Cat Bucyrus 40E Hydraulic Excavator Operating Instructions Manual BI651418 – PDF DOWNLOAD

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Cat Bucyrus 40E Hydraulic Excavator Operating Instructions Manual BI651418 – PDF DOWNLOAD

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Cat Bucyrus 40E Hydraulic Excavator Operating Instructions Manual BI651418 – PDF DOWNLOAD

Language : English
Pages : 232
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus 40E Hydraulic Excavator Operating Instructions Manual BI651418 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH200
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 40E Hydraulic Excavator Operating Instructions Manual BI651418 – PDF DOWNLOAD

1 INTRODUCTION............................................................................................................................................................... 11
	PREFACE.................................................................................................................................................................. 13
	WARRANTY................................................................................................................................................................. 14
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15
		Warnings and symbols................................................................................................................................................. 15
	DESIGNATED USE........................................................................................................................................................... 16
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 17
		Selection and qualification of personnel; basic responsibilities..................................................................................................... 18
		Safety instructions governing specific operational phases............................................................................................................ 18
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19
		Warning of special dangers........................................................................................................................................... 20
		Gas, dust, steam and smoke........................................................................................................................................... 21
		Hydraulic equipment.................................................................................................................................................. 21
		Noise................................................................................................................................................................ 21
		Oil, grease and other chemical substances............................................................................................................................ 21
		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 ................................................................................................................................................... 39
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 40
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 59
		Refuelling .......................................................................................................................................................... 59
		Switching the electrical system on and off .......................................................................................................................... 62
		Battery main switch ................................................................................................................................................. 63
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 64
	VENTILATION AND HEATING ................................................................................................................................................. 66
		Air conditioner (optional) .......................................................................................................................................... 66
		Auxiliary heating (optional) ........................................................................................................................................ 66
	TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 67
		Running-in specifications for components of the crawler tracks....................................................................................................... 67
		TRAVELLING .......................................................................................................................................................... 68
		Locking the superstructure .......................................................................................................................................... 72
		Track parking brake ................................................................................................................................................. 72
	TRANSPORTING THE MACHINE ................................................................................................................................................ 73
		Transport - Safety instructions ..................................................................................................................................... 73
	WORKING OPERATION ....................................................................................................................................................... 75
		SAFETY INSTRUCTIONS ................................................................................................................................................. 75
		Before starting work ................................................................................................................................................ 77
		Slewing and braking the superstructure .............................................................................................................................. 78
		Working ............................................................................................................................................................. 79
		After daily operation ............................................................................................................................................... 80
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ...................................................................................................................... 81
		Securing the machine ................................................................................................................................................ 82
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) .......................................................................................................... 83
	LIFTING OPERATIONS ...................................................................................................................................................... 84
		Safety instructions ................................................................................................................................................. 84
		Load-hooks on backhoe buckets. ...................................................................................................................................... 85
	NOTES ................................................................................................................................................................... 89
3 INSPECTION AND SERVICING................................................................................................................................................... 91
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS .......................................................................................................................... 93
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 99
	ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID ..............................................................................................................................100
		Environmentally compatible hydraulic fluid - operating instructions .................................................................................................100
		Environmentally compatible hydraulic fluid, conversion ..............................................................................................................100
		Environmentally compatible hydraulic fluid - Sampling ...............................................................................................................101
	ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS ........................................................................................................................102
		Lubricants for bearings .............................................................................................................................................102
		Gearbox oils ........................................................................................................................................................102
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................103
		Intervals............................................................................................................................................................103
		Change of engine oil l...............................................................................................................................................103
		Oils / Greases ......................................................................................................................................................103
		Cleaning jobs .......................................................................................................................................................103
		Components ..........................................................................................................................................................103
		Plan V ..............................................................................................................................................................105
		Plan N ..............................................................................................................................................................107
		Plan T and W ........................................................................................................................................................109
		Plan A – E ..........................................................................................................................................................111
	LUBRICATING CHART – GREASE (LOADING BUCKET) .............................................................................................................................116
		Lubricating chart – Grease / Loading bucket (legend) ................................................................................................................117
		Filling quantities - Grease..........................................................................................................................................117
	LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND) ....................................................................................................................118
		Lubricating chart – Grease / Backhoe bucket (legend) ................................................................................................................119
		Filling quantities - Grease..........................................................................................................................................119
	INSPECTION PLAN - OIL ...................................................................................................................................................120
		Inspection plan – Oil (legend) ).....................................................................................................................................121
		Filling quantities - oil ............................................................................................................................................122
		Filling quantities - other...........................................................................................................................................122
	LUBRICANTS ..............................................................................................................................................................123
		Notes on the selection of oils and greases ..........................................................................................................................123
		I. Oils for combustion engine .......................................................................................................................................124
		II. Oils for hydraulic system (selection) ...........................................................................................................................125
		III.a Oils for pump gearbox .........................................................................................................................................126
		III.b Oils for swing gearbox ........................................................................................................................................127
		III.c Oils for travel gearbox .......................................................................................................................................128
		V. Greases for bearings and slewing rings ...........................................................................................................................129
	SERVICING WORK ..........................................................................................................................................................130
		Hose line for oil and cooling liquid changes ........................................................................................................................130
	ENGINE ..................................................................................................................................................................131
		Engine - Safety instructions ........................................................................................................................................131
		Checking the engine oil level / Topping up  .........................................................................................................................131
		Changing the engine oil .............................................................................................................................................132
		Replacing the engine oil filters ....................................................................................................................................133
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................134
	COOLING SYSTEM ..........................................................................................................................................................135
		Temperature .........................................................................................................................................................135
		Cooler and cooling liquid............................................................................................................................................135
		Topping up with coolant .............................................................................................................................................136
		Changing the coolant ................................................................................................................................................136
	AIR-INTAKE SYSTEM .......................................................................................................................................................138
		Main filter elements ................................................................................................................................................138
		Safety filter element ...............................................................................................................................................140
		Air-intake lines ....................................................................................................................................................140
		Dust collection .....................................................................................................................................................140
	FUEL SYSTEM .............................................................................................................................................................141
		Fuel system - Safety instructions ...................................................................................................................................141
		Fuel pre-filter, Draining off water .................................................................................................................................141
		Fuel pre-filter, replace ............................................................................................................................................142
		Secondary fuel filter, replace ......................................................................................................................................143
		Fuel tank - Venting .................................................................................................................................................144
		Cleaning the fuel tank ..............................................................................................................................................144
		Refuelling station (optional) .......................................................................................................................................145
		Water trap (option)..................................................................................................................................................146
	ELECTRICAL SYSTEM  ......................................................................................................................................................148
		Electrical system - Safety instructions .............................................................................................................................148
		Floodlight projector, safety instructions  ..........................................................................................................................149
		Floodlight projector, replacing a defective xenon bulb ..............................................................................................................150
		Battery .............................................................................................................................................................151
	HYDRAULIC SYSTEM ........................................................................................................................................................153
		Hydraulic system - Safety instructions ..............................................................................................................................153
		Depressurizing the hydraulic system .................................................................................................................................153
		Checking the hydraulic oil level ....................................................................................................................................154
		Topping up with hydraulic oil .......................................................................................................................................154
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................155
		Bypass valves (working circuit) .....................................................................................................................................156
		Bypass valves (cooling circuit) .....................................................................................................................................157
		Breather filter .....................................................................................................................................................158
		High-pressure filter for working hydraulics .........................................................................................................................159
		High-pressure filters for the servo circuit and the feeding circuit of the slewing pump .............................................................................160
		Changing the hydraulic oil ..........................................................................................................................................161
		Venting the hydraulic system.........................................................................................................................................163
		Cleaning the hydraulic oil cooler....................................................................................................................................164
		Pressure accumulator ................................................................................................................................................165
	PUMP TRANSFER GEARBOX ...................................................................................................................................................166
		Checking the gearbox oil level / Topping up with oil ................................................................................................................166
		Changing the gearbox oil ............................................................................................................................................167
	SLEWING GEARBOX .........................................................................................................................................................169
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................169
		Changing the gearbox oil ............................................................................................................................................169
		Gearbox venting .....................................................................................................................................................170
		Output pinion .......................................................................................................................................................170
	TRAVEL GAERBOX ..........................................................................................................................................................171
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................171
		Travel gearbox - Changing the oil ...................................................................................................................................171
		Gearbox venting .....................................................................................................................................................171
	 CRAWLER TRACKS .........................................................................................................................................................172
		Track rollers, support rollers, track pads ..........................................................................................................................172
		Track tensioner .....................................................................................................................................................174
		Pressure-accumulator inspection regulations .........................................................................................................................175
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................175
	SLEWING RING ............................................................................................................................................................176
		Slewing ring - Instructions..........................................................................................................................................176
		Bearing races........................................................................................................................................................176
	CENTRAL LUBRICATING .....................................................................................................................................................178
		Design and function .................................................................................................................................................178
		Check for each Operation:............................................................................................................................................179
		Malfunctions.........................................................................................................................................................180
		Blockade of a lub point..............................................................................................................................................181
		Ventilation of the lubricating pump..................................................................................................................................182
		Cleaning the grease sieve............................................................................................................................................182
		Manual lubrication...................................................................................................................................................183
	OTHER MAINTENANCE .......................................................................................................................................................185
		Heating and air conditioning ........................................................................................................................................185
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................186
		Putting the excavator out of operation...............................................................................................................................186
		Battery storage......................................................................................................................................................186
		Recommissioning......................................................................................................................................................186
	NOTES ...................................................................................................................................................................187
4 REPAIR WORK................................................................................................................................................................189
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................191
	FIRE AND EXPLOSION HAZARD ...............................................................................................................................................193
	ENGINE...................................................................................................................................................................194
	ELECTRICAL SYSTEM .......................................................................................................................................................195
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................195
		Assisted starting (with jumper cables)...............................................................................................................................195
		Starting the engine with jumper cables (external batteries ..........................................................................................................195
	HYDRAULIC SYSTEM.........................................................................................................................................................197
		Repair – Instructions ...............................................................................................................................................197
		Hydraulic hoses – Instructions ......................................................................................................................................197
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................198
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................199
	NOTES ...................................................................................................................................................................201
5 ANNEX......................................................................................................................................................................203
	TROUBLESHOOTING .........................................................................................................................................................205
		Instructions on troubleshooting .....................................................................................................................................205
		Layout of the fault table ...........................................................................................................................................205
		Possible causes .....................................................................................................................................................205
		Measures ............................................................................................................................................................205
		Section .............................................................................................................................................................205
	FAULT TABLES ............................................................................................................................................................206
		Combustion engine - Fault table .....................................................................................................................................206
		,Working hydraulics – Fault table ...................................................................................................................................206
		Track drive – Fault table ...........................................................................................................................................208
		Slewing mechnism – Fault table ......................................................................................................................................209
		Central lubricating system – Fault table ............................................................................................................................210
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................211
	ABBREVIATIONS ...........................................................................................................................................................213
	TECHNICAL DATA ..........................................................................................................................................................215
6 INDEX......................................................................................................................................................................227

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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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