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Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651437 – PDF DOWNLOAD
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Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651437 – PDF DOWNLOAD
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Description
Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651437 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651437 – PDF DOWNLOAD
Language : English
Pages : 232
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651437 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 70
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 Terex|O&K mechanic or by attending an Terex|O&K training course for operators or maintenance personnel. The Terex|O&K 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|O&K operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Terex|O&K 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|O&K aftersales service.
- The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651437 – PDF DOWNLOAD
1 INTRODUCTION............................................................................................................................................................... 11 PREFACE.................................................................................................................................................................. 13 WARRANTY................................................................................................................................................................. 14 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15 Warnings and symbols................................................................................................................................................. 15 DESIGNATED USE........................................................................................................................................................... 16 ORGANIZATIONAL MEASURES.................................................................................................................................................. 17 Selection and qualification of personnel; basic responsibilities..................................................................................................... 18 Safety instructions governing specific operational phases............................................................................................................ 18 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19 Warning of special dangers........................................................................................................................................... 20 Gas, dust, steam and smoke........................................................................................................................................... 21 Hydraulic equipment.................................................................................................................................................. 21 Noise................................................................................................................................................................ 21 Oil, grease and other chemical substances............................................................................................................................ 21 Ether ............................................................................................................................................................... 21 Transporting and recommissioning .................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 22 NOTES ................................................................................................................................................................... 23 2 OPERATION.................................................................................................................................................................. 25 OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 27 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 29 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 30 Excavator layout..................................................................................................................................................... 31 Undercarriage........................................................................................................................................................ 32 Superstructure....................................................................................................................................................... 32 Drive................................................................................................................................................................ 32 Hydraulic system..................................................................................................................................................... 32 Pump Managing System (PMS)........................................................................................................................................... 32 Programmable Logic Controller (PLC) ................................................................................................................................. 32 Demand control / Zero-flow regulation................................................................................................................................ 33 Automatic engine speed reduction .................................................................................................................................... 33 Electrical system ................................................................................................................................................... 33 Signs ............................................................................................................................................................... 35 DRIVER'S CAB ........................................................................................................................................................ 36 Entering and leaving the machine - Safety instructions .............................................................................................................. 36 Windscreen washer ................................................................................................................................................... 37 Driver's seat ....................................................................................................................................................... 38 Fire-extinguisher ................................................................................................................................................... 39 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 40 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 59 Refuelling .......................................................................................................................................................... 59 Switching the electrical system on and off .......................................................................................................................... 62 Battery main switch ................................................................................................................................................. 63 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 64 Fuel preheating system (optional) ................................................................................................................................... 65 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 66 VENTILATION AND HEATING ................................................................................................................................................. 68 Air conditioner (optional) .......................................................................................................................................... 68 Auxiliary heating (optional) ........................................................................................................................................ 68 TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 69 Running-in specifications for components of the crawler tracks....................................................................................................... 69 TRAVELLING .......................................................................................................................................................... 70 Locking the superstructure .......................................................................................................................................... 74 Track parking brake ................................................................................................................................................. 74 TRANSPORTING THE MACHINE ................................................................................................................................................ 75 Transport - Safety instructions ..................................................................................................................................... 75 WORKING OPERATION ....................................................................................................................................................... 77 SAFETY INSTRUCTIONS ................................................................................................................................................. 77 Before starting work ................................................................................................................................................ 79 Slewing and braking the superstructure .............................................................................................................................. 80 Working ............................................................................................................................................................. 81 After daily operation ............................................................................................................................................... 82 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ...................................................................................................................... 83 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 and W ........................................................................................................................................................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. Oils for combustion engine .......................................................................................................................................124 II. Oils for hydraulic system (selection) ...........................................................................................................................125 III.a Oils for pump gearbox .........................................................................................................................................126 III.b Oils for swing gearbox ........................................................................................................................................127 III.c Oils for travel gearbox .......................................................................................................................................128 V. Greases for bearings and slewing rings ...........................................................................................................................129 SERVICING WORK ..........................................................................................................................................................130 Hose line for oil and cooling liquid changes ........................................................................................................................130 ENGINE ..................................................................................................................................................................131 Engine - Safety instructions ........................................................................................................................................131 Checking the engine oil level / Topping up .........................................................................................................................131 Changing the engine oil .............................................................................................................................................132 Replacing the engine oil filters ....................................................................................................................................133 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................134 COOLING SYSTEM ..........................................................................................................................................................135 Temperature .........................................................................................................................................................135 Cooler and cooling liquid............................................................................................................................................135 Topping up with coolant .............................................................................................................................................136 Changing the coolant ................................................................................................................................................136 AIR-INTAKE SYSTEM .......................................................................................................................................................138 Dust trap, cleaning .................................................................................................................................................138 Main filter elements ................................................................................................................................................139 Safety filter element ...............................................................................................................................................141 Air-intake lines ....................................................................................................................................................141 FUEL SYSTEM .............................................................................................................................................................142 Fuel system - Safety instructions ...................................................................................................................................142 Fuel pre-filter, Draining off water .................................................................................................................................142 Fuel pre-filter, replace ............................................................................................................................................143 Secondary fuel filter, replace ......................................................................................................................................144 Fuel tank - Venting .................................................................................................................................................145 Cleaning the fuel tank ..............................................................................................................................................145 Refuelling station (optional) .......................................................................................................................................146 Water trap (option)..................................................................................................................................................147 ELECTRICAL SYSTEM ......................................................................................................................................................149 Electrical system - Safety instructions .............................................................................................................................149 Floodlight projector, safety instructions ..........................................................................................................................150 Floodlight projector, replacing a defective xenon bulb ..............................................................................................................151 Battery .............................................................................................................................................................152 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 ...................................................................................................................................................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 SLEWING RING ............................................................................................................................................................177 Slewing ring - Instructions..........................................................................................................................................177 Bearing races........................................................................................................................................................177 CENTRAL LUBRICATING .....................................................................................................................................................179 Design and function .................................................................................................................................................179 Check for each Operation:............................................................................................................................................180 Malfunctions.........................................................................................................................................................181 Blockade of a lub point..............................................................................................................................................182 Ventilation of the lubricating pump..................................................................................................................................183 Cleaning the grease sieve............................................................................................................................................183 Manual lubrication...................................................................................................................................................184 OTHER MAINTENANCE .......................................................................................................................................................185 Heating and air conditioning ........................................................................................................................................185 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................186 Putting the excavator out of operation...............................................................................................................................186 Battery storage......................................................................................................................................................186 Recommissioning......................................................................................................................................................186 NOTES ...................................................................................................................................................................187 4 REPAIR WORK................................................................................................................................................................189 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................191 FIRE AND EXPLOSION HAZARD ...............................................................................................................................................193 ENGINE...................................................................................................................................................................194 ELECTRICAL SYSTEM .......................................................................................................................................................195 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................195 Assisted starting (with jumper cables)...............................................................................................................................195 Starting the engine with jumper cables (external batteries ..........................................................................................................195 HYDRAULIC SYSTEM.........................................................................................................................................................197 Repair – Instructions ...............................................................................................................................................197 Hydraulic hoses – Instructions ......................................................................................................................................197 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................198 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................199 NOTES ...................................................................................................................................................................201 5 ANNEX......................................................................................................................................................................203 TROUBLESHOOTING .........................................................................................................................................................205 Instructions on troubleshooting .....................................................................................................................................205 Layout of the fault table ...........................................................................................................................................205 Possible causes .....................................................................................................................................................205 Measures ............................................................................................................................................................205 Section .............................................................................................................................................................205 FAULT TABLES ............................................................................................................................................................206 Combustion engine - Fault table .....................................................................................................................................206 ,Working hydraulics – Fault table ...................................................................................................................................206 Track drive – Fault table ...........................................................................................................................................208 Slewing mechnism – Fault table ......................................................................................................................................209 Central lubricating system – Fault table ............................................................................................................................210 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................211 ABBREVIATIONS ...........................................................................................................................................................213 TECHNICAL DATA ..........................................................................................................................................................215 6 INDEX......................................................................................................................................................................227
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