CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725041 – PDF DOWNLOAD

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CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725041 – PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725041 – PDF DOWNLOAD

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

DESCRIPTION:

CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725041 – PDF DOWNLOAD

PREFACE:

• These operating instructions are designed to famil- iarize the operator with the machine and its
  designated 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:

TABLE OF CONTENTS:

CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725041 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE 1-6
ORGANIZATIONAL MEASURES 1-7
Selection and qualification of personnel; basic responsibilities 1-7
Safety instructions governing specific operational phases 1-8
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-9
Warning of special dangers 1-10
Gas, dust, steam and smoke 1-11
Hydraulic equipment 1-11
Noise 1-11
Oil, grease and other chemical substances 1-11
Ether 1-11
Transporting and recommissioning 1-11
FIRE AND EXPLOSION HAZARD 1-12
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE EXCAVATOR 2-6
Excavator layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Pump Managing System (PMS) 2-8
Programmable Logic Controller (PLC) 2-8
Demand control / Zero-flow regulation 2-9
Automatic engine speed reduction 2-9
Electrical system 2-9
Signs 2-11
DRIVER’S CAB 2-12
Entering and leaving the machine – Safety instructions 2-12
Windscreen washer 2-13
Driver’s seat 2-14
Adjusting the control consoles 2-15
Fire-extinguisher 2-16
OPERATING INSTRUCTIONS RH40E
Table of contents
vi BA RH40E(3 725 041.00)-EN
MONITORING, WARNING AND CONTROL ELEMENTS 2-18
PUTTING THE MACHINE INTO OPERATION 2-37
Refuelling 2-37
Switching the electrical system on and off 2-40
Battery main switch 2-41
Preheating system for engine and hydraulic oil (optional) 2-42
Fuel preheating system (optional) 2-43
STARTING AND STOPPING THE ENGINES 2-44
VENTILATION AND HEATING 2-46
Air conditioner (optional) 2-46
Auxiliary heating (optional) 2-46
TRAVELLING, SAFETY INSTRUCTIONS 2-47
Running-in specifications for components of the crawler tracks 2-47
TRAVELLING 2-48
Locking the superstructure 2-52
Track parking brake 2-52
TRANSPORTING THE MACHINE 2-53
Transport – Safety instructions 2-53
WORKING OPERATION 2-55
SAFETY INSTRUCTIONS 2-55
Before starting work 2-57
Slewing and braking the superstructure 2-58
Working 2-59
After daily operation 2-60
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-61
Securing the machine 2-62
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-63
LIFTING OPERATIONS 2-64
Safety instructions 2-64
Load-hooks on backhoe buckets. 2-65
NOTES 2-69
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
FIRE AND EXPLOSION HAZARD 3-9
ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID 3-10
Environmentally compatible hydraulic fluid – operating instructions 3-10
Environmentally compatible hydraulic fluid, conversion 3-10
Environmentally compatible hydraulic fluid – Sampling 3-11
ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS 3-12
Lubricants for bearings 3-12
Gearbox oils 3-12
OPERATING INSTRUCTIONS RH40E
Table of contents
BA RH40E(3 725 041.00)-EN vii
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-13
Intervals 3-13
Change of engine oil l 3-13
Oils / Greases 3-13
Cleaning jobs 3-13
Components 3-13
Plan V 3-15
Plan N 3-17
Plan T and W 3-19
Plan A – E 3-21
LUBRICATING CHART – GREASE 3-26
Lubricating chart – Grease (legend) 3-27
Filling quantities – Grease 3-27
INSPECTION PLAN – OIL 3-28
Inspection plan – Oil (legend) ) 3-29
Filling quantities – oil 3-30
Filling quantities – other 3-30
LUBRICANTS 3-31
Notes on the selection of oils and greases 3-31
I. Oils for combustion engine 3-32
II. Oils for hydraulic system 3-33
III.a Oils for pump gearbox 3-34
III.b Oils for swing gearbox 3-35
III.c Oils for travel gearbox 3-36
V. Greases for bearings and slewing rings 3-37
SERVICING WORK 3-38
Hose line for oil and cooling liquid changes 3-38
ENGINE 3-39
Engine – Safety instructions 3-39
Checking the engine oil level / Topping up 3-39
Changing the engine oil 3-40
Replacing the engine oil filters 3-41
Cold-starting fluid (ether) – Replacing the pressure vessel 3-42
COOLING SYSTEM 3-43
Temperature 3-43
Cooler and cooling liquid 3-43
Topping up with coolant 3-44
Changing the coolant 3-44
AIR-INTAKE SYSTEM 3-46
Dust trap, cleaning 3-46
Main filter elements 3-47
Safety filter element 3-49
Air-intake lines 3-49
FUEL SYSTEM 3-50
Fuel system – Safety instructions 3-50
Fuel pre-filter, Draining off water 3-50
Fuel pre-filter, replace 3-51
OPERATING INSTRUCTIONS RH40E
Table of contents
viii BA RH40E(3 725 041.00)-EN
Secondary fuel filter, replace 3-52
Fuel tank – Venting 3-53
Cleaning the fuel tank 3-53
Refuelling station (optional) 3-54
Water trap (option) 3-55
ELECTRICAL SYSTEM 3-57
Electrical system – Safety instructions 3-57
Floodlight projector, safety instructions 3-58
Floodlight projector, replacing a defective xenon bulb 3-59
Battery 3-60
HYDRAULIC SYSTEM 3-62
Hydraulic system – Safety instructions 3-62
Depressurizing the hydraulic system 3-62
Checking the hydraulic oil level 3-63
Topping up with hydraulic oil 3-63
Changing the hydraulic oil return-flow (hydraulic oil reservoir) 3-64
Bypass valves (working circuit) 3-65
Bypass valves (cooling circuit) 3-66
Breather filter 3-67
High-pressure filter for working hydraulics 3-68
High-pressure filters for the servo circuit and the feeding circuit of the slewing pump 3-69
Changing the hydraulic oil 3-70
Venting the hydraulic system 3-72
Cleaning the hydraulic oil cooler 3-73
Pressure accumulator 3-74
PUMP TRANSFER GEARBOX 3-75
Checking the gearbox oil level / Topping up with oil 3-75
Changing the gearbox oil 3-76
SLEWING GEARBOX 3-78
Gearbox – Checking the oil level / Topping up with oil 3-78
Changing the gearbox oil 3-78
Gearbox venting 3-79
Output pinion 3-79
TRAVEL GEARBOX 3-80
Gearbox – Checking the oil level / Topping up with oil 3-80
Travel gearbox – Changing the oil 3-80
Gearbox venting 3-80
CRAWLER TRACKS 3-81
Track rollers, support rollers, track pads 3-81
Track tensioner 3-83
Track tensioner 3-83
Pressure-accumulator inspection regulations 3-84
Checking the gas charging pressure in the pressure accumulator 3-84
SWING RING 3-85
Swing ring – Instructions 3-85
Bearing races 3-85
OPERATING INSTRUCTIONS RH40E
Table of contents
BA RH40E(3 725 041.00)-EN ix
CENTRAL LUBRICATING 3-87
Design and function 3-87
Greasing cycle 3-89
Venting the grease pump 3-91
Venting the grease lines 3-91
Unblocking a grease line 3-91
Cleaning the grease sieves 3-92
Lubricating the grease distributor of the working equipment 3-92
OTHER MAINTENANCE 3-93
Heating and air conditioning 3-93
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-94
Putting the excavator out of operation 3-94
Battery storage 3-94
Recommissioning 3-94
NOTES 3-95
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
FIRE AND EXPLOSION HAZARD 4-5
ENGINE 4-6
ELECTRICAL SYSTEM 4-7
Assisted starting (with jumper cables) – Safety instructions 4-7
Assisted starting (with jumper cables) 4-7
Starting the engine with jumper cables (external batteries 4-7
HYDRAULIC SYSTEM 4-9
Repair – Instructions 4-9
Hydraulic hoses – Instructions 4-9
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-10
WELDING OPERATIONS – SAFETY INSTRUCTIONS 4-11
NOTES 4-13
5 ANNEX 5-1
TROUBLESHOOTING 5-3
Instructions on troubleshooting 5-3
Layout of the fault table 5-3
Possible causes 5-3
Measures 5-3
Section 5-3
FAULT TABLES 5-4
Combustion engine – Fault table 5-4
,Working hydraulics – Fault table 5-4
Working hydraulics – Fault table 5-5
Track drive – Fault table 5-6
Slewing mechnism – Fault table 5-7
OPERATING INSTRUCTIONS RH40E
Table of contents
x BA RH40E(3 725 041.00)-EN
Central lubricating system – Fault table 5-8
HYDRAULIC CIRCUIT DIAGRAM 5-9
ABBREVIATIONS 5-11
TECHNICAL DATA 5-13
6 INDEX 6-1

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