Cat Bucyrus RH 40E Hydraulic Excavator Operating Instructions Manual BI651417 – PDF DOWNLOAD

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Cat Bucyrus RH 40E Hydraulic Excavator Operating Instructions Manual BI651417 – PDF DOWNLOAD

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Cat Bucyrus RH 40E Hydraulic Excavator Operating Instructions Manual BI651417 – PDF DOWNLOAD

Language : English
Pages :  234
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus RH 40E Hydraulic Excavator Operating Instructions Manual BI651417 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH40E
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 Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel. The Bucyrus HEX 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 Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX 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 Bucyrus HEX aftersales 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 RH 40E Hydraulic Excavator Operating Instructions Manual BI651417 – 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
		Adjusting the control consoles ...................................................................................................................................... 39
		Fire-extinguisher ................................................................................................................................................... 40
	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 .......................................................................................................................................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  .........................................................................................................................133
		Changing the engine oil .............................................................................................................................................134
		Replacing the engine oil filters ....................................................................................................................................135
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................136
	COOLING SYSTEM ..........................................................................................................................................................137
		Temperature .........................................................................................................................................................137
		Cooler and cooling liquid............................................................................................................................................137
		Topping up with coolant .............................................................................................................................................138
		Changing the coolant ................................................................................................................................................138
	AIR-INTAKE SYSTEM .......................................................................................................................................................140
		Dust trap, cleaning .................................................................................................................................................140
		Main filter elements ................................................................................................................................................141
		Safety filter element ...............................................................................................................................................143
		Air-intake lines ....................................................................................................................................................143
	FUEL SYSTEM .............................................................................................................................................................144
		Fuel system - Safety instructions ...................................................................................................................................144
		Fuel pre-filter, Draining off water .................................................................................................................................144
		Fuel pre-filter, replace ............................................................................................................................................145
		Secondary fuel filter, replace ......................................................................................................................................146
		Fuel tank - Venting .................................................................................................................................................147
		Cleaning the fuel tank ..............................................................................................................................................147
		Refuelling station (optional) .......................................................................................................................................148
		Water trap (option)..................................................................................................................................................149
	ELECTRICAL SYSTEM  ......................................................................................................................................................151
		Electrical system - Safety instructions .............................................................................................................................151
		Floodlight projector, safety instructions  ..........................................................................................................................152
		Floodlight projector, replacing a defective xenon bulb ..............................................................................................................153
		Battery .............................................................................................................................................................154
	HYDRAULIC SYSTEM ........................................................................................................................................................156
		Hydraulic system - Safety instructions ..............................................................................................................................156
		Depressurizing the hydraulic system .................................................................................................................................156
		Checking the hydraulic oil level ....................................................................................................................................157
		Topping up with hydraulic oil .......................................................................................................................................157
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................158
		Bypass valves (working circuit) .....................................................................................................................................159
		Bypass valves (cooling circuit) .....................................................................................................................................160
		Breather filter .....................................................................................................................................................161
		High-pressure filter for working hydraulics .........................................................................................................................162
		High-pressure filters for the servo circuit and the feeding circuit of the slewing pump .............................................................................163
		Changing the hydraulic oil ..........................................................................................................................................164
		Venting the hydraulic system.........................................................................................................................................166
		Cleaning the hydraulic oil cooler....................................................................................................................................167
		Pressure accumulator ................................................................................................................................................168
	PUMP TRANSFER GEARBOX ...................................................................................................................................................169
		Checking the gearbox oil level / Topping up with oil ................................................................................................................169
		Changing the gearbox oil ............................................................................................................................................170
	SLEWING GEARBOX .........................................................................................................................................................172
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................172
		Changing the gearbox oil ............................................................................................................................................172
		Gearbox venting .....................................................................................................................................................173
		Output pinion .......................................................................................................................................................173
	TRAVEL GEARBOX ..........................................................................................................................................................174
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................174
		Travel gearbox - Changing the oil ...................................................................................................................................174
		Gearbox venting .....................................................................................................................................................174
	CRAWLER TRACKS ..........................................................................................................................................................175
		Track rollers, support rollers, track pads ..........................................................................................................................175
		Track tensioner .....................................................................................................................................................177
		Pressure-accumulator inspection regulations .........................................................................................................................178
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................178
	SWING RING ..............................................................................................................................................................179
		Swing ring - Instructions............................................................................................................................................179
		Bearing races........................................................................................................................................................179
	CENTRAL LUBRICATING .....................................................................................................................................................181
		Design and function .................................................................................................................................................181
		Greasing cycle  .....................................................................................................................................................183
		Venting the grease pump .............................................................................................................................................185
		Venting the grease lines ............................................................................................................................................185
		Unblocking a grease line ............................................................................................................................................185
		Cleaning the grease sieves ..........................................................................................................................................186
		Lubricating the grease distributor of the working equipment .........................................................................................................186
	OTHER MAINTENANCE .......................................................................................................................................................187
		Heating and air conditioning ........................................................................................................................................187
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................188
		Putting the excavator out of operation ..............................................................................................................................188
		Battery storage .....................................................................................................................................................188
		Recommissioning .....................................................................................................................................................188
	NOTES ...................................................................................................................................................................189
4 REPAIR WORK................................................................................................................................................................191
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................193
	FIRE AND EXPLOSION HAZARD ...............................................................................................................................................195
	ENGINE...................................................................................................................................................................196
	ELECTRICAL SYSTEM .......................................................................................................................................................197
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................197
		Assisted starting (with jumper cables)...............................................................................................................................197
		Starting the engine with jumper cables (external batteries ..........................................................................................................197
	HYDRAULIC SYSTEM.........................................................................................................................................................199
		Repair – Instructions ...............................................................................................................................................199
		Hydraulic hoses – Instructions ......................................................................................................................................199
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................200
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................201
	NOTES ...................................................................................................................................................................203
5 ANNEX......................................................................................................................................................................205
	TROUBLESHOOTING .........................................................................................................................................................207
		Instructions on troubleshooting .....................................................................................................................................207
		Layout of the fault table ...........................................................................................................................................207
		Possible causes .....................................................................................................................................................207
		Measures ............................................................................................................................................................207
		Section .............................................................................................................................................................207
	FAULT TABLES ............................................................................................................................................................208
		Combustion engine - Fault table .....................................................................................................................................208
		,Working hydraulics – Fault table ...................................................................................................................................208
		Track drive – Fault table ...........................................................................................................................................210
		Slewing mechnism – Fault table ......................................................................................................................................211
		Central lubricating system – Fault table ............................................................................................................................212
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................213
	ABBREVIATIONS ...........................................................................................................................................................215
	TECHNICAL DATA ..........................................................................................................................................................217
	NOTES ...................................................................................................................................................................227
6 INDEX......................................................................................................................................................................229

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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]

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