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CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725018 – PDF DOWNLOAD
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CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725018 – PDF DOWNLOAD
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Description
CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725018 – PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725018 – PDF DOWNLOAD
Language : English
Pages : 234
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725018 – PDF DOWNLOAD
PREFACE:
- These operating instructions are designed to famil- iarize the operator with the machine and its
desig- nated use. - The operating instructions contain important in- formation 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 avail- able 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, troubleshoot- ing 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 pre- vention 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 con- struction-machine specialist. They cannot
provide basic know-how. This can be acquired, for exam- ple, in several days’ instruction by a
qualified Bu- cyrus 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. - All Bucyrus HEX operating manuals are issued in German and then translated. Even a good transla-
tion may give rise to questions which Bucyrus HEX will be pleased to answer. - The operating instructions are not work instruc- tions for carrying out major repairs.
Such work is willingly done for you by the Bucyrus HEX 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:
Customer Support: [email protected]
TABLE OF CONTENTS:
CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725018 – 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 Transporting and recommissioning...................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD................................................................................................................................................. 22 2 OPERATION................................................................................................................................................................... 23 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 25 FIRE AND EXPLOSION HAZARD................................................................................................................................................. 27 DESCRIPTION OF THE EXCAVATOR.............................................................................................................................................. 28 Excavator layout ..................................................................................................................................................... 29 Undercarriage......................................................................................................................................................... 30 Superstructure........................................................................................................................................................ 30 Drive................................................................................................................................................................. 30 Hydraulic system...................................................................................................................................................... 30 Pump Managing System (PMS)............................................................................................................................................ 30 Demand control / Zero-flow regulation................................................................................................................................. 30 Automatic engine speed reduction ..................................................................................................................................... 30 Electrical system .................................................................................................................................................... 30 Sign ................................................................................................................................................................. 33 Fire-extinguisher .................................................................................................................................................... 34 DRIVER'S CAB ............................................................................................................................................................. 35 Entering and leaving the machine - Safety instructions ............................................................................................................... 35 Driver's seat ........................................................................................................................................................ 36 Adjusting the control consoles ....................................................................................................................................... 37 Windscreen washer .................................................................................................................................................... 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 Preheating system for engine and hydraulic oil (optional) ............................................................................................................ 63 Fuel preheating system (optional) .................................................................................................................................... 64 STARTING AND STOPPING THE ENGINES ........................................................................................................................................ 65 Starting the engines ................................................................................................................................................. 65 Shutting off the engine ............................................................................................................................................. 66 Emergency stop ....................................................................................................................................................... 66 VENTILATION AND HEATING .................................................................................................................................................. 67 Air conditioner (optional) ........................................................................................................................................... 67 Auxiliary heating (optional) ......................................................................................................................................... 67 DRIVING .................................................................................................................................................................. 68 SAFETY INSTRUCTIONS .................................................................................................................................................. 68 TRAVELLING ........................................................................................................................................................... 69 Locking the superstructure ........................................................................................................................................... 73 Track parking brake .................................................................................................................................................. 73 TRANSPORTING THE MACHINE ................................................................................................................................................. 74 Transport - Safety instructions ...................................................................................................................................... 74 WORKING OPERATION ........................................................................................................................................................ 76 Safety Instructions .................................................................................................................................................. 76 Before starting work ................................................................................................................................................. 78 Slewing and braking the superstructure ............................................................................................................................... 79 Working .............................................................................................................................................................. 80 After daily operation ................................................................................................................................................ 81 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ....................................................................................................................... 82 Securing the machine ................................................................................................................................................. 84 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ........................................................................................................... 85 LIFTING OPERATIONS ....................................................................................................................................................... 86 Safety instructions .................................................................................................................................................. 86 Load-hooks on backhoe buckets. ....................................................................................................................................... 87 NOTES .................................................................................................................................................................... 91 3 INSPECTION AND SERVICING.................................................................................................................................................... 93 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ........................................................................................................................... 95 FIRE AND EXPLOSION HAZARD ................................................................................................................................................101 ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID ...............................................................................................................................102 Environmentally compatible hydraulic fluid - operating instructions ..................................................................................................102 Environmentally compatible hydraulic fluid, conversion ...............................................................................................................102 Environmentally compatible hydraulic fluid - Sampling ................................................................................................................103 ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS .........................................................................................................................104 Lubricants for bearings ..............................................................................................................................................104 Gearbox oils .........................................................................................................................................................104 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................105 Intervals.............................................................................................................................................................105 Change of engine oil l................................................................................................................................................105 Oils / Greases .......................................................................................................................................................105 Cleaning jobs ........................................................................................................................................................105 Components ...........................................................................................................................................................105 Plan V ...............................................................................................................................................................107 Plan N ...............................................................................................................................................................109 Plan T ...............................................................................................................................................................111 Plan A – E ...........................................................................................................................................................113 LUBRICATING CHART – GREASE ...............................................................................................................................................118 Lubricating chart – Grease (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.a Oil for combustion engines (oil change interval 500 OH) ..........................................................................................................124 I.b Oils for combustion engines (oil change interval 250 OH) .........................................................................................................125 II. Oils for hydraulic system (selection) ............................................................................................................................126 III.a Oils for pump transfer gearbox .................................................................................................................................127 III.b Oils for swing gearbox .........................................................................................................................................128 III.c Oils for travel gearbox ........................................................................................................................................129 V. Greases for bearings and slewing rings ............................................................................................................................130 SERVICING WORK ...........................................................................................................................................................131 Hose line for oil and cooling liquid changes .........................................................................................................................131 ENGINE ...................................................................................................................................................................132 Engine - Safety instructions .........................................................................................................................................132 Checking the engine oil level / Topping up ..........................................................................................................................132 Changing the engine oil ..............................................................................................................................................133 Replacing the oil filter .............................................................................................................................................134 Centrifuge (optional).................................................................................................................................................135 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................136 COOLING SYSTEM ...........................................................................................................................................................137 Radiators ............................................................................................................................................................137 Topping up cooling liquid ............................................................................................................................................137 Cooling liquid change.................................................................................................................................................138 Water filter .........................................................................................................................................................139 AIR-INTAKE SYSTEM ........................................................................................................................................................140 Main filter element ..................................................................................................................................................140 Safety filter element ................................................................................................................................................142 Air-intake lines .....................................................................................................................................................142 Dust collection ......................................................................................................................................................142 FUEL SYSTEM ..............................................................................................................................................................143 Fuel system - Safety instructions ....................................................................................................................................143 Replacing the fuel filter ............................................................................................................................................144 Venting the fuel system ..............................................................................................................................................144 Cleaning the fuel tank ...............................................................................................................................................145 Refuelling station (optional) ........................................................................................................................................145 Water trap (option)...................................................................................................................................................146 ELECTRICAL SYSTEM .......................................................................................................................................................148 Electrical system - Safety instructions ..............................................................................................................................148 Alternator - Instructions ............................................................................................................................................148 Battery main switch / Main fuse ......................................................................................................................................149 Battery ..............................................................................................................................................................149 Floodlight projector, safety instructions ...........................................................................................................................152 Floodlight projector, replacing a defective xenon bulb ...............................................................................................................153 HYDRAULIC SYSTEM .........................................................................................................................................................154 Hydraulic system - Safety instructions ...............................................................................................................................154 Depressurizing the hydraulic system ..................................................................................................................................154 Checking the hydraulic oil level .....................................................................................................................................155 Topping up with hydraulic oil ........................................................................................................................................155 Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................156 Bypass valves (working circuit) ......................................................................................................................................157 Bypass valves (cooling circuit) ......................................................................................................................................158 Breather filter ......................................................................................................................................................159 High-pressure filter for working hydraulics ..........................................................................................................................160 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump ..............................................................................161 Changing the hydraulic oil ...........................................................................................................................................162 Venting the hydraulic system..........................................................................................................................................164 Cleaning the hydraulic oil cooler.....................................................................................................................................165 Pressure accumulator .................................................................................................................................................166 PUMP TRANSFER GEARBOX PUMP TRANSFER GEARBOX ..............................................................................................................................167 Checking the gearbox oil level / Topping up with oil .................................................................................................................167 Changing the gearbox oil .............................................................................................................................................168 SLEWING GEARBOX ..........................................................................................................................................................170 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................170 Changing the gearbox oil .............................................................................................................................................170 Gearbox venting ......................................................................................................................................................171 Output pinion ........................................................................................................................................................171 TRAVEL GAERBOX ...........................................................................................................................................................172 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................172 Travel gearbox - Changing the oil ....................................................................................................................................172 Gearbox venting ......................................................................................................................................................172 CRAWLER TRACKS ...........................................................................................................................................................173 Track rollers, support rollers, track pads ...........................................................................................................................173 Track tensioner ......................................................................................................................................................175 Pressure-accumulator inspection regulations ..........................................................................................................................176 Checking the gas charging pressure in the pressure accumulator........................................................................................................176 Idlers ...............................................................................................................................................................177 SLEWING RING .............................................................................................................................................................178 Slewing ring - Instructions...........................................................................................................................................178 Bearing races.........................................................................................................................................................178 CENTRAL LUBRICATING ......................................................................................................................................................180 Design and function ..................................................................................................................................................180 Greasing cycle ......................................................................................................................................................182 Venting the grease pump ..............................................................................................................................................184 Venting the grease lines .............................................................................................................................................184 Unblocking a grease line .............................................................................................................................................184 Cleaning the grease sieves ...........................................................................................................................................185 Lubricating the grease distributor of the working equipment...........................................................................................................185 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................186 Putting the excavator out of operation................................................................................................................................186 Battery storage.......................................................................................................................................................186 Recommissioning.......................................................................................................................................................187 NOTES ....................................................................................................................................................................189 4 REPAIR WORK.................................................................................................................................................................191 REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................193 FIRE AND EXPLOSION HAZARD ................................................................................................................................................195 ENGINE....................................................................................................................................................................196 ELECTRICAL SYSTEM ........................................................................................................................................................197 Assisted starting (with jumper cables) – Safety instructions .........................................................................................................197 Assisted starting (with jumper cables)................................................................................................................................197 Starting the engine with jumper cables (external batteries ...........................................................................................................197 HYDRAULIC SYSTEM..........................................................................................................................................................199 Repair – Instructions ................................................................................................................................................199 Hydraulic hoses – Instructions .......................................................................................................................................199 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................200 WELDING OPERATIONS - SAFETY INSTRUCTIONS .................................................................................................................................201 NOTES ....................................................................................................................................................................203 5 ANNEX.......................................................................................................................................................................205 TROUBLESHOOTING ..........................................................................................................................................................207 Instructions on troubleshooting ......................................................................................................................................207 Layout of the fault table ............................................................................................................................................207 Possible causes ......................................................................................................................................................207 Measures .............................................................................................................................................................207 Section ..............................................................................................................................................................207 FAULT TABLES .............................................................................................................................................................208 Combustion engine - Fault table ......................................................................................................................................208 Working hydraulics – Fault table .....................................................................................................................................209 Track drive – Fault table ............................................................................................................................................210 Slewing mechnism – Fault table .......................................................................................................................................211 Central lubricating system – Fault table .............................................................................................................................212 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................213 ABBREVIATIONS ............................................................................................................................................................215 TECHNICAL DATA ...........................................................................................................................................................217 6 INDEX.......................................................................................................................................................................229
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V
