Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651447 – PDF DOWNLOAD
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Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651447 – PDF DOWNLOAD
Language : English
Pages : 218
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Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651447 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 40 E
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
- The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
! operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair) and / or
transport
- In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified GERMANY Germany mechanic or by attending an Terex-Germany training course for operators or maintenance personnel. The Terex-Germany after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. 1 Complies with VDMA recommendation “Operating instructions” All Terex Germany operating manuals are issued in German and then translated.
- Even a good translation may give rise to questions which Terex Germany will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex Germany after- sales service. The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately.
- The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
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TABLE OF CONTENTS:
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651447 – PDF DOWNLOAD
1 INTRODUCTION............................................................................................................................................................... 11 PREFACE.................................................................................................................................................................. 13 WARRANTY................................................................................................................................................................. 14 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15 Warnings and symbols................................................................................................................................................. 15 DESIGNATED USE........................................................................................................................................................... 16 ORGANIZATIONAL MEASURES.................................................................................................................................................. 17 Selection and qualification of personnel; basic responsibilities..................................................................................................... 18 Safety instructions governing specific operational phases............................................................................................................ 18 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19 Warning of special dangers........................................................................................................................................... 20 Gas, dust, steam and smoke........................................................................................................................................... 21 Hydraulic equipment.................................................................................................................................................. 21 Noise................................................................................................................................................................ 21 Oil, grease and other chemical substances............................................................................................................................ 21 Transporting and recommissioning..................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 22 NOTES ................................................................................................................................................................... 23 2 OPERATION.................................................................................................................................................................. 25 OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 27 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 29 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 30 Excavator layout..................................................................................................................................................... 31 Undercarriage........................................................................................................................................................ 32 Superstructure....................................................................................................................................................... 32 Drive................................................................................................................................................................ 32 Hydraulic system..................................................................................................................................................... 32 Pump Managing System (PMS)........................................................................................................................................... 32 Programmable Logic Controller (PLC) ................................................................................................................................. 32 Central Management System (CMS) ..................................................................................................................................... 32 Demand control / Zero-flow regulation................................................................................................................................ 33 Automatic engine speed reduction .................................................................................................................................... 33 Board-Control-System (BCS) .......................................................................................................................................... 33 Electrical system ................................................................................................................................................... 33 Sign ................................................................................................................................................................ 35 Entering and leaving the machine Safety instructions................................................................................................................. 36 Ramp-type ladder (optional) ......................................................................................................................................... 37 Ramp-type ladder (optional) ......................................................................................................................................... 38 EMERGENCY STOP pushbuttons .......................................................................................................................................... 40 Windscreen washer ................................................................................................................................................... 40 Driver's seat ....................................................................................................................................................... 41 Fire extinguisher.................................................................................................................................................... 42 Fire extinguisher (option) .......................................................................................................................................... 42 Automatic fire-extinguishing system (optional)....................................................................................................................... 43 Harness (optional)................................................................................................................................................... 44 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 48 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 78 Refuelling .......................................................................................................................................................... 78 Service station (tanklift) .......................................................................................................................................... 79 Switching the electrical system on and off .......................................................................................................................... 85 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 86 Starting the engines ................................................................................................................................................ 86 AIR CONDITIONER (OPTION)................................................................................................................................................. 89 Back-up heating (option) ............................................................................................................................................ 91 DRIVING SAFETY INSTRUCTIONS ............................................................................................................................................. 93 TRAVELLING .............................................................................................................................................................. 94 Superstructure basic position ....................................................................................................................................... 94 Travelling forwards/backwards ....................................................................................................................................... 94 Emergency machine drive ............................................................................................................................................. 98 Locking the superstructure ..........................................................................................................................................100 Track parking brake .................................................................................................................................................100 TRANSPORTING THE MACHINE ................................................................................................................................................101 Transport - Safety instructions .....................................................................................................................................101 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................102 WORKING OPERATION .......................................................................................................................................................104 Before starting work ................................................................................................................................................104 Slewing and braking the superstructure ..............................................................................................................................104 Braking the superstructure ..........................................................................................................................................104 Working .............................................................................................................................................................105 After daily operation ...............................................................................................................................................106 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................107 Securing the machine ................................................................................................................................................109 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................110 NOTES ...................................................................................................................................................................111 3 INSPECTION AND SERVICING...................................................................................................................................................113 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................115 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................121 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................123 Intervals............................................................................................................................................................123 Change of engine oil l...............................................................................................................................................123 Air-intake system ...................................................................................................................................................123 Oils / Greases ......................................................................................................................................................123 Cleaning jobs .......................................................................................................................................................123 Components ..........................................................................................................................................................123 Plan V ..............................................................................................................................................................125 Plan N ..............................................................................................................................................................127 Plan T ..............................................................................................................................................................129 Plan A – E ..........................................................................................................................................................131 LUBRICATING CHART – GREASE (LOADING BUCKET) .............................................................................................................................140 Lubricating chart – Grease / Backhoe bucket (legend) ................................................................................................................141 Filling quantities - Grease..........................................................................................................................................141 Lubricating chart – Grease / Backhoe bucket .........................................................................................................................142 Lubricating chart – Grease / Backhoe bucket (legend) ................................................................................................................143 Filling quantities - Grease..........................................................................................................................................143 INSPECTION PLAN - OIL ...................................................................................................................................................144 Inspection plan – Oil (legend) ......................................................................................................................................145 Filling quantities - oil ............................................................................................................................................146 Filling quantities - other...........................................................................................................................................146 LUBRICANTS ..............................................................................................................................................................147 Notes on the selection of oils and greases ..........................................................................................................................147 I. Oils for combustion engines ......................................................................................................................................148 II. Oils for hydraulic system .......................................................................................................................................149 III.a Oils for pump gearboxes .......................................................................................................................................150 III.b Oils for swing gearboxes ......................................................................................................................................151 III.c Oils for travel gearboxes .....................................................................................................................................152 V. Greases for bearings and slewing rings ...........................................................................................................................153 SERVICING WORK ..........................................................................................................................................................154 Hose line for oil and cooling liquid changes ........................................................................................................................154 ENGINE ..................................................................................................................................................................155 Engine - Safety instructions ........................................................................................................................................155 Checking the engine oil level / Topping up .........................................................................................................................156 Checking the oil level in the engine oil reservoir / topping up (optional) ..........................................................................................157 Changing the engine oil .............................................................................................................................................157 Draining the oil off the engine oil reservoir (optional) ............................................................................................................159 Replacing the oil filter ............................................................................................................................................161 Replacing the oil filter (oil interval prolonging) ..................................................................................................................161 Centrifuge (optional)................................................................................................................................................162 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................163 COOLING SYSTEM ..........................................................................................................................................................164 Radiators ...........................................................................................................................................................164 Cooling liquid ......................................................................................................................................................166 Water filter ........................................................................................................................................................167 AIR-INTAKE SYSTEM .......................................................................................................................................................168 Main filter elements ................................................................................................................................................168 Safety filter element ...............................................................................................................................................170 Air-intake lines ....................................................................................................................................................171 Dust collection .....................................................................................................................................................171 FUEL SYSTEM .............................................................................................................................................................172 Fuel system - Safety instructions ...................................................................................................................................172 Replacing the fuel filters ..........................................................................................................................................172 Venting the fuel system .............................................................................................................................................173 Cleaning the fuel tanks .............................................................................................................................................173 Water trap (option)..................................................................................................................................................175 ELECTRICAL SYSTEM ......................................................................................................................................................177 Electrical system - Safety instructions .............................................................................................................................177 Alternator - Instructions ...........................................................................................................................................177 Battery .............................................................................................................................................................178 Switchgear cabinet ..................................................................................................................................................180 Equipotential bonding ...............................................................................................................................................182 Floodlight projector, replacing the lamp ............................................................................................................................184 HYDRAULIC SYSTEM ........................................................................................................................................................186 Hydraulic system - Safety instructions ..............................................................................................................................186 Depressurizing the hydraulic system .................................................................................................................................186 Checking the hydraulic oil level ....................................................................................................................................187 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................189 Bypass valves (hydraulic oil reservoir) .............................................................................................................................191 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................192 Bypass valves (filter housing - cooling system) .....................................................................................................................193 Breather filter .....................................................................................................................................................194 Filter (control circuit and auxiliary control circuit)...............................................................................................................195 High-pressure filter for working hydraulics .........................................................................................................................196 High-pressure filters for slewing circuit ...........................................................................................................................197 Changing the hydraulic oil ..........................................................................................................................................198 Venting the hydraulic system.........................................................................................................................................201 Cleaning the hydraulic oil cooler....................................................................................................................................202 Electronic excavator control.........................................................................................................................................203 Pressure accumulator - Emergency lowering............................................................................................................................204 PUMP TRANSFER GEARBOX ...................................................................................................................................................205 Checking the gearbox oil level / Topping up with oil ................................................................................................................205 Gearbox venting .....................................................................................................................................................207 Pump transfer gearbox lube oil filters ..............................................................................................................................208 SLEWING GEARBOX .........................................................................................................................................................209 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................209 Changing the gearbox oil ............................................................................................................................................209 Gearbox venting .....................................................................................................................................................210 SWING GEARBOX ...........................................................................................................................................................211 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................211 Changing the gearbox oil ............................................................................................................................................212 Gearbox venting .....................................................................................................................................................213 TRAVEL GAERBOX ..........................................................................................................................................................214 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................214 Travel gearbox - Changing oil .......................................................................................................................................215 Pre-chamber - Changing the oil ......................................................................................................................................215 Brake chamber - Changing oil ........................................................................................................................................216 Breather filter .....................................................................................................................................................216 CRAWLER TRACKS ..........................................................................................................................................................217 Track roller, Support roller ........................................................................................................................................218 Track tensioner .....................................................................................................................................................219 Pressure-accumulator inspection regulations .........................................................................................................................220 Checking the gas charging pressure in the pressure accumulator.......................................................................................................220 SLEWING RING ............................................................................................................................................................221 Slewing ring - Instructions..........................................................................................................................................221 Bearing races........................................................................................................................................................221 CENTRAL LUBRICATING .....................................................................................................................................................223 Design ..............................................................................................................................................................223 Function ............................................................................................................................................................224 Filling up the grease container .....................................................................................................................................225 Breather filter .....................................................................................................................................................225 Checking the greasing pressure ......................................................................................................................................226 Unblocking a grease line.............................................................................................................................................227 Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................228 Grease filter (Filling the grease container) ........................................................................................................................229 Grease filter (Grease lines) ........................................................................................................................................230 OTHER MAINTENANCE .......................................................................................................................................................231 Engine ..............................................................................................................................................................231 Heating and air conditioning ........................................................................................................................................231 RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................232 Pressure-accumulator inspection regulations .........................................................................................................................233 Extract from the German regulations..................................................................................................................................233 Checking the gas charging pressure in the pressure accumulator.......................................................................................................233 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................234 Monitoring, warning and control elements ............................................................................................................................234 Checking the on-board crane..........................................................................................................................................234 Drive unit...........................................................................................................................................................235 On-board crane.......................................................................................................................................................235 On-Board crane, checking tightness of fastening bolts ...............................................................................................................236 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................237 Putting the excavator out of operation...............................................................................................................................237 Battery storage......................................................................................................................................................237 Recommissioning......................................................................................................................................................238 NOTES ..................................................................................................................................................................239 4 REPAIR WORK................................................................................................................................................................241 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................243 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................245 REPAIR WORK, ENGINE......................................................................................................................................................246 ELECTRICAL SYSTEM .......................................................................................................................................................247 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................247 Assisted starting (with jumper cables)...............................................................................................................................247 Starting the engine with jumper cables (external batteries ..........................................................................................................247 HYDRAULIC SYSTEM.........................................................................................................................................................249 Repair instructions .................................................................................................................................................249 Hydraulic hoses – Instructions .....................................................................................................................................249 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................250 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................252 NOTES ...................................................................................................................................................................254 5 ANNEX......................................................................................................................................................................257 TROUBLESHOOTING .........................................................................................................................................................259 Instructions on troubleshooting .....................................................................................................................................259 Layout of the fault table ...........................................................................................................................................259 Possible causes .....................................................................................................................................................259 Measures ............................................................................................................................................................259 Section .............................................................................................................................................................259 FAULT TABLES ............................................................................................................................................................260 Combustion engine - Fault table .....................................................................................................................................260 Working hydraulics – Fault table ....................................................................................................................................261 Track drive – Fault table ...........................................................................................................................................262 Slewing mechnism – Fault table ......................................................................................................................................263 Central lubricating system – Fault table ............................................................................................................................264 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................265 ABBREVIATIONS ...........................................................................................................................................................266 ABBREVIATIONS .......................................................................................................................................................267 TECHNICAL DATA ..........................................................................................................................................................269 NOTES ...................................................................................................................................................................279 6 INDEX......................................................................................................................................................................281
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M
