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Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651491 – PDF DOWNLOAD
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Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651491 – PDF DOWNLOAD
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Description
Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651491 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651491 – PDF DOWNLOAD
Language : English
Pages : 220
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651491 – 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 Hydraulic Excavator RH 40E Operating Instructions Manual BI651491 – 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 Demand control / Zero-flow regulation.................................................................................................................................. 32 Automatic engine speed reduction....................................................................................................................................... 32 Electrical system...................................................................................................................................................... 32 Sign................................................................................................................................................................... 35 Fire-extinguisher...................................................................................................................................................... 36 DRIVER'S CAB............................................................................................................................................................... 37 Entering and leaving the machine - Safety instructions................................................................................................................. 37 Driver's seat.......................................................................................................................................................... 38 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 40 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 59 Refuelling............................................................................................................................................................. 59 Service Station (optional equipment)................................................................................................................................... 60 Switching the electrical system on and off............................................................................................................................. 61 Battery main switch.................................................................................................................................................... 62 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 63 VENTILATION AND HEATING.................................................................................................................................................... 65 DRIVING.................................................................................................................................................................... 66 SAFETY INSTRUCTIONS.................................................................................................................................................... 66 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................................................................................................................................. 77 Working................................................................................................................................................................ 78 After daily operation.................................................................................................................................................. 79 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 80 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 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.................................................................................................................................................................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...............................................................................................................................................121 Filling quantities - other.............................................................................................................................................122 LUBRICANTS.................................................................................................................................................................123 I. Oils for combustion engines and compressors (selection).............................................................................................................123 II. Oils for hydraulic system (selection)..............................................................................................................................124 III. Oils for gearboxes (selection)....................................................................................................................................125 V. Greases for bearings and slewing rings..............................................................................................................................126 SERVICING WORK.............................................................................................................................................................127 Hose line for oil and cooling liquid changes...........................................................................................................................127 ENGINE.....................................................................................................................................................................128 Engine - Safety instructions...........................................................................................................................................128 Checking the V-belt tension............................................................................................................................................128 Retensioning the alternator/fan belt...................................................................................................................................128 Checking and adjusting the valve clearance.............................................................................................................................128 Checking the engine oil level / Topping up.............................................................................................................................128 Changing the engine oil................................................................................................................................................129 Replacing the oil filter...............................................................................................................................................130 Centrifuge (optional)..................................................................................................................................................131 COOLING SYSTEM.............................................................................................................................................................132 Radiators..............................................................................................................................................................132 Cooling liquid.........................................................................................................................................................133 Water filter...........................................................................................................................................................134 AIR-INTAKE SYSTEM..........................................................................................................................................................135 Main filter elements...................................................................................................................................................135 Safety filter element..................................................................................................................................................137 Air-intake lines.......................................................................................................................................................137 Dust collection........................................................................................................................................................137 FUEL SYSTEM................................................................................................................................................................138 Fuel system - Safety instructions......................................................................................................................................138 Replacing the fuel filter..............................................................................................................................................139 Venting the fuel system................................................................................................................................................139 Cleaning the fuel tanks................................................................................................................................................140 Refuelling station (optional)..........................................................................................................................................140 Water trap (option)....................................................................................................................................................141 ELECTRICAL SYSTEM..........................................................................................................................................................143 Electrical system - Safety instructions................................................................................................................................143 Alternator - Instructions..............................................................................................................................................143 Battery main switch / Main fuse........................................................................................................................................144 Battery................................................................................................................................................................144 HYDRAULIC SYSTEM...........................................................................................................................................................147 Hydraulic system - Safety instructions.................................................................................................................................147 Depressurizing the hydraulic system....................................................................................................................................147 Checking the hydraulic oil level.......................................................................................................................................148 Topping up with hydraulic oil..........................................................................................................................................148 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................149 Bypass valves (working circuit)........................................................................................................................................150 Bypass valves (cooling circuit)........................................................................................................................................151 Breather filter........................................................................................................................................................152 High-pressure filter for working hydraulics............................................................................................................................153 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump................................................................................154 Changing the hydraulic oil.............................................................................................................................................155 Venting the hydraulic system...........................................................................................................................................157 Cleaning the hydraulic oil cooler......................................................................................................................................158 Pressure accumulator...................................................................................................................................................159 PUMP TRANSFER GEARBOX......................................................................................................................................................160 Checking the gearbox oil level / Topping up with oil...................................................................................................................160 Changing the gearbox oil...............................................................................................................................................160 SLEWING GEARBOX............................................................................................................................................................162 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................162 Changing the gearbox oil...............................................................................................................................................162 Gearbox venting........................................................................................................................................................163 Output pinion..........................................................................................................................................................163 TRAVEL GAERBOX.............................................................................................................................................................164 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................164 Travel gearbox - Changing the oil......................................................................................................................................164 Gearbox venting........................................................................................................................................................164 CRAWLER TRACKS.............................................................................................................................................................165 Track rollers, support rollers, track pads.............................................................................................................................165 Track tensioner........................................................................................................................................................167 Pressure-accumulator inspection regulations............................................................................................................................168 Checking the gas charging pressure in the pressure accumulator.........................................................................................................168 Idlers.................................................................................................................................................................169 SLEWING RING...............................................................................................................................................................170 Slewing ring - Instructions............................................................................................................................................170 Bearing races..........................................................................................................................................................170 CENTRAL LUBRICATING........................................................................................................................................................172 Design and function....................................................................................................................................................172 Greasing cycle.........................................................................................................................................................174 Venting the grease pump................................................................................................................................................176 Venting the grease lines...............................................................................................................................................176 Unblocking a grease line...............................................................................................................................................176 Cleaning the grease sieves.............................................................................................................................................177 Lubricating the grease distributor of the working equipment............................................................................................................177 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................178 Putting the excavator out of operation.................................................................................................................................178 Battery storage........................................................................................................................................................178 Recommissioning........................................................................................................................................................179 NOTES......................................................................................................................................................................180 REPAIR WORK....................................................................................................................................................................183 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................185 FIRE AND EXPLOSION HAZARD..................................................................................................................................................187 ENGINE.....................................................................................................................................................................188 ELECTRICAL SYSTEM..........................................................................................................................................................189 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................189 Assisted starting (with jumper cables).................................................................................................................................189 Starting the engine with jumper cables (external batteries.............................................................................................................189 HYDRAULIC SYSTEM...........................................................................................................................................................191 Repair.................................................................................................................................................................191 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................192 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................193 NOTES......................................................................................................................................................................195 ANNEX..........................................................................................................................................................................197 TROUBLESHOOTING............................................................................................................................................................199 Instructions on troubleshooting........................................................................................................................................199 Layout of the fault table..............................................................................................................................................199 Possible causes........................................................................................................................................................199 Measures...............................................................................................................................................................199 Section................................................................................................................................................................199 FAULT TABLES...............................................................................................................................................................200 Combustion engine - Fault table........................................................................................................................................200 Working hydraulics – Fault table.......................................................................................................................................201 Track drive – Fault table..............................................................................................................................................202 Slewing mechnism – Fault table.........................................................................................................................................203 Central lubricating system – Fault table...............................................................................................................................204 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................206 ABBREVIATIONS..............................................................................................................................................................209 TECHNICAL DATA.............................................................................................................................................................211 INDEX..........................................................................................................................................................................215
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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