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Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651506 – PDF DOWNLOAD
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Description
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651506 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651506 – PDF DOWNLOAD
Language : English
Pages : 230
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651506 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 40 E
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
- The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
! operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair) and / or
transport
- In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified GERMANY Germany mechanic or by attending an Terex-Germany training course for operators or maintenance personnel. The Terex-Germany after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. 1 Complies with VDMA recommendation “Operating instructions” All Terex Germany operating manuals are issued in German and then translated.
- Even a good translation may give rise to questions which Terex Germany will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex Germany after- sales service. The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately.
- The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651506 – PDF DOWNLOAD
TABLE OF CONTENTS.............................................................................................................................................................. 5 INTRODUCTION................................................................................................................................................................... 11 PREFACE.................................................................................................................................................................... 13 WARRANTY................................................................................................................................................................... 14 FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 15 Warnings and symbols................................................................................................................................................... 15 DESIGNATED USE............................................................................................................................................................. 16 ORGANIZATIONAL MEASURES.................................................................................................................................................... 17 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases.............................................................................................................. 18 Special work in conjunction with utilization of the machine and mainten ance and repairs as well as trouble shooting during work; disposal of parts and consumables.... 19 Warning of special dangers............................................................................................................................................. 20 Gas, dust, steam and smoke............................................................................................................................................. 21 Hydraulic equipment.................................................................................................................................................... 21 Noise.................................................................................................................................................................. 21 Oil, grease and other chemical sub stances............................................................................................................................. 21 Transporting and recommission ing...................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22 NOTES...................................................................................................................................................................... 23 OPERATION...................................................................................................................................................................... 25 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 27 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 29 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 30 Excavator layout....................................................................................................................................................... 31 Undercarriage.......................................................................................................................................................... 32 Superstructure......................................................................................................................................................... 32 Drive.................................................................................................................................................................. 32 Hydraulic system....................................................................................................................................................... 32 Pump Managing System (PMS)............................................................................................................................................. 32 Stored Program Control (SPC)........................................................................................................................................... 32 Demand control / Zero-flow regulation.................................................................................................................................. 33 Automatic engine speed reduction....................................................................................................................................... 33 Electrical system...................................................................................................................................................... 33 Sign................................................................................................................................................................... 35 DRIVER'S CAB........................................................................................................................................................... 36 Entering and leaving the machine - Safety instructions................................................................................................................. 36 EMERGENCY STOP pushbuttons............................................................................................................................................. 37 Windscreen washer...................................................................................................................................................... 38 Driver's seat.......................................................................................................................................................... 39 Adjusting the control consoles......................................................................................................................................... 40 Fire-extinguisher...................................................................................................................................................... 41 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 42 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 65 Refuelling............................................................................................................................................................. 65 Switching the electrical system on and off............................................................................................................................. 67 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 68 Heating (optional)..................................................................................................................................................... 70 Air conditioner (optional)............................................................................................................................................. 71 DRIVING.................................................................................................................................................................... 72 SAFETY INSTRUCTIONS.................................................................................................................................................... 72 TRAVELLING............................................................................................................................................................. 73 Locking the superstructure............................................................................................................................................. 77 Track parking brake.................................................................................................................................................... 77 TRANSPORTING THE MACHINE................................................................................................................................................... 78 Transport - Safety instructions........................................................................................................................................ 78 WORKING OPERATION.......................................................................................................................................................... 80 SAFETY INSTRUCTIONS.................................................................................................................................................... 80 Before starting work................................................................................................................................................... 82 Slewing and braking the superstructure................................................................................................................................. 82 Working................................................................................................................................................................ 83 After daily operation.................................................................................................................................................. 84 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 85 Securing the machine................................................................................................................................................... 87 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)............................................................................................................. 88 LIFTING OPERATIONS......................................................................................................................................................... 89 Safety instructions.................................................................................................................................................... 89 Load-hooks on backhoe buckets.......................................................................................................................................... 90 NOTES...................................................................................................................................................................... 95 INSPECTION AND SERVICING....................................................................................................................................................... 97 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS............................................................................................................................. 99 FIRE AND EXPLOSION HAZARD..................................................................................................................................................105 ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID.................................................................................................................................106 Environmentally compatible hydraulic fluid - operating instructions....................................................................................................106 Environmentally compatible hydraulic fluid, conversion.................................................................................................................106 Environmentally compatible hydraulic fluid - Sampling..................................................................................................................107 ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS...........................................................................................................................108 Lubricants for bearings................................................................................................................................................108 Gearbox oils...........................................................................................................................................................108 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................109 Intervals..............................................................................................................................................................109 Change of engine oil l.................................................................................................................................................109 Oils / Greases.........................................................................................................................................................109 Cleaning jobs..........................................................................................................................................................109 Components.............................................................................................................................................................109 Plan V.................................................................................................................................................................111 Plan N.................................................................................................................................................................113 Plan T.................................................................................................................................................................115 Plan A – E.............................................................................................................................................................117 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................122 Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................123 Filling quantities - Grease............................................................................................................................................123 LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND).......................................................................................................................124 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................125 Filling quantities - Grease............................................................................................................................................125 INSPECTION PLAN - OIL......................................................................................................................................................126 Inspection plan – Oil (legend) ).......................................................................................................................................127 Filling quantities - oil...............................................................................................................................................128 Filling quantities - other.............................................................................................................................................128 LUBRICANTS.................................................................................................................................................................129 I. Oils for combustion engines and compressors (selection).............................................................................................................129 II. Oils for hydraulic system (selection)..............................................................................................................................130 III. Oils for gearboxes (selection)....................................................................................................................................131 V. Greases for bearings and slewing rings..............................................................................................................................132 SERVICING WORK.............................................................................................................................................................133 Hose line for oil and cooling liquid changes...........................................................................................................................133 ENGINE.....................................................................................................................................................................134 Engine - Safety instructions...........................................................................................................................................134 Checking the V-belt tension............................................................................................................................................134 Retensioning the alternator/fan belt...................................................................................................................................134 Checking and adjusting the valve clearance.............................................................................................................................134 Checking the engine oil level / Topping up.............................................................................................................................134 Changing the engine oil................................................................................................................................................135 Replacing the oil filter...............................................................................................................................................136 Centrifuge (optional)..................................................................................................................................................137 COOLING SYSTEM.............................................................................................................................................................138 Radiators..............................................................................................................................................................138 Cooling liquid.........................................................................................................................................................139 Water filter...........................................................................................................................................................140 AIR-INTAKE SYSTEM..........................................................................................................................................................141 Main filter elements...................................................................................................................................................141 Safety filter element..................................................................................................................................................143 Air-intake lines.......................................................................................................................................................143 Dust collection........................................................................................................................................................143 FUEL SYSTEM................................................................................................................................................................144 Fuel system - Safety instructions......................................................................................................................................144 Replacing the fuel filter..............................................................................................................................................145 Venting the fuel system................................................................................................................................................145 Cleaning the fuel tanks................................................................................................................................................146 Refuelling station (optional)..........................................................................................................................................146 Water trap (option)....................................................................................................................................................147 ELECTRICAL SYSTEM..........................................................................................................................................................149 Electrical system - Safety instructions................................................................................................................................149 Alternator - Instructions..............................................................................................................................................149 Battery................................................................................................................................................................150 Switchgear cabinet.....................................................................................................................................................152 HYDRAULIC SYSTEM...........................................................................................................................................................155 Hydraulic system - Safety instructions.................................................................................................................................155 Depressurizing the hydraulic system....................................................................................................................................155 Checking the hydraulic oil level.......................................................................................................................................156 Topping up with hydraulic oil..........................................................................................................................................156 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................157 Bypass valves (working circuit)........................................................................................................................................158 Bypass valves (cooling circuit)........................................................................................................................................159 Breather filter........................................................................................................................................................160 High-pressure filter for working hydraulics............................................................................................................................161 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump................................................................................162 Changing the hydraulic oil.............................................................................................................................................163 Venting the hydraulic system...........................................................................................................................................165 Cleaning the hydraulic oil cooler......................................................................................................................................166 Pressure accumulator...................................................................................................................................................167 PUMP TRANSFER GEARBOX......................................................................................................................................................168 Checking the gearbox oil level / Topping up with oil...................................................................................................................168 Changing the gearbox oil...............................................................................................................................................169 SLEWING GEARBOX............................................................................................................................................................171 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................171 Changing the gearbox oil...............................................................................................................................................171 Gearbox venting........................................................................................................................................................172 TRAVEL GAERBOX.............................................................................................................................................................173 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................173 Travel gearbox - Changing the oil......................................................................................................................................173 Gearbox venting........................................................................................................................................................173 CRAWLER TRACKS.............................................................................................................................................................174 Track rollers, support rollers, track pads.............................................................................................................................174 Track tensioner........................................................................................................................................................176 Pressure-accumulator inspection regulations............................................................................................................................177 Checking the gas charging pressure in the pressure accumulator.........................................................................................................177 .SLEWING RING..............................................................................................................................................................178 Slewing ring - Instructions............................................................................................................................................178 Bearing races..........................................................................................................................................................178 CENTRAL LUBRICATING........................................................................................................................................................180 Design and function....................................................................................................................................................180 Checking the greasing pressure.........................................................................................................................................183 Blockade of a greasing point...........................................................................................................................................183 Cleaning the grease strainers..........................................................................................................................................184 Bleeding the grease pump...............................................................................................................................................185 Bleeding the line system...............................................................................................................................................186 Manual greasing........................................................................................................................................................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........................................................................................................................................................190 NOTES......................................................................................................................................................................191 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.................................................................................................................................................................201 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................202 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................203 NOTES......................................................................................................................................................................205 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..................................................................................................................................................216 ABBREVIATIONS..............................................................................................................................................................219 TECHNICAL DATA.............................................................................................................................................................221 INDEX..........................................................................................................................................................................225
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