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Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651440 – PDF DOWNLOAD
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Description
Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651440 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651440 – PDF DOWNLOAD
Language : English
Pages : 230
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651440 – 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 BI651440 – 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 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 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 64 VENTILATION AND HEATING ................................................................................................................................................. 66 Air conditioner (optional) .......................................................................................................................................... 66 TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 67 Running-in specifications for components of the crawler tracks....................................................................................................... 67 TRAVELLING .......................................................................................................................................................... 68 Locking the superstructure .......................................................................................................................................... 72 Track parking brake ................................................................................................................................................. 72 TRANSPORTING THE MACHINE ................................................................................................................................................ 73 Transport - Safety instructions ..................................................................................................................................... 73 WORKING OPERATION ....................................................................................................................................................... 75 SAFETY INSTRUCTIONS ................................................................................................................................................. 75 Before starting work ................................................................................................................................................ 77 Slewing and braking the superstructure .............................................................................................................................. 78 Working ............................................................................................................................................................. 79 After daily operation ............................................................................................................................................... 80 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ...................................................................................................................... 81 Securing the machine ................................................................................................................................................ 83 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) .......................................................................................................... 84 LIFTING OPERATIONS ...................................................................................................................................................... 85 Safety instructions ................................................................................................................................................. 85 Load-hooks on backhoe buckets. ...................................................................................................................................... 86 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 (LOADING BUCKET) .............................................................................................................................118 Lubricating chart – Grease / Loading bucket (legend) ................................................................................................................119 Filling quantities - Grease..........................................................................................................................................119 LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND) ....................................................................................................................120 Lubricating chart – Grease / Backhoe bucket (legend) ................................................................................................................121 Filling quantities - Grease..........................................................................................................................................121 INSPECTION PLAN - OIL ...................................................................................................................................................122 Inspection plan – Oil (legend) ).....................................................................................................................................123 Filling quantities - oil ............................................................................................................................................124 Filling quantities - other...........................................................................................................................................124 LUBRICANTS ..............................................................................................................................................................125 I. Oils for combustion engine .......................................................................................................................................125 II. Oils for hydraulic system (selection) ...........................................................................................................................126 III.a Oils for pump 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 engine oil filters ....................................................................................................................................134 COOLING SYSTEM ..........................................................................................................................................................135 Temperature .........................................................................................................................................................135 Radiators and cooling liquid.........................................................................................................................................135 Topping up cooling liquid............................................................................................................................................136 Change cooling liquid ...............................................................................................................................................136 AIR-INTAKE SYSTEM .......................................................................................................................................................138 Main filter elements ................................................................................................................................................138 Safety filter element ...............................................................................................................................................140 Air-intake lines ....................................................................................................................................................140 Dust collection .....................................................................................................................................................140 FUEL SYSTEM .............................................................................................................................................................141 Fuel system - Safety instructions ...................................................................................................................................141 Primary fuel filter, drain off water ................................................................................................................................141 Primary fuel filter, replace ........................................................................................................................................142 Secondary fuel filter, replace ......................................................................................................................................143 Venting the fuel system .............................................................................................................................................144 Cleaning the fuel tank ..............................................................................................................................................144 Refuelling station (optional) .......................................................................................................................................145 Water trap (option)..................................................................................................................................................146 ELECTRICAL SYSTEM ......................................................................................................................................................148 Electrical system - Safety instructions .............................................................................................................................148 Floodlight projector, replacing the lamp ............................................................................................................................149 Battery .............................................................................................................................................................150 HYDRAULIC SYSTEM ........................................................................................................................................................152 Hydraulic system - Safety instructions ..............................................................................................................................152 Depressurizing the hydraulic system .................................................................................................................................152 Checking the hydraulic oil level ....................................................................................................................................153 Topping up with hydraulic oil .......................................................................................................................................153 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................154 Bypass valves (working circuit) .....................................................................................................................................155 Bypass valves (cooling circuit) .....................................................................................................................................156 Breather filter .....................................................................................................................................................157 High-pressure filter for working hydraulics .........................................................................................................................158 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump .............................................................................159 Changing the hydraulic oil ..........................................................................................................................................160 Venting the hydraulic system.........................................................................................................................................162 Cleaning the hydraulic oil cooler....................................................................................................................................163 Pressure accumulator ................................................................................................................................................164 PUMP TRANSFER GEARBOX ...................................................................................................................................................165 Checking the gearbox oil level / Topping up with oil ................................................................................................................165 Changing the gearbox oil ............................................................................................................................................166 SLEWING GEARBOX .........................................................................................................................................................168 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................168 Changing the gearbox oil ............................................................................................................................................168 Gearbox venting .....................................................................................................................................................169 Output pinion .......................................................................................................................................................169 TRAVEL GAERBOX ..........................................................................................................................................................170 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................170 Travel gearbox - Changing the oil ...................................................................................................................................170 Gearbox venting .....................................................................................................................................................170 CRAWLER TRACKS .........................................................................................................................................................171 Track rollers, support rollers, track pads ..........................................................................................................................171 Track tensioner .....................................................................................................................................................173 Pressure-accumulator inspection regulations .........................................................................................................................174 Checking the gas charging pressure in the pressure accumulator.......................................................................................................174 .SLEWING RING ...........................................................................................................................................................175 Slewing ring - Instructions..........................................................................................................................................175 Bearing races........................................................................................................................................................175 CENTRAL LUBRICATING .....................................................................................................................................................177 Design and function .................................................................................................................................................177 Greasing cycle .....................................................................................................................................................179 Venting the grease pump .............................................................................................................................................181 Venting the grease lines ............................................................................................................................................181 Unblocking a grease line ............................................................................................................................................181 Cleaning the grease sieves ..........................................................................................................................................182 Lubricating the grease distributor of the working equipment..........................................................................................................182 OTHER MAINTENANCE .......................................................................................................................................................183 Heating and air conditioning ........................................................................................................................................183 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................184 Putting the excavator out of operation...............................................................................................................................184 Battery storage......................................................................................................................................................184 Recommissioning......................................................................................................................................................184 NOTES ...................................................................................................................................................................185 4 REPAIR WORK................................................................................................................................................................187 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................189 FIRE AND EXPLOSION HAZARD ...............................................................................................................................................191 ENGINE...................................................................................................................................................................192 ELECTRICAL SYSTEM .......................................................................................................................................................193 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................193 Assisted starting (with jumper cables)...............................................................................................................................193 Starting the engine with jumper cables (external batteries ..........................................................................................................193 HYDRAULIC SYSTEM.........................................................................................................................................................195 Repair ..............................................................................................................................................................195 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................196 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................197 NOTES ...................................................................................................................................................................199 5 ANNEX......................................................................................................................................................................201 TROUBLESHOOTING .........................................................................................................................................................203 Instructions on troubleshooting .....................................................................................................................................203 Layout of the fault table ...........................................................................................................................................203 Possible causes .....................................................................................................................................................203 Measures ............................................................................................................................................................203 Section .............................................................................................................................................................203 FAULT TABLES ............................................................................................................................................................204 Combustion engine - Fault table .....................................................................................................................................204 ,Working hydraulics – Fault table ...................................................................................................................................204 Track drive – Fault table ...........................................................................................................................................206 Slewing mechnism – Fault table ......................................................................................................................................207 Central lubricating system – Fault table ............................................................................................................................208 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................209 ABBREVIATIONS ...........................................................................................................................................................211 TECHNICAL DATA ..........................................................................................................................................................213 6 INDEX......................................................................................................................................................................225
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