M0107880

October 2019

68 18 14 61

50

50

M0107880 VOL 1 of 2
Component Locations
57 Schematic Machine Schematic Machine

(Dimensions: 48 inches x 35 inches)

Description Description

B
Location Location Location Location

A C
Accumulator Gp (Access Ladder) B-10 1 Pump Gp - RH Swing H-4 37
Accumulator Gp (Aux Manifold) C-9 2* Pump Gp - RH Swing Charge I-4 38

62 47 Accumulator Gp (Service Arm)

Cooler - LH Oil (Gear Box)
B-7
D-2
3
4
Radiator - Hydraulic Oil Cooler
Radiator - LH Engine Oil Cooler
J-7
C-2
39
40
Cooler - RH Oil (Gear Box) I-2 5 Radiator - RH Engine Oil Cooler H-2 41
Cylinder - Service Arm B-8 6 Tank Gp - Hydraulic F-12 42
Cylinder Gp - Access Ladder B-10 7 Valve - Auxiliary Manifold C-10 43*

63 Filter - Pilot
Filter - Return (Tank)
E-8
G-11
8
9
Valve - Block
Valve - Bypass 1
B-7
H-13
44
45
Filter Gp - Hydraulic I-8 10 Valve - Bypass 2 D-14 46
Filter Gp - LH Oil D-3 11 Valve - Pressure Reducing Valve F-6 47

6040 FS Hydraulic Mining Shovel

Filter Gp - LH Oil 1 (Swing Chg) D-4 12 Valve - Shutoff E-11 48
Filter Gp - LH Oil 2 (Swing Chg) D-5 13 Valve Gp - Access Ladder Control B-10 49
53 53
Hydraulic System
Filter Gp - LH Pump Main Relief Valve (Hydro) D-11 14 Valve Gp - Check G-11 50
Filter Gp - RH Oil I-3 15 Valve Gp - Check (Access Ladder) B-11 51
Filter Gp - RH Oil 1 (Swing Chg) H-3 16 Valve Gp - Check (Arm) B-8 52
Filter Gp - RH Oil 2 (Swing Chg) H-4 17 Valve Gp - Check (Pilot) E-8 53
DHX1-UP
Filter Gp - RH Pump Main Relief Valve (Hydro) G-11 18 Valve Gp - Check (Tank) F-11 54
Motor Gp - Engine Cooler Drive J-8 19 Valve Gp - Check LH Pump E-13 55
69 Motor Gp - LH Engine Cooler Drive C-2 20 Valve Gp - Check RH Pump G-13 56
Motor Gp - RH Engine Cooler Drive H-2 21 Valve Gp - Flushing F-7 57
Motor Gp - Swing D-11 22 Valve Gp - LH Check (Gearbox Oil Cooling) D-2 58

60 Pump - LH PTO Oil Circulation

Pump - RH PTO Oil Circulation
D-4
F-4
23
24
Valve Gp - LH Orifice (Shutoff)
Valve Gp - LH Pump Control
D-2
E-7
59
60
Pump Gp - LH Circulation E-2 25 Valve Gp - LH Swing Block D-8 61
67

36 Page,
Pump Gp - LH Hyd And Engine Oil Cooling C-3 26 Valve Gp - Logic (Solenoid) E-8 62

55 Pump Gp - LH Main 1
Pump Gp - LH Main 2
B-3
E-3
27
28
Valve Gp - Relief
Valve Gp - Relief (Tank)
F-8
E-11
63
64
Pump Gp - LH Pilot E-5 29 Valve Gp - RH Check (Gearbox Oil Cooling) I-2 65

56 Pump Gp - LH Swing
Pump Gp - LH Swing Charge
D-4
A-4
30
31
Valve Gp - RH Orifice (Shutoff)
Valve Gp - RH Pump Control
I-2
E-9
66
67
8 Pump Gp - RH Circulation J-2 32 Valve Gp - RH Swing Block I-7 68
Pump Gp - RH Hyd And Engine Oil Cooling I-4 33 Valve Gp - Safety Integrity Level G-8 69

1 51 Pump Gp - RH Main 1
Pump Gp - RH Main 2
J-3
G-3
34
35
Valve Gp - Sutoff (Suction Line 1)
Valve Gp - Sutoff (Suction Line 2)
F-10
F-10
70
71
NOT SHOWN Pump Gp - RH Pilot G-5 36
* NOTE : NOT SHOWN

VIEW OF AREA “B”

Volume 1 of 2: Main Hydraulic

66 FLUID POWER SYMBOLS

13 45 46
BASIC COMPONENT SYMBOLS

MAIN AUX

PUMP OR MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION PUMP PUMP

65
(FIXED) (2 - SECTION) (VARIABLE & PRESSURE
COMPENSATED)

59 12
VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES (VARIABLE & PRESSURE
COMPENSATED)

15 22 22 VALVE ENVELOPES VALVES VALVE PORTS

30 64
16 58 ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY

CONTROL VALVES CHECK VALVES

27 54 42 AB A B

P T P T
BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

FLUID STORAGE RESERVOIRS

17 11 9
36 VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

MEASUREMENT ROTATING SHAFTS

37 28 31
PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

71 COMBINATION CONTROLS
34 29
3
SOLENOID SOLENOID SOLENOID SOLENOID & SERVO THERMAL DETENT

38
OR MANUAL & PILOT PILOT OR MANUAL

23 70 44
MANUAL CONTROL SYMBOLS

PUSH - PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

33 52 RELEASED PRESSURE PILOT CONTROL SYMBOLS REMOTE SUPPLY PRESSURE

6
26 25 22 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE

32 35 24 48 ACCUMULATORS CROSSING & JOINING LINES HYDRAULIC & PNEUMATIC CYLINDERS

SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

VIEW OF AREA “C” HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

VIEW OF AREA “A” FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE
DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING 3 POSITION 2 POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW IN

BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER
DIRECTION

ENCLOSURE - FRONT VIEW CHASSIS - FRONT VIEW HYDRAULIC TANK © 2019 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow,” the “Power Edge”
and Cat “Modern Hex” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without
permission.

ELECTRICAL SYMBOLS TABLE

HYDRAULIC SYMBOLS (ELECTRICAL)

G
M
40 20 TRANSDUCER
(FLUID)
TRANSDUCER
(GAS / AIR)
GENERATOR ELECTRIC MOTOR

PRESSURE SWITCH PRESSURE SWITCH TEMPERATURE ELECTRICAL WIRE

(ADJUSTABLE) SWITCH

10 21 WIRE NUMBER IDENTIFICATION CODES

ELECTRICAL SCHEMATIC EXAMPLE HYDRAULIC SCHEMATIC EXAMPLE

CURRENT STANDARD CURRENT STANDARD

41
HARNESS IDENTIFICATION CODE THIS EXAMPLE
INDICATES WIRE 135 IN HARNESS “AG”

19 WIRE
COLOR
WIRE

49 325-AG135 PK-14
CIRCUIT NUMBER
IDENTIFICATION WIRE COLOR
39
CIRCUIT NUMBER WIRE GAUGE*
*Wire gauge is shown in AWG (American Wire Gauge)
IDENTIFICATION but could also be shown in metric denoted with mm 325-PK

PREVIOUS STANDARD
19 WIRE WIRE COLOR

325-PK-14 B A

CIRCUIT NUMBER WIRE GAUGE* (EXAMPLE VALVE)

IDENTIFICATION *Wire gauge is shown in AWG (American Wire Gauge)
but could also be shown in metric denoted with mm

5
4

COOLER GP ACCESS LADDER - RIGHT VIEW COOLER DRIVE - REAR VIEW

 14 13 12 11 10 9 8 7 6 5 4 3 2 1

(32) PUMP GP
RH CIRCULATION
468-2693

(39) RADIATOR
J HYDRAULIC OIL COOLER XD X1 X2 J
535-4973
M0107880 VOL 1 of 2
(Dimensions: 48 inches x 35 inches)

(34) PUMP GP
M2 RH MAIN 1
P
544-1056
(38) PUMP GP
RH SWING CHARGE B MB
(19) MOTOR GP - ENGINE COOLER DRIVE
471-5775
468-2695
U
P
(65) VALVE GP - RH CHECK (GEARBOX OIL COOLING)
Vg max Vg min 483-5363

(10) FILTER GP - HYDRAULIC M1 R T K K1 M S

S2
RIGHT CRAWLERS 534-6371
D3 C
(15) FILTER GP
(33) PUMP GP - RH HYD AND RH OIL
BUCKET S5 (66) VALVE GP - RH ORIFICE (SHUTOFF)
ENGINE OIL COOLING 438-6551
FORWARD REVERSE 512-1045 479-2766
I LEFT CRAWLERS
BOOM
BOOM

A1
I
A B
BUCKET
Z X2 X1
(5) COOLER - RH OIL (GEAR BOX)
FORWARD REVERSE TUBE ASSEMBLY 1 TUBE ASSEMBLY 2 533-9066
(TA 1)
SLEW (TA 2)
BUCKET CLAM
D1 D8 (68) VALVE GP - RH SWING BLOCK
STICK R
STICK
D2 D9 479-3032
U
D10 P
CLOSE OPEN
SLEW
D3
D11 A1
D4 DRAIN A B B2 B1

COLLECTORS LH Z
36 Page,

RH

D5 D12 R

D6 D13

D7 D14
L3 L4 S2 L1 L2 S1

CONNECTS TO
AA S3 D4 S1
(21) MOTOR GP - RH ENGINE COOLER DRIVE
VOL 2, LOC C-1 D2 468-2695
H P
U
T
U
H
CONNECTS TO
AB
VOL 2, LOC C-1
U
D5
P (17) FILTER GP
D1
RH OIL 2 (SWING CHG) (16) FILTER GP
438-6551 RH OIL 1 (SWING CHG) (41) RADIATOR - RH ENGINE OIL COOLER
(45) VALVE - BYPASS 1 438-6551
C T C T 535-3260
535-5033 T1 Fa T1 Fa
CONNECTS TO
VOL 2, LOC G-1 AC
A C

A C

ST ST

(50) VALVE GP - CHECK

(18) FILTER GP 533-7219
RH PUMP MAIN RELIEF VALVE (HYDRO)
534-5426 U
P X1 X2
(37) PUMP GP
U RH SWING
P 468-9833

G G
(35) PUMP GP
RH MAIN 2
U (69) VALVE GP - SAFETY INTEGRITY LEVEL 544-1056
P 486-4349
D6
XD X1 X2
(56) VALVE GP L
CHECK RH PUMP
TANK WITH RETURN OIL (9) FILTER - RETURN (TANK) (36) PUMP GP
535-5181
U U
3 3
P P
RH PILOT
526-8327
CONNECTS TO
2
1 1
2 468-9854 L
P3 SWING BALANCE
VOL 2, LOC G-1 AD VALVE
X1 X2
X5 X6

Y2 Y1 M2
P T
P4 U
P
P A M G T1
C

(54) VALVE GP (47) VALVE B MB

CHECK (TANK) PRESSURE REDUCING VALVE

(57) VALVE GP
U
486-3480
A B 533-7257 T
FLUSHING
SUCTION CONNECTION 479-2706 Vg min Vg max Vg max Vg min
FOR THE PUMPS
P

F CONNECTS TO
AE
P
F
VOL 2, LOC H-1 A L M1 R T K K1 M S
CONNECTS TO
(70) VALVE GP T
AF
VOL 2, LOC G-1 SUTOFF (SUCTION LINE 1) T
S M1 T2 R D7 C
441-9900 T P
(24) PUMP - RH PTO OIL CIRCULATION S4
(63) VALVE GP
(71) VALVE GP 534-4656
U
RELIEF P
SUTOFF (SUCTION LINE 2)
(42) TANK GP - HYDRAULIC U
486-3487
T 479-2710
CONNECTS TO
547-8320
AG B A
VOL 2, LOC F-1
U
T PUMPS RIGHT
T
A T
P P T
A

PUMPS LEFT P
(25) PUMP GP
S1 LH CIRCULATION
(62) VALVE GP (60) VALVE GP 468-2693
CONNECTS TO S2
AH
LOGIC (SOLENOID) LH PUMP CONTROL
VOL 2, LOC E-1
U U
(64) VALVE GP S3 P 494-6545 P
(29) PUMP GP XD X1 X2
486-4348
RELIEF (TANK) S4
LH PILOT
CONNECTS TO
VOL 2, LOC F-1
AJ 479-2932 S5 468-9854
(67) VALVE GP (8) FILTER - PILOT
RH PUMP CONTROL
486-4348 484-8882 C
E S6 E
S7 (28) PUMP GP - LH MAIN 2
D10 M2 544-1056
S8
P
S9 A M G T1

P1 S10 (53) VALVE GP - CHECK (PILOT) B MB

TUBE ASSEMBLY 3 534-2590
(TA 3)
CONNECTS TO (48) VALVE - SHUTOFF (58) VALVE GP - LH CHECK (GEARBOX OIL COOLING)
VOL 2, LOC F-1 AK
P2 533-9648 Vg min Vg max Vg max Vg min
483-5363

(55) VALVE GP
CHECK LH PUMP M1 R T K K1 M S
535-5181
U S M1 T2 R
(14) FILTER GP - LH PUMP MAIN RELIEF VALVE (HYDRO) P (50) VALVE GP - CHECK D14 C
513-0756 533-7219 (23) PUMP - LH PTO OIL CIRCULATION
534-4656 S7
U (59) VALVE GP - LH ORIFICE (SHUTOFF)
CONNECTS TO P
VOL 2, LOC E-1 AL 479-2766
B D
C (61) VALVE GP
LH SWING BLOCK
ST
(13) FILTER GP (11) FILTER GP
ST 479-3032
(12) FILTER GP - LH OIL 1 (SWING CHG) LH OIL
U
T C LH OIL 2
(22) MOTOR GP - SWING A1
438-6551 438-6551
D 488-5417
A B (SWING CHG)
438-6551 D9
U (30) PUMP GP D11
D
Z P LH SWING
(46) VALVE - BYPASS 2 468-9833
(22) MOTOR GP - SWING C T C T
U
535-5033 P
488-5417 T1 Fa T1 Fa

U
R (4) COOLER - LH OIL (GEAR BOX)
P
U
P 533-9066

A1
A B

Z
CONNECTS TO
VOL 2, LOC C-1 AM U (20) MOTOR GP - LH ENGINE COOLER DRIVE
P (2) ACCUMULATOR GP U U
468-2695
P T
(43) VALVE - AUXILIARY MANIFOLD (AUX MANIFOLD)
534-2275 469-3062 R X1 X2

(40) RADIATOR - LH ENGINE OIL COOLER

SECOND 535-3260
(26) PUMP GP - LH HYD AND ENGINE OIL COOLING
CONNECTS TO SPEED CONTROL
VOL 2, LOC F-1 AN
512-1045

C T
X2 X1
C
P1 P2
A1 A4 A3 A2 NOT USED

SWING BRAKE
CONNECTS TO AP
VOL 2, LOC D-1 PROPEL PRESSURE BOOST

CONNECTS TO
VOL 2, LOC C-1 AR
B2 B1

(7) CYLINDER GP LUBE PUMP STATION

ACCESS LADDER (6) CYLINDER - SERVICE ARM
486-9966 493-2098
A
C
(1) ACCUMULATOR GP (44) VALVE - BLOCK L3 L4 S2 L1 L2 S1
B
(ACCESS LADDER) 499-9701
CONNECTS TO (3) ACCUMULATOR GP
VOL 2, LOC C-1 AS 469-3064 D8 S8 D12
U U
A
(SERVICE ARM) S10
P P C 469-3062
A B
B B
B A B

CONNECTS TO
LINE PATTERNS
AT A P
VOL 2, LOC D-1
B T X1
Pressure Line
R P P XD X2
(51) VALVE GP
(27) PUMP GP - LH MAIN 1 Pilot / Load Sensing Pressure
CHECK L
(ACCESS LADDER) C C R P A B P R P P
(52) VALVE GP - CHECK (ARM) 544-1056
A
Drain / Return Lines
482-5115 B 482-5115
P
L
Air Line
R

Component Group
(49) VALVE GP M2

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS ACCESS LADDER CONTROL P

CALLOUTS
PILOT PUMP OUTPUT 484-3605 C

MAIN PUMP OUTPUT

B MB YY Taps (Pressure, Sampling, Sensor - by letter)
TRACK TENSION CONTROL CIRCUIT P P U
(31) PUMP GP - LH SWING CHARGE T DL DL D Connectors (By letter)
RIGHT TRAVEL MOTOR CIRCUIT
TRAVEL RIGHT CONTROL CIRCUIT
T T
471-5775
Vg max Vg min
TRAVEL LEFT CONTROL CIRCUIT Callout Number Component
(Machine Location from (52) VALVE GP - CONTROL Name
FAN COOLING CONTROL CIRCUIT Component LocationsTable)
SUPPLY LINE
138-1234 Part Number

LUBE PUMP CONTROL CIRCUIT S9 M1 R T K K1 M S

2 SPEED TRAVEL CONTROL CIRCUIT
LEFT TRAVEL MOTOR CIRCUIT D13 C
A SWING BRAKE CONTROL CIRCUIT
DRAIN / RETURN LINE
S6 A
ACCESS LADDER / SERVICE ARM CONTROL CIRCUIT
CHARGE PUMP OUTPUT
THIS SCHEMATIC IS FOR THE 6040 FS HYDRAULIC MINING SHOVEL HYDRAULIC SYSTEM
MAIN PUMP CONTROL CIRCUIT VOLUME 1 of 2: MAIN HYDRAULIC
SWING CONTROL CIRCUIT
MEDIA NUMBER: M0107880
Do not operate or work on this product unless you have
read and understood the instruction and warnings in the SCHEMATIC PART NUMBER: 569-1147, CHANGE: 00, VERSION: -
relevant Operation and Maintenance Manuals and Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
relevant service literature. Failure to follow the instruc- in neutral and with parking brake set.
tions or heed the warnings could result in injury or
death. Proper care is your responsibility. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

14 13 12 11 10 9 8 7 6 5 4 3 2 1
 M0107880
October 2019
Component Locations
Schematic Machine
Description
Location Location
Accumulator (LH Travel) C-5 101
Accumulator (RH Travel) J-5 102
Accumulator Gp - LH Track Tension C-6 103
Accumulator Gp - Oil (Es) C-10 104

103 Accumulator Gp - RH Track Tension

Cylinder Gp - LH Boom
J-10
E-13
105
106

M0107880 VOL 2 of 2
Cylinder Gp - LH Bucket G-14 107
Cylinder Gp - LH Clam D-12 108

(Dimensions: 48 inches x 35 inches)

Cylinder Gp - LH Stick E-13 109
110 Cylinder Gp - LH Track Tension D-6 110
Cylinder Gp - RH Boom G-13 111
Cylinder Gp - RH Bucket G-14 112
Cylinder Gp - RH Clam D-12 113
Cylinder Gp - RH Stick F-13 114
Cylinder Gp - RH Track Tension I-9 115

D Manifold - Pilot Control C-7 116*

129 118 129 Manifold As - Track Tension
Motor Gp - LH Travel
I-14
E-5
117
118

120 Motor Gp - RH Travel

Swivel Gp
J-4
F-5
119
120

122
Valve - Float
Valve - LH Travel Control
F-12
F-5
121
122 6040 FS Hydraulic Mining Shovel
Hydraulic System
Valve - Relief (LH Travel) C-4 123
Valve - Relief (RH Travel) J-5 124

125
E Valve - RH Travel Control
Valve Gp - Emergency Lowering Check
G-3
C-10
125
126 DHX1-UP

134 119 135 Valve Gp - Emergency Stop

Valve Gp - LH Anti Cavitation Check
C-10
E-4
127*
128
Valve Gp - LH Travel Motor Control D-3 129
Valve Gp - Main Control 1 H-10 130

133 128 115 B A

Valve Gp - Main Control 2 F-10 131

101 123 Valve Gp - Relief (Clam)

Valve Gp - RH Anti Cavitation Check
D-13
G-4
132
133
105 Valve Gp - RH Travel Motor Control I-4 134

36 Page,
Valve Gp - Track Tension Relief I-13 135
* NOTE : NOT SHOWN

Tap Locations
Pressure, Sampling, and Sensor
Tap Schematic
124 102 134 117 Number
Description
Location
A RH Track Tension Pressure I-13
B LH Track Tension Pressure H-13
VIEW OF AREA “E” VIEW OF AREA “D” C Bucket Cylinder Rod End Pressure H-9
(ROTATED FOR CLARITY) (ROTATED FOR CLARITY) D Bucket Cylinder Head End Pressure H-9
Volume 2 of 2: Implements

CHASSIS - FRONT VIEW UNDERCARRIAGE

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS

MAIN AUX

PUMP OR MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION PUMP PUMP
(FIXED) (2 - SECTION) (VARIABLE & PRESSURE
COMPENSATED)

VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES (VARIABLE & PRESSURE
COMPENSATED)

104 126 VALVE ENVELOPES VALVES VALVE PORTS

114 109

F
ONE POSITION TWO POSITION THREE POSITION TWO - WAY THREE - WAY FOUR - WAY

CONTROL VALVES CHECK VALVES

AB A B

P T P T
BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

FLUID STORAGE RESERVOIRS

VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

MEASUREMENT ROTATING SHAFTS

PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID SOLENOID SOLENOID SOLENOID & SERVO THERMAL DETENT

OR MANUAL & PILOT PILOT OR MANUAL

107 MANUAL CONTROL SYMBOLS

PUSH - PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

RELEASED PRESSURE PILOT CONTROL SYMBOLS REMOTE SUPPLY PRESSURE

112
EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE

ACCUMULATORS CROSSING & JOINING LINES HYDRAULIC & PNEUMATIC CYLINDERS

106
108 SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE

DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING 3 POSITION 2 POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

132 BIDIRECTIONAL BIDIRECTIONAL

FLOW IN ONE
DIRECTION
PARALLEL
FLOW
CROSS
FLOW
FLOW IN
EITHER
DIRECTION

© 2019 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow,” the “Power Edge”
and Cat “Modern Hex” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without
permission.

113
ELECTRICAL SYMBOLS TABLE
HYDRAULIC SYMBOLS (ELECTRICAL)

111
G
M
TRANSDUCER TRANSDUCER GENERATOR ELECTRIC MOTOR
(FLUID) (GAS / AIR)

121

PRESSURE SWITCH PRESSURE SWITCH TEMPERATURE ELECTRICAL WIRE

130 (ADJUSTABLE) SWITCH

WIRE NUMBER IDENTIFICATION CODES

C ELECTRICAL SCHEMATIC EXAMPLE

CURRENT STANDARD
HYDRAULIC SCHEMATIC EXAMPLE
CURRENT STANDARD

HARNESS IDENTIFICATION CODE THIS EXAMPLE

INDICATES WIRE 135 IN HARNESS “AG”
WIRE WIRE
COLOR

D 325-AG135 PK-14
CIRCUIT NUMBER
IDENTIFICATION WIRE COLOR

CIRCUIT NUMBER WIRE GAUGE*

*Wire gauge is shown in AWG (American Wire Gauge)
IDENTIFICATION but could also be shown in metric denoted with mm 325-PK

PREVIOUS STANDARD

WIRE WIRE COLOR

325-PK-14 B A

131 CIRCUIT NUMBER

IDENTIFICATION
WIRE GAUGE*
*Wire gauge is shown in AWG (American Wire Gauge)
but could also be shown in metric denoted with mm
(EXAMPLE VALVE)

VIEW OF AREA “F”

(ROTATED FOR CLARITY)

MACHINE - FRONT RIGHT VIEW

 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RH TRAVEL GEARBOX

(102) ACCUMULATOR
(RH TRAVEL)
(124) VALVE
549-8570 (119) MOTOR GP - RH TRAVEL
RELIEF (RH TRAVEL)
(119) MOTOR GP - RH TRAVEL 534-3416 468-9852
468-9852
J J
M0107880 VOL 2 of 2

T1 T1
(Dimensions: 48 inches x 35 inches)

T2 T2
SECOND SECOND
SPEED PARK SPEED PARK
CONTROL BRAKE CONTROL BRAKE

BRAKE BRAKE

(105) ACCUMULATOR GP - RH TRACK TENSION RELEASE RELEASE

470-7270 (115) CYLINDER GP - RH TRACK TENSION VALVE VALVE

467-1669

MB MB
TRAVEL TRAVEL
RETARDER RETARDER
VALVE VALVE

B B

I I
(117) MANIFOLD AS - TRACK TENSION
441-4928
A (134) VALVE GP
RH TRAVEL MOTOR CONTROL
442-8374
P1 T1

A1

B1
36 Page,

A2
(135) VALVE GP - TRACK TENSION RELIEF
B2
479-2708

C
A3

B3 (130) VALVE GP - MAIN CONTROL 1

533-7595
P2 T2
B T T
AE
CONNECTS TO

H VOL 1, LOC F-14

H
B4 rs

A4 ps

D
BUCKET

B3 rs

A3 ps

AC CONNECTS TO
VOL 1, LOC H-14
(112) CYLINDER GP - RH BUCKET
467-1571
STICK

B2 rs
(133) VALVE GP
A2 ps RH ANTI CAVITATION
G CHECK T
G
469-3916 T T
AF
CONNECTS TO
(125) VALVE VOL 1, LOC F-14
RH TRAVEL CONTROL
BOOM 535-5151
(111) CYLINDER GP - RH BOOM T1
B1 A1 T2 T T
465-8707
B1 rs
CONNECTS TO
AD
VOL 1, LOC G-14
A1 ps

L L

(107) CYLINDER GP - LH BUCKET St2 St1

467-1571
C
SPARE
B A
4
(114) CYLINDER GP - RH STICK P1 3
8 DRAIN CONNECTS TO
465-8688 7
AG
VOL 1, LOC F-14
DRAIN

6 SECOND SPEED CONTROL CONNECTS TO

AN
5 TRACK TENSION VOL 1, LOC C-14

(120) SWIVEL GP
B A C
533-7125
(121) VALVE - FLOAT
F 534-0900 St2 St1
F
L L

(131) VALVE GP - MAIN CONTROL 2 P

AK CONNECTS TO
533-7595 VOL 1, LOC E-14

T T1 B1 A1 T2 T T
T

(122) VALVE - LH TRAVEL CONTROL

535-5154
B4 rs T T CONNECTS TO
AJ
VOL 1, LOC E-14
(109) CYLINDER GP - LH STICK A4 ps (128) VALVE GP T
465-8688
LH ANTI CAVITATION
CHECK
469-3916
BOOM

B3 rs

A3 ps
(106) CYLINDER GP - LH BOOM
465-8707 CONNECTS TO
E AH VOL 1, LOC E-14 E
STICK CONNECTS TO
AL VOL 1, LOC D-14

B2 rs

A2 ps
(129) VALVE GP
LH TRAVEL MOTOR CONTROL
442-8374
BUCKET

(113) CYLINDER GP - RH CLAM

522-1531 B1 rs B B
TRAVEL
TRAVEL
RETARDER
ps RETARDER
A1 VALVE
VALVE

MB MB

RF KF
RF

(132) VALVE GP - RELIEF (CLAM) KF

MP CLAM
479-3026 BRAKE
RELEASE
BRAKE
RELEASE
VALVE VALVE

D X
P1
CONNECTS TO
D
AT
RF KF VOL 1, LOC B-14
(118) MOTOR GP - LH TRAVEL
468-9852 CONNECTS TO
T1 T1 AP VOL 1, LOC C-14
PARK PARK
SECOND SECOND
BRAKE BRAKE
(108) CYLINDER GP - LH CLAM SPEED T2 SPEED T2
CONTROL CONTROL
522-1531

(103) ACCUMULATOR GP
LH TRACK TENSION
(118) MOTOR GP - LH TRAVEL
470-7270 468-9852
(101) ACCUMULATOR
(LH TRAVEL) (123) VALVE
549-8570 RELIEF(LH TRAVEL) AM CONNECTS TO
VOL 1, LOC C-14
(104) ACCUMULATOR GP - OIL (ES) 534-3416
469-3062 (110) CYLINDER GP
LH TRACK TENSION LH TRAVEL GEARBOX CONNECTS TO
AS VOL 1, LOC B-14
467-1669

C (127) VALVE GP
CONNECTS TO
C
EMERGENCY STOP AR VOL 1, LOC C-14
486-4347

TRAVEL TRAVEL TRAVEL TRAVEL

ENGINE OFF
LOWERING STICK STICK LEFT LEFT RIGHT RIGHT CLAM CLAM CONNECTS TO
AA
A P R PISTON FLOAT FWD REV FWD REV PISTON ROD VOL 1, LOC H-14

MA8 A8 MA7 A7 MA6 A6 MA5 A5 MA4 A4 MA3 A3 MA2 A2 MA1 A1 P3 P1

RIGHT CRAWLERS
CONNECTS TO
U AB VOL 1, LOC H-14
P P4
P2
BUCKET

FORWARD REVERSE
(126) VALVE GP
BOOM EMERGENCY LOWERING CHECK
BOOM

LEFT CRAWLERS
485-3747
BUCKET

MB8 B8 MB7 B7 MB6 B6 MB5 B5 MB4 B4 MB3 B3 MB2 B2 MB1 B1

FORWARD REVERSE

SLEW SWING SWING STICK BOOM BOOM BOOM BUCKET BUCKET

BUCKET CLAM LEFT RIGHT ROD PISTON FLOAT ROD ROD PISTON
(116) MANIFOLD - PILOT CONTROL
B STICK
STICK
534-6072 B
CLOSE OPEN
SLEW
LINE PATTERNS
Pressure Line

Pilot / Load Sensing Pressure

Drain / Return Lines

Air Line

Component Group

CALLOUTS
SWING RIGHT
U YY Taps (Pressure, Sampling, Sensor - by letter)
P
SWING LEFT
U DL DL D Connectors (By letter)
P
Callout Number Component

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS (Machine Location from (52) VALVE GP - CONTROL Name
Component LocationsTable)
138-1234 Part Number
PILOT PUMP OUTPUT
A MAIN PUMP OUTPUT A
TRACK TENSION CONTROL CIRCUIT
RIGHT TRAVEL MOTOR CIRCUIT THIS SCHEMATIC IS FOR THE 6040 FS HYDRAULIC MINING SHOVEL HYDRAULIC SYSTEM
TRAVEL RIGHT CONTROL CIRCUIT
TRAVEL LEFT CONTROL CIRCUIT VOLUME 2 of 2: IMPLEMENTS
LEFT TRAVEL MOTOR CIRCUIT
SWING BRAKE CONTROL CIRCUIT
Do not operate or work on this product unless you have MEDIA NUMBER: M0107880
read and understood the instruction and warnings in the
DRAIN / RETURN LINE relevant Operation and Maintenance Manuals and SCHEMATIC PART NUMBER: 569-1147, CHANGE: 00, VERSION: -
CLAM CYLINDER CONTROL CIRCUIT relevant service literature. Failure to follow the instruc- Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
BUCKET CYLINDER CONTROL CIRCUIT tions or heed the warnings could result in injury or
in neutral and with parking brake set.
BOOM CYLINDER CONTROL CIRCUIT death. Proper care is your responsibility.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
STICK CYLINDER CONTROL CIRCUIT
Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

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