, checking oil level / Topping
Noise and vibration information 5-11 up with oil 3-70
Noise emission information 5-11 Pump drive gearbox, pre-chamber 3-73
notes 3-1 Pump drive gearbox, venting 3-73
NOTES 2-91, 4-13, 5-15 Pump gearbox cooling circuit, replace oil filter 3-
NOTES 1-1 75
Notes on the selection of oils and greases 3-29 Putting the excavator out of operation 3-104
PUTTING THE EXCAVATOR OUT OF OPERA-
O TION AND RECOMMISSIONING 3-104
PUTTING THE MACHINE INTO OPERATION 2-
Oil for combustion engines (On-Board Crane, 58
option) 3-30
6-4
BA 6040(3 847 027.00)-EN
Index
R T
Recommissioning 3-104 Time-out before restart 2-63
Repair 4-6 Track drive – Fault table 5-5
Repair work - Safety instructions 4-4 Track parking brake 2-74
Replacing fuses 3-45 Track rollers 3-85
Replacing lamps and bulbs 3-45 Track tensioner 3-86
Reservoirs for used grease at the A-frame, empty- Trainer's / instructor's seat 2-35
ing 3-100 Transport - Safety instructions 2-75
Transporting and recommissioning 1-11
S Transporting the machine 2-75
TRAVEL GEARBOX 3-81
Safety instructions for excavators with electric Travel gearbox - Breather filter 3-83
motor 1-13, 3-3, 4-3 Travel gearbox - Changing oil 3-82
Safety instructions governing specific operational Travel gearbox - Checking the oil level / Topping
phases 1-8 up with oil 3-81
Section 5-3 TRAVELLING 2-70
Securing the machine 2-84 Travelling forwards/backwards 2-70
Selection and qualification of personnel; basic travellING, SAFETY INSTRUCTIONS 2-69
responsibilities 1-8 TROUBLESHOOTING 5-3
Service station (tanklift) 2-58
Servicing Intervals 3-9 U
Servicing switch 2-31
SERVICING WORK 3-36 Unblocking a grease line. 3-95
Shovel layout 2-7 Undercarriage 2-8
Signs 2-12
SLEWING GEARBOX 3-76 V
Slewing mechnism – Fault table 5-6
SLEWING RING 3-88 Venting the hydraulic system 3-66
Slewing ring - Instructions 3-88 Vibration information 5-11
Slip ring assembly, servicing work 3-45
Special work in conjunction with utilization of the W
machine and maintenance and repairs as well
as troubleshooting during work; disposal of Warning of special dangers 1-10
parts and consumables 1-9 Warnings and symbols 1-5
Superstructure 2-8 Warranty 1-4
Superstructure basic position 2-70 Welding and flame cutting works - Safety instruc-
Superstructure holding brake 2-74 tions 4-8
SWING GEARBOX 3-78 Windscreen washer 2-31
Swing gearbox - Changing the gearbox oil 3-76, Working 2-80
3-79 Working hydraulics – Fault table 5-4
Swing gearbox - Gearbox - Checking the oil level / WORKING OPERATION 2-78
Topping up with oil 3-78 Working operation - Safety instructions 2-76
Swing gearbox - venting 3-80
Swing gearbox, venting 3-77 X
Swinging ladder 2-25
Swinging the superstructure 2-79 Xenon floodlight projector (optional), replacing the
Switching the cab interior lighting on and off 2-28 lamp 3-46
Switching the electric motor on and off 2-62
Switching the maintenance lights on and off 2-29
6-5
BA 6040(3 847 027.00)-EN
Index
6-6

01 Oper Instr 6040 AC 3847027 en

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BA 6040(3 847 027.

Published by: Caterpillar Global Mining HMS GmbH

The Operation and Maintenance Manual is in 6 sections;

Part 1 INTRODUCTION Operating personnel

Part 3 INSPECTION AND Inspection and servicing personnel

Part 4 REPAIR WORK Repair personnel

Part 5 ANNEX Operating personnel

PREFACE _______________________________________________________________________ 1-3

FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-5

DESIGNATED USE ________________________________________________________________ 1-6

ORGANIZATIONAL MEASURES _____________________________________________________ 1-7

ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS____ 1-12

FIRE AND EXPLOSION HAZARD____________________________________________________ 1-14

2 OPERATION _____________________________________________________________________ 2-1

OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3

FIRE AND EXPLOSION HAZARD_____________________________________________________ 2-5

DESCRIPTION OF THE SHOVEL_____________________________________________________ 2-6

Swinging ladder_________________________________________________________________ 2-25

MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-40

PUTTING THE MACHINE INTO OPERATION __________________________________________ 2-58

TRAVELLING, SAFETY INSTRUCTIONS ______________________________________________ 2-69

TRANSPORTING THE MACHINE____________________________________________________ 2-75

WORKING OPERATION - SAFETY INSTRUCTIONS ____________________________________ 2-76

WORKING OPERATION ___________________________________________________________ 2-78

ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS ________________________ 2-83

ON-BOARD CRANE (OPTIONAL)____________________________________________________ 2-86

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

LUBRICATING CHART – GREASE___________________________________________________ 3-24

INSPECTION PLAN - OIL __________________________________________________________ 3-26

LUBRICANTS ___________________________________________________________________ 3-29

LUBRICANTS / CONSUMABLES ____________________________________________________ 3-30

SERVICING WORK _______________________________________________________________ 3-36

ELECTRIC MOTOR _______________________________________________________________ 3-37

Electric motor, greasing___________________________________________________________ 3-38

ELECTRICAL SYSTEM ____________________________________________________________ 3-39

HYDRAULIC SYSTEM_____________________________________________________________ 3-48

PUMP DRIVE GEARBOX __________________________________________________________ 3-69

SWING GEARBOX _______________________________________________________________ 3-75

SWING GEARBOX _______________________________________________________________ 3-77

TRAVEL GEARBOX ______________________________________________________________ 3-80

Travel gearbox - Breather filter _____________________________________________________ 3-82

CRAWLER TRACKS ______________________________________________________________ 3-83

SWING RING ____________________________________________________________________ 3-87

CENTRAL LUBRICATING __________________________________________________________ 3-89

OTHER MAINTENANCE ___________________________________________________________ 3-98

ON-BOARD CRANE, DRIVE UNIT __________________________________________________ 3-101

PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ______________ 3-103

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

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