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Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651507 – PDF DOWNLOAD
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Description
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651507 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651507 – PDF DOWNLOAD
Language : English
Pages : 232
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651507 – 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651507 – PDF DOWNLOAD
TABLE OF CONTENTS.............................................................................................................................................................. 5 INTRODUCTION................................................................................................................................................................... 11 PREFACE.................................................................................................................................................................... 13 WARRANTY................................................................................................................................................................... 14 FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 15 Warnings and symbols................................................................................................................................................... 15 DESIGNATED USE............................................................................................................................................................. 16 ORGANIZATIONAL MEASURES.................................................................................................................................................... 17 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases.............................................................................................................. 18 Special work in conjunction with utilization of the machine and mainten ance and repairs as well as trouble shooting 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 sub stances............................................................................................................................. 21 Transporting and recommission ing...................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22 NOTES...................................................................................................................................................................... 23 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 Stored Program Control (SPC)........................................................................................................................................... 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 EMERGENCY STOP pushbuttons............................................................................................................................................. 37 Windscreen washer...................................................................................................................................................... 38 Driver's seat.......................................................................................................................................................... 39 Adjusting the control consoles......................................................................................................................................... 40 Fire-extinguisher...................................................................................................................................................... 41 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 42 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 67 Refuelling............................................................................................................................................................. 67 Switching the electrical system on and off............................................................................................................................. 69 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 70 Heating................................................................................................................................................................ 73 DRIVING.................................................................................................................................................................... 74 SAFETY INSTRUCTIONS.................................................................................................................................................... 74 TRAVELLING............................................................................................................................................................. 75 Locking the superstructure............................................................................................................................................. 79 Track parking brake.................................................................................................................................................... 79 TRANSPORTING THE MACHINE................................................................................................................................................... 80 Transport - Safety instructions........................................................................................................................................ 80 WORKING OPERATION.......................................................................................................................................................... 82 SAFETY INSTRUCTIONS.................................................................................................................................................... 82 Before starting work................................................................................................................................................... 84 Slewing and braking the superstructure................................................................................................................................. 84 Working................................................................................................................................................................ 85 After daily operation.................................................................................................................................................. 86 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 87 Securing the machine................................................................................................................................................... 89 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)............................................................................................................. 90 LIFTING OPERATIONS......................................................................................................................................................... 91 Safety instructions.................................................................................................................................................... 91 Load-hooks on backhoe buckets.......................................................................................................................................... 92 NOTES...................................................................................................................................................................... 97 INSPECTION AND SERVICING....................................................................................................................................................... 99 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................101 FIRE AND EXPLOSION HAZARD..................................................................................................................................................107 ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID.................................................................................................................................108 Environmentally compatible hydraulic fluid - operating instructions....................................................................................................108 Environmentally compatible hydraulic fluid, conversion.................................................................................................................108 Environmentally compatible hydraulic fluid - Sampling..................................................................................................................109 ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS...........................................................................................................................110 Lubricants for bearings................................................................................................................................................110 Gearbox oils...........................................................................................................................................................110 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................111 Intervals..............................................................................................................................................................111 Change of engine oil l.................................................................................................................................................111 Oils / Greases.........................................................................................................................................................111 Cleaning jobs..........................................................................................................................................................111 Components.............................................................................................................................................................111 Plan V.................................................................................................................................................................113 Plan N.................................................................................................................................................................115 Plan T.................................................................................................................................................................117 Plan A – E.............................................................................................................................................................119 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................124 Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................125 Filling quantities - Grease............................................................................................................................................125 LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND).......................................................................................................................126 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................127 Filling quantities - Grease............................................................................................................................................127 INSPECTION PLAN - OIL......................................................................................................................................................128 Inspection plan – Oil (legend) ).......................................................................................................................................129 Filling quantities - oil...............................................................................................................................................130 Filling quantities - other.............................................................................................................................................130 LUBRICANTS.................................................................................................................................................................131 I. Oils for combustion engines and compressors (selection).............................................................................................................131 II. Oils for hydraulic system (selection)..............................................................................................................................132 III. Oils for gearboxes (selection)....................................................................................................................................133 V. Greases for bearings and slewing rings..............................................................................................................................134 SERVICING WORK.............................................................................................................................................................135 Hose line for oil and cooling liquid changes...........................................................................................................................135 ENGINE.....................................................................................................................................................................136 Engine - Safety instructions...........................................................................................................................................136 Checking the V-belt tension............................................................................................................................................136 Retensioning the alternator/fan belt...................................................................................................................................136 Checking and adjusting the valve clearance.............................................................................................................................136 Checking the engine oil level / Topping up.............................................................................................................................136 Changing the engine oil................................................................................................................................................137 Replacing the oil filter...............................................................................................................................................138 Centrifuge (optional)..................................................................................................................................................139 COOLING SYSTEM.............................................................................................................................................................140 Radiators..............................................................................................................................................................140 Cooling liquid.........................................................................................................................................................141 Water filter...........................................................................................................................................................142 AIR-INTAKE SYSTEM..........................................................................................................................................................143 Main filter elements...................................................................................................................................................143 Safety filter element..................................................................................................................................................145 Air-intake lines.......................................................................................................................................................145 Dust collection........................................................................................................................................................145 FUEL SYSTEM................................................................................................................................................................146 Fuel system - Safety instructions......................................................................................................................................146 Replacing the fuel filter..............................................................................................................................................147 Venting the fuel system................................................................................................................................................147 Cleaning the fuel tanks................................................................................................................................................148 Refuelling station (optional)..........................................................................................................................................148 Water trap (option)....................................................................................................................................................149 ELECTRICAL SYSTEM..........................................................................................................................................................151 Electrical system - Safety instructions................................................................................................................................151 Alternator - Instructions..............................................................................................................................................151 Battery................................................................................................................................................................152 Switchgear cabinet.....................................................................................................................................................154 HYDRAULIC SYSTEM...........................................................................................................................................................157 Hydraulic system - Safety instructions.................................................................................................................................157 Depressurizing the hydraulic system....................................................................................................................................157 Checking the hydraulic oil level.......................................................................................................................................158 Topping up with hydraulic oil..........................................................................................................................................158 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................159 Bypass valves (working circuit)........................................................................................................................................160 Bypass valves (cooling circuit)........................................................................................................................................161 Breather filter........................................................................................................................................................162 High-pressure filter for working hydraulics............................................................................................................................163 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump................................................................................164 Changing the hydraulic oil.............................................................................................................................................165 Venting the hydraulic system...........................................................................................................................................167 Cleaning the hydraulic oil cooler......................................................................................................................................168 Pressure accumulator...................................................................................................................................................169 PUMP TRANSFER GEARBOX......................................................................................................................................................170 Checking the gearbox oil level / Topping up with oil...................................................................................................................170 Changing the gearbox oil...............................................................................................................................................171 SLEWING GEARBOX............................................................................................................................................................173 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................173 Changing the gearbox oil...............................................................................................................................................173 Gearbox venting........................................................................................................................................................174 TRAVEL GAERBOX.............................................................................................................................................................175 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................175 Travel gearbox - Changing the oil......................................................................................................................................175 Gearbox venting........................................................................................................................................................175 CRAWLER TRACKS.............................................................................................................................................................176 Track rollers, support rollers, track pads.............................................................................................................................176 Track tensioner........................................................................................................................................................178 Pressure-accumulator inspection regulations............................................................................................................................179 Checking the gas charging pressure in the pressure accumulator.........................................................................................................179 SLEWING RING...............................................................................................................................................................180 Slewing ring - Instructions............................................................................................................................................180 Bearing races..........................................................................................................................................................180 CENTRAL LUBRICATING........................................................................................................................................................182 Design and function....................................................................................................................................................182 Checking the greasing pressure.........................................................................................................................................185 Blockade of a greasing point...........................................................................................................................................185 Cleaning the grease strainers..........................................................................................................................................186 Bleeding the grease pump...............................................................................................................................................187 Bleeding the line system...............................................................................................................................................188 Manual greasing........................................................................................................................................................189 OTHER MAINTENANCE..........................................................................................................................................................190 Heating and air conditioning...........................................................................................................................................190 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................191 Putting the excavator out of operation.................................................................................................................................191 Battery storage........................................................................................................................................................191 Recommissioning........................................................................................................................................................192 NOTES......................................................................................................................................................................193 REPAIR WORK....................................................................................................................................................................195 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................197 FIRE AND EXPLOSION HAZARD..................................................................................................................................................199 ENGINE.....................................................................................................................................................................200 ELECTRICAL SYSTEM..........................................................................................................................................................201 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................201 Assisted starting (with jumper cables).................................................................................................................................201 Starting the engine with jumper cables (external batteries.............................................................................................................201 HYDRAULIC SYSTEM...........................................................................................................................................................203 Repair.................................................................................................................................................................203 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................204 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................205 NOTES......................................................................................................................................................................207 ANNEX..........................................................................................................................................................................209 TROUBLESHOOTING............................................................................................................................................................211 Instructions on troubleshooting........................................................................................................................................211 Layout of the fault table..............................................................................................................................................211 Possible causes........................................................................................................................................................211 Measures...............................................................................................................................................................211 Section................................................................................................................................................................211 FAULT TABLES...............................................................................................................................................................212 Combustion engine - Fault table........................................................................................................................................212 Working hydraulics – Fault table.......................................................................................................................................213 Track drive – Fault table..............................................................................................................................................214 Slewing mechnism – Fault table.........................................................................................................................................215 Central lubricating system – Fault table...............................................................................................................................216 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................218 ABBREVIATIONS..............................................................................................................................................................221 TECHNICAL DATA.............................................................................................................................................................223 INDEX..........................................................................................................................................................................227
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