Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651435 – PDF DOWNLOAD

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Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651435 – PDF DOWNLOAD

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Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651435 – PDF DOWNLOAD

Language : English
Pages : 236
Downloadable : Yes
File Type : PDF

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Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651435 – 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

• 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 Terex O&K mechanic or by attending an Terex O&K training course for operators or maintenance personnel. The Terex O&K 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 O&K operating manuals are issued in German and then translated.
• Even a good translation may give rise to questions which Terex O&K 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 O&K 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 Hydraulic Excavator RH 40E Operating Instructions Manual BI651435 – 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..................................................................................................... 17
		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
		Ether ............................................................................................................................................................... 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
		Demand control / Zero-flow regulation................................................................................................................................ 33
		Automatic engine speed reduction .................................................................................................................................... 33
		Electrical system ................................................................................................................................................... 33
		Signs ............................................................................................................................................................... 35
		DRIVER'S CAB ........................................................................................................................................................ 36
		Entering and leaving the machine - Safety instructions .............................................................................................................. 36
		Windscreen washer ................................................................................................................................................... 37
		Driver's seat ....................................................................................................................................................... 38
		Fire-extinguisher ................................................................................................................................................... 40
		Fire extinguishing system (optional) ................................................................................................................................ 41
		Trainer's / instructor's seat ....................................................................................................................................... 41
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 42
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 61
		Refuelling .......................................................................................................................................................... 61
		Switching the electrical system on and off .......................................................................................................................... 64
		Battery main switch ................................................................................................................................................. 65
		Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 66
		Fuel preheating system (optional) ................................................................................................................................... 67
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 68
	VENTILATION AND HEATING ................................................................................................................................................. 70
		Air conditioner (optional) .......................................................................................................................................... 70
		Auxiliary heating (optional) ........................................................................................................................................ 70
	TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 71
		Running-in specifications for components of the crawler tracks....................................................................................................... 71
		TRAVELLING .......................................................................................................................................................... 72
		Locking the superstructure .......................................................................................................................................... 76
		Track parking brake ................................................................................................................................................. 76
	TRANSPORTING THE MACHINE ................................................................................................................................................ 77
		Transport - Safety instructions ..................................................................................................................................... 77
	WORKING OPERATION ....................................................................................................................................................... 79
		Safety instructions ................................................................................................................................................. 79
		Before starting work ................................................................................................................................................ 81
		Slewing and braking the superstructure .............................................................................................................................. 82
		Working ............................................................................................................................................................. 83
		After daily operation ............................................................................................................................................... 84
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ...................................................................................................................... 85
		Securing the machine ................................................................................................................................................ 86
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) .......................................................................................................... 87
	LIFTING OPERATIONS ...................................................................................................................................................... 88
		Safety instructions ................................................................................................................................................. 88
		Load-hooks on backhoe buckets. ...................................................................................................................................... 89
	NOTES ................................................................................................................................................................... 93
3 INSPECTION AND SERVICING................................................................................................................................................... 95
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS .......................................................................................................................... 97
	FIRE AND EXPLOSION HAZARD................................................................................................................................................103
	ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID ..............................................................................................................................104
		Environmentally compatible hydraulic fluid - operating instructions .................................................................................................104
		Environmentally compatible hydraulic fluid, conversion ..............................................................................................................104
		Environmentally compatible hydraulic fluid - Sampling ...............................................................................................................105
	ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS ........................................................................................................................106
		Lubricants for bearings .............................................................................................................................................106
		Gearbox oils ........................................................................................................................................................106
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................107
		Intervals............................................................................................................................................................107
		Change of engine oil l...............................................................................................................................................107
		Oils / Greases ......................................................................................................................................................107
		Cleaning jobs .......................................................................................................................................................107
		Components ..........................................................................................................................................................107
		Plan V ..............................................................................................................................................................109
		Plan N ..............................................................................................................................................................111
		Plan T and W ........................................................................................................................................................113
		Plan A – E ..........................................................................................................................................................115
	LUBRICATING CHART – GREASE ..............................................................................................................................................120
		Lubricating chart – Grease (legend) .................................................................................................................................121
		Filling quantities - Grease..........................................................................................................................................121
	INSPECTION PLAN - OIL ...................................................................................................................................................122
		Inspection plan – Oil (legend) ).....................................................................................................................................123
		Filling quantities - oil ............................................................................................................................................124
		Filling quantities - other...........................................................................................................................................124
	LUBRICANTS ..............................................................................................................................................................125
		Notes on the selection of oils and greases ..........................................................................................................................125
		I. Oils for combustion engine .......................................................................................................................................126
		II. Oils for hydraulic system (selection) ...........................................................................................................................127
		III.a Oils for pump gearbox .........................................................................................................................................128
		III.b Oils for swing gearbox ........................................................................................................................................129
		III.c Oils for travel gearbox .......................................................................................................................................130
		V. Greases for bearings and slewing rings ...........................................................................................................................131
	SERVICING WORK ..........................................................................................................................................................132
		Hose line for oil and cooling liquid changes ........................................................................................................................132
	ENGINE ..................................................................................................................................................................133
		Engine - Safety instructions ........................................................................................................................................133
		Checking the engine oil level / Topping up  .........................................................................................................................134
		Changing the engine oil .............................................................................................................................................135
		Replacing the engine oil filters ....................................................................................................................................136
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................137
	COOLING SYSTEM ..........................................................................................................................................................138
		Temperature .........................................................................................................................................................138
		Cooler and cooling liquid............................................................................................................................................138
		Topping up with coolant .............................................................................................................................................139
		Changing the coolant ................................................................................................................................................139
	AIR-INTAKE SYSTEM .......................................................................................................................................................141
		Dust trap, cleaning .................................................................................................................................................141
		Main filter elements ................................................................................................................................................142
		Safety filter element ...............................................................................................................................................144
		Air-intake lines ....................................................................................................................................................144
	FUEL SYSTEM .............................................................................................................................................................145
		Fuel system - Safety instructions ...................................................................................................................................145
		Fuel pre-filter, Draining off water .................................................................................................................................145
		Fuel pre-filter, replace ............................................................................................................................................146
		Secondary fuel filter, replace ......................................................................................................................................147
		Fuel tank - Venting .................................................................................................................................................148
		Cleaning the fuel tank ..............................................................................................................................................148
		Refuelling station (optional) .......................................................................................................................................149
		Water trap (option)..................................................................................................................................................150
	ELECTRICAL SYSTEM  ......................................................................................................................................................152
		Electrical system - Safety instructions .............................................................................................................................152
		Floodlight projector, safety instructions  ..........................................................................................................................153
		Floodlight projector, replacing a defective xenon bulb ..............................................................................................................154
		Battery .............................................................................................................................................................155
	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
		Cleaning the hydraulic oil reservoir  ...............................................................................................................................166
		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
		Output pinion .......................................................................................................................................................174
	TRAVEL GEARBOX ..........................................................................................................................................................175
		Travel gearbox - Checking the oil level .............................................................................................................................175
		Travel gearbox - Changing the oil ...................................................................................................................................175
		Travel 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
	SWING RING ..............................................................................................................................................................180
		Swing ring - Instructions............................................................................................................................................180
		Bearing races........................................................................................................................................................180
	CENTRAL LUBRICATING .....................................................................................................................................................182
		Design and function .................................................................................................................................................182
		Greasing cycle  .....................................................................................................................................................184
		Venting the grease pump .............................................................................................................................................186
		Venting the grease lines ............................................................................................................................................186
		Unblocking a grease line ............................................................................................................................................186
		Cleaning the grease sieves ..........................................................................................................................................187
		Lubricating the grease distributor of the working equipment..........................................................................................................187
	OTHER MAINTENANCE .......................................................................................................................................................188
		Heating and air conditioning ........................................................................................................................................188
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................189
		Putting the excavator out of operation...............................................................................................................................189
		Battery storage......................................................................................................................................................189
		Recommissioning......................................................................................................................................................189
	NOTES ...................................................................................................................................................................191
4 REPAIR WORK................................................................................................................................................................193
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................195
	FIRE AND EXPLOSION HAZARD ...............................................................................................................................................197
	ENGINE...................................................................................................................................................................198
	ELECTRICAL SYSTEM .......................................................................................................................................................199
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................199
		Assisted starting (with jumper cables)...............................................................................................................................199
		Starting the engine with jumper cables (external batteries ..........................................................................................................199
	HYDRAULIC SYSTEM.........................................................................................................................................................201
		Repair – Instructions ...............................................................................................................................................201
		Hydraulic hoses – Instructions ......................................................................................................................................201
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................202
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................203
	NOTES ...................................................................................................................................................................205
5 ANNEX......................................................................................................................................................................207
	TROUBLESHOOTING .........................................................................................................................................................209
		Instructions on troubleshooting .....................................................................................................................................209
		Layout of the fault table ...........................................................................................................................................209
		Possible causes .....................................................................................................................................................209
		Measures ............................................................................................................................................................209
		Section .............................................................................................................................................................209
	FAULT TABLES ............................................................................................................................................................210
		Combustion engine - Fault table .....................................................................................................................................210
		Working hydraulics – Fault table ....................................................................................................................................211
		Track drive – Fault table ...........................................................................................................................................212
		Slewing mechnism – Fault table ......................................................................................................................................213
		Central lubricating system – Fault table ............................................................................................................................214
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................215
	ABBREVIATIONS ...........................................................................................................................................................217
	TECHNICAL DATA ..........................................................................................................................................................219
6 INDEX......................................................................................................................................................................231

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