Cat 6090ACFS Hydraulic Shovel Operation and Maintenance Manual BI015806 - PDF DOWNLOAD

BI015806 October 2014

Operation and Maintenance Manual 6090ACFS Hydraulic Shovel

No. DHS90005

BI015806

BI015806

Hydraulic Excavator 6090ACFS RH 400 E No. No. DHS90005 O&K Mining GmbH

Update .01, see pages 107 and 153a

2 803 900.00 en

Update to version .01, see pages 107 and 153a

BI015806

OPERATING INSTRUCTIONS RH 400 E

_______________________________________________________________________________________ Published by:

O & K Mining GmbH

Dept. 340 - Documentation D-44149 Dortmund, Karl-Funke-Straße 36 Tel. 49 (0) 231 922-4340 Fax 49 (0) 231 922-5300

© Copyright by O&K, Printed in Germany

_______________________________________________________________________________________ Update to version .01, see pages 107 and 153a 2 803 900.00 en

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OPERATING INSTRUCTIONS RH 400 E

Die O&K Mining operating manual is in 6 sections; the sections are designed for different target groups: 2804050

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

_______________________________________________________________________________________ Update to version .01, see pages 107 and 153a 2 803 900.00 en

BI015806

OPERATING INSTRUCTIONS RH 400 E

_______________________________________________________________________________________ Update to version .01, see pages 107 and 153a 2 803 900.00 en

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OPERATING INSTRUCTIONS RH 400 E

PART 1 - INTRODUCTION................................................................................................. 1 Preface ............................................................................................................................... 3 Warranty............................................................................................................................. 3 FUNDAMENTAL SAFETY INSTRUCTIONS ...................................................................... 4 Warnings and symbols..................................................................................................... 4

Designated use .................................................................................................................................................. 4

Organizational measures ................................................................................................. 5 Selection and qualification of personnel; basic responsibilities ................................. 6 Safety instructions governing specific operational phases.......................................... 6

Standard operation............................................................................................................................................. 6 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables...................................................................... 7

Warning of special dangers ............................................................................................. 8

Electric energy.................................................................................................................................................... 8 Gas, dust, steam and smoke ............................................................................................................................. 8 Hydraulic and pneumatic equipment .................................................................................................................. 9 Noise .................................................................................................................................................................. 9 Oil, grease and other chemical substances ....................................................................................................... 9

Transporting and recommissioning ................................................................................ 9 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS ................................................................................................................. 10 Fire and explosion hazard.............................................................................................. 12 NOTES.............................................................................................................................. 13

Update to version .01, see pages 107 and 153a

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PART 2 - OPERATION ..................................................................................................... 15 Operation - Safety instructions...................................................................................... 17 Fire and explosion hazard .............................................................................................. 19 DESCRIPTION OF THE EXCAVATOR ............................................................................ 20

Excavator layout ........................................................................................................................................ 21 Undercarriage ............................................................................................................................................ 21 Superstructure ........................................................................................................................................... 21 Loading bucket........................................................................................................................................... 21 Undercarriage ............................................................................................................................................ 22 Superstructure ........................................................................................................................................... 22 Drive.......................................................................................................................................................... 22 Hydraulic system........................................................................................................................................ 22 Pump Managing System (PMS) ................................................................................................................. 22 Stored Program Control (SPC)................................................................................................................... 22 Demand control / Zero-flow regulation........................................................................................................ 23 Board Control System (BCS) ..................................................................................................................... 23 Electrical system........................................................................................................................................ 23 Power supply ............................................................................................................................................. 23 Signs ......................................................................................................................................................... 25 Warning and instruction signs .................................................................................................................... 25 Machine number ........................................................................................................................................ 25 Electric motor number................................................................................................................................ 25 Component numbers.................................................................................................................................. 25 Entering and leaving the machine Safety instructions ................................................................................ 26 Ramp-type ladder ...................................................................................................................................... 26 Access ....................................................................................................................................................... 27 Escape ladder ............................................................................................................................................ 27 Ramp lighting............................................................................................................................................. 27 Cab interior lamp ....................................................................................................................................... 28 Servicing lighting ....................................................................................................................................... 29 110 V socket .............................................................................................................................................. 29 EMERGENCY STOP pushbuttons ............................................................................................................. 30 Unlocking the EMERGENCY STOP button ................................................................................................ 30 Windscreen washer.................................................................................................................................... 31 Driver's seat............................................................................................................................................... 32 Adjusting the backrest ................................................................................................................................ 32 Adjusting the lumbar support...................................................................................................................... 32 Adjusting the seat cushion.......................................................................................................................... 32 Adjusting the armrests ............................................................................................................................... 32 Fore-and-aft adjustment............................................................................................................................. 32 Adjusting the seat suspension .................................................................................................................... 32 Fore-and-aft adjustment of the seat plate................................................................................................... 32 Passenger seat .......................................................................................................................................... 33 Adjusting the backrest ................................................................................................................................ 33 Adjusting the seat cushion.......................................................................................................................... 33 Adjusting the armrests ............................................................................................................................... 33 Fore-and-aft adjustment............................................................................................................................. 33 Adjusting the seat suspension .................................................................................................................... 33 Fire extinguisher ........................................................................................................................................ 34

Update to version .01, see pages 107 and 153a

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Extinguishing agent .......................................................................................................................................... 34 Inspection ......................................................................................................................................................... 34 Automatic fire-extinguishing system................................................................................................................. 35 Inspection ......................................................................................................................................................... 35

MONITORING, WARNING AND CONTROL ELEMENTS................................................ 36 PUTTING THE MACHINE INTO OPERATION ................................................................. 60 Refilling of consumables................................................................................................ 60

Refilling - Safety instructions ............................................................................................................................ 60 Service station (tanklift) .................................................................................................................................... 60 Lowering the service station............................................................................................................................. 60 Raising the service station ............................................................................................................................... 60 Refilling / draining ............................................................................................................................................. 60 Electrical system on / off .................................................................................................................................. 63 Battery main switch .......................................................................................................................................... 63 Switch-disconnector ......................................................................................................................................... 64 Switching on ..................................................................................................................................................... 64 Shutting off ....................................................................................................................................................... 64 Off-load disconnector ....................................................................................................................................... 64 Switching on ..................................................................................................................................................... 64 Shutting off ....................................................................................................................................................... 64 Motor protective relay....................................................................................................................................... 65 Switching the electric motor on and off ............................................................................................................ 66 Before switching on the electric motor ............................................................................................................. 66 Switching on ..................................................................................................................................................... 67 Shutting off ....................................................................................................................................................... 68 EMERGENCY STOP ....................................................................................................................................... 68

TRAVELLING - SAFETY INSTRUCTIONS ...................................................................... 69 TRAVELLING ................................................................................................................... 70

Superstructure basic position ........................................................................................................................... 70 Travelling forwards/backwards......................................................................................................................... 70 Regulating the travelling speed ........................................................................................................................ 71 Travelling on level ground ................................................................................................................................ 71 Cornering.......................................................................................................................................................... 71 Turning ............................................................................................................................................................. 71 Travelling over longer distances....................................................................................................................... 73 Locking the superstructure............................................................................................................................... 74 Track parking brake ......................................................................................................................................... 74

Transporting the machine .............................................................................................. 75

Transport - Safety instructions ......................................................................................................................... 75 Transport .......................................................................................................................................................... 75

WORKING OPERATIONS - SAFETY INSTRUCTIONS................................................... 76 WORKING OPERATION .................................................................................................. 78

Before starting work ......................................................................................................................................... 78 Warming up...................................................................................................................................................... 78 Switching on the electronic excavator control .................................................................................................. 78 Slewing and braking the superstructure ........................................................................................................... 78

Update to version .01, see pages 107 and 153a

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Braking the superstructure ............................................................................................................................... 78 Working ............................................................................................................................................................ 79 Raising and lowering the boom ........................................................................................................................ 79 Extending and retracting the bucket or backhoe bucket stick.......................................................................... 79 Filling and emptying the bucket........................................................................................................................ 79 Opening and closing the bucket ....................................................................................................................... 79 Lowering the equipment in an emergency ....................................................................................................... 79 After daily operation.......................................................................................................................................... 80 Parking the machine......................................................................................................................................... 80

ASSEMBLY OF WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................... 81

Securing the machine....................................................................................................................................... 83

Corrosion protection for pins and bearings (bushings and hubs) ............................. 84

Voler A.C.: ........................................................................................................................................................ 84 Application of Voler A.C. .................................................................................................................................. 84

NOTES.............................................................................................................................. 85

Update to version .01, see pages 107 and 153a

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PART 3 - INSPECTION AND SERVICING ....................................................................... 87 Inspection and servicing - Safety instructions............................................................. 89

Fire and Explosion Hazard ............................................................................................................................... 93

Inspection and servicing plans - Instructions .............................................................. 95

Intervals ............................................................................................................................................................ 95 Oils / Greases................................................................................................................................................... 95 Cleaning jobs.................................................................................................................................................... 95 Oil-check service.............................................................................................................................................. 95 Contact the O&K Mining After-Sales Service. .................................................................................................. 95 Plan V - Once prior to initial commissioning..................................................................................................... 97 Plan V - Once prior to initial commissioning..................................................................................................... 98 Plan N - After initial commissioning and during the running-in period.............................................................. 99 Plan T - Every 10 OH or every working shift .................................................................................................. 101 Plan W - Every 60 OH or once a week .......................................................................................................... 101 Plan A - after every 250 OH ........................................................................................................................... 103 Plan C - after every 1000 OH ......................................................................................................................... 103 Plan B - after every 500 OH ........................................................................................................................... 103 Plan D - after every 5000 OH ......................................................................................................................... 103 Plan E - after every 10000 OH ....................................................................................................................... 103

LUBRICATING CHART - GREASE / LOADING BUCKET............................................. 108

Lubricating chart - Grease / Loading bucket (legend) .................................................................................... 109 Refilling quantities - Grease ........................................................................................................................... 109

INSPECTION PLAN - OIL .............................................................................................. 110

Inspection plan - Oil (legend) ......................................................................................................................... 111 Refilling quantities - Oil................................................................................................................................... 112 Refilling quantities - Others ............................................................................................................................ 112

LUBRICANTS ................................................................................................................. 113 I. Oils for combustion engines and compressors (selection) ................................... 113 II. Oils for hydraulic systems (selection) .................................................................... 114 III. Oils for gearboxes (selection)................................................................................. 115 V. Greases for bearings and slewing rings ................................................................ 116 SERVICING WORK ........................................................................................................ 117

Hosepipe for oil and coolant changes ............................................................................................................ 117

ELECTRIC MOTOR........................................................................................................ 118

Electric motor - Safety instructions................................................................................................................. 118 Greasing the electric motors .......................................................................................................................... 118 Cleaning the electric motor............................................................................................................................. 118

ELECTRICAL SYSTEM.................................................................................................. 119

Electrical System - Safety Instructions ........................................................................................................... 119 Battery main switch ........................................................................................................................................ 119 Battery ............................................................................................................................................................ 120

Update to version .01, see pages 107 and 153a

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Checking the battery fluid level....................................................................................................................... 120 Checking the battery charge .......................................................................................................................... 120 Removing and installing the battery ............................................................................................................... 120 Charging the batteries .................................................................................................................................... 121 Control cabinet ............................................................................................................................................... 122 Venting filter ................................................................................................................................................... 122 Cleaning the pre-filter ..................................................................................................................................... 122 Emptying the dust collector ............................................................................................................................ 122 Filter element.................................................................................................................................................. 122 Checking and cleaning the filter element ....................................................................................................... 123 Control cabinet ............................................................................................................................................... 124 Venting filter ................................................................................................................................................... 124 Replacing the filter element............................................................................................................................ 124 Checking the filter element............................................................................................................................. 124 Slip ring unit.................................................................................................................................................... 125

HYDRAULIC SYSTEM ................................................................................................... 126

Hydraulic system - Safety instructions............................................................................................................ 126 Depressurizing the hydraulic system.............................................................................................................. 126 Checking the hydraulic oil level / Topping up ................................................................................................. 127 Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) .............................................................. 129 Bypass valves (hydraulic oil reservoir) ........................................................................................................... 131 Cleaning the filter sieves ................................................................................................................................ 131 Replacing the hydraulic oil return-flow filters (filter housing - cooling system) ............................................... 132 Bypass valves (filter housing - cooling system).............................................................................................. 133 Cleaning the filter sieves ................................................................................................................................ 133 Breather filters ................................................................................................................................................ 134 Replacing the filter elements .......................................................................................................................... 134 High-pressure filter for working hydraulics ..................................................................................................... 134 Checking / cleaning the filter elements .......................................................................................................... 135 Replacing the filter elements .......................................................................................................................... 135 High-pressure filter for the servo circuits........................................................................................................ 136 Checking / cleaning the filter elements .......................................................................................................... 136 Replacing the filter elements .......................................................................................................................... 136 High-pressure filters for pump-flushing circuit................................................................................................ 137 Checking / cleaning the filter elements .......................................................................................................... 137 Replacing the filter elements .......................................................................................................................... 137 High-pressure filters for feeding circuits/slewing gear pumps........................................................................ 138 Checking / cleaning the filter elements .......................................................................................................... 138 Replacing the filter elements .......................................................................................................................... 138 High-pressure filters for slewing circuit .......................................................................................................... 139 Changing the hydraulic oil .............................................................................................................................. 140 Drawing off the hydraulic oil ........................................................................................................................... 140 Cleaning the hydraulic oil reservoir ................................................................................................................ 141 Filling in hydraulic oil ...................................................................................................................................... 142 Venting the hydraulic system.......................................................................................................................... 143 Venting the hydraulic components ................................................................................................................. 143 Cleaning the hydraulic oil cooler..................................................................................................................... 144 Cleaning ......................................................................................................................................................... 144 Pressure accumulator - Emergency lowering ................................................................................................ 145 Pressure-accumulator inspection regulations ................................................................................................ 145 Extract from the German regulations ............................................................................................................. 145 Extract from the German acceptance regulations.......................................................................................... 145 Checking the gas charging pressure in the pressure accumulator ................................................................ 145

Update to version .01, see pages 107 and 153a

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OPERATING INSTRUCTIONS RH 400 E

PUMP TRANSFER GEARBOX ...................................................................................... 146

Checking the gearbox oil level / Topping up .................................................................................................. 146 Drawing off oil................................................................................................................................................. 146 Filling in oil...................................................................................................................................................... 147 Gearbox venting ............................................................................................................................................. 148 Pre-chamber................................................................................................................................................... 148 Checking the oil level ..................................................................................................................................... 148

SLEWING GEARBOX .................................................................................................... 149

Gearbox - Checking the oil level / Topping up ............................................................................................... 149 Changing the gearbox oil ............................................................................................................................... 149 Draining off oil ................................................................................................................................................ 149 Filling in new oil / Topping up ......................................................................................................................... 150 Gearbox venting ............................................................................................................................................. 150 Venting bore ................................................................................................................................................... 150 Slewing gear neck .......................................................................................................................................... 150

TRAVEL GEARBOXES .................................................................................................. 151

Travel gearbox - Checking the oil level / Topping up ..................................................................................... 151 Travel gearbox - Changing the oil .................................................................................................................. 151 Main gearbox - Draining off oil ....................................................................................................................... 151 Preliminary gearbox - Draining off oil ............................................................................................................. 151 Main and preliminary gearbox - Filling in oil ................................................................................................... 152 Pre-chamber - Draining off oil ........................................................................................................................ 152 Pre-chamber - Filling in oil.............................................................................................................................. 152

CRAWLER TRACKS ...................................................................................................... 153

Cleaning ......................................................................................................................................................... 153 Track rollers ................................................................................................................................................... 153 Topping up oil................................................................................................................................................. 153 Cleaning ......................................................................................................................................................... 153 Track roller fastening...................................................................................................................................... 154 Support rollers ................................................................................................................................................ 154 Support roller fastening .................................................................................................................................. 154 Track tensioner .............................................................................................................................................. 154 Design ............................................................................................................................................................ 154 Technical data ................................................................................................................................................ 155 Function.......................................................................................................................................................... 155 Pressure-accumulator inspection regulations ................................................................................................ 155 Extract from the German regulations ............................................................................................................. 155 Extract from the German acceptance regulations.......................................................................................... 155 Checking the gas charging pressure in the pressure accumulator ................................................................ 156 Idlers............................................................................................................................................................... 157 Checking the oil level ..................................................................................................................................... 157 Filling in oil...................................................................................................................................................... 157 Greasing the idler guides ............................................................................................................................... 157

SLEWING RING ............................................................................................................. 158

Slewing ring - Instructions .............................................................................................................................. 158 Bearing races ................................................................................................................................................. 158 Internal gearing .............................................................................................................................................. 158 Slewing ring - Checking the grease filling ...................................................................................................... 159 Slewing ring - Filling in grease........................................................................................................................ 159 Slewing ring - Checking the screws for tightness........................................................................................... 159

Update to version .01, see pages 107 and 153a

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OPERATING INSTRUCTIONS RH 400 E

CENTRAL LUBRICATING SYSTEM.............................................................................. 160

Design and function........................................................................................................................................ 160 Filling the grease container ............................................................................................................................ 161 Breather filter.................................................................................................................................................. 161 Checking the greasing pressure .................................................................................................................... 162 Unblocking a grease line ................................................................................................................................ 162 Cleaning the grease sieve.............................................................................................................................. 162 Cleaning ......................................................................................................................................................... 162

AIR CONDITIONER ........................................................................................................ 163

Venting filter ................................................................................................................................................... 163 Cleaning the pre-filter ..................................................................................................................................... 163 Emptying the dust collector ............................................................................................................................ 163 Filter element.................................................................................................................................................. 163 Checking and cleaning the filter element ....................................................................................................... 164

OTHER MAINTENANCE WORK .................................................................................... 165

Cooling system ............................................................................................................................................... 165

RAMP-TYPE LADDER ................................................................................................... 166

Guide pulleys and locking bolt........................................................................................................................ 166 Pressure-accumulator inspection regulations ................................................................................................ 167 Extract from the German regulations ............................................................................................................. 167 Extract from the German acceptance regulations.......................................................................................... 167 Checking the gas charging pressure in the pressure accumulator ................................................................ 167

ON-BOARD CRANE ....................................................................................................... 168

Monitoring, warning and control elements...................................................................................................... 168 Checking the on-board crane ......................................................................................................................... 168 Extract from the inspection and testing regulations ....................................................................................... 168 Drive unit ........................................................................................................................................................ 169 Crane engine.................................................................................................................................................. 169 Air-intake system............................................................................................................................................ 169 Hydraulic system ............................................................................................................................................ 169 On-board crane .............................................................................................................................................. 169 Servicing......................................................................................................................................................... 169

PUTTING OUT OF OPERATION AND RECOMMISSIONING ....................................... 170

Putting the excavator out of operation............................................................................................................ 170 Battery storage ............................................................................................................................................... 170 Recommissioning........................................................................................................................................... 170 Immobilization for more than 3 months .......................................................................................................... 170

NOTES............................................................................................................................ 171

Update to version .01, see pages 107 and 153a

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PART 4 - REPAIR WORK .............................................................................................. 173 Repair work - Safety instructions ................................................................................ 175 HYDRAULIC SYSTEM ................................................................................................... 178 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ........................................ 178 WELDING OPERATIONS............................................................................................... 179 Welding operations - Safety instructions ................................................................... 179 NOTES............................................................................................................................ 181

Update to version .01, see pages 107 and 153a

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PART 5 - ANNEX............................................................................................................ 183 TROUBLESHOOTING.................................................................................................... 185 Instructions on troubleshooting .................................................................................. 185 Layout of the fault table................................................................................................ 185

Fault ............................................................................................................................................................... 185 Possible causes ............................................................................................................................................. 185 Measures........................................................................................................................................................ 185 Section ........................................................................................................................................................... 185

FAULT TABLES ............................................................................................................. 187

Working hydraulics, Fault table ...................................................................................................................... 187 Track drive, Fault table................................................................................................................................... 188 Slewing mechanism, Fault table..................................................................................................................... 189 Central lubricating system, Fault table ........................................................................................................... 190 Tightening torques and angles, Table ............................................................................................................ 191

ABBREVIATIONS........................................................................................................... 193 TECHNICAL DATA......................................................................................................... 195

Update to version .01, see pages 107 and 153a

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PART 6 - INDEX ............................................................................................................. 198

Update to version .01, see pages 107 and 153a

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Update to version .01, see pages 107 and 153a

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OPERATING INSTRUCTIONS RH 400 E PART 1 - INTRODUCTION 2804051

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS RH 400 E 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].

2804199

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 O&K Mining mechanic or by attending an O&K Mining training course for operators or maintenance personnel.

The O&K-Mining after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.

All O&K Mining operating manuals are issued in German and then translated. Even a good translation may give rise to questions which O&K Mining 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 O&K Mining 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.

Warranty

2732604

O&K Mining GmbH´s warranty is subject among other things to the maintenance works described in the operating instructions having been performed by the O&K Mining Service or by a workshop authorized in writing by O&K Mining to perform such work.

The proper execution of the servicing works must be documented on the O&K Mining Service checklists.

[1] Complies with VDMA recommendation "Operating instructions"

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OPERATING INSTRUCTIONS RH 400 E FUNDAMENTAL SAFETY INSTRUCTIONS Complies with VDMA recommendation "Operating Instructions"

2261165

Warnings and symbols The following signs are used in the operating instructions to designate instructions of particular importance: Precautionary rules and measures designed to protect the machine operator and other persons from lifethreatening danger or injuries and to prevent extensive damage.

Information and precautionary measures designed to prevent damage to the machine or other property.

Designated use

2441649

The machine has been built in accordance with state-of-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property.

The machine must be used only in technically perfect condition in accordance with its designated use and the instructions set out in the operating instructions, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

The excavator with backhoe or loading bucket attachment is designed solely for excavating and loading: – excavated soils, – sand, – gravel,

Operating the machine within the limits of the desigated use also involves observing the instructions set out in the operating instructions and complying with the inspection and maintenance directives.

Using the excavator or its attachments for purposes other than or extending beyond those stated above, e.g.: –- for lifting or transporting persons, – as a working platform, – for lifting crane loads without the equipment being approved for this purpose, – for driving in posts, sheetpiles supports, etc. without the equipment being approved for this purpose, is considered contrary to the designated use.

Improper use may involve a lifethreatening risk for operators or other personnel or may cause injury or extensive damage.

The manufacturer/supplier cannot be held liable for any damage resulting from other than the designated use. The risk involved in such misuse lies with the user.

Noise emission specifications in acc. with the 3rd Ordinance of the Machine Safety Act of 18th January 1991 resp. with EC Machine Directive, Annex I, para. 1.7.4 f.

If the earth-moving machine is operated in accordance with the designated use, the installation of driver´s seats complying with ISO 7096 ensures that the considered vibration accelerations azw (measured as per ISO 2631, Part 1) fulfil the requirements of protecting the driver against wholebody vibration.

– blasted rock, – ore, – coal, and other raw materials.

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OPERATING INSTRUCTIONS RH 400 E Organizational measures

2804057

The operating instructions must always be at hand at the place of use of the machine, e.g. by stowing them in the place provided for such purpose.

In addition to the operating instructions, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment or traffic regulations.

The operating instructions must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the operating instructions and in particular the chapter on safety before beginning work. Reading the operating instructions after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance.

Check - at least from time to time - whether the personnel is carrying out the work in compliance with the operating instructions and paying attention to risks and safety factors.

For reasons of security, long hair must be tied back or otherwise secured, garments must be closefitting and no jewellery, such as rings, may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts.

Use protective equipment wherever required by the circumstances or by law.

Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine immediately and report the malfunction to the competent authori~ty/person.

Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturers can be relied on to do so.

Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the operating instructions for routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

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OPERATING INSTRUCTIONS RH 400 E Selection and qualification of personnel; basic responsibilities

Safety instructions governing specific operational phases

Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

Standard operation

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorized personnel works on or with the machine.

Define the machine operator's responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

Work on chassis and brake systems must be performed by skilled personnel only, which has been specially trained for such work.

Work on hydraulic systems must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Avoid any operational mode that might be prejudicial to safety.

Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working area and the bearing capacity of the soil.

Take the necessary precautions to ensure that the machine is in a safe and reliable state.

Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional.

Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine's working behaviour) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it.

In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified immediately.

Start the machine from the driver's seat only.

During start-up and shut-down procedures always watch the indicators in accordance with the operating instructions.

Before setting the machine in motion, make sure that nobody is at risk.

Before starting work or travelling with the machine, check that braking, signalling and lighting systems are fully functional.

Before setting the machine in motion always check that the accessories have been safely stowed away.

In conditions of poor visibility and after dark always switch on the lighting system.

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OPERATING INSTRUCTIONS RH 400 E Persons accompanying the driver must be seated on the passenger seat provided for this purpose.

When crossing underpasses and bridges or when passing under overhead lines always make sure that there is sufficient clearance.

Always keep a distance from the working face and from slopes.

Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables

Avoid any operation that might be a risk to machine stability.

Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

On sloping terrain always adapt your travelling speed to the prevailing ground conditions.

In any work concerning the operation, conversion or adjustment of the machine and its safetyoriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the operating instructions and the information on maintenance work.

Before leaving the driver's seat always secure the machine against inadvertent movement and unauthorized use. Switch off the electric motors.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: – removing the ignition key and – attaching a warning sign.

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movements.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or otherwise safetyoriented ladders and working platforms. Never use machine parts as a climbing aid.

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OPERATING INSTRUCTIONS RH 400 E Wear a safety harness when carrying out maintenance work at greater heights.

Warning of special dangers

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

Electric energy

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair.

Never use aggressive detergents. Use lint-free cleaning rags.

Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switch-gear cabinets.

Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

If your machine comes into contact with a live wire – do not leave the machine

Ensure during cleaning of the machine that the temperature sensors of the fire-warning and firefighting systems do not come into contact with hot cleaning agents as this might activate the firefighting system.

– drive the machine out of the hazard zone; warn others against approaching and touching the machine

After cleaning remove all covers and tapes applied for that purpose.

– do not leave the machine until the damaged or contacted line has been safely de-energized.

After cleaning, examine all fuel, lubricant, brake and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defect found must be rectified without delay.

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

Always tighten any screwed connections that have been loosened during maintenance and repair.

Gas, dust, steam and smoke

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of maintenance and repair work.

Operate internal combustion engines and fueloperated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

– have the live wire de-energized

Observe the regulations in force at the respective site.

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

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OPERATING INSTRUCTIONS RH 400 E Hydraulic and pneumatic equipment Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

Depressurize all system sections and pressure pipes (hydraulic system, compressed-air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Transporting and recommissioning The machine must be loaded and transported only in accordance with the operating instructions.

Use only appropriate means of transport and lifting gear of adequate capacity.

The recommisioning procedure must be strictly in accordance with the operating instructions.

Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

Noise During operation, all sound baffles of the machine must be closed.

Always wear the prescribed ear protectors.

Oil, grease and other chemical substances When handling oil, grease or other chemical substances, observe the product-related safety regulations (see safety specifications).

Be careful when handling hot consumables (risk of burning or scalding).

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OPERATING INSTRUCTIONS RH 400 E ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS The safety and accident-prevention regulations valid in the respective country must be observed.

The following requirements are based on extracts from the German accident prevention regulations "Electrical Systems (VGB 4)".

The installation, modification and repair of the electromechanical component of electrical systems and modules must be delegated only to qualified electricians or to firms employing such experts.

A „qualified electrician“ in the context of this regulation is a person who, on the basis of specialized training, know-how and experience as well as knowledge of the relevant regulations, is capable of judging the extent of the work assigned to him and of recognizing any potential hazards.

The machine owner/contractor must inform all persons working on electrical installations and components or in the vicinity of components conducting electricity during operation, or who are responsible for the operation of electrical systems, of the potential danger of electricity and must instruct them on the accident prevention regulations relevant to their work. Instruction in safety measures is to be repeated at intervals appropriate to the operating conditions. If necessary, special working regulations must be displayed.

The excavator and its electrical systems must be adequately secured against other potential hazards of electricity, e.g. fire and explosion.

Electrical systems and components must be protected against the presence of too high voltage in the event of failures, eg. body contact.

Any parts of electrical systems and components conducting current when in operation must be secured against contact by personnel.

2731699

Any parts of the electrical system conducting current when in operation must be housed in lock-up switchgear cabinets. Hazard warning signs are displayed on these lock-up cabinets: VOLTAGE HAZARD The switchgear cabinets must be secured against unauthorized opening. The key must be kept by the electrician in charge.

Electrical systems and components must not be used unless they comply with the operational and local safety requirements. They must be in an orderly state and must be kept in such a state.

Any defects or malfunctions occurring in electrical systems or components must be reported to the electrician in charge.

Before switching on any systems, the excavator operator must check that no one is working on the machine or its electrical systems.

The trailing cable must never be driven over, buried or ripped away. The excavator equipment must never be set down on the trailing cable. When the excavator is being moved, the cable must never be pulled or dragged over the ground.

Whenever work is being carried out on electrically powered excavators, the general rules of engineering – especially those concerning low and medium voltage – must be observed. Regulations such as those issued by the German VDE, e.g. specification VDE 0100, should be observed in their respectively valid version.

Before commencing any work on electrical systems and components, the electrician in charge (or an electrician appointed by him) must switch the power of all circuits and lock them in the OFF state as follows: • Switch voltage supply to all systems to OFF. • Check with voltage detectors that all systems are voltage-free.

• Lock switches/systems to prevent them from being switched on.

The above procedures must be carried out in the given sequence.

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OPERATING INSTRUCTIONS RH 400 E The user/contractor must provide all the necessary protective equipment and adopt the necessary safety procedures. He must ensure that the safety equipment is used and that the safety procedures are observed.

The excavator operator and all personnel working on the excavator must use the protective equipment and carry out the specified safety procedures.

It is strictly forbidden to work on any systems or components while they are conducting current.

Fatal injury can occur.

If work has to be done in special cases on systems or components conducting current, appropriate safety measures suited to the specific circumstances must be taken. Work must not be done on „live“ systems and components except by the electrician in charge. The machine user/contractor must also be notified.

The excavator and its electrical systems must not be switched on again until the safety procedures outlined above have been cancelled and all working areas are prepared for the resumption of operations. Start-up orders can be given only by the person in charge (qualified electrician). Time-based switch-on agreements are strictly forbidden.

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OPERATING INSTRUCTIONS RH 400 E Fire and explosion hazard 2800159

Prior to commencing work, obtain information - on the national and corporate rules for the prevention of accidents.

Pay particular attention to hazards caused by combustible and easily flammable substances.

- on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the excavator.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard.

Do not store or handle any flammable substances during operation.

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units or objects.

Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where – combustible substances such as coal dust or tar are present.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

If necessary, also cover the ground with fireprotective blankets.

Ensure sufficient ventilation.

Clean the excavator before starting a job.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: – dry-powder, – carbon-dioxide or – foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

LIFE-THREATENING DANGER Call the fire brigade.

Have all your welding, flame cutting and grinding work approved.

– open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the excavator.

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OPERATING INSTRUCTIONS RH 400 E NOTES

2804180

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OPERATING INSTRUCTIONS RH 400 E

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OPERATING INSTRUCTIONS RH 400 E PART 2 - OPERATION 2804052

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS RH 400 E

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OPERATING INSTRUCTIONS RH 400 E Operation - Safety instructions

2804059

Operating instructions

Safety belt

Never operate the machine before having read and understood the operating instructions.

Pay special attention to: the "Fundamental Safety Instructions" and to all warning and instruction signs attached to the machine.

Familiarize yourself with the layout, the functioning and the sense of actuation of the control elements prior to starting up the machine.

Activate the control elements from the driver's seat only.

Keep the operating instructions with the machine at all times.

For machines with a safety belt for operating personnel: Check the safety belt attached to the driver's seat. In the event of damage or after an accident, have it replaced immediately.

Apply the safety belt before starting work.

Operating personnel The operating personnel must be fully informed of the operation and application of this or comparable machines.

The necessary know-how can be acquired in several days' instruction, e.g. by an O&K mechanic or by attending an O&K operator's training course.

Personal protective gear and working clothing Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation.

Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in control levers being inadvertently activated.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the equipment and component combinations approved by O&K. Clear-cut data are given in the technical specification.

Never install and commission other equipment and component combinations without O&K having first inspected and approved the project.

Before starting work or travelling with the machine, check that the braking, signalling and lighting systems are fully functional.

Poor visibility may result in accidents. Always clean the windows and the glass covers of all lamps before starting the machine.

Check that all warning and instruction signs attached to the machine are present and legible.

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OPERATING INSTRUCTIONS RH 400 E Entering and leaving the machine Use only the ladders, steps, platforms and grab handles provided when entering and leaving the machine.

Always keep ladders, steps and platforms in a non-slip, safe state and remove any oil, grease, soil, snow, ice and other foreign matter immediately.

Hazard range The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its equipment and attachments or of swinging loads.

Persons within the hazard zone Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

Marshallers The marshaller must keep outside the hazard zone.

Have a marshaller to assist you: – when you have no clear overview over the hazard zone of the machine, – when reversing, – when shunting.

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie/camera).

Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller.

Stop the machine immediately if you lose contact with the marshaller.

Securing the machine Secure the machine as described under "Securing the machine" before: – mounting or dismantling the attachment, – parking the machine after daily operation, – carrying out any servicing or repair work.

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OPERATING INSTRUCTIONS RH 400 E Fire and explosion hazard 2800160

Safety instructions Avoid smoking and open fire on, next to and below the machine.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard.

Do not store such substances on the excavator.

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units or objects.

Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where – combustible substances such as coal dust or tar are present, – open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks may cause fire on the ground that can spread to the excavator.

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OPERATING INSTRUCTIONS RH 400 E DESCRIPTION OF THE EXCAVATOR

2803901

Fig.1 Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 20 2 803 900.00 en BESCHR.DOC

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OPERATING INSTRUCTIONS RH 400 E Excavator layout (Fig. 1) 36 -

Battery charger, batteries and battery main switch

37 -

Control cabinet

38 -

control cabinet

39 -

Service station (tank lift)

40 -

Air conditioner

42 -

On-board crane

43 -

Hydraulic system (on-board crane) with drive

44 -

Grease container for central lubricating system

51 -

Ramp-type ladder

52 -

Ladder

53 -

Ladder

Superstructure

54 -

Emergency ladder

11 -

Electric motor

55 -

Counterweight

12 -

Control cabinet, medium-high voltage supply, switch disconnector

13 -

Control cabinet, motor protection relay, offload disconnector

Loading bucket 61 -

Boom

17 -

Hydraulic oil tank

62 -

TriPower linkage

18 -

Cooler

63 -

Stick

19 -

Filter housing - cooling system

64 -

Bottom-dump bucket

20 -

Pump transfer gearbox

65 -

Boom cylinder

21 -

Working pump

66 -

Stick cylinder

22 -

Slewing pump

67 -

Bucket cylinder

23 -

Servo system pump

68 -

Bottom-dump cylinder

24 -

Gearbox recirculation pump

69 -

Control valves

25 -

Filling pump

70 -

Quick-action valve

27 -

Fan drive pump

28 -

Cooling oil pump

29 -

Slewing gear

30 -

Travel block androtor

31 -

Driver's cab

32 -

Control stand with BCS

33 -

Control cabinet (with CMS and PMS)

34 -

Control cabinet

35 -

Control cabinet (warm-up system)

Undercarriage 1-

Track drive

2-

Idler

3-

Track roller

4-

support roller

5-

Crawler track

6-

Track tensioner

7-

Slewing ring

8-

Ladder

9-

Slip ring assembly

10 -

Cable guide for drag cable

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OPERATING INSTRUCTIONS RH 400 E Undercarriage

Stored Program Control (SPC)

The undercarriage of the hydraulic excavator serves as a stable base and for travelling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and superstructure are connected by means of a slewing ring.

The SPC controls the functions –

electric motor Start

–

electric motor Stop

–

central lubricating system

Superstructure

–

further auxiliary functions

The superstructure accommodates the drive and part of the hydraulic and electrical equipment.

Further information is given in the technical manual: Stored-program control.

Drive

Electronic Hydraulic Servo-Control (EHSC)

The drive unit comprises electric motors, pump transfer gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Hydraulic system All working and travelling movements are performed hydraulically. The movements are controlled by servovalves. The working commands are initiated by hand and transmitted to the valves via electronic control circuits. The oil supply from the superstructure to the undercarriage is ensured by the rotor. The hydraulic system is overloadprotected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

The EHSC is an electrohydraulic servocontrol. Together with the PMS, it provides for optimum interaction between drive hydraulic circuit and working movements.

The required working movements are recognized by microcontroller-assisted scanning of the operating elements (hand levers, pedals) and transmitted to electrohydraulic valves.

In the system sequence, the drive regulation is first activated to provide hydraulic working energy. Only then are working movements enabled.

Further information is given in the technical manual: Electronic Hydraulic Servo-Control.

Pump Managing System (PMS) The Pump Managing System (PMS) with overlimit regulation ensures optimum utilization of the installed or preset engine power. The electronic pump demand control prevents the machine from demanding more hydraulic power than the diesel engines can furnish. A microprocessor ensures that the hydraulic output power of the pump is optimally suited to the actual operation conditions.

The PMS box (load-limit regulator) is installed in a control cabinet in the driver's cab.

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OPERATING INSTRUCTIONS RH 400 E Demand control / Zero-flow regulation

Electrical system

In the fine-control range, swivelling of the hydraulic pumps, and thus variation of the oil flow, are proportional to control lever and pedal valve travel.

This means that, during work, the pumps supply only as much hydraulic oil as required to perform the working movement. In the neutral position of the control levers, the pumps are automatically swivelled to zero flow.

Supply voltage (medium-high voltage)

Control voltage (low voltage)

480 V

These special features offer the following advantages:

Emergency light (low voltage)

24 V

• reduced power consumption

Auxiliary voltage (low voltage, alternating)

24 V

• minimum power losses

various consumers (low voltage)

7200 V 480 V, 208 V, 120 V

• reduced temperature of the hydraulic oil

Power supply

• greater service life of hydraulic pumps and electric motors.

The electric power is supplied to the excavator via a trailing cable to a connection box.

Board Control System (BCS) The BCS is a data-evaluating and data-processing system whose function is to collect, evaluate and store data about the excavator's operating status and to display these to the operator.

The BCS is based on a microprocessor. The measured values (actual values) supplied by sensors and transducers installed in the excavator are compared with preset nominal values. Out-of-limit conditions are display in the form of error messages in the driver's cab.

Critical operating conditions are additionally indicated by optical and acoustic warning signals.

Further details are set out in the Board Control System operating instructions.

Fig. 2

The power is then transmitted via the slip ring assembly to the circuit breaker in the switchgear cabinet (Fig. 2).

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OPERATING INSTRUCTIONS RH 400 E

Fig.3

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OPERATING INSTRUCTIONS RH 400 E Signs Warning and instruction signs Observe the warning and instruction signs attached to the machine.

Keep the signs legible and clean.

Replace signs immediately if they have become illegible.

New warning and instruction signs can be ordered from the O&K Spare Parts Service. The ordering part numbers are set out in the spare-parts list of the machine.

Fig. 3 shows the location of warning and instruction signs on the machine.

Fig. 5

Electric motor number The serial number plate (Fig. 6) for the electric motor is located on the electric motor.

Machine number The identification plate with the machine number is attached to the front side of the A-frame (arrow, Fig. 4 and/or 5)

Fig. 6

Component numbers Fig. 4

Other larger units also have identification plates indicating, among other things, their serial number.

On steel components, the O&K part number or the serial number may be stamped into the metal at a clearly visible place.

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OPERATING INSTRUCTIONS RH 400 E Entering and leaving the machine Safety instructions Clean off oil, grease, soil, mud, snow, ice and other substances from footwear, grab handles, ladders and steps.

Keep ladders, steps, platforms and grab handles in a non-slippery condition.

Risk of injury due to slipping.

For entering and leaving use only the ladders, steps, platforms and grab handles provided (cf. illustration in Figs. 7 and 8).

Fig. 8

Ramp-type ladder Retracting or extending the ramp-type ladder (Fig. 7).

Fig. 9

Fig. 7

Retracting the ramp-type ladder – Actuate switch (1, Fig. 8 and/or Fig. 9).

The switch (1) is located beside the superstructure entrance door.

Retract ladder completely and allow to engage.

The hydraulic functions are not fully enabled until the ladder has engaged.

Extending the ramp-type ladder – Press pedal (2, Fig. 8) and actuate switch (1).

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OPERATING INSTRUCTIONS RH 400 E Access

Ramp lighting

Access to the excavator is also provided by the ladders (1 and 2, Fig. 10).

The ramp-type ladder can be illuminated in the dark.

Secure the access way with the rod (3) after entering or leaving the excavator.

The lighting is switched on with a pull switch (Fig. 12) and/or with the switch (1, Fig. 13).

The pull switch is located beside the ramp-type ladder and is operated with a rod (3, Fig. 12) from the ground.

Fig. 12

The switch (1, Fig. 13) is located in the driver's cab.

Fig. 10

Escape ladder The escape ladder (1, Fig. 11) is located beside the driver's cab.

Fig. 13

Fig. 11

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OPERATING INSTRUCTIONS RH 400 E Cab interior lamp The interior lamp in the driver's cab and the amenity is switched on and off with the switch (2, Fig. 14).

Fig. 16

The interior lamp can also be switched on and off with the switch (1, Fig. 16).

Fig. 14

Switch position

0 - lamp off 1 - lamp on 2 - not connected.

The interior lamp can be used even when the electrical system is switched off.

Therefore switch off the interior lamp when leaving the machine. The batteries may be discharged if the interior lamp is left on for prolonged periods.

Fig. 15

The interior lamp in the driver's cab can be switched on and off separately from the amenity with the switch (112, Fig. 15).

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OPERATING INSTRUCTIONS RH 400 E Servicing lighting

110 V socket

Switch on the lamps in the modules with switches (111, Fig. 17 and 3, Fig. 1).

The sockets (3, Fig. 19 and 4, Fig. 20) are located in the engine module (3 on the right and left side each.

Switch (111, Fig. 17) is located in the control column in the driver's cab.

Fig. 19

Fig. 17

Switch (3, Fig. 18) is located beside the entrance door in the platform.

Fig. 20

Fig. 18

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OPERATING INSTRUCTIONS RH 400 E EMERGENCY STOP pushbuttons Both electric motors are switched off with the EMERGENCY STOP pushbuttons.

In an emergency, press the EMERGENCY stop button (116, Fig. 21, 1, Fig. 22, 1, Fig. 23 or 2, Fig. 24) or pull the rod (3, Fig. 25).

The EMERGENCY STOP pushbuttons are located – in the control column in the driver's cab (116, Fig. 21) – at the entrance to the superstructure (1, Fig. 22)

Fig. 23

– beside the electric motors (1, Fig. 23) – beside the control cabinet (1, Fig. 24) – on the righthand side of the excavator near the counterweight.

The latter one is operated with a pulling rope (3, Fig. 25).

Fig. 24

Fig. 21

Fig. 25

Unlocking the EMERGENCY STOP button An EMERGENCY STOP button must be unlocked after an actuation.

Fig. 22

– pull out the EMERGENCY STOP button (Figs.

21 - 24).

– depress the unlocking button of the EMERGENCY STOP button (Fig. 25)

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BI015806

OPERATING INSTRUCTIONS RH 400 E Windscreen washer The reservoir of the windscreen washing system (1, Fig. 26) is installed in the cab module. For the reservoir capacity, refer to the "Refilling quantities Other" table.

Fig. 26

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 31 BESCHR.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Driver's seat

Adjusting the seat cushion

The driver's seat (Fig. 27) can be adjusted in inclination, height and fore-and-aft position. The seat suspension can be adjusted to suit the driver's weight.

The seat cushion inclination is adjusted by pulling the handle (4) upwards. Bring seat cushion into the desired position by moving the body forwards or back. Release handle (4).

Never adjust the seat while driving.

Concentrate on the road to avoid accidents.

Before carrying out any seat adjustments: – stop the machine – set the control lever to "0"

Adjusting the armrests The armrests can be raised and lowered as required.

To adjust the inclination of the armrests, turn knobs (6) clockwise or counter-clockwise.

Fore-and-aft adjustment The fore-and-aft position is adjusted with lever (1).

Pull lever (1) upwards, slide seat into the desired position and engage the lever (1).

Adjusting the seat suspension he seat suspension can be continuously adjusted with the button (2).

Higher weight - push button (2) upwards (hard springs).

Lower weight - push button (2) downwards (soft springs).

Optimum setting +/- 50 mm spring travel.

Fore-and-aft adjustment of the seat plate

Fig. 27

Adjusting the backrest The backrest inclination can be adjusted by pulling the handle (5) upwards. Lean against the backrest to move it to the desired position. Release handle (5).

The fore-and-aft position is adjusted with the lever (8). Pull lever (8) upwards, slide plate into the desired position and engage the lever (8).

Adjusting the lumbar support The backrest is equipped with an upper and a lower air chamber.

Press button (7) upwards - lower air chamber is filled with air.

Press button (3) upwards - upper air chamber is filled with air.

Press button (7 or 3) downwards - the air supply to the chambers is reduced.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 32 2 803 900.00 en BESCHR.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Passenger seat

Adjusting the seat cushion

The passenger seat (Fig. 28) can be adjusted in inclination, height and fore-and-aft position. The seat suspension can be adjusted to suit the passenger's weight.

Adjust the seat cushion inclination by pulling the handle (4) upwards. Bring seat cushion into the desired position by moving the body forwards or back. Release handle (4).

Adjusting the armrests The armrests can be raised and lowered as required.

To adjust the inclination of the armrests, turn knobs (6) clockwise or counter-clockwise.

Fore-and-aft adjustment The fore-and-aft position is adjusted with lever (1).

Pull lever (1) upwards, slide seat into the desired position and engage the lever (1).

Adjusting the seat suspension The seat suspension can be continuously adjusted with the handwheel (2).

Fig. 28

Adjusting the backrest The backrest inclination can be adjusted by pulling the handle (5) upwards. Lean against the backrest to move it to the desired position. Release handle (5).

Higher weight - turn handwheel (2) clockwise (hard springs).

Lower weight - turn handwheel (2) counterclockwise (soft springs).

The value on the handwheel scale and the weight of the passenger should be coordinated (optimum suspension).

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 33 BESCHR.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Fire extinguisher

Handling

The excavator is equipped with one fire extinguisher (arrow, Fig. 29).

•

Pull out securing pin (2, Fig. 30).

•

Strike knob (3) hard, then release again.

•

Operate the extinguishing gun.

Inspection Have the extinguisher inspected at regular intervals by an expert. This is required by local authorities and insurance companies and is in the interest of your own safety.

Fig. 29

Have the extinguisher checked at the prescribed intervals by authorized testing agencies.

The excavator operator and the maintenance personnel must familiarize themselves with the handling of the fire extinguisher so that they can act fast and efficiently in the event of fire breaking out.

Such instruction should be given by a qualified instructor.

Extinguishing agent Each fire extinguisher is filled with 12 kg Glutex.

This extinguishing agent is used for fighting class A, B and C fires. Fires are extinguished fast, completely and without residues.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 34 2 803 900.00 en BESCHR.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Automatic fire-extinguishing system (optional) The excavator operator and the maintenance personnel must familiarize themselves with the automatic fire-extinguishing system.

Such instruction should be given by a qualified instructor.

The fire-extinguishing system is activated automatically in an emergency.

Refill extinguishers immediately after use ready for further deployment.

The automatic fire-extinguishing system prevents fire from spreading. It is, however, assumed that the machine is thoroughly cleaned of combustible and easily flammable substances.

Inspection Have the extinguishing system inspected regularly by an expert. This is required by authorities and insurance companies and is in the interest of your own safety.

Have the fire-extinguishing system checked at the prescribed intervals by authorized testing agencies.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 35 BESCHR.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E MONITORING, WARNING AND CONTROL ELEMENTS

2803902

Fig.1 Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 36 2 803 900.00 en KONTROL1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 1) No. Element

Function

1

BCS

Electronic measuring-data collection and processing system

Collection of essential operating data of the excavator.

2

Monitor

BCS

Displays the data collected.

Gives warning and provides help if necessary.

3

UP button

Selects the BCS program.

Positions the cursor.

4

DOWN button

Selects the BCS program.

Positions the cursor.

5

ENTER button

Confirms a program.

Activates a desired program.

6

BACK button

Recalls the Service menu.

7

HOLD button

Freezes actual service data.

8

PRINT button

Recalls the Print menu.

9

SERV. button

Recalls the Service menu.

10

HELP button

Recalls the Help menu.

11

BL+ button

Adjusts BCS monitor background lighting.

12

BL- button

Adjusts BCS monitor background lighting.

Symbol

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 37 KONTROL1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 2

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 38 2 803 900.00 en KONTROL1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 2) No. Element

Function

21

Switch

Fan, front

Activates the air conditioner fan.

22

Switch

Blower, front

Activates the air conditioner blower

23

Thermostat

front

Adjusts the desired temperature.

25

Switch

Fan, rear

Deactivates the air conditioner fan

26

Switch

Blower, rear

Deactivates the air conditioner blower

27

Thermostat

rear

Adjusts the desired temperature.

Symbol

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 39 KONTROL1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 3

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 40 2 803 900.00 en KONTROL1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 3) No. Element

Funcion

31

Warning lamp

Main pump 1 contamination

Lights up when the main pump is contaminated with metal particles.

32

Warning lamp

Main pump 2 contamination

Lights up when the main pump is contaminated with metal particles.

33

Warning lamp

Main pump 3 contamination

Lights up when the main pump is contaminated with metal particles.

34

Warning lamp

Main pump 4 contamination

Lights up when the main pump is contaminated with metal particles.

35

Warning lamp

Slewing pump 1 contamination

Lights up when the slewing pump is contaminated with metal particles.

36

Warning lamp

Slewing pump 2 contamination

Lights up when the slewing pump is contaminated with metal particles.

37

Warning lamp

Slewing pump 3 contamination

Lights up when the slewing pump is contaminated with metal particles.

38

Warning lamp

Slewing pump 1

Lights up when the temperature in the slewing pump is too high.

39

Warning lamp

Slewing pump 2

Lights up when the temperature in the slewing pump is too high.

40

Warning lamp

Slewing pump 3

Lights up when the temperature in the slewing pump is too high.

41

Warning lamp

Boom cylinder left (option)

Lights up when the differential pressure in the boom cylinder is too high.

42

Warning lamp

Boom cylinder right (option)

Lights up when the differential pressure in the boom cylinder is too high.

Symbol

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 41 KONTROL1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 4

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 42 2 803 900.00 en KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 4) No. Element

Function

43

Warning lamp

Main pump 5 contamination

Lights up when the main pump is contaminated with metal particles.

44

Warning lamp

Main pump 6 contamination

Lights up when the main pump is contaminated with metal particles.

45

Warning lamp

Main pump 7 contamination

Lights up when the main pump is contaminated with metal particles.

46

Warning lamp

Main pump 8

Lights up when the main pump is contaminated with metal particles.

47

Warning lamp

Slewing pump 4 contamination

Lights up when the slewing pump is contaminated with metal particles.

48

Warning lamp

Slewing pump 5 contamination

Lights up when the slewing pump is contaminated with metal particles.

49

Warning lamp

Slewing pump 6 contamination

Lights up when the slewing pump is contaminated with metal particles.

50

Warning lamp

Slewing pump 4

Lights up when the temperature in the slewing pump is too high.

51

Warning lamp

Slewing pump 5

Lights up when the temperature in the slewing pump is too high.

52

Warning lamp

Slewing pump 6

Lights up when the temperature in the slewing pump is too high.

53

Warning lamp

Stick cylinder left (option)

Lights up when the differential pressure in the stick cylinder is too high.

54

Warning lamp

Stick cylinder right (option)

Lights up when the differential pressure in the stick cylinder is too high.

Symbol

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 43 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 5

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 44 2 803 900.00 en KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 5) No. Element

Function

55

Warning lamp

Slewing gearbox 1 contamination

Lights up when the slewing gearbox is contaminated with metal particles.

56

Warning lamp

Slewing gearbox 2 contamination

Lights up when the slewing gearbox is contaminated with metal particles.

57

Warning lamp

Slewing gearbox 3 contamination

Lights up when the slewing gearbox is contaminated with metal particles.

58

Warning lamp

Slewing gearbox 4 contamination

Lights up when the slewing gearbox is contaminated with metal particles.

59

Warning lamp

Slewing gearbox 5 contamination

Lights up when the slewing gearbox is contaminated with metal particles.

60

Warning lamp

Slewing gearbox 6 contamination

Lights up when the slewing gearbox is contaminated with metal particles.

61

Warning lamp

Pump transfer gearbox 1 contamination left

Lights up when the pump transfer gearbox is contaminated with metal particles.

62

Warning lamp

Lights up when the pump transfer gearbox is Pump transfer contaminated with metal particles. gearbox 2 contamination right

63

Warning lamp

Min. hydraulic oil level

Lights up when the hydraulic oil level in the hydraulic oil tank is too low.

64

Warning lamp

Hydraulic oil filter

Lights up when the flow resistance in the filter is too high. Replace filter elements if the warning lamp fails to go out when the oil is at operating temperature.

65

Warning lamp

Bucket cylinder

Lights up when the differential pressure in the bucket cylinder is too high left (option).

66

Warning lamp

Bucket cylinder

Lights up when the differential pressure in the bucket cylinder is too high right (option)

Symbol

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 45 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 6

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 46 2 803 900.00 en KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 6) No. Element

Function

69

Indicator lamp

Boom/stick angle

Lights up when the boom/stick angle is in the normal working range.

70

Warning lamp

Boom/stick angle

Lights up when the boom/stick angle is in the hazard range.

(The tracks may be damaged by the working equipment) Increase the angle.

Buzzer (118) sounds until the angle has resumed the normal working range.

71

Button

Starting (electric motor 1 left) ON

Starts the electric motor.

72

Button

Stopping (electric motor 1 left) OFF

Shuts off the electric motor.

81

Button

Starting (electric motor 2 right) ON

Starts the electric motor.

82

Button

Stopping (electric motor 2 right) OFF

Shuts off the electric motor.

Symbol

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 47 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 7

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 48 2 803 900.00 en KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 7) No. Element

Function

Symbol

91

Switch

Travel motors

Preselection: CW: 1st gear stage forward / reverse travel CCW: 2nd gear stage (fast gear) Only parallel forward travel is possible.

When the switch is in this posi tion and another travel func tion(e.g. reverse travel) is switched on, there is an auto matic change to 1st gear.

92

Switch

Undercarriage parking brake

CCW: CW:

brake permanently applied.

The excavator cannot be driven.

Every time the excavator stops, the undercarriage brake is auto matically applied after ca. 8 s.

The undercarriage brake is automatically released when the Travel function is activated Actuate switch only when the excavator is stationary.

Never use as a service brake.

93

Button

Reset

Activate after a fault in the central lubricating system.

94

Switch

Electronic excavator control

Activates and deactivates the electronic excavator control.

The electronic excavator control is activated only after switch (94) and button (125) are depressed.

95

Switch

96

Switch

ECO (Power Control)

Adjusts the hydraulic power (flow rate) CCW: 80% hydraulic power (flow rate) CW: 100% hydraulic power free for options

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 49 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 8

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 50 2 803 900.00 en KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 8) No. Element 99

Switch

100 Switch

Function Slewing gear modem

not activated: slewing motors running at 100% hydraulic power activated: slewing motors running at 70% hydraulic power

Superstructure holding brake

Disables the slewing function and brakes the superstructure.

Symbol

Actuate switch only when the excavator is stationary.

Never use as a service brake.

101 Switch

Windscreen wiper

Activates permanent/intermittent wiping.

102 Switch

Windscreen wiper

Activates permanent/intermittent wiping.

103 Switch

free for options

104 Switch

free for options

105 Switch

free for options

106 Switch

free for options

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 51 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 9

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 52 2 803 900.00 en KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 7) No. Element

Function

107 Switch

Emergency operat. boom/stick

Lowers the boom and stick when actuated in an emergency.

108 Button

Dumper count

RESET

109 Switch

free for options

110 Switch

free for options

111 Switch

Lighting

Switches on the lighting on the superstructure and for servicing work.

112 Button

Lighting

Switches the cab lighting on and off.

113 Switch

free for options

114 Switch

free for options

115 Key-switch

The complete electrical system is all-pole disconnected from the supply by the onboard switch-disconnector.

116 Button

EMERGENCY STOP

Symbol

Switches both electric motors off.

Even after actuation of EMERGENCY STOP button (116), the medium-high voltage (7200 V) from the transformer station continues to be supplied to the excavator via the trailing cable and the slip-ring unit (primary side).

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 53 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 10

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 54 2 803 900.00 en KONTROL3.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 10) No. Element

Function

117 Buzzer

Gives an acoustic warning signal if a fault is reported.

Symbol

– Fault in electric motor system (motor 1 and/or 2; left and/or right) – Hydraulic oil level too low – Pump transfer gearbox temperature (1 and/or 2; left and/or right) too high – Slewing pump temperature (1, 2 and/or 3; left and/or right) too high – Slewing gearbox temperature (1, 2, 3, 4, 5 and/or 6) too high – Fault in lubricating system Lower equipment to the ground and shut off the electric motors immediately if buzzer (117) sounds and the BCS indicates a fault. Buzzer (117) continues to sound until the fault has been rectified.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 55 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 11

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 56 2 803 900.00 en KONTROL3.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 11) No. Element

Function

117 Buzzer (continued)

Gives an acoustic warning signal if a fault is reported.

Symbol

– Pump transfer gearbox (1 and/or 2; left and/or right) contaminated – Working pump (1, 2, 3 and/or 4; left and/or right) contaminated – Slewing motor (1, 2, 3, 4, 5 and/or 6) contaminated – Slewing circuit temperature (1, 2, 3, 4, 5 and/or 6) too high – Lubricating system pressure too low – Grease level in lubricating system too low – On-board voltage 24 V too low Buzzer (117) continues to sound until the fault has been rectified.

118 Buzzer

Gives an acoustic warning signal when the stick/boom angle is too small.

Warning lamp (70) also lights up.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 57 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Fig. 12

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 58 2 803 900.00 en KONTROL3.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E (Fig. 12) No. Element 121 Button

Function Dumper count

Hold button depressed for ca. 2 s. until an acoustic signal is heard. Release button (121). Releasing the button terminates the dumper count. free for options

122 Button 123 Button

Symbol

Boom floating position

If actuated: boom cylinders are pressurized when retracted.

Actuate button (123) only when control lever (136) is in "0" position.

124 Button

Warning signal

Activates the horn.

125 Button

Electronic excavator control

Switches the electronic excavator control on and off.

The electronic excavator control is operational only after button (125) and switch (94) are activated.

131 Pedal

Bottom-dump bucket

Opens/closes bottom-dump bucket.

132 Pedal

Travelling, left track

forward/reverse

133 Pedal

Travelling, right track

forward/reverse

135 Control lever

Lifts and lowers the bucket stick.

Slews and brakes the superstructure.

136 Control lever

Lifts and lowers the boom.

Tipping and rearward tilting of bucket.

141 Radio 142 Cigarette lighter

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 59 KONTROL2.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E PUTTING THE MACHINE INTO OPERATION Before daily start-up, carry out the works in accordance with servicing plan T (see Part 3 "Inspection and servicing") Check before daily start-up that the machine has been cleaned from combustible and flammable substances.

There is otherwise an increased risk of fire and explosion.

Refilling of consumables

2803903

Ref. Fig. 1

Fluid

Express coupling for

4

gearbox oil for left pump transfer gearbox

refilling resp. draining

5

gearbox oil for right pump transfer gearbox

refilling resp. draining

10

hydraulic oil tank and filter chamber - cooling

refilling resp. draining

11

grease container - central lubricating system

refilling

Refilling or draining of fluids requires a service vehicle.

Refilling - Safety instructions Lowering the service station

Handling of consumables Observe the saftety data sheets when handling consumables.

Pull out control knob (21, Fig. 1) of valve (22) with pull chord (25) to let down the service station to its lowermost position. Turn control knob (21) by 90° and let engage.

Service station (tanklift) The excavator is equipped with a central service station (Fig. 1) for refilling. The service station is installed on the machine frame and can be reached from the ground under the superstructure. The express coupling for refilling permits refilling of different consumables (liquids).

Raising the service station Disengage control knob (21) of valve (22), turn by 90° and depress to raise the service station.

Refilling / draining For refilling / draining of fluids, unscrew the cap of the corresponding express coupling (Fig. 3).

Attach the express coupling of the service vehicle filling hose to the express coupling of the tanklift and fill in / drain the fluid.

Remove the filling hose and refit the cap on the express coupling.

Fig. 1

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 60 2 803 900.00 en BETR1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Units / reservoirs

Measuring point

Remarks

Transfer gearbox

Dipstick (Fig. 2)

Top up oil when the oil level has reached the minumum mark.

Hydraulic oil reservoir and filter chamber cooling

BCS indicator panel (Fig. 3) Level indicator (1, Fig. 4) Rating plate (2, Figs. 4 and 5)

Oil level checking: extend piston rods of stick and bucket cylinder halfway; stabd working equipment on the ground; check oil level at an oil temperature of approx. 50 °C with the engines stopped; top up oil when the level is at the min. mark of the indicator; the BCS gives a level warning.

Fig. 2

Fig. 4

Fig. 3

Fig. 5

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 61 BETR1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Units / reservoirs Grease container central lubricating system

Fig. 6

Measuring point BCS indicator panel (Fig. 6)

Remarks The BCS gives a warning signal when the grease container is empty.

The indicator is actived with toggle switch (33, Fig. 7).

Stop filling when the grease container is full.

Indicator lamp (34) lights up.

After filling the indicator must be deactivated with toggle switch (33).

Fig. 7

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 62 2 803 900.00 en BETR1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Electrical system on / off

Battery main switch

The electrical system is switched on with keyswitch (115, Fig. 8). To do so, insert the key into the switch and turn clockwise.

The battery main switch (5, Fig. 9) is located above the batteries in the driver's cab. The battery main disconnects the whole electrical system from the battery supply. In "OFF" position the battery main switch • prevents unauthorized starting of the electric motors, and • the batteries from inadvertent discharging

Fig. 8 Fig. 9

The two switch positions are: I = ON 0 = OFF Do not set the battery main switch to "OFF" when the electric motors are running. The voltage spikes produced during shut-off may cause irreparable damage to electrical components with consequential automatic shutdown of the motors.

With the switch in "OFF" position, only the automatic fire-extinguishing system remains ready for operation.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 63 BETR1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Switch-disconnector

Off-load disconnector

The switch-disconnector is located in the control cabinet (1, Fig. 10) for the 7200 V medium-high voltage supply.

The switch-disconnector is used to to switch the voltage from the transformer station on and off.

The off-load disconnectors are located in the control cabinets (1, Fig. 11) (Motor panel for lefthand and righthand electric motor).

The primary side of the switch-disconnector carries 7200 V. The switch-disconnector is off circuit only after the power has been shut off at the transformer station.

Switching on • pull locking device (3) upwards; • shift lever (2) fully upwards (position I); • engage locking device (3).

Fig.11

Switching on • shift lever (2) fully upwards (position I); Shutting off • pull lever completely downwards (position 0); • protect lever (2) with a padlock against unauthorized actuation.

Fig. 10

Cut out off-load disconnector only when the electric motor is off.

Risk of explosion.

Shutting off • Draw out locking device (3) and hold; • Pull lever (2) completely downwards (position 0); • Engage locking device (3); • Protect lever (2) with a padlock against unauthorized actuation.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 64 2 803 900.00 en BETR1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Motor protective relay Layout (Fig. 12)

A fault in the motor system triggers the motor protective relay shutting off the electric motor automatically.

Depending on the fault, one of the warning lamps (10) lights up.

After rectification of the fault: • depress key (6) ESC • depress key (7) ENTER; a menu appears on the display screen (1) • depress keys (2) or (3) until "RESET Trip / Target" appears • depress key (7) ENTER; preset option "YES" is displayed

Fig. 12

• depress key (7) ENTER once again

1 2 3 4 5 6 7

• indicator lamp (8) is lit up (motor protective relay functional)

Display (menu) Key - Scrolling through display text Key - Scrolling through display text Key - Cursor (O&K Mining Service) Key - Cursor (O&K Mining Service) Key - Escape (starts the main menu) Key - Enter (release of motor protective relay after a fault 8 Indicator lamp - Ready 9 Indicator lamp - Motor under tension 10 Warning lamps (fault indication)

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 65 BETR1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Switching the electric motor on and off

2803904

Before switching on the electric motor Before switching on the electric motor, check that nobody is working on the electrical system or on the excavator itself.

The electric motor can be switched on and operated only after the following safety interlocks have been released: – battery main switch (5, Fig. 1) in "ON" position; – EMERGENCY STOP button (Fig. 2) unlocked; – switch-disconnector (1, Fig. 3) in position I - "ON"; – off-load disconnector (1, Fig. 4) in position I - "ON"; – indicator lamp (8, Fig. 5) lit up.

Fig. 3

Fig. 4

Fig. 1

Fig. 5

Fig. 2

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 66 2 803 900.00 en BETR1.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Switching on Do not depress keys (72 resp. 82, Fig. 6) during start-up of an electric motor.

The electric motors are interlocked during start-up. nd The 2 electric motor can be started only after about 15 seconds have elapsed after the start-up phase of st the 1 electric motor.

The electric motor switched on first must not be loaded while the 2nd electric motor is being started.

• Insert the key into key-switch (115) and turn clockwise.

• The BCS screen (Fig. 7) displays the message: "Electric motors ready for start-up".

• Depress the Start key (71, Fig. 6) of electric motor (1, LH) briefly.

The starting procedure is controlled by the SPC. If the electric motor does not start up, wait 15 minutes before repeating the starting procedure.

• Depress the Start key (81, Fig. 6) of electric motor (1, RH) briefly.

An emergency stop is only possible with the EMERGENCY STOP pushbuttons.

Due to en electric timing circuit (SPC), the electric motors can be started up to 4 times in an hour at most (in 15-minute intervals).

If an EMERGENCY STOP button is depressed during the starting phase, it is always necessary to reset both motor protective relays to operating condition.

Fig. 6

Fig. 7

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OPERATING INSTRUCTIONS RH 400 E Shutting off During interruptions and on completion of the work stand working equipment on the ground.

In the event of a ground fault in the 7200 V system, the BCS gives a warning signal.

In this case, the excavator driver must inform the responsible electrician from his position in the superstructure. The electrician must try to locate the cause of the fault.

EMERGENCY STOP Depress the EMERGENCY STOP button (Fig. 9) only in the event of an emergency.

Actuating the EMERGENCY STOP buttons shuts off the motors.

Even after shut-off of the electric motors, the medium-high voltage (7200 V) from the transformer station continues to be supplied to the excavator via the trailing cable and the slip-ring unit (primary side).

Fig. 8

Shut off the electric motors only after the working equipment has been lowered to the ground.

To spare the vacuum contactors, shut off the electric motors unloaded, i.e. without activating hydraulic units with the control elements at the same time.

• Depress the Stop key (72, Fig. 8) briefly. The electric motor (1, LH) is stopped.

• Depress the Stop key (82) briefly. The electric motor (2, RH) is stopped.

• Turn the key in key-switch (115) counterclockwise and withdraw. The control voltage is shut off.

Fig. 9

Depress or pull out the EMERGENCY STOP button (Fig. 9). The buttons remain in their locked position.

Do not shut off both electric motors at the same time.

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OPERATING INSTRUCTIONS RH 400 E TRAVELLING - SAFETY INSTRUCTIONS Raise the attachment only so far that the machine can still be driven without any risk under overhead power lines.

Close the cab door.

If the machine is fitted with a safety belt for the operator, fasten the belt.

If the superstructure is turned by more than 90°C from the BASIC POSITION, the excavator travels in the opposite direction to that selected.

If the position of the superstructure in relation to the undercarriage is not exactly known, touch the accelerator lightly to see which direction the machine takes, before initiating the full travelling movement.

Warn persons in the immediate vicinity by sounding the horn before setting off.

Never cross slopes diagonally.

Take the utmost care on slippery, greasy ground.

2803905

Running-in specifications for components of the crawler tracks Prior to initial commissioning and/or after repair work, run in the crawler tracks as follows: - Raise the equipment (Fig. 1) - Drive the excavator approx. 50 m forwards.

- Drive the excavator approx. 50 m backwards.

- Stop the excavator.

- Measure the temperature of each idler, track roller and support roller with an infrared thermometer. (after reaching a max. temperature of approx. 100°C, wait until the idlers, track rollers and support rollers have cooled down).

- Repeat this running-in procedure up to 10 times.

- Check all idlers, track rollers and support rollers for leaks.

If the machine is to be driven a longer distance, the superstructure must be secured against turning by means of the superstructure holding brake

Fig. 1

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OPERATING INSTRUCTIONS RH 400 E TRAVELLING

2803906

Superstructure basic position

Travelling forwards/backwards

The travel direction of the excavator and sense of actuation of the pedals (132 and 133, Fig. 2) are the same only when the excavator is in its BASIC POSITION (Fig. 1).

Travelling forwards – Depress pedals (132 and 133) forwards The excavator moves in the direction of the idler (2, Fig. 1) Travelling backwards – Depress pedals (132 and 133, Fig. 2) backwards The excavator moves in the direction of the drive sprocket (4, Fig. 1)

Fig. 1

If the superstructure is slewed out of its basic position by more than 90°(Fig. 3), the excavator moves in a direction opposite to the direction in which the pedals (132 and 133, Fig. 2) are depressed.

Fig. 3

The pedals return automatically to their "0" position when released.

Reverse the excavator only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

Never travel across slopes.

When travelling uphill or downhill, the travel drive must always be at the rear. Travel only in the basic position of the excavator and only forwards.

Be extremely careful on slippery and greasy ground.

Fig. 2

If the operator is not completely sure of the position of the superstructure with regard to the undercarriage, the pedals (132 and 133) should be depressed by a small amount to find out which way the excavator moves before initiating the full travelling movement.

All instructions with regard to travelling speed regulation and travel direction control are applicable only as long as the crawler tracks have sufficient grip and do not slip.

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OPERATING INSTRUCTIONS RH 400 E Regulating the travelling speed Travelling on level ground Regulate the travelling speed with • the pedals (132 and 133, Fig. 4) and • by setting switch (91, Fig. 5) to the right (slow gear) This gear permits all forward / reverse travel movements.

• by setting switch (91) to the left (fast gear) With the fast gear, the excavator can be driven only parallel forwards.

The travel gearbox changes automatically into 1st gear as soon as another travelling function (e.g. reversing, cornering) is initiated.

Fig.5

Travelling uphill and downhill Change the speed range only when the excavator is stationary.

Read and observe "Travelling - Safety instructions".

When travelling uphill or downhill, use the first speed range (slow range) only.

If the travelling speed becomes too high when travelling downhill, release the pedals (132 and 133, Fig. 4).

The excavator is braked automatically and stops.

Cornering

Fig. 4

To take a righthand corner forwards – depress only pedal (132) forwards To take a lefthand corner forwards – depress only pedal (133) forwards Turning To turn to the right – depress pedal (132) forwards and pedal (133) backwards To turn to the left – depress pedal (133) forwards and pedal (132) backwards

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OPERATING INSTRUCTIONS RH 400 E Important: Change the position of the undercarriage - parallel or transverse to the working face - only by cornering forwards / backwards (Fig. 6).

Use the the same procedure to drive the excavator out of depressions (Fig. 7):

Fig. 7

Fig. 6

Cornering to the left: forwards from pos. 1 to pos. 2 backwards from pos. 2 to pos. 3 forwards from pos. 3 to pos. 4

Cornering to the left from pos. 1 to pos. 2 Cornering to the right from pos. 2 to pos. 3 Never use the working equipment to raise one side of the undercarriage and then turn the undercarriage by initiating the slewing and/or the travelling function.

This procedure is contrary to the excavator's designated use. There is a risk of accidents. In addition, the tracks, slewing gear, roller bearing slewing ring, or bucket backwall and bucket front wall are subjected to inadmissibly high stresses.

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OPERATING INSTRUCTIONS RH 400 E Travelling over longer distances Read and observe "Travelling - Safety instructions".

Travel forwards only with the excavator in basic position.

When travelling, pay attention to sufficient headroom, e.g. under cable bridges high-tension cables.

Keep the loading bucket close to the ground (Fig. 8). For more uniform loading of the tracks, however, the equipment must be kept at a steep angle.

Loading bucket equipment (Fig. 8) 1) Fully extend boom cylinder 1.

2) Extend bucket cylinder 2.

3) Extend stick cylinder 3.

4) Retract bucket cylinder 2 and stick cylinder 3 until the desired position of the equipment (Fig. 8) is reached.

Lower the equipment when travelling beneath obstacles.

If the equipment position has to be adjusted: • stop the excavator • make the adjustment • then continue travelling After travelling for 15 minutes without interruption, stop the excavator and check the temperature of the track rollers: If the temperature does not exceed ca. 100 °C – continue travelling If the temperature is higher – stop travelling. Resume travelling only when the track rollers have cooled down to ca. 40 °C.

Fig. 8

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OPERATING INSTRUCTIONS RH 400 E Locking the superstructure

Track parking brake

The excavator is equipped with six superstructure holding brakes. These brakes are used to block the superstructure and the undercarriage.

The excavator is equipped with four track brakes integrated in the track drives.

The superstructure holding brakes are parking brakes.

Switch the parking brakes on: • when the excavator is being parked • when travelling over longer distances • To activate the parking brakes, press switch (100, Fig. 9).

The track brakes are parking brakes which relieve the hydrostatic travel drives during working operation and protect the excavator from rolling forwards and backwards.

The brakes are controlled by means of the travel pedals (132 and 133, Fig. 10). When the pedals are in neutral position, the brakes are applied and the excavator is braked. During travelling, the brakes are released.

Fig. 10

The track brakes can also be activated with switch (92, Fig. 9).

Fig. 9

Depending on the position of this switch, the brakes are either permanently engaged or automatically applied after ca. 8 sec. each time the excavator stops.

In this switch position, the brakes are released as soon as the "Travel" function is activated.

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OPERATING INSTRUCTIONS RH 400 E Transporting the machine Transport - Safety instructions The machine must be loaded and transported only after all safety regulations have been observed and complied with.

Entrust loading and transporting of the machine to a company experienced in the transport of heavy equipment.

The responsibility for loading and transporting lies with the transport company or their representative.

Remove oil, grease, soil, mud, snow, ice and other materials from the excavator's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Secure the transport vehicle against rolling away.

Use only tying equipment of sufficient strength (the weights and dimensions of the excavator are set out in the "Technical specifications").

2441641

Transport The dimensions and the service weight of the fully assembled excavator do not allow the excavator to be transported in an undismantled state on a lowbed trailer over public roads.

Therefore, the following components and modules must be dismantled beforehand.

Weights and suspension points are marked on the modules.

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OPERATING INSTRUCTIONS RH 400 E WORKING OPERATIONS - SAFETY INSTRUCTIONS Read the sections "Fundamental safety instructions" and "Operation safety instructions" carefully and observe the instructions given in them.

Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life.

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements.

Sound the hooter to warn persons in the immediate vicinity before starting work.

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk.

Ensure that the attachment has adequate clearance below overhead power lines and structures.

Trenches and working faces may give way. Keep well clear of them.

2803924

Running-in instructions for hydraulic cylinders Compression of an oil / air mixture in a hydraulic cylinder may result in detonations which might damage pistons and sealing rings.

Prior to initial commissioning and / or after repairs, run in the hydraulic cylinders as follows: – Start up the engines and run at low speed. The pressure-limiting valve in the hydraulic system must not respond.

– In the first two working cycles, retract and extend the pistons of the hydraulic cylinders to max. ½ to ¾ stroke (not to the limit stop). Never change direction suddenly. The waiting time between changes of direction must be at least 4 seconds.

– In the next eight working cycles, retract and extend the pistons of the hydraulic cylinders to the limit stop. The waiting time between changes of direction must be at least 4 seconds.

– When all hydraulic cylinders have been run in, the excavator can operate at a higher engine speed.

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OPERATING INSTRUCTIONS RH 400 E

At low temperatures, switch on the electric motors and activate all hydraulic functions for about 10 minutes (bring to operating temperature).

For further instructions see under "Lubricants" If the BCS detects a fault in conjunction with – the motor temperature – the bearing temperature – the motor winding temperature – the hydraulic oil level – the temperature of a pump transfer gearbox – the temperature of a slewing pump – the temperature of a slewing gearbox – the lubricating system lower the working equipment and shut off the electric motors

Parts of the attachment may damage the machine if they are moved into extreme positions (e.g. as shown in Fig. 1).

Work carefully, avoiding extreme positions of this kind.

Fig. 1

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OPERATING INSTRUCTIONS RH 400 E WORKING OPERATION Before starting work Prior to initial commissioning and after repairs to the central lubricating system or the hydraulic cylinders, move the unloaded equipment for ca.

5 min.

This is necessary to ensure an adequate supply of grease to the cylinder bearings when work starts.

Warming up At low outdoor temperatures it is necessary to run the hydraulic system up to operating temperature.

The temperatures at which warming up is necessary depend on the type of hydraulic oil used; cf.

OILS FOR HYDRAULIC SYSTEMS.

2803907

Slewing and braking the superstructure The superstructure can be slewed only when the superstructure holding brake is released.

To slew the superstructure to the right – shift control lever (135) to the right To slew the superstructure to the left – shift control lever (135) to the left On being released, the control lever returns automatically to the "0" position.

Braking the superstructure The superstructure is braked only by setting the control lever (135) into the opposite direction (countering).

To warm up: switch on the electric motors and then make the excavator perform unloaded working movements for about 10 minutes.

In an emergency, apply the parking brake with switch (100, Fig. 2).

Fig. 1

Switching on the electronic excavator control The electronic excavator control is switched on and off with pushbutton (125, Fig. 1) and switch (94, Fig. 2).

Electronic excavator control activated – operator is seated on driver's seat and switch (94) is actuated.

Fig. 2

Electronic excavator control deactivated – driver's seat is empty and/or switch (94) is in OFF position.

The electronic excavator control is activated only after both, pushbutton (125, Fig. 1) and switch (94, Fig. 2) are in the ON position.

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OPERATING INSTRUCTIONS RH 400 E Working

Filling and emptying the bucket

On being released, all control levers for working operation return automatically to the "0" position.

To fill/tip back the bucket – shift control lever (136) to the left To empty the bucket by dumping/tipping – shift control lever (136) to the right

Level a surface only in the bucket's digging direction. Never "beat" or "sweep" with the bucket.

Loading bucket: Close the bucket completely before starting to excavate. Never level off a surface with the front shell of the bucket open.

Opening and closing the bucket To open the bucket – press pedal (131) forwards To close the bucket – press pedal (131) backwards

Raising and lowering the boom

Lowering the equipment in an emergency

To raise the boom – pull control lever (136, Fig. 3) backwards To lower the boom – pull control lever (136) forward To lower the boom with pressure – depress button (123) and push control lever (136) forwards

In the event of the electronic excavator control and/or the electric motors failing, lower the equipment as follows: • Switch on the electrical system with key-switch (115, Fig. 4).

• Depress switch (107).

• Depress pushbuttons (122 and 123, Fig. 3).

Extending and retracting the bucket or backhoe bucket stick To extend the stick – push control lever (135) forwards To retract the stick – push control lever (135) backwards

Fig.3

Fig.4

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OPERATING INSTRUCTIONS RH 400 E After daily operation Parking the machine • Park the machine on level and stable ground.

This is particularly important in winter to prevent freezing of the tracks.

• Set the working equipment down on the ground.

• Shut off the electric motors.

• Shift both control levers in all directions to depressurize the hydraulic cylinders.

• Withdraw the key from the electrical system key-switch.

• Close the cab window.

• Lock the cab door and all lockable hatches and covers on the machine.

• Clean the machine of coarse dirt and of combustible and easily flammable substances, if possible with a steam jet (rubber parts and electric components with compressed air - refer to instruction plate).

There is otherwise a risk of fire and explosion.

Escaping oil pollutes the environment.

Repair leaks (or have them repaired) immediately.

Report accidents involving oil to the user of the machine.

• Check the superstructure, undercarriage and working equipment for damage, and all steel components for cracks or fractures.

Report any damage detected to the user immediately.

• Clean off coarse dirt, ice and snow from the fins and fan wheel of the hydraulic oil cooler.

• Fill up the fuel tank of the on-board crane (after each job).

• Check the crane motor and the hydraulic system (on-board crane) visually for leaks.

• Inspect the engines, the hydraulic system, the track rollers, support rollers, idlers and gearboxes visually for leaks.

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OPERATING INSTRUCTIONS RH 400 E ASSEMBLY OF WORKING EQUIPMENT - SAFETY INSTRUCTIONS

2441646

Personnel

Tools and auxiliaries

Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from O&K. The operating manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to lifethreatening situations.

Tools, hoists, slings, trestles and other devices must be in a reliable, safe state.

Metal splinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Use only the steps, platforms and handrails when climbing onto or off the machine.

Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Personal protective gear and working clothes Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear and gloves.

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

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OPERATING INSTRUCTIONS RH 400 E

Securing the machine Carry out work on the attachment only if the machine is secured as described in the "Securing the machine" section.

Protective roof against falling objects The machine is equipped with an integrated cab-protection roof (FOPS).

Selecting the attachments The machine can be equipped with various attachments.

The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by O&K for this type of machine.

Never install and commission other equipment and component combinations without O&K first having inspected and approved the project in writing.

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OPERATING INSTRUCTIONS RH 400 E Securing the machine Risk of injury The machine must not be started by unauthorized persons.

Therefore, secure the machine.

Observe the accident prevention regulations.

Depressurize pipeline systems, on which work is to be carried out, by appropriate measures.

Protective shrouds of moving machine parts may only be opened or removed when the drive unit is stationary and protected against inadvertent starting.

Before carrying out fitting works, the machine and the equipment must be protected against inadvertent starting by placing chocks under the tracks and by standing the working equipment on the ground.

Hydraulic and lubricating systems: Close all open bores, pipe and hose connections with pressure-resistant plugs.

Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of non reusable oils without polluting the environment.

All components of O&K machines have been carefully purpose-coordinated. Trouble-free operation and a long service life can only be achieved with original O&K spare parts.

Respect the sequence of working operations when fitting or replacing the attachments. The sequence has been determined and tested by qualified experts.

Secure the machine as described below: – before carrying out any fitting and modification work on the working equipment, – before carrying out any servicing and repair work on the machine.

• Park the machine on level and stable ground.

• Lock the superstructure.

• Stand the working equipment on the ground.

• Shut off the motors.

• Depressurize the hydraulic system.

• Withdraw the key from the key-switch.

• Before carrying out works on the electrical system or before performing welding work on the machine, disconnect the batteries and withdraw the plug from the load-limit regulator module of the PMS. Insulate the connecting terminals and plugs properly.

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OPERATING INSTRUCTIONS RH 400 E Corrosion protection for pins and bearings (bushings and hubs) Use Voler A.C. (Manke) anti-corrosive agent only.

Other agents are not approved by O&K. All pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated with Voler A.C. anti-corrosive agent before fitting.

Voler A.C.: • permits easy fitting and dismantling • protects against rust, oxidation and similar wear • prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminium and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden.

Part nos. for Voler A.C. SN 0 271 554 - 0.5 l spray can (CFC-free) SN 1 438 473 - 0.5 kg tin SN 1 438 219 - 4.5 kg bucket

2281259

Application of Voler A.C. • Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel.

Any rust patches must be thoroughly removed.

All parts must present a dry, bright metal surface.

• Apply a thin layer of Voler A.C. on pins and all bearings using a brush or a spray can. Pin shafts and bearings must be completely covered by the protective layer.

If the protective layer of a pin already treated with Voler A.C. is damaged, these areas must be touched up before fitting the part.

• Fitting and securing of pins If the pin is too heavy to be fitted manually, apply Voler A.C. at first only on abt. a quarter of the pin's length Then position pin by means of a lifting gear ready for fitting.

Apply Voler A.C. on the remaining length of pin shaft, fit pin and secure.

Available from the O&K Spare-Parts Service

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OPERATING INSTRUCTIONS RH 400 E NOTES

2804180

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OPERATING INSTRUCTIONS RH 400 E PART 3 - INSPECTION AND SERVICING

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2804053

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS RH 400 E Inspection and servicing - Safety instructions Operating instructions No inspection and servicing work must be carried out until the operating instructions have been read and understood.

Pay special attention to: "Fundamental safety instructions" and all warnings and safety instructions attached to the machine.

The operating instructions list all jobs to be done. The descriptions of job sequences, however, provide only experienced personnel with the necessary instructions.

The operating instructions must be kept with the machine at all times.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

The necessary know-how can be acquired in a several day's instruction, e.g. by an O&K-Mining mechanic or by attending an O&K-Mining training course.

Personal protective equipment and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

2732327

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulical connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out servicing work only if the machine is secured as described in the section "Securing the machine".

Climbing onto and off the machine Use only the ladders, steps, platforms and handrails provided when climbing onto or off the machine.

Always keep ladders, steps, platforms and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately.

Always face the machine when climbing on and off.

Checking the state of tools Use only fully functional, reliable tools.

Select the right tool for the job.

Wrenches of the wrong size, for example, may slip and cause injury.

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OPERATING INSTRUCTIONS RH 400 E

Cleaning jobs Prior to commencing work, clean your working area, if necessary and possible, with a stream jet (rubber parts and electric components with compressed air - refer to the instruction label).

Use only lint-free cleaning rags when working on the hydraulic system.

Cleaning agents and solvents may give off harmful, readily flammable vapours.

Never work with such agents except on well ventilated premises; never inhale the vapours and never smoke.

Prevent solvents and cleaning agents from coming into contact with your skin. Wear gloves.

Observe the instructions on the packaging.

Handling flammable liquids When handling flammable liquids: - never smoke, - keep away from unshielded light sources and naked flames.

Consumables often have low flash points and are readily ignited.

Never attempt to extinguish burning liquids with water. Use: - dry powder, - carbon dioxide or - foam extinguishers.

Water used for extinguishing purposes would vapourize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing hazards.

Notify the fire brigade.

Fastening and securing elements Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

Spare parts Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturers can be relied on to do so.

Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Never set foot withing reach of the emerging oil jet.

Avoid contact with the skin. Wear gloves and firm protective clothing.

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with warm soapy water and apply a barrier cream. Never use fuels or solvents for cleaning the skin.

If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

Visisble oil losses Have any visible leakage repaired immediately.

Escaping oil is an environmental hazard.

Soak up any oil that has escaped with a binding agent.

Sweep up binding agent and dispose of it separately from other waste.

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OPERATING INSTRUCTIONS RH 400 E

Relieving residual pressure in the hydraulic system Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with its attachments supported on the ground and its electric motor is switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, the system must be depressurized (without leaving the driver's seat): - Stand working equipment on the ground - Switch off the electric motor - Move all control levers and pedals repeatedly into all directions.

Screwed connections, piping, hydraulic hoses Repair any leakage in the piping and hose system immediately.

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

If oil has penetrated into the skin, consult a doctor immediately.

Never repair damaged piping; always replace them.

Replace hydraulic hoses immediately on detecting any damage or moist areas.

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

Non-polluting disposal Dispose of oils, greases, cooling liquids, detergents, solvents and oilcontaining components, such as filters, cleaning rags, replaced wearing parts and unusable machine parts, without polluting the environment and separately from other waste.

Do not dispose of these substances together with household wastes.

Fill these substances into the containers provided for such purposes.

Like any other oil, also biodegradable, "environmental-friendly" hydraulic oil must be disposed of separately.

Do not allow oils and oily wastes to penetrate into the soil or into water.

They are an environmental hazard.

Seals Individual spares may contain asbestos. Such spares or their packaging are marked with: Never process spares containing asbestos mechanically.

Inhaling asbestos dust is a health hazard.

Clean sealing faces prior to assembly.

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BI015806

OPERATING INSTRUCTIONS RH 400 E

Handling batteries

Selecting oils and greases

Batteries give off explosive gases.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Wear gloves, firm protective clothing and goggles when handling batteries.

If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery.

They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watch-straps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Use the recommended qualities only, matching viscosities with the temperature level.

Prior to work on the electrical system Prior to any work on the electrical system involving tools, spares etc. coming into contact with electric cables or contacts, switch off battery main switches.

Filters Replace/clean all filter elements or filter cartridges within the specified periods.

All filters are coordinated carefully with the equipment. Original O&KMining parts must be used to ensure smooth running and a long service life of the hydraulic units.

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

After servicing To prevent corrosion, coat all bright metal parts with a grease film.

On completing work, re-install all protective devices.

Never switch on the electric motor while work is being done on the machine.

Carry out performance tests with the machine.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 92 2 803 900.00 en INSP.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Fire and Explosion Hazard

2800161

Safety Instructions Avoid smoking and open fire on, next to and below the machine.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard. Do not store such substances on the excavator.

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to the instruction label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units.

Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where - combustible substances such as coal dust or tar are present.

- open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks may cause fire on the ground that can spread to the excavator.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 93 INSP.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 94 2 803 900.00 en INSP.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Inspection and servicing plans - Instructions

2803908

Intervals

Oils / Greases

The inspection and servicing plan lists all jobs which have to be done on the machine at regular intervals.

For the specification of oils and greases to be used, refer to the "Lubricants" section.

The numerals in the "Oil / Grease" column of the inspection and servicing plans have the following meaning:

The individual inspection and servicing plans are marked with letters providing a link between the operating hours (OH) recorded by the hours-run meter of the machine and the inspection and servicing plans.

Plan

1)

Do all jobs ....

V

....once prior to initial commissioning

N

.... after initial commissioning and during the running-in period.

T

.... every 10 OH or every working shift

W

....every 60 OH or once a week

A

....after every 250 OH

B

....after every 500 OH

C

....after every 1000 OH

D

....after every 5000 OH

E

....after every 10000 OH

1)

1)

I

Oils for combustion engines and compressors

II

Oils for hydraulic systems

III

Oils for gearboxes

V

Greases for bearings and slewing rings

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

Clean the excavator thoroughly after servicing, especially if combustible and easily flammable substances (such as oil, grease, fuel, detergents) have been spilled.

There is otherwise a high risk of fire and explosions.

whichever comes first

OH = Bh = Operating hours

Oil-check service The oil-change intervals can be extended if you have the O&K Mining oil checks carried out.

Contact the O&K Mining After-Sales Service.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 95 INSP.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 96 2 803 900.00 en INSP.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan V – Once prior to initial commissioning

Location

Servicing work

Electric motor

Lubricate

Electrical system Battery Terminals and connectors EMERGENCY STOP function Slip ring assembly Switchgear cabinet (medium voltage) Switchgear cabinet (off-load disconnector) Lighting Earth cable (potential compensation)

Check battery charge Check for tightness Check for correct functioning Visual inspection Check for condensation/drain off water Check for condensation/drain off water Check for correct functioning Check for tightness

Monitoring, warning and control elements BCS

Page 1 of 2 Quantity/ No. 2x2 2 5 1 1 2

Check that working and travelling movements are functioning correctly Check that indicators are functioning correctly Check function of monitor

Hydraulic oil reservoir Hydraulic cylinders

Check for correct functioning 1) Check operating pressure Check oil level Bleed systems

Pump transfer gearbox – Pre-chamber

Check oil level Check oil level

2 2x9

Slewing gearbox Expansion reservoir Slewing gear neck

Check oil level Lubricate

6 6x2

Travel gearbox – Pre-chamber

Check oil level Check oil level

2 2x2

Slewing ring Internal gearing

Check grease filling

Undercarriage Track roller – Expansion reservoir Support roller Track Idler Idler guide

Check for free movement Check oil level Check for free movement Check tension Check for leaks Grease

2x7 2x7 2x3 2 2 2x2

Superstructure Driver's cab – Door – Hinge

Lubricate

3x3

Hydraulic system

1)

1

1

To be carried out by the O&K Mining After-Sales Service.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 97 PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan V – Once prior to initial commissioning Page 2 of 2 Location

Servicing work

Quantity/ No.

Central lubricating system Grease container

Check filling level

1

Ramp-type ladder – Guide pulleys – Locking bolt

Lubricate Lubricate

3 1

Service station (tank lift)

Check operation

1 4 2 5 1 1

– Battery

Lubricate Lubricate Lubricate Lubricate Check oil level (cf. "On-board Crane" operating instructions) Check oil level (cf. "Crane Drive Engine" operating instructions) Check charge condition

All lines, fittings and connections

Visual inspection for leaks, wearing marks

All articulated joints and hinges

Lubricate

On-board crane – Bearings – Joint (column/boom) – Cylinder bearing – Slewing ring Hydraulic oil reservoir Crane drive engine

1 2

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 98 2 803 900.00 en PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan N – After initial commissioning and during the running-in period Location After 60 OH Electrical system Switchgear cabinet (medium voltage) – Mechanical connections – Lines – Terminals and connections Switchgear cabinet (off-load disconnector) – Mechanical connections – Lines – Terminals and connections Hydraulic system Oil cooler – Bearing – Fastening screws Return-flow filter Magnetic rod Filter housing - Cooling system – Return-flow filter – Magnetic rod Pressure accumulator - Emergency lowering Pressure accumulator - Ramp-type ladder

Servicing work

Check for tightness Check for tightness Check for tightness Check for tightness Check for tightness Check for tightness

Check for tightness Replace Check/clean Replace Check/clean Check pressure Check pressure

Slewing gearbox Fastening screws

Check for tightness (torque wrench)

Travel gearbox Fastening screws

Check for tightness

Page 1 of 2 Quantity/ No.

1

2

2x7 2 3 1 1 1

Superstructure Fastening screws, especially at superstructure Check for tightness / console / driver's cab Undercarriage Diaphragm accumulator - Track tensioner Idler

Check pressure Check oil level

All lines, fittings and connections

Visual inspection for leaks, wearing marks

2x2 2

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 99 PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan N – After initial commissioning and during the running-in period Location

Servicing work

Page 2 of 2 Quantity/ No.

After 100 OH Change oil

2)

2

Slewing gearbox

Change oil

2)

6

Travel gearbox – Pre-chamber

Change oil 2) Change oil

2)

2 2x2

Pump transfer gearbox

Slewing ring Fastening screws (slewing ring, undercarriage Check tightness and superstructure) (torque wrench) After 250 OH Superstructure Fastening screws, especially at superstructure Check for tightness / console / driver's cab After 500 OH resp. 3 months

3)

Slewing ring Fastening screws (slewing ring, undercarriage Check tightness and superstructure) (torque wrench) 2)

Cf. "Refilling quantities - Oil" table

3)

When a lost of preload of the bolts is found in the course of the check, checking shall be carried out after 500 OH resp. 3 month.

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 100 2 803 900.00 en PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan T

– Every 10 OH or every working shift

(whichever comes first)

Plan W – Every 60 OH or once a week (whichever comes first) Location Electrical system Switchgear cabinet (medium voltage) – Electrical components Switchgear cabinet (off-load disconnector) – Electrical components Switchgear cabinet – Breather filter – Pre-filter Lighting

Page 1 of 2 Servicing work

Quantity/ No.

Plan T

Plan W

Check for condensation, remove moisture Visual inspection Check for condensation, remove moisture Visual inspection

1

l

l

2

l

l l

Check/clean Check for correct functioning

1

l

l

l l

l

l

l l

l l

BCS

Check that working and travelling movements are functioning correctly Check functioning of indicators Check display unit

Hydraulic system Hydraulic oil reservoir Oil cooler Fins / fan wheel

Visual inspection for leaks Check oil level Check/clean Remove dirt, ice and snow

1 2

Pump transfer gearbox

Check oil level

2

Slewing gearbox Expansion reservoir

Check oil level

6

l

l

Travel gearbox

Check for leaks

2

l

l

Undercarriage Track tension Track roller – Expansion reservoir Support roller Idler Idler guide

Visual inspection Check for leaks and free movement Check oil level Check for leaks and free movement Check for leaks Lubricate

2 2x7 2x7 2x3 2 2x2

l

l l l l l l

Monitoring, warning and control elements

l

l l l l l

l l

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 101 PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan T

– Every 10 OH or every working shift

(whichever comes first)

Plan W – Every 60 OH or once a week (whichever comes first)

Page 2 of 2

Location

Servicing work

Air conditioner – Breather filter – Pre-filter

Check/clean

2

Central lubricating system Grease container

Check pressure Check filling level (BCS)

1 1

On-board crane Crane drive engine – Fuel filter Hydraulic oil reservoir – Return-flow filter (contamination indicator)

4)

Check oil level 4) Drain water (cf. "Crane Drive Engine" operating instructions 4) Check oil level 4) Check

All lines, fittings and connections

Visual inspection for leaks, wearing marks

Excavator

General cleaning

4)

Quantity/ No.

Plan T

Plan W

l l

l l

1 1

l

l l

1 1

l l

l l

l

l l

before each deployment

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 102 2 803 900.00 en PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan A

–

after every 250 OH

Plan C

–

after every 1000 OH

Plan B

–

after every 500 OH

Plan D

–

after every 5000 OH

Plan E

–

after every 10000 OH

(at 250, 750, 1250 ... OH)

(at 1000, 2000, 3000, 4000 ... OH)

(at 500, 1500, 2500 ... OH)

(at 5000, 15000, 25000 ... OH)

(at 10000, 20000, 30000, ... OH)

Page 1 of 4 Location

Servicing work

Quantity/ Plan Plan Plan Plan Plan No. A B C D E l

Servicing acc. to W or T Elektric motor Electrical system Battery and cable connection Earth cable (potential compensation) Switchgear cabinet – Breather filter – Filter element Switchgear cabinet (medium voltage) – Electrical components – Breather filter Switchgear cabinet (off-load disconnector – Electrical components – Breather filter Slip ring assembly Mechanical components

Lubricate

5)

2x2

Check for tightness Check for tightness

Clean Replace Clean/dry

l

l

l

l

l

l

l

l l

l l

l l

l l

l

l

l

l

l l l

l l l

l l

l l

l

l

l l l l

l l l l

l l

l l

l l

l l

l l l l l

l l l l l

2)

1 1

Check for tightness Clean Replace Clean/dry

1 1

Check for tightness Clean Replace Visual inspection Check for tightness

2x1 2x1 1

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 103 PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan A

– after every 250 OH

Plan C

– after every 1000 OH

Plan B

– after every 500 OH

Plan D

– after every 5000 OH

Plan E

– after 10000 OH

(at 250, 750, 1250 ... OH)

(at 500, 1500, 2500 ... OH)

(at 1000, 2000, 3000, 4000 ... OH)

(at 5000, 15000, 25000 ... OH)

(at 10000, 20000, 30000, ... OH)

Page 2 of 4 Location Hydraulic system Oil cooler – Bearing – Fastening screws – Rubber bearings Return-flow filter High-pressure filter Magnetic rod Bypass valve Filter housing (cooling system) – Return-flow filter – Bypass valve – Magnetic rod Filter (pilot control circuit) Filter (pump flushing circuit) Filter (feeding circuit) Breather filter (hydraulic oil reservoir) Hydraulic oil reservoir Cylinders (seals and guide rings)

Servicing work

Quantity/ Plan Plan Plan Plan Plan No. A B C D E

Check for tightness Check condition Replace Check/clean Replace Check/clean Clean sieve

2x7 2x4 4 2 2x4

l l

l l l l

l

l

Replace Clean sieve Check/clean Check/clean Replace Check/clean Replace Check/clean Replace Replace

3 3 1 2x1 2x1 2x1 2x1 2x1 2x1 2

l

l

l l

l l

l

l

l

l

Carry out oil analysis 5) Change oil Replace

1 2) 1

l

l

l l l l l l l

l l l l l l l

l l l l l l l l l l

l l l l l l l l l l

l

l l l

2)

Cf. "Refilling quantities - Oil" table

5)

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than after 3 years

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 104 2 803 900.00 en PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan A

– after every 250 OH

Plan C

– after every 1000 OH

Plan B

– after 500 OH

Plan D

– after every 5000 OH

Plan E

– after every 10000 OH

(at 250, 750, 1250 ... OH)

(at 500, 1500, 2500 ... OH)

(at 1000, 2000, 3000, 4000 ... OH)

(at 5000, 15000, 25000 ... OH)

(at 10000, 20000, 30000, ... OH)

Page 3 of 4 Location

Servicing work

Pump transfer gearbox – Pre-chamber – Breather filter

Change oil Check oil level Clean

2 2x9 2x1

Slewing gearbox – Venting bore – Slewing gear neck

Change oil Check/clean 6) Lubricate

6 6 6x2

Travel gearbox

Check oil level Change oil Clean Check oil level Change oil

2 2) 2 2x4 2x2 2x2

– Magnetic screw – Pre-chamber Slewing ring Gearing/pinion Fastening screws (slewing ring, undercarriage and superstructure) Superstructure Cab – Bearing – Fastening screws – Rubber bearing – Door – Hinge Air conditioner – Breather filter – Filter element

Check grease filling Check condition Check for tightness (torque wrench)

Quantity/ Plan Plan Plan Plan Plan No. A B C D E 2)

l

1

Lubricate

3x3

Clean Replace

2 2

Cf. "Refilling quantities - Oil" table

6)

Lubricate bearings at least once a year

l l l

l l l

l

l l l

l l l

l l l l l

l l l l l

2)

l

l

l

l

l l

l l

l l

l l l

l l

l l

l l

l

l

l

l

l l

l l

Check for tightness Check condition

2)

l l l

l

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 105 PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Plan A

– after every 250 OH

Plan C

– after every 1000 OH

Plan B

– after every 500 OH

Plan D

– after every 5000 OH

Plan E

– after every 10000 OH

(at 250, 750, 1250 ... OH

(at 500, 1500, 2500 ... OH)

(at 1000, 2000, 3000, 4000 ... OH)

(at 5000, 15000, 25000 ... OH)

(at 10000, 20000, 30000, ... OH)

Page 4 of 4 Location

Servicing work

Central lubricating system Grease sieve Grease container – Breather filter Ramp-type ladder – Guide pulleys – Locking bolt

Quantity/ Plan Plan Plan Plan Plan No. A B C D E

Check/clean

2x2

l

l

l

Check/replace

1

l

l

l

Lubricate Lubricate

3 1

l l

l l

l l

Lubricate Lubricate Lubricate Lubricate 2) Change oil Replace Replace (cf. "On-board Crane" operating instructions) Clean engine 2) Change oil Replace oil filter Check for tightness Replace Replace Replace Check for tightness (cf. "Crane Drive Engine" operating instructions)

4 2 5 1 1 1 1

l l l l

l l l l

l

l

l l l l l l l l

l l l l l l l l

l l l l l l l l

1 1 1

l l l l

l l l l

l l

l l l l

l l l l l l l l l

l l l l l l l l l

l l l l l l l l l

7)

On-board crane – Bearing – Joint (column/boom) – Cylinder bearing – Slewing ring Hydraulic system – Return-flow filter – Breather filter Crane drive engine – Fastening screws – Air filter – Fuel pre-filter – Fuel filter – Battery cable connection

1 1 2

Steel components

Visual inspection

l

l

l

All articulated joints and hinges

Lubricate

l

l

l

2)

Cf. "Refilling quantities - Oil" table

7)

Do all servicing jobs at least once a year and when necessary

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 106 2 803 900.00 en PLAN.DOC

BI015806 BA 6090ACFS (2 803 900.01)-EN

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

No. of

Page 5 Plan Plan Plan Plan Plan A B C D E   

Check pressure (see Service Manual)

2x2



- Diaphragm

Replace

2x2

Track roller

Check for leaks and free movement

2x7



Support roller

Check for leaks and free movement

2x2

Idler

Check for leaks and free movement

2x1

Carbody – crawler frame fastening bolts

Replace after 30.000 OH (see Service Manual)

52

Location

Servicing work

Undercarriage

Check wear (see Service Manual)

Diaphragm accumulator

Update to version .01, see pages 107 and 153a































107

BI015806

OPERATING INSTRUCTIONS RH 400 E LUBRICATING CHART - GREASE / LOADING BUCKET

2803909

Fig. 1 Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 108 2 803 900.00 en PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Lubricating chart - Grease / Loading bucket (legend) No.

Greasing point

Number

Lubricant properties

Grease every ... operating hours

1

Central lubricating system - grease container

1

V

10

2

Idler guide

2x2

60

3

Hinge (cab)

3x3

1000

4

Slewing gear neck

6x2

3000

5

Ramp-type ladder – Deflection roller

3

1000

– Locking bolt

1

6

On-board crane

I

1)

1)

1000

2)

– bearing

4

– articulated joint (column / boom)

2

– cylinder bearing

5

– slewing ring

1

250

V

1)

250 250

Graphite spray

250

All other greasing points are supplied with grease by the central lubricating system.

Refilling quantities - Grease Greasing point, component

Lubricant properties

Central lubricating system - grease container Internal gearing - roller bearing slewing ring Track rollers 1)

Cf. section "LUBRICANTS"

2)

at least every year and if required

Filling quant. in kg 500

V

1)

600 14 x

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 109 PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E INSPECTION PLAN - OIL

2803909

Fig. 2 Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 110 2 803 900.00 en PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Inspection plan - Oil (legend) No.

Location

Number

Lubricant 1) properties

Check oil level every ... OH

Change oil every ... OH

II

10

10000

10

1000

3

Hydraulic system

1

4

Pump transfer gearbox

2

3)

III 4

– Pre-chamber

2x9

5

Slewing gearbox

6

6

Travel gearbox

2

500

III

10

5000

500

5000

500

5000

III – Pre-chamber

2x2

7

Track rollers

2x7

III

10

8

On-board crane – Crane drive engine

1

I

10

250

– Hydraulic oil tank

1

II

10

1000

4) 4)

1)

Cf. section "LUBRICANTS"

2)

The maintenance interval can be prolonged if regular oil analyses are carried out and after approval of the Diesel engine manufacturer has been obtained

3)

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years

4)

Change oil at least once a year

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 111 PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E Refilling quantities - Oil Location

Filling quantity (liters)

Oil

Hydraulic system – Hydraulic oil reservoir and filter housing - cooling system

10000

II

Pump transfer gearbox

2 x 60

– Pre-chamber (working pumps)

8x2

– Pre-chamber (hydraulic pumps)

10 x 1

Slewing gearbox

6 x 22

Travel gearbox

2 x 215

III III III

– Pre-chamber

4 x 2.5

Idler (permanent oil filling)

2 x 36

Track rollers (permanent oil filling)

14 x 45

Support rollers (permanent oil filling)

6 x 15

III III III

On-board crane – crane drive engine

5.5

– hydraulic oil reservoir

50

I II

Refilling quantities - Others Location

Filling quantity (liters)

Fuel tank of crane drive engine

25

Screen-washer

13

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 112 2 803 900.00 en PLAN.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E LUBRICANTS 2804268

I.

Oils for combustion engines and compressors (selection)

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 113 SCHMIER.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E

II.

Oils for hydraulic systems (selection)

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 114 2 803 900.00 en SCHMIER.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E III.

Oils for gearboxes (selection)

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 2 803 900.00 en 115 SCHMIER.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E V.

Greases for bearings and slewing rings

Update to version .01, see pages 107 and 153a _______________________________________________________________________________________ 116 2 803 900.00 en SCHMIER.DOC

BI015806

OPERATING INSTRUCTIONS RH 400 E SERVICING WORK 2803911

Hosepipe for oil and coolant changes Catch escaping oil and discard in accordance with environmental regulations.

The hydraulic tank and the slewing gearboxes are moreover equipped with special drain valves (1, Fig. 2).

These valves permit oil changes without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more readily.

Filling and draining can be done by means of a hose through the service station (tank lift) (Fig. 1).

For filling and draining, a flexible hose is connected to the express coupling on the service station and to the service vehicle at the other end.

The filling operations require overpressure, whereas the draining operations require low pressure.

Fig. 2

To change the oil, proceed as follows: – Place a container for used oil under the corresponding automatic drain valve (for container capacity refer to the "Refilling quantities - Oil" chapter).

– Unscrew the protective cap of the automatic drain valve.

– Screw on draining hose (2) The valve opens and the oil flows out.

– When the oil has drained away, unscrew the hose. The valve closes automatically.

Fig. 1

– Screw protective cap back in place.

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OPERATING INSTRUCTIONS RH 400 E ELECTRIC MOTOR 2803912

Electric motor - Safety instructions

Grease the bearing at the back of greasing nipple (2, Fig. 2).

Read and observe: "Inspection and Servicing - Safety Instructions" and the operating instructions for the electric motor.

Switch off the electric motors.

Secure the machine as indicated under "Securing the machine".

Wear protective gloves and firm working clothing.

Greasing the electric motors Fig. 2

Grease the bearings at regular intervals while the electric motors are running. (cf. operating instructions issued by the motor manufacturer) Grease the bearing in front through greasing nipple (1, Fig. 1).

The newly injected grease squeezes the used grease out of the bearing.

Therefore continue to inject new grease until it reemerges from the bearing.

Cleaning the electric motor Clean the electric motor with compressed air only.

It is not permissible to clean the electric motors or any other live parts of the excavator with steam cleaner and steam jet.

More information on the described servicing work on the electric motors is set out in the operating instructions issued by the motor manufacturer.

Fig. 1

Any other servicing work beyond that outlined above is carried out by the O&K Mining AfterSales Service or by the motor manufacturer's agent.

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OPERATING INSTRUCTIONS RH 400 E ELECTRICAL SYSTEM 2803922

Electrical System - Safety Instructions Read and observe: Inspection and Servicing - Safety Instructions.

Risk of injury through battery acid and gases.

Wear goggles, working gloves and firm working clothing.

Carry out voltage and continuity checks only with a test lamp or measuring instrument. Never check by "touching ground" with a bare wire. The resulting short circuit damages the alternator and the electric modules of the PMS.

Battery main switch The battery main switch (Fig. 1) is located in the pedestal above the batteries.

Fig. 1

The electrical circuit diagrams are attached to the spare parts list. Further information is given in the O&K booklet "Working with circuit diagrams".

Disconnect electrical circuits from the supply with the switchdisconnector and the battery main switch before working on the electrical system. This prevents accidents, inadvertent starting of the electric motor, and short circuits.

Cables and cable lugs must not come into contact with other metal parts. Replace broken or damaged cables together with their cable lugs.

On withdrawal of the key from the key-switch (control panel in cab), the electrical lines from the key-switch to the consumers are de-energized.

The lines from the batteries to the key-switch, however, are still energized. With the battery main switch, these lines can be de-energized, too. Shut off the electrical system with the battery main switch when carrying out repair work or during prolonged downtimes of the excavator.

Battery main switch (Fig. 1): – Position I = ON – Position 0 = OFF In position "0", the lever can be withdrawn from the battery main switch.

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OPERATING INSTRUCTIONS RH 400 E Removing and installing the battery

Battery Checking the battery fluid level

Read and observe "Inspection and Servicing - Safety Instructions.

Wear protective gloves and firm working clothing.

Switch off the electric motors before removing the batteries.

Turn key in key-switch to position "0" and withdraw.

Set battery main switch (Fig. 3) to "OFF" position.

Disconnect and reconnect terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuiting.

(Not applicable in the case of maintenance-free batteries) • Unscrew caps (Fig. 2).

• If checking insets are provided, the battery fluid must reach at least to their base.

• If no checking insets are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened for a length of at least 10 mm.

• If the fluid level is too low, top up with distilled water only.

Fig. 2

Checking the battery charge The acid temperature must be 20°C.

Fig. 3

• Unscrew battery caps.

• Measure the acid density of the battery with a commercially available acid tester (Fig. 3).

The acid density is in direct correlation with the battery charge.

Acid density kg / dm3

Charge

Normal Tropics 1,28

1,23

fully charged

1,20

1,12

half charged,

1,12

1,08

discharged, recharge

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OPERATING INSTRUCTIONS RH 400 E The batteries (1, Fig. 4) are located in the pedestal. The 12-volt batteries are connected in series, so that the system voltage is 24V. • Detach battery holder (2).

• Disconnect the cable lug from the negative terminal of the battery.

• Disconnect the cable lug from the positive terminal of the battery.

Charging the batteries The batteries are charged by battery charger (4) only after the power supply to the electrical system has been switched on with the switch-disconnector.

The battery main switch (5) must be in position "I" = ON.

• Insulate the cable lugs.

• Remove the battery.

Before installing new batteries, the contact areas of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.

• Install the new batteries.

• Connect the cable lug to the positive terminal of the battery.

Tighten the clamping screws of the cable lugs without using force to prevent deformation.

• Connect the cable lug to the negative terminal of the battery.

• Then apply special terminal grease or acid-free Vaseline on battery terminal posts and clamping lugs.

Fig. 4

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OPERATING INSTRUCTIONS RH 400 E Control cabinet

Emptying the dust collector

Venting filter

• Loosen wing nut (15).

The control cabinet is vented by air sucked into the cabinet by a fan through a filter (Fig. 5).

• Remove dust collector (14, Fig. 6) together with insert (16).

• Draw insert (16) out of dust collector (14) and empty.

• Slide insert (16) back into dust collector (14).

When re-asssembling the collector make sure that the opening in insert (16) is at the top.

Pay attention to the TOP marking when refitting the dust collector.

Filter element Fig. 5

• Remove dust collector (14, Fig. 6).

Cleaning the pre-filter

• Unscrew wing nut (17, Fig. 7).

• Unscrew wing nut (11).

• Withdraw filter element (18) without losing the washer under nut (17).

• Remove cover (12) and housing (13).

• Clean housing (13).

• Re-assemble the pre-filter

• Replace or clean filter element (18).

• Refit dust collector (14).

Fig 6

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OPERATING INSTRUCTIONS RH 400 E Checking and cleaning the filter element Check the filter paper of the element by inserting a lamp into the element (Fig. 7). Any deterioration is then easily visible.

Replace damaged or deformed elements immediately.

Fig. 8

Blow filter element (Fig. 8) dry with compressed air by moving the compressed-air nozzle up and down inside the element.

The pressure at the nozzle must not exceed 6 bars.

Fig .7

Check the element seal. If the seal is damaged, replace also the filter element.

Cleaning with compressed air allows the filter element to be re-used immediately.

Cleaning is completed when all dust has been blown out.

Never clean a filter element by beating it against hard objects.

Replace the main filter element after 1000 operating hours or 3 cleaning cycles, but in any case after one year of operation at the latest.

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OPERATING INSTRUCTIONS RH 400 E Control cabinet Never clean filter elements by beating them against hard objects.

Venting filter The control cabinet (12, Fig. 10) for the switchdisconnector and the one for the no-load connectors are vented by air sucked into the cabinets by fans and cleaned by filters (20).

Checking the filter element Check the filter paper of the element by inserting a lamp into the element (Fig. 11). Any deterioration is then easily visible.

Replace damaged or deformed elements immediately.

Fig. 9

Replacing the filter element • Unscrew the nuts (21, Fig. 9).

• Remove holder (22).

• Withdraw filter element (20).

• Clean filter element (20) from the inside with dry compressed air (Fig. 10).

Fig. 11

• Insert the filter element and fasten with holder (22, Fig. 9).

The pressure at the nozzle must not exceed 6 bars. The nozzle must be moved up and down in the filter element ca. 3 cm in front of the crinkled paper insert.

Cleaning is completed when all dust has been blown out.

Fig. 10

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OPERATING INSTRUCTIONS RH 400 E Slip ring unit Clean the slip ring unit (Fig. 12) regularly.

• Remove all traces of dirt.

• Clean insulators and check for damage.

• Check condition of slip ring contact surfaces removing all traces of oxydation, beads of molten metal or smouldered parts. Apply a thin layer of contact grease.

• Check carbon brushes for wear.

Fig. 12

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OPERATING INSTRUCTIONS RH 400 E HYDRAULIC SYSTEM 2803913

Hydraulic system - Safety instructions Read and observe: "Inspection and servicing - Safety instructions".

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated.

Shut off the electric motors.

Risk of burning from hot hydraulic components (e.g. hydraulic oil reservoir, cylinders, valves) .

Secure the machine as described under "Securing the machine".

Avoid potentially harmful skin contact with hydraulic oils.

Wear protective gloves and firm protective clothing.

Depressurizing the hydraulic system Hydraulic systems must not be opened unless they are completely depressurized. Even when an excavator is parked on a horizontal surface with the working equipment resting on the ground (Fig. 1) and with its electric drive motors shut off, there may still be a considerable amount of residual pressure in parts of the hydraulic system, e.g. primary pressure resulting from the last movements before immobilization.

Residual pressure disappears only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be depressurized.

Fig. 1

• Locate the system section to be opened.

• Depressurize the system section to be opened, combining the described measures if necessary.

• Open the depressurized system section with care.

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OPERATING INSTRUCTIONS RH 400 E Examples of system sections: 1) working hydraulics 2) precharged return-flow line

Checking the hydraulic oil level / Topping up

Depressurizing

• Bring the hydraulic oil to operating temperature (ca. 50°C).

• Park the excavator on a horizontal surface.

• Park the machine on a reasonably horizontal surface.

• Set the working equipment down on the ground.

• Move all hydraulic cylinders to their central positions.

• Shut off the drive motors.

• Switch on the electrical system.

The oil level must be between the ½ and ¾ marks of the inspection glass (1, Fig. 3).

Section 1: working hydraulics – Shift both control levers repeatedly in all directions (Fig. 2)

Fig. 3

The hydraulic oil level is monitored by the BCS. A warning is displayed on the monitor (Fig. 4) if the hydraulic oil level is too low. Shut off the motors, locate cause and rectify.

Fig. 2

Section 2: return-flow line After shutting down the motors, the precharging pressure decreases rapidly through the precharging valve. The return-flow line can be opened without taking any special measures.

Fig. 4

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OPERATING INSTRUCTIONS RH 400 E

Fig. 7

Fill in hydraulic oil from the service station (Fig. 7).

Fig. 5

Set working equipment down on the ground as shown on the sign (Fig. 5).

The sign (2, Fig. 6) is attached beside the inspection glass (1).

• Unscrew the cap of express coupling (10).

Connect the filling hose of the service vehicle to this coupling.

The hosepipe and its use are described under "Hosepipe for oil and coolant changes".

• Fill in hydraulic oil until the oil level is between ½ and ¾ marks on the inspection glass (1, Fig. 6) (oil grade cf. "Filling quantities - Oil").

• Remove filling hose. The express coupling closes automatically.

• Screw on protective cap.

Fig. 6

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OPERATING INSTRUCTIONS RH 400 E Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) Read and observe: "Inspection and servicing - Safety instructions".

Shut off motors.

Risk of scalding due to hot engine oil.

The hydraulic oil reservoir may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 8

Hydraulic oil can also be filled in through the return-flow filter (Fig. 8).

• Remove cover (3, Fig. 9).

The return-flow filters must be replaced: – when servicing works are being carried out in accordance with the servicing plan; – when the BCS displays a warning on the monitor (Fig. 10). In this case the filter elements (9, Fig. 8) are heavily contaminated; – after repairs of the hydraulic system; – in the event of damage.

Fig. 9

• Fill in hydraulic oil through the opening (Fig. 8) until the oil level is between ½ and ¾ of the inspection glass (oil grade cf. "Filling quantities Oil").

• Before installing the cover (3, Fig. 9), check the sealing ring and replace if damaged.

• Install cover with sealing ring.

Fig. 10

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OPERATING INSTRUCTIONS RH 400 E • Remove cover (3, Fig. 11) with sealing ring (5).

If metal filings are detected, locate cause and rectify. Contact the O&K Service if necessary.

• Remove retaining disk (7).

• Remove cap (8) with sealing rings (10 and 11).

• Check sealing rings for damage, replacing if necessary.

• Withdraw filter element (9) from basket (12).

• Insert a new filter element.

• Install basket (12).

• Insert filter element (9) and cap (8) together with sealing rings (10 and 11).

• Clean magnetic rod (4).

• Install cover (3) together with sealing ring (5).

• Also replace return-flow filter in filter housing (cooling system).

The return-flow filters are located under the cap (30, Fig. 12).

(Cf. "Hydraulic oil return-flow filter / Filter housing (cooling system).

Fig. 11

If a filter element (9) is damaged, remove basket (12) and check / clean.

Fig. 12

• Slacken screws (13); remove clip (14) and washer (15).

• Lift out basket (12) and clean with paraffin oil.

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OPERATING INSTRUCTIONS RH 400 E Bypass valves (hydraulic oil reservoir) Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding due to hot hydraulic oil.

The hydraulic oil reservoir may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

• The sieves of the bypass valves in the filter housing (cooling system) must also be cleaned.

The bypass valves are located under the cover (30, Fig. 15).

(Cf. "Bypass valves/Filter housing (cooling system").

Cleaning the filter sieves • Remove cover (3, Fig. 13 and/or Fig. 14) together with sealing ring (5, Fig. 14).

• Unscrew screws (22).

Fig. 14

• Remove holder (26) and sieve (21).

• Clean sieve (21) in white spirit or paraffin oil, or replace if necessary.

• Remove bypass valve (23) together with sealing ring (24).

• Check sealing ring for damage, replacing if necessary.

• Re-insert bypass valve (23) with sealing ring (24).

• Fasten sieve (21) with holder (26).

• Install cover (3, Fig. 13) together with sealing ring (5).

Fig. 15

Fig. 13

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OPERATING INSTRUCTIONS RH 400 E Replacing the hydraulic oil return-flow filters (filter housing - cooling system) Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

The hydraulic oil reservoir may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig.17

Replace the return-flow filters together with the return-flow filters in the hydraulic oil reservoir.

• Remove cover (30, Fig. 16 and/or Fig. 17) together with sealing ring (36, Fig. 17).

• Remove cap (33) together with sealing rings (32 and 37).

• Withdraw filter element (35).

• Check sealing rings for damage, replacing if necessary.

• Insert a new filter element (35) and install cover (30) together with sealing rings (32 and 37).

• Clean magnetic rod (31).

• Install cover (30) together with sealing ring (36).

Fig.16

If metal filings are detected, locate the cause and rectify.

Contact the O&K Service if necessary.

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OPERATING INSTRUCTIONS RH 400 E Bypass valves (filter housing - cooling system)

• Remove cover (30, Fig. 18 and/or Fig. 19) together with sealing ring (36, Fig. 19).

• Unscrew screws (22).

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

The hydraulic oil reservoir may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

• Remove holder (26) and sieve (21).

• Clean sieve (21) in white spirit or paraffin; replace if necessary.

• Withdraw bypass valve (23) together with sealing ring (24).

• Check sealing ring for damage, replacing if necessary.

• Re-install bypass valve (23) together with sealing ring (24).

• Fasten sieve (21) with holder (26).

• Install cover (30) together with sealing ring (36).

Cleaning the filter sieves Clean the bypass valves together with the bypass valves in the hydraulic oil reservoir.

Fig. 18 Fig.19

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OPERATING INSTRUCTIONS RH 400 E Breather filters Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

The hydraulic oil reservoir may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

High-pressure filter for working hydraulics To filter the hydraulic oil at the high-pressure end of the working hydraulic system, the machine is equipped with eight high-pressure filters (Fig. 21).

The filters are located between the transfer gearboxes.

Replacing the filter elements The breather filters (20, Fig. 20) ensure venting of the hydraulic oil reservoir at varying hydraulic oil levels.

Fig. 21

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

Fig.20

• Unscrew screws (21). Remove holder (22) and withdraw filter element (20).

• Check filter element, replacing if necessary.

The filter housings may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

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OPERATING INSTRUCTIONS RH 400 E Checking / cleaning the filter elements

Replacing the filter elements

• Unscrew drain plug (11, Fig. 22) and drain the hydraulic oil from the filter housing (9). (place a suitable recipient under the filter housing)

• Remove the filter element as described under "Checking the filter element".

• Unscrew filter housing (9).

• Disengage filter element (15) with a slight turn from its retaining catch and withdraw from filter housing (9).

• Clean filter element (15) in white spirit or paraffin oil.

Replace filter element (15) if it is damaged.

• Clean filter housing (9) and sealing surfaces on filter head with white spirit or paraffin oil.

• Insert new filter element into filter housing (9) and refit to filter head with new, lightly oiled sealing rings (10 and 14) and new retaining ring (13).

• Check for leaks after putting the filter into operation.

• Clean filter housing (9) and sealing surfaces on filter head with white spirit or paraffin oil.

• Check seals (10 and 14), replacing if necessary.

• Reassemble the filter element in the reverse order.

• Check for leaks after putting the filter into operation.

Fig. 22

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OPERATING INSTRUCTIONS RH 400 E High-pressure filter for the servo circuits The excavator is equipped with one high-pressure filter (1, Fig. 23) for each servo circuit. The filters are located above the transfer gearboxes.

Checking / cleaning the filter elements • Remove filter housing (5, Fig. 24) and pour out the used oil.

• Withdraw filter element (6) from filter housing (5).

• Clean filter element (6) in white spirit or paraffin oil.

Replace filter element if it is damaged.

• Check seals (7 and 8), replacing if necessary.

• Clean filter housing (5) and sealing surfaces at filter head with white spirit or paraffin oil.

• Reassemble the filter element in the reverse order.

• Check for leaks after putting the filter into operation.

Fig. 23

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig.24

Replacing the filter elements • Remove the filter elements as described under "Checking the filter elements".

• Install new filter element (6, Fig. 24) and reassemble with new, slightly oiled sealing rings (7 and 8).

• Check the high-pressure filter for leaks after putting it into operation.

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OPERATING INSTRUCTIONS RH 400 E High-pressure filters for pump-flushing circuit The excavator has a high-pressure filter for each flushing circuit (2, Fig. 25). The filters are located above the transfer gearboxes.

Checking / cleaning the filter elements • Remove filter housing (5, Fig. 26) and pour out the used oil.

• Withdraw filter element (6) from filter housing (5).

• Clean filter element (6) in white spirit or paraffin oil.

Replace filter element if it is damaged.

• Check seals (7 and 8), replacing if necessary.

• Clean filter housing and sealing surfaces at filter head with white spirit or paraffin oil.

• Reassemble the filter element in the reverse order.

• Check for leaks after putting the filter into operation.

Fig. 25

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 26

Replacing the filter elements • Remove filter elements as described under "Checking the filter elements".

• Install new filter element (6, Fig. 26) and reassemble with new, slightly oiled sealing rings (7 and 8).

• Check the high-pressure filter for leaks after putting it into operation.

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OPERATING INSTRUCTIONS RH 400 E High-pressure filters for feeding circuits/slewing gear pumps The excavator has one high-pressure filter (3, Fig. 27) for each feeding circuit. The high-pressure filters are located above the transfer gearboxes.

Checking / cleaning the filter elements • Unscrew drain plug (11, Fig. 28) and drain the hydraulic oil from the filter housing (9).

• Unscrew filter housing (9).

• Withdraw filter element (15) from filter housing (5).

• Clean filter element (15) in white spirit or paraffin oil.

• Replace the filter element if it is damaged.

• Clean filter housing (9) and sealing surfaces on filter head with white spirit or paraffin oil.

• Check seals (10 and 14), and replace if necessary.

• Re-assemble the filter element in reverse order.

• Check for leaks after putting the filter into operation.

Fig. 27

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig.28

Replacing the filter elements • Remove filter elements as described under "Checking the filter elements".

• Install new filter element (15, Fig. 28) and reassemble with a new, lightly oiled sealing rings (10 and 14).

• Check the high-pressure filters for leaks after putting them into operation.

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OPERATING INSTRUCTIONS RH 400 E High-pressure filters for slewing circuit Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Each of the six slewing circuits is equipped with a high-pressure filter. The high-pressure filters are mounted to the left and right of the slewing gearboxes.

The high-pressure filters (1, Fig. 29) cannot be cleaned.

If metal filings enter a slewing circuit, the relevant high-pressure filter (1) must be replaced.

Fig. 29

• Loosen flange (2) and remove the contaminated high-pressure filter.

• Install a new high-pressure filter.

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OPERATING INSTRUCTIONS RH 400 E Changing the hydraulic oil Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors.

Risk of scalding from hot hydraulic oil.

The hydraulic oil reservoir may also be hot.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Never start up the drive motors when the hydraulic oil reservoir is empty.

Irreparable damage can be caused to the hydraulic pumps by allowing them to run dry.

Drawing off the hydraulic oil Draw off the hydraulic oil with the service station (Fig. 30).

Fig. 30

• Bring the hydraulic oil to operating temperature (ca. 50 °C).

• Retract the hydraulic cylinders as far as possible and set the working equipment down on the ground.

• Shut off the engines.

• Unscrew cap of express coupling (10).

• Connect filling hose of service vehicle.

The hosepipe and its use are described under "Hosepipe for oil and coolant changes".

• Remove the filling hose. The express coupling closes automatically.

• Screw on protective cap.

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OPERATING INSTRUCTIONS RH 400 E Cleaning the hydraulic oil reservoir

Risk of explosion Read and observe: "Inspection and servicing - Safety instructions".

Shut off the motors Use no white spirit, paraffin oil or other solvents for cleaning purposes.

Use diesel fuel or special flushing oil.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

Discard contaminated hydraulic oil separately from other waste without polluting the environment.

• Place a collecting recipient for the flushing oil under the drain plug (1, Fig. 32) of the hydraulic oil reservoir.

• Unscrew drain plug (1).

• Clean the inside of the hydraulic oil reservoir with diesel fuel or flushing oil.

• Remove all deposits and all cleaning-agent residues thoroughly.

• Screw drain plug (1) in again.

• Refit cover (3, Fig. 31).

• Draw off hydraulic oil as described under "Drawing off the hydraulic oil".

• Remove cover (3, Fig. 31).

• Remove return-flow filter.

Fig. 32

Fig. 31

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OPERATING INSTRUCTIONS RH 400 E Filling in hydraulic oil Fill in hydraulic oil with the service station (Fig. 33).

• The oil level is also monitored by the BCS and displayed on the monitor (Fig 35).

• Vent the hydraulic system.

• Check the oil level in the hydraulic oil reservoir and top up if necessary.

• Unscrew the hosepipe. The express coupling closes automatically.

• Screw on protective cap.

Fig. 33

• Unscrew cap of express coupling (10).

The hosepipe and its use are described under "Hosepipe for oil and coolant changes".

• Connect filling hose of service vehicle.

Fill in hydraulic oil until the oil level is between ½ and ¾ of the inspection glass (1, Fig. 34) (oil grade cf. "Filling quantities - Oil").

Fig. 35

Hydraulic oil can also be filled in through the return-flow filter.

• Remove cover (3, Fig. 36).

• Fill in hydraulic oil until the oil level is between ½ and ¾ of the inspection glass (1, Fig. 34) (oil grade cf. "Filling quantities - Oil").

Fig. 34

Fig.36

• Vent the hydraulic system.

• Check the oil level in the hydraulic oil reservoir and top up if necessary.

• Install cover (3, Fig. 36).

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BI015806

OPERATING INSTRUCTIONS RH 400 E Venting the hydraulic system Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented • after assembly on site and prior to initial commissioning, • before each recommissioning of the excavator, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes, • after each hydraulic oil change, • after replacement of hoses or lines.

Venting the hydraulic components – Hydraulic pumps and hydraulic motors (with electric motors shut off).

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions.

– Hydraulic cylinder Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Figs. 37 and 38) must be either completely retracted or completely extended.

Fig. 38

Always admit oil first to that side of the cylinder where the piston (2) is. This is • the piston-side port (3) when the piston rod is retracted (1, Fig. 37), • the rod-side port (4) when the piston rod is extended (1, Fig. 38).

If, for assembly reasons, the piston rod is in middle position, admit oil first to the piston-side port (4).

When oil is admitted for the first time to the cylinder, the oil flow must be reduced. Therefore extend or retract the piston rod as slowly as possible.

The screws/nozzles of the following components must be opened until oil emerges bubble-free from the opening: Always vent only the system section that has been opened.

– the travel brake valve at the venting screw, – the oil cooler manifold at the mini-measuring ports, – the servo system at the venting screws of the control blocks (under the servo caps), – the intake line at the venting screw (with drive motors stationary).

Fig. 37

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BI015806

OPERATING INSTRUCTIONS RH 400 E Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

Shut off the motors.

Never start cleaning work until the cooler fan blades have stopped turning.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

Allow the hydraulic oil cooler to cool down.

Wear protective gloves and firm protective clothing.

Cleaning The hydraulic oil coolers are located in the oil cooler module.

Clean the hydraulic oil coolers at regular intervals.

• Shut off the motors.

• Remove any accumulated dirt.

• Clean the fan blades (2).

• Clean the radiators with a jet of water or compressed air from outside to inside.

• Leave hydraulic oil coolers to dry.

• Check the hydraulic motors (1) for free movement.

In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan.

The speeds of the fan motors (1, Fig. 39) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C.

Fig. 39

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BI015806

OPERATING INSTRUCTIONS RH 400 E Extract from the German acceptance regulations

Pressure accumulator - Emergency lowering To permit the working equipment to be lowered in an emergency, the machine is equipped with a pressure accumulator (1, Fig. 40).

The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Fig. 40

Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

For measuring the precharge pressure in the pressure accumulator, observe the instructions set out in the booklet "Filling and testing device for pressure accumulators" annexed to this documentation.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Group

Inspections prior to commissioning at the factory

II p ≥ l bar and p·x l ≤ 200

Pressure testing Prototype and pressure test certified by the manufacturer

at the place of use Inspection certificate (Check of correctness and correct installation) issued by an expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and fluid.

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BI015806

OPERATING INSTRUCTIONS RH 400 E PUMP TRANSFER GEARBOX Read and observe: "Inspection and servicing - Safety instructions".

Shut off the electric motors The gearbox housings may also be hot.

Secure the machine as described under "Securing the machine".

Avoid potentially harmful skin contact with gearbox oil.

Wear protective gloves and firm protective clothing.

2803914

Drawing off oil Draw off gearbox oil with the service station (Fig. 2) through – express coupling (4) for the lefthand pump transfer gearbox – express coupling (5) for the righthand pump transfer gearbox.

Checking the gearbox oil level / Topping up Park the machine as described under "Securing the machine".

• Screw out dipstick (1, Fig. 1), wipe clean and screw back in place.

• Screw out dipstick (1) a second time.

The oil level must reach at least the lower mark on the dipstick (1); top up if necessary.

• Screw dipstick (1) back in place.

Fig. 2

• Unscrew cap of express coupling and connect hosepipe of service vehicle.

The hosepipe and its use are described under "Hosepipe for oil and coolant changes".

• Remove hose when the oil has been drawn off.

The coupling closes automatically.

• Screw on protective cap.

Fig. 1

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BI015806

OPERATING INSTRUCTIONS RH 400 E Filling in oil Fill in gearbox oil with the service station (Fig. 3) through – express coupling (4) for the lefthand pump transfer gearbox – express coupling (5) for the righthand pump transfer gearbox.

Fig. 4

The oil level must reach at least the upper mark on the dipstick (1, Fig. 4).

• Remove hose when oil has been filled in. The coupling closes automatically.

• Screw on protective cap.

Fig. 3

• Unscrew cap of express coupling and connect hosepipe of service vehicle.

The hosepipe and its use are described under "Hosepipe for oil and coolant changes".

Oil can also be filled in through the bore in the breather valve (2, Fig. 5).

The oil level must reach the upper mark on the dipstick (1, Fig. 4).

Fig. 5

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BI015806

OPERATING INSTRUCTIONS RH 400 E Gearbox venting

Pre-chamber

The gearbox is vented through the breather valve (2, Fig. 6).

Checking the oil level

Clean breather valve (2) in accordance with the servicing plan.

• Unscrew breather valve (2), clean with white spirit or paraffin oil, and blow dry with compressed air.

• Screw breather valve (2) back in place.

Check the oil level in the pre-chambers at regular intervals.

Unscrew plugs (4, Fig. 7 and 4, Fig. 8). The oil level must reach the lower edge of the opening.

Top up if necessary by unscrewing overflow inserts (3) and filling in oil through the opening until it emerges at the plug opening.

If oil leaks out of one of the overflow inserts (3, Fig. 7 or 3, Fig. 8), the external sealing of the relevant hydraulic pump must be checked.

Fig. 6

Fig. 7

Fig. 8

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BI015806

OPERATING INSTRUCTIONS RH 400 E SLEWING GEARBOX Read and observe: "Inspection and servicing - Safety instructions".

Shut off the electric motors.

The gearbox housings may also be hot.

Secure the machine as described under "Securing the machine".

Avoid potentially harmful skin contact with gearbox oil.

Wear protective gloves and firm protective clothing.

Fig. 1

2803915

Changing the gearbox oil Draining off oil • Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Fig. 2

• Unscrew cap from automatic drain valve.

Gearbox - Checking the oil level / Topping up • Park the machine as described under "Securing the machine".

• Check the oil level visually at the expansion tanks (6, Fig. 1). The expansion tanks must be 1 abt. /3 full of gearbox oil; top up if necessary.

• Connect hose to drain valve (9, Fig. 2) and drain off oil completely. Unscrewing the cover (8, Fig. 1) allows the used oil to drain off more readily.

The hosepipe and its use are described under "Hosepipe for oil and coolant changes".

The oil level is visible from outside (light/dark area).

The hosepipe (5, Figs. 1 and 2) connects the gearbox (3, Fig. 2) with the expansion tank (6, Fig. 1).

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BI015806

OPERATING INSTRUCTIONS RH 400 E The drain valve (9, Fig. 3) is accessible from the undercarriage.

• Remove hose. The drain valve closes automatically.

• Screw on protective cap.

Gearbox venting The gearbox is vented through the cap (8, Fig. 4).

Venting bore Check venting bore in cap (8) for contamination; clean if necessary.

Slewing gear neck Grease bearing above lubricating nipple (11, Fig. 5) at regular intervals.

Fill in grease until used grease emerges at the points marked with an arrow.

Fig. 3

Filling in new oil / Topping up • Unscrew cap (8, Fig. 4) and fill in new oil through expansion tank (6). The expansion tank must be ca. 1/3 full of gearbox oil.

Fig. 5

Fig. 4

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BI015806

OPERATING INSTRUCTIONS RH 400 E TRAVEL GEARBOXES Read and observe: "Inspection and servicing - Safety instructions".

Shut off the electric motors.

Risk of scalding from hot gearbox oil.

The gearbox housings may also be hot.

Secure the machine as described under "Securing the machine".

Avoid potentially harmful skin contact with gearbox oil.

Wear protective gloves and firm protective clothing.

Travel gearbox - Checking the oil level / Topping up Park the machine as described under "Securing the machine".

The oil level must be visible in the level gauge (4, Fig. 1); top up with gearbox oil if necessary.

2803916

Travel gearbox - Changing the oil Park the machine as described under "Securing the machine".

Main gearbox - Draining off oil Move the excavator until the screw plugs (1, 2 and 3, Fig. 2) are in the position shown in the diagram: – screw plug (1) in horizontal position – screw plug (2) in bottom position – screw plug (3) at ca. 23° from horizontal (2 o'clock position).

• Place a collecting recipient for used oil under the main gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

• Unscrew plug (2) and drain off oil completely.

Slackening plug (3) allows the oil to run out more readily.

• Clean plugs (2 and 3).

• Screw in plug (2).

Fig. 1 Fig. 2

Preliminary gearbox - Draining off oil • Place a collecting recipient for used oil under the preliminary gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

• Unscrew plug (5, Fig. 1) and drain off oil completely.

• Clean plug (5) and screw back in place.

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BI015806

OPERATING INSTRUCTIONS RH 400 E Main and preliminary gearbox - Filling in oil

Pre-chamber - Draining off oil

Move the excavator until the screw plugs (1 and 3, Fig. 3) are in the positions shown in the diagram:

• Place a collecting recipient for used oil under the pre-chamber. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

• Unscrew plugs (1, Fig. 5), clean, and screw back into place.

• Unscrew plugs (1 and 3). Fill in oil through opening in plug (3) until it flows out of the opening of plug (1) or the oil level is visible in the level gauge (4, Fig. 4).

Pre-chamber - Filling in oil • Unscrew plugs (2, Fig. 5) and overflow (3).

• Fill in oil through the opening of the overflow (3) until it flows out of the opening of the plug (2).

Fig. 3

Fig. 5

Fig. 4

If oil emerges from the overflow (3, Fig. 5), the external sealing of the driving motor must be checked.

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BI015806

OPERATING INSTRUCTIONS RH 400 E CRAWLER TRACKS

2803917

Cleaning

Track rollers

Clean tracks, track and support rollers, sprockets and idlers at regular intervals and whenever necessary. Cleaning is especially important in winter to prevent

The track rollers (2, Fig. 1) have a permanent oil filling.

• the tracks from being thrown off

Check the oil level in the expansion tanks (3, Fig. 2) regularly.

• oil from leaking out of track and support rollers, sprockets and idlers • excessive wear and • track breakage.

Fig. 2

The oil level is visible from outside; it must reach the upper edge of the holder (arrow, Fig. 2). Top up oil if necessary.

Fig. 1

Topping up oil

To clean the tracks:

Unscrew cover (2, Fig. 2) of expansion tank (3) or protective cap of express coupling (4).

Pour oil into the expansion tank (3) or fill through express coupling (4) until the level reaches the upper edge of the holder (arrow, Fig. 3). Close expansion tightly and/or screw protective cap back in place on express coupling (4).

• raise one side of the excavator with the working equipment and let crawler track turn; • clean side member of track support; • clean track and support rollers (2 and 1, Fig. 1) thoroughly; • clean sliding planes on idler guides.

Cleaning Check venting bore in cover (2, Fig. 2) for accumulated dirt and clean, if necessary.

Inspect all track rollers visually for leaks and free movement.

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BI015806 BA 6090ACFS (2 803 900.01)-EN

Carbody-crawler frame fastening bolts, replace The fastening bolts as well as the tempered disks (1 and 2, Fig. 2a) must be replaced any time that they are removed or after 30.000 operating hours of the machine.

Do not re-use removed bolts.

To tighten these bolts to the prescribed tightening torque, heavy hydraulically driven equipment is necessary.

For more detailed information see: - Service Manual, chapter 2.9 "Tightening Procedure for bolts" for tightening torques used, - Service Manual, chapter 3.2.1 "Torque Tools" for description of hydraulic torque tools, - Service Manual, chapter 4 “Undercarriage” for bolts replacement procedure.

Fig. 2a

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153a

BI015806

OPERATING INSTRUCTIONS RH 400 E Track roller fastening

Track tensioner

Check fastening screws (4, Fig. 3) at regular intervals for tightness:

Design

• Tighten the screws with a torque wrench to the prescribed tightening torque (cf. "Tightening torques" table).

The tracks are tensioned by means of the hydraulic pressure built up during travelling. Figs. 4 and 5 show parts of the track and the tensioner:

Fig. 4 Fig. 3

Support rollers The support rollers (1, Fig. 3) have a permanent oil filling.

Inspect all support rollers visually at regular intervals for leaks and free movement.

Support roller fastening

1 Crawler track 2 Idler 3 Drive sprocket 4 Support roller 5 Pressure accumulator 6 Pressure cylinder 7 Pressure limiting valve 8 Track roller 9 Mini-measuring port (minimess) 10 Stopcock 11 Check valve

Check fastening screws (3, Fig. 3) regularly for tightness: • Tighten the screws with a torque wrench to the prescribed tightening torque (cf. "Tightening torques" table).

Fig. 5

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BI015806

OPERATING INSTRUCTIONS RH 400 E Technical data Track tensioning pressure ca. 60 bars Pressure limiting valve 400 bars Gas pressure in pressure accumulator (nitrogen filling pressure) 48 bars

Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Function The tensioning system is under a permanent pressure of ca. 60 bars which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the electric motors are running.

Retensioning is not required.

The tracks can be slackened for cleaning or repair work.

To do so: • stop the electric motors • open both pressure limiting valves (7, Fig. 6) to slacken the tracks.

• When the work is finished, screw the pressure limiting valves (7) down to the limit stop.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Fig. 6

The pressure limiting valves (7) are preset to a pressure of 400 bars and sealed in this position.

This lead seal must not be removed and the pressure setting of 400 bars must not be changed.

The stopcocks (10) are permanently open. They must not be closed except for dismantling of the pressure accumulators (5).

For the rest, the track tensioner is maintenancefree.

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BI015806

OPERATING INSTRUCTIONS RH 400 E Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

The above pressure tests are required to ensure the efficient functioning of the track tensioner. They are not a substitute for the inspections specified in the "Pressure Vessel Regulations".

Group IV p ≥ l bar p·x l ≥ 1000

Before checking the gas charging pressure (nitrogen filling pressure) in the pressure accumulator, the track must first be slackened, i.e. the hydraulic part of the tensioning system must be depressurized. Cf. "Function".

For measuring the precharge pressure in the pressure accumulator, observe the instructions set out in the booklet "Filling and testing device for pressure accumulators" annexed to this documentation.

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Internal inspection: every 10 years for noncorrosive fluids; otherwise pressure testing every 5 years: every 10 years by an expert

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BI015806

OPERATING INSTRUCTIONS RH 400 E Idlers

Greasing the idler guides

The idlers have a permanent oil filling.

Grease the idler guides (arrow, Fig. 8) at regular intervals in accordance with the inspection plan.

Inspect the idlers visually for leaks after each working shift. If leaks are detected, check oil level.

Checking the oil level The checking plug (arrow, Fig. 7) is located on the inside of the idler.

Fig 8

• Withdraw protective cap from greasing nipple.

• Clean greasing nipple.

• Press filling nozzle of grease gun onto greasing nipple.

Fig. 7

To check the oil level, the checking plug must be ca. 30° above the horizontal axis (2 o'clock position) (Fig. 7). Unscrew the checking plug. The oil level must reach the lower edge of the opening.

• Inject grease until the fresh grease emerges from the idler guide.

• Wipe off used grease with cleaning rags.

• Place protective cap back on greasing nipple.

If the oil level is below the opening, move the excavator until the plug opening is in the horizontal plane (3 o'clock position). If no oil emerges from the opening in this position, it is essential to check the idler seals.

Work can be continued temporarily with the excavator if the oil level is topped up and checked at short intervals.

Filling in oil The checking-plug opening must be in the same position as for oil-level checking (2 o'clock position). Fill in oil up to the lower edge of the opening.

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BI015806

OPERATING INSTRUCTIONS RH 400 E SLEWING RING Read and observe: "Inspection and servicing - Safety instructions.

Shut off the electric motors.

Wear protective gloves and firm protective clothing.

2803918

Internal gearing The internal gearing (1, Fig. 2) and the pinion (2) are enclosed in a housing (3, Fig. 3). The housing forms a grease-filled trough in which the pinion of the slewing mechanism moves.

Slewing ring - Instructions The grease filling must be replaced: – when repairs have been carried out on the slewing ring, the slewing ring seals or the slewing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the slewing ring.

Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

Fig. 2

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 1). The amount of grease used up during operation is replenished by the central lubricating system.

The housings have a check opening which is closed with a cover (2, Fig. 3). For checking, the cover must be removed.

Bearing races The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing .

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 1).

Fig. 3

Fig. 1

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BI015806

OPERATING INSTRUCTIONS RH 400 E Slewing ring - Checking the grease filling Read and observe: "Inspection and servicing - Safety instructions.

Shut off the motors Wear protective gloves and firm protective clothing.

Slewing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Add grease when • the housing has been replaced

At regular intervals

• old grease has been removed in the course of other work.

• check internal gearing and teeth of slewing mechanism pinion for condition

Always fill in fresh grease by hand.

• check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm of grease over its whole circumference (Fig. 4).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued slewing movements.

Risk of accidents. Never slew the superstructure when refilling grease.

Slewing ring - Checking the screws for tightness The fastening screws of the slewing ring in the superstructure and the undercarriage are tightened with their respective check torque (cf. "Tightening torques" table).

When these values are reached, the fastening screws are perfectly tight.

Loosen slack screws before tightening them with a torque wrench to the prescribed torque (cf. table "Tightening torques and angles).

Fig. 4

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BI015806

OPERATING INSTRUCTIONS RH 400 E CENTRAL LUBRICATING SYSTEM

2803919

Design and function The excavator is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those set out in the "Lubricating chart - Grease".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and the engines are running. All greasing points connected to the system are greased at regular intervals.

The grease pumps (2, Fig. 1) with attached grease container pump grease through the greasing lines to the main distributors.

Fig. 2

As soon as the grease container is empty, the BCS (Fig. 3) gives a warning signal. In the event of a fault, the "dumping" function is switched off automatically after 15 min.

Work can be continued when the grease container is filled with grease.

Fig. 1

The grease pumps (2) with the grease container are located on the superstructure.

The lubricating system control elements are located on the panel (Fig. 2).

Fig. 3

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BI015806

OPERATING INSTRUCTIONS RH 400 E Filling the grease container

Breather filter

Fill grease the container through the service station (Fig. 4).

Check/change the breather filter at regular intervals.

The hosepipe and its use are described under "Hosepipe for oil and coolant changes".

• Unscrew wing nut (1, Fig. 5).

• Switch on the display system with the toggle switch (33, Fig. 4).

• Check filter element. Replace if necessary.

• Unscrew cap of express coupling (11).

• Withdraw cover (7, Fig. 6) and filter element (8).

• Re-install breather filter.

• Connect filling hose of service vehicle.

• The indicator lamp (34) lights up when the grease container is full.

• Remove hose.

The express coupling closes automatically.

• Screw on protective cap.

Fig. 5

Fig. 4

Fig. 6

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BI015806

OPERATING INSTRUCTIONS RH 400 E Checking the greasing pressure Once a week, check that the oil pressure indicated by the pressure gauge (4, Fig. 7) is 28 - 30 bars.

This oil pressure is increased to 300 350 bars greasing pressure by means of a pressure intensifier.

If this is not the case, switch off the electric motors and check the central lubricating system.

If the lubricating pressure is lower, not all greasing points are supplied with grease.

Unblocking a grease line Put the excavator back into operation only when the lubricating system is working properly and the unloaded working equipment has been actuated for ca. 5 min. This is necessary to ensure that sufficient grease is supplied to the cylinder bearings.

Cleaning the grease sieve Check the grease sieves at regular intervals for contamination and clean if necessary.

The grease sieves must also be cleaned after an obstruction in one of the greasing points.

Cleaning • Loosen plug (5, Fig. 7).

• Withdraw sieve and clean with white spirit or paraffin oil.

• Re-insert sieve and fasten with plug (5).

Fig. 7

Higher greasing pressures may cause a greasing line to burst.

Always replace or refill the grease container in good time, as air otherwise penetrates into the lubricating system and causes trouble.

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BI015806

OPERATING INSTRUCTIONS RH 400 E AIR CONDITIONER

2803923

Venting filter

Emptying the dust collector

The driver's cab is ventilated by air sucked into the cab by two fans and a filter for each fan (Fig. 1).

• Loosen wing nut (15, Fig. 1) • Remove dust collector (14, Fig. 2 together with insert (16).

• Draw insert (16) out of dust collector (14) and empty.

• Slide insert (16) back into dust collector (14).

When re-asssembling the collector make sure that the opening in insert (16) is at the top.

Pay attention to the TOP marking when refitting the dust collector.

Fig. 1

Filter element Cleaning the pre-filter

• Remove dust collector (14, Fig. 1).

• Unscrew wing nut (11, Fig. 1).

• Unscrew wing nut (17, Fig. 2).

• Remove cover (12) and housing (13).

• Clean housing (13).

• Withdraw filter element (18) without losing the washer under nut (17).

• Re-assemble the pre-filter

• Replace or clean filter element (18).

• Refit dust collector (14).

Fig. 2

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BI015806

OPERATING INSTRUCTIONS RH 400 E Checking and cleaning the filter element Check the filter paper of the element by inserting a lamp into the element (Fig. 3). Any deterioration is then easily visible.

Replace damaged or deformed elements immediately.

Fig. 4

Blow filter element (Fig. 4) dry with compressed air by moving the compressed-air nozzle up and down inside the element.

The pressure at the nozzle must not exceed 6 bars.

Fig. 3

Check the element seal. If the seal is damaged, replace also the filter element.

Cleaning with compressed air allows the filter element to be re-used immediately.

Cleaning is completed when all dust has been blown out.

Never clean a filter element by beating it against hard objects.

Replace the main filter element after 1000 operating hours or 3 cleaning cycles, but in any case after one year of operation at the latest.

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BI015806

OPERATING INSTRUCTIONS RH 400 E OTHER MAINTENANCE WORK

2803920

Cooling system

Never clean radiators with a wire brush or similar hard objects.

To remove stubborn dirt, remove radiator and clean.

Clean the radiators at regular intervals.

• Shut off the motors.

• Remove any accumulated dirt.

• Clean the fan blades (2, Fig. 1).

• Clean the radiators with a jet of water or compressed air from outside to inside.

• Leave radiators to dry.

• Check hydraulic motors (1) for free movement.

Fig. 1

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BI015806

OPERATING INSTRUCTIONS RH 400 E RAMP-TYPE LADDER To allow the ramp-type ladder (Fig. 1) to be lowered in an emergency, the ladder mechanism is equipped with a pressure accumulator (1, Fig. 2).

The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

2803921

Guide pulleys and locking bolt Lubricate the bearings (1, Fig. 3) of the guide pulleys at regular intervals and apply a few drops of oil on the locking bolt (2).

Fig. 3 Fig. 1

Fig. 2

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OPERATING INSTRUCTIONS RH 400 E Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

For measuring the precharge pressure in the pressure accumulator, observe the instructions set out in the booklet "Filling and testing device for pressure accumulators" annexed to this documentation.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Group III p ≥ l bar and p·x l ≥ 200 bars

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and operating fluids.

p·x l ≤ 1000 bars

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BI015806

OPERATING INSTRUCTIONS RH 400 E ON-BOARD CRANE Monitoring, warning and control elements

2732110

Checking the on-board crane Extract from the inspection and testing regulations The on-board crane is approved in accordance with the Accident Prevention Regulations for Cranes (VBG 9, applicable only in Germany).

The on-board crane must be inspected regularly in accordance with the regulations in force in the country of use.

Fig. 1

1 2 3 4 5 6 7 8 9 10 11 12 21 22 23 24

Monitoring lamp - alternator Warning lamp - engine oil pressure Warning lamp - engine temperature Monitoring lamp - air filter Key-switch - electrical system ON/OFF Button - engine start Monitoring lamp - preheating system (option) Button - speed variation Monitoring lamp - crane in operation Warning lamp - malfunction Button - EMERGENCY STOP Button - emergency lowering of winch Control lever - extending and retracting of boom extension Control lever - folding the boom Control lever - slewing the boom Control lever - winch ON/OFF

The inspections must be requested by the user of the crane. The expert or specialist entrusted with the inspection can be appointed at the user's discretion.

The user must ensure, however, that the appointed person meets the requirements.

The user is obliged to make available all documents required for the inspection and to ensure the smooth running of the inspection. He is furthermore obliged to provide, if required, crane operators and auxiliary personnel and the required test loads.

The result of the inspection is to be documented in an inspection record signed by the inspector.

The inspection record serves as proof on the part of the user that the inspections have been carried out. The inspection record must contain all data required for crane identification and for the performance of further regular inspections.

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BI015806

OPERATING INSTRUCTIONS RH 400 E Drive unit

Air-intake system

The drive unit comprises:

Never start up the engine when the air filter (6, Fig. 3) is removed.

– crane engine – hydraulic system Crane engine

Hydraulic system

See operating instructions for the crane engine.

See crane operating instructions.

• Fill up fuel tank through filler (5, Fig. 2) after each deployment.

• Prior to each deployment, check the hydraulic oil level at the inspection glass (12, Fig. 2); top up if necessary.

• Prior to each deployment check the engine oil level with the dipstick (1); top up if necessary.

• Regularly, at least once a year – – – – –

change engine oil replace engine oil filter (2) check / replace air filter (6, Fig. 3) replace fuel prefilter (3, Fig. 2) replace fuel filter (4)

• Check batteries (7) and cable connections at regular intervals.

• Check contamination of hydraulic oil filter regularly at contamination indicator (arrow, Fig, 2).

• Regularly, but at least once a year – replace the hydraulic oil filter (14) and the breather filter (13).

On-board crane Servicing • Lubricate all bearings regularly and as required, and spray slewing ring with a graphite spray (Fig. 4) 1234-

bearing joint (column/boom) cylinder bearing slewing ring

4 lube points 2 lube points 5 lube points

Fig. 2

Fig. 3

Fig. 4

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OPERATING INSTRUCTIONS RH 400 E PUTTING OUT OF OPERATION AND RECOMMISSIONING

2804045

Putting the excavator out of operation

Recommissioning

• Park the excavator on firm and level ground.

• Remove the covers.

• Set the working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.

• Degrease / clean all protected components.

• Set all control element to "0".

• Check grease filling in grease container.

• Clean the machine.

• Oil level

• Lock the superstructure • Carry out a visual inspection of the excavator.

• Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.

• Protect all bright metal parts (e.g. piston rods) from rust and dirt.

• Remove the batteries; cf. "Battery storage".

• Secure the machine against unauthorized starting by: – – – – –

withdrawing the key from the key-switch setting the battery main switch to OFF setting the switch-disconnector to OFF locking the cab door securing all lockable hatches.

• Cover up all openings

• Check track tension (visual inspection) - slewing gearbox - pump transfer gearbox - travel gearboxes - engine (on-board crane)

• Check oil level in hydraulic oil reservoir.

• Check battery acid density and level.

• Install batteries and reconnect.

• Set battery main switch to ON – set switch-disconnector to ON. • Function checks: - superstructure holding brake - track brake - lighting system - signalling equipment • Vent the hydraulic system.

Immobilization for more than 3 months • Have gearbox oil and hydraulic oil analyzed.

Battery storage During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C. Observe the following points with regard to maintenance: • Clean the batteries.

• Check the acid density and the electrolyte level of the battery every two weeks.

• Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.

• Keep the batteries clean and dry on the outside.

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OPERATING INSTRUCTIONS RH 400 E NOTES

2804180

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OPERATING INSTRUCTIONS RH 400 E

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BI015806

OPERATING INSTRUCTIONS RH 400 E PART 4 - REPAIR WORK

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2804054

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS RH 400 E

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OPERATING INSTRUCTIONS RH 400 E Repair work - Safety instructions

2804219

Operating instructions

Prestressed units

Never carry out repair work without having read and understood the operating instructions.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Never open defective prestressed units but replace them as an entirety.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

The operating manual contains no information on this point.

Repair personnel Repair personnel must have knowhow and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from O&K Mining.

Working in greater heights Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Dismantling components Never do dismantling while the machine is at operating temperature.

Oils, greases, brake fluid or coolants may have a high temperature and result in burning or scalding.

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate reassembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

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OPERATING INSTRUCTIONS RH 400 E

Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of O&K. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibration-insulation material.

Never start up the drive engines while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

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OPERATING INSTRUCTIONS RH 400 E Fire and Explosion Hazard Safety Instructions Prior to commencing work, make yourself familiar – with the national and corporate rules for the prevention of accidents. Pay particular attention to hazards caused by combustible and easily flammable substances.

– on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the excavator.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard. Do not store or handle any flammable substances during operation.

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to the instruction label), when, for example, oil, grease or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units. Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where – combustible substances such as coal dust or tar are present.

– open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

2800162

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the excavator.

Provide suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

If necessary, also cover the ground with fire-protective blankets.

Ensure sufficient ventilation.

Clean the excavator before starting a job.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water. Use: – dry-powder, – carbon-dioxide or – foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes shortcircuits in the electrical system.

DANGER TO LIFE Have all your welding, flame cutting and grinding work approved.

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OPERATING INSTRUCTIONS RH 400 E HYDRAULIC SYSTEM 2804218

Repair

PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS 2411963

Always depressurize the hydraulic system before disconnecting any hydraulic hoses.

Replace damaged or leaking hydraulic hoses by new ones. Use original O&K-Mining spare parts. These parts are specially suitable for the respective function. Do not re-use used hoses.

Dispose of spilt oil and oily wastes without polluting the environment.

These wastes must not be allowed to penetrate into the soil.

Hydraulic hoses should be replaced after a service life of 6 years.

Read and observe also the "Inspection and servicing - Safety instructions" chapter.

The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So: – Never handle accumulators mechanically, never weld or solder.

– Testing and servicing work must be carried out by experts only.

– Prior to any testing and servicing work, depressurize the hydraulic part of the system.

– To dismantle the accumulator, always wear goggles and working gloves.

– Fill accumulator with nitrogen only, never with compressed air or oxygen.

– Report any defects or damage to the machine owner without delay.

– Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately.

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OPERATING INSTRUCTIONS RH 400 E WELDING OPERATIONS Welding operations - Safety instructions Never perform welding operations unless you are qualified to do so.

Observe the accident prevention regulations.

Any work on receptacles that contain or have contained substances – which are combustible or which encourage combustion, – which are susceptible to explosion, – or which may develop health-hazardous gases, vapours, mist or dust during welding operations must be carried out only under expert supervision and only by experienced persons authorized to do such work.

Detailed information on the correct execution of welding operations is given in the technical manual "Welding for maintenance and repair".

Should you have any problems or queries, apply to the O&K Mining after-sales service department.

If parts of the machine have to be dimantled, read and take note of the following sections: "Assembling attachments - safety instructions", "Inspection and servicing - safety instructions", "Repair - safety instructions".

2804217

Prior to any welding operations on the machine: – Set battery main switch to OFF Protect the disconnected terminals and plugs from short-circuiting and soiling by covering them with foil or adhesive tape.

Attach the welding-current pincers close to the welding zone (max. 2 - 3 m).

The welding current must not flow via the ball resp. the roller bearing slewing ring, via pin couplings, articulated joints or hydraulic cylinders.

An electric current flowing over an air gap (in an articulated joint, for instance) generates sparks that damage metallic surfaces.

On completion of the welding operation, restore all electrical connections.

Set battery main switch to ON.

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OPERATING INSTRUCTIONS RH 400 E

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OPERATING INSTRUCTIONS RH 400 E NOTES 2804180

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OPERATING INSTRUCTIONS RH 400 E

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OPERATING INSTRUCTIONS RH 400 E PART 5 - ANNEX

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2804055

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS RH 400 E

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OPERATING INSTRUCTIONS RH 400 E TROUBLESHOOTING

2804216

Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

Fault

For this reason, it is vital to read through the relevant section of the operating instructions once again before rectifying any faults.

The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

If you are unable to detect the cause of the fault or to rectify it, apply to the O&K Mining after-sales service.

Study the problem carefully. First think, then act.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the O&K Mining after-sales service. Exact data allow for fast troubleshooting.

– Which warning signals preceded the fault?

Never do any jobs for which you are not qualified.

– Has this defect already occurred?

The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

– Is it one or several simultaneously occurring faults?

Ask yourself the following questions:

– What repair and servicing work was carried out previously?

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the operating instructions. If there is no entry, the O&K Mining after-sales service should be consulted.

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OPERATING INSTRUCTIONS RH 400 E

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OPERATING INSTRUCTIONS RH 400 E FAULT TABLES

2804046

Working hydraulics, Fault table Fault Working and slewing functions not operational No boom function No bucket function No backhoe function

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

No stick function Working movements too slow Power loss in working hydraulics

1) Contact the O&K Mining Service

Uncontrolled working movements Cause Servo control not activated / defective

•

Section Working

P

• • • • •

•

Malfunction of pressure-relief valve

1)

•

•

Servo system pump defective

1)

• • • • •

• Malfunction of primary / secondary pressure-relief valves

•

ECO power switch in 80%-position

•

Hydraulic oil temperature too high, oil cooler contaminated

•

1) P Hydraulic oil cooler cleaning

P/R

• Malfunction of solenoid valves

1)

• Malfunction of control spool

1)

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OPERATING INSTRUCTIONS RH 400 E Track drive, Fault table Fault No forward travel and no reversing possible Maximum travel speed cannot be reached Insufficient traction power

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the O&K Mining Service Cause

Section

•

•

•

Malfunction of pressure-relief valve

1)

•

•

•

Servo system pump defective

1)

•

•

•

Malfunction of travel valve (pedal)

1)

•

•

Malfunction of control spool

1)

•

ECO power switch in 80%-position

P

•

Hydraulic oil temperature too high, oil cooler contaminated

Hydraulic oil cooler cleaning

P/R

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OPERATING INSTRUCTIONS RH 400 E Slewing mechanism, Fault table Fault No slewing possible No righthand or lefthand slewing Slewing performance insufficient Uncontrolled slewing movement

Cause

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the O&K Mining Service Sectiont

•

Servo control not activated / defective

•

Superstructure holding brake applied

P

Pressure-relief valve adjusted at too low level / defective

1)

Servo system pump defective

1)

•

Malfunction in feed-pressure circuit of slewing pump

1)

•

Malfunction in high-pressure circuit of slewing system

1)

•

Malfunction of moment-regulating valve

1)

•

Malfunction in slewing pump displacement cylinder

1)

Excessive leakage in slewing motor

1)

•

•

• •

•

•

• •

Working

P

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OPERATING INSTRUCTIONS RH 400 E Central lubricating system, Fault table Fault Grease pump not working Automatic circuit breaker on Grease pump not working, indicator lamp lit Grease pump working, but delivering no grease Greasing pressure too high or too low

Remedial action

Check Adjust Replace Top up Reduce Clean Vent

P E W A S R L

1) Contact the O&K Mining Service Cause •

Timer defective

P/W

Lines between timer and hydraulic motor defective

P/W

Hydraulic motor defective

P/W

•

Grease pump defective

P/W

•

Grease sieve clogged

P/R

•

Distributor defective

P/W

•

Grease container empty

P/A

•

Grease pump not sucking up grease

P/L

•

Leaking lines

P/L

•

Non-return valve defective

P/W

Pressure switch defective

E

•

• •

•

•

•

Section

•

•

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OPERATING INSTRUCTIONS RH 400 E Tightening torques and angles, Table Bolt

Slewing ring Slewing ring/superstructure – tightening torque (pre-assembly) – joining torque – tightening torque (max.)

Slewing ring/undercarriage – tightening torque (pre-assembly) – joining torque – tightening torque (max.)

Slewing gearbox Counter weight – tightening torque (pre-assembly) – joining torque – tightening torque (max.)

2732107

Bolt size

M 42 x 3x 420 / 10.9 / SW 65

M 42 x 3 x 470 / 10.9 / SW 65

MA Nm

M 64 x 4 x 640 / 12.9 / SW 95

Checking torque Nm

120 ± 4

3000

150 ± 4

3000

180 ± 4

15000

2500 1400 5900 2500 1100 5900

M 24 x 600 / 10.9 / SW 36

Tightening angle*

960 1000 4500 22000

Track rollers

M 36 x 240 / 10.9 / SW 55

3300

Support rollers

M 30 x 190 / 12.9 / SW 46

2000

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OPERATING INSTRUCTIONS RH 400 E

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OPERATING INSTRUCTIONS RH 400 E ABBREVIATIONS

A A A2 A4 abt.

ABE acc.

Ah AOT API approx.

AUT

Four-wheel drive Ampere (SI base unit of electric current) 2-point bracing (claws) 4-point bracing (claws) about General Operating Permit [Germany] according to Ampere hours (SI base unit of quantity of electricity) Upper part of boom American Petroleum Institute approximately Lower part of boom

BA Bh

= OI = Operating instructions = OH = Operating hour

CE

Communauté Européenne = European community Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee 1 centimeter (= /100 m) Cubic centimeters per revolution

CECE CEN cm 3 cm /rev

dia.

DIN

Decibel (sound intensity according to measuring method A) Diameter German Industrial Standard

EDS eff. e.g. etc.

Electronic diagnostic system effective for example etcetera

Fig. FOPS FS

Figure, serial number of illustration Falling objects protective structures Rock shovel (working equipment)

GLR

Full-load controller (electronic module for PMS)

HD HDS Hydr.

Heavy duty Heavy duty small Hydraulic, Hydraulics

i i.e.

IFN

Transmission ratio

dB(A)

id est = that is ISO service rating, blocked

2261966

incl.

ISO

including, inclusive of International Standardization Organization

kg 3 kg/dm

Kilogram (unit of weight) Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

km/h kNm kW l Lb/in² LC LDA LED l/min LpA LPS LS LS LwA

Liter Pounds per square inch (= psi) Long crawler Charge pressure-dependent full-load limiter Light-emitting diode Liters per minute Sound pressure at workplace Load-sensing Power System Limited slip Load sensing Sound power level of the machine in stationary operation

min.

-1 min mm MONO

Meters Tightening torque 1 Milliampere (= /1000A) maximal, maximum Mobile hydraulics (excavator) Mobile hydraulic excavator for road and rail operation minimal, minimum Revolutions per minute Millimeter (=1/1000 m) Monoblock boom

N N, kN NLGI NLGI-Klasse Nm No.

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency - lubricant classification acc. to DIN 51 818 Newtonmeter (unit of torque) Number

OH OLS op.inst.

OW

Operating hour O&K load stabilization Operating instructions Superstructure

m MA MA max.

MH MHS

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OPERATING INSTRUCTIONS RH 400 E ABBREVIATIONS O&K

Orenstein & Koppel AG

PLA PMS P/No. PS

bulldozer blade Pump Managing System Part number (O&K) Metric horsepower (1 PS = 0.74 kW)

Qty.

Quantity

R, r resp.

RH ROPS rpm

Radius Respectively Crawler hydraulics (excavator) Roll-over protective structures -1 Revolutions per minute (= min )

SAE sec./s.

SN StVO StVZO

Society of Aotomotive Engineers (USA) Second Item number German Road Traffic Regulations German regulations authorizing the use of vehicles for road traffic Width across flats

SW

typ.

Metric ton (= 1000 kg) Civil Engineering Employer's Liability Insurance Association Technical Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of slewing torque) Typical

U/min UW

Revolutions per minute Undercarriage

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

t TBG THB TL tm

W

Watt (unit of electric power)

°C °kW

Degrees Celsius (temperature) Degrees crank angle

> <

greater than less than

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2462197

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OPERATING INSTRUCTIONS RH 400 E NOTES

2804180

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OPERATING INSTRUCTIONS RH 400 E PART 6 - INDEX

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2804056

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS RH 120 E PART 6 - INDEX

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

2804056

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS RH 120 E

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OPERATING INSTRUCTIONS RH 120 E INDEX

2486289

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A ABBREVIATIONS .................................................. 193 Access.....................................................................27 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS.....................................................10 Adjusting the armrests ....................................... 32; 33 Adjusting the backrest ........................................ 32; 33 Adjusting the lumbar support....................................32 Adjusting the seat cushion.................................. 32; 33 Adjusting the seat suspension ............................ 32; 33 After daily operation .................................................80 AIR CONDITIONER ............................................... 163 Air-intake system ................................................... 169 Application of Voler A.C. ..........................................84 ASSEMBLY OF WORKING EQUIPMENT SAFETY INSTRUCTIONS ....................................81 Automatic fire-extinguishing system ................... 34; 35

B Battery ................................................................... 120 Battery main switch.......................................... 63; 119 Battery storage....................................................... 170 Bearing races......................................................... 158 Before starting work .................................................78 Before switching on the electric motor ......................66 Board Control System (BCS)....................................23 Braking the superstructure .......................................78 Breather filter ......................................................... 161 Breather filters ....................................................... 134 Bypass valves (filter housing - cooling system)....... 133 Bypass valves (hydraulic oil reservoir).................... 131

C Cab interior lamp .....................................................28 CENTRAL LUBRICATING SYSTEM....................... 160 Central lubricating system, Fault table.................... 190 Changing the gearbox oil........................................ 149 Changing the hydraulic oil ...................................... 140 Charging the batteries ............................................ 121 Checking / cleaning the filter elements..............................135; 136; 137; 138 Checking and cleaning the filter element......... 123; 164 Checking the battery charge................................... 120 Checking the battery fluid level ............................... 120 Checking the filter element ..................................... 124 Checking the gas charging pressure in the pressure accumulator ............... 145; 156; 167 Checking the gearbox oil level / Topping up............ 146 Checking the greasing pressure ............................. 162 Checking the hydraulic oil level / Topping up .......... 127 Checking the oil level ..................................... 148; 157 Checking the on-board crane.................................. 168 Cleaning ................................................ 144; 153; 162 Cleaning jobs ...........................................................95 Cleaning the electric motor..................................... 118 Cleaning the filter screens ...................................... 133 Cleaning the grease sieve ...................................... 162

Cleaning the hydraulic oil cooler............................. 144 Cleaning the hydraulic oil reservoir......................... 141 Cleaning the pre-filter..................................... 122; 163 Component numbers ............................................... 25 Control cabinet .............................................. 122; 124 Cooling system ...................................................... 165 Cornering................................................................. 71 Corrosion protection for pins and bearings (bushings and hubs)............................................. 84 Crane engine ......................................................... 169 CRAWLER TRACKS.............................................. 153

D Demand control / Zero-flow regulation...................... 23 Depressurizing the hydraulic system ...................... 126 DESCRIPTION OF THE EXCAVATOR .................... 20 Design ................................................................... 154 Design and function ............................................... 160 Designated use.......................................................... 4 Draining off oil ....................................................... 149 Drawing off oil........................................................ 146 Drawing off the hydraulic oil ................................... 140 Drive........................................................................ 22 Drive unit ............................................................... 169 Driver's seat............................................................. 32

E Electric energy ........................................................... 8 ELECTRIC MOTOR............................................... 118 Electric motor number.............................................. 25 Electric motor - Safety instructions......................... 118 Electrical system.............................................. 23; 119 Electrical System - Safety Instructions ................... 119 Electrical system on / off.......................................... 63 Electronic Hydraulic Servo-Control (EHSC) .............. 22 Emergency Stop ...................................................... 68 EMERGENCY STOP pushbuttons ........................... 30 Emptying the dust collector ............................ 122; 163 Entering and leaving the machine Safety instructions................................................ 26 Escape ladder.......................................................... 27 Excavator layout ...................................................... 21 Extending and retracting the bucket or backhoe bucket stick........................................ 79 Extinguishing agent.................................................. 34 Extract from the German acceptance regulations ................................................ 145; 155; Extract from the German regulations.............. 155; 167 Extract from the inspection and testing regulations ......................................................... 168

F FAULT TABLES..................................................... 187 Filling and emptying the bucket ................................ 79 Filling in hydraulic oil ............................................. 142 Filling in new oil / Topping up................................. 150 Filling in oil .................................................... 147; 157

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M Filling the grease container ...................................... 161 Filter element ................................................... 122; 163 Fire and explosion hazard...................... 12; 19; 93; 177 Fore-and-aft adjustment....................................... 32; 33 Fore-and-aft adjustment of the seat plate .................. 32 Function ................................................................... 155

G Gas, dust, steam and smoke ....................................... 8 Gearbox - Checking the oil level / Topping up ......... 149 Gearbox venting ............................................... 148; 150 Greases for bearings and slewing rings................... 116 Greasing the electric motors .................................... 118 Greasing the idler guides ......................................... 157 Guide pulleys and locking bolt ................................. 166

H High-pressure filter for the servo circuits.................. 136 High-pressure filter for working hydraulics ............... 134 High-pressure filters for feeding circuits/slewing gear pumps ................................. 138 High-pressure filters for pump-flushing circuit.......... 137 High-pressure filters for slewing circuit .................... 139 Hosepipe for oil and coolant changes ...................... 117 Hydraulic and pneumatic equipment............................ 9 Hydraulic system................................ 22; 126; 169; 178 Hydraulic system - Safety instructions ..................... 126

I Idlers ........................................................................ 157 Immobilization for more than 3 months .................... 170 Inspection............................................................. 34; 35 Inspection and servicing - Safety instructions ............ 89 Inspection and servicing plans - Instructions ............. 95 INSPECTION PLAN - OIL ........................................ 110 Inspection plan - Oil (legend) ................................... 111 Instructions on troubleshooting ................................ 185 Internal gearing ........................................................ 158 Intervals...................................................................... 95 INTRODUCTION .......................................................... 1

L Layout of the fault table............................................ 185 Loading bucket........................................................... 21 Locking the superstructure......................................... 74 Lowering the equipment in an emergency ................. 79 Lowering the service station....................................... 60 LUBRICANTS........................................................... 113 LUBRICATING CHART - GREASE / loading bucket ...................................................... 108 Lubricating chart - Grease / Loading bucket (legend)....................................... 109

Machine number......................................................... 25 Main and preliminary gearbox - Filling in oil ............. 152 Main gearbox - Draining off oil ................................. 151 Monitoring, warning and control elements................ 168 Motor protective relay................................................. 65

N Noise ............................................................................ 9 NOTES ....................................................................... 13 NOTES ............................................... 85; 171; 181; 196

O Off-load disconnector ................................................. 64 Oil, grease and other chemical substances ................. 9 Oil-check service ........................................................ 95 Oils / Greases............................................................. 95 Oils for combustion engines and compressors ........ 113 Oils for gearboxes .................................................... 115 Oils for hydraulic systems ........................................ 114 ON-BOARD CRANE......................................... 168; 169 Opening and closing the bucket................................. 79 OPERATION .............................................................. 15 Operation - Safety instructions ................................... 17 Organizational measures ............................................. 5 OTHER MAINTENANCE WORK.............................. 165

P Parking the machine .................................................. 80 PART 3 - INSPECTION AND SERVICING................. 87 PART 4 - REPAIR WORK ........................................ 173 PART 5 - ANNEX ..................................................... 183 PART 6 - INDEX....................................................... 198 Passenger seat .......................................................... 33 Plan A....................................................................... 103 Plan B....................................................................... 103 Plan C....................................................................... 103 Plan D....................................................................... 103 Plan E....................................................................... 103 Plan N......................................................................... 99 Plan T ....................................................................... 101 Plan V......................................................................... 97 Plan W...................................................................... 101 Power supply.............................................................. 23 Pre-chamber............................................................. 148 Pre-chamber - Draining off oil .................................. 152 Pre-chamber - Filling in oil ....................................... 152 Preface ......................................................................... 3 Preliminary gearbox - Draining off oil ....................... 151 Pressure accumulator - Emergency lowering........... 145 PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS.................................... 178 Pressure-accumulator inspection regulations.................................................... 155; 167 Pump Managing System (PMS) ................................. 22 PUMP TRANSFER GEARBOX ................................ 146 PUTTING OUT OF OPERATION AND RECOMMISSIONING .................................. 170 Putting the excavator out of operation...................... 170 PUTTING THE MACHINE INTO OPERATION........... 60

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R Raising and lowering the boom.................................. 79 Raising the service station ......................................... 60 Ramp lighting ............................................................. 27 Ramp-type ladder............................................... 26; 166 Recommissioning..................................................... 170 Refilling - Safety instructions...................................... 60 Refilling / draining....................................................... 60 Refilling of consumables ............................................ 60 Refilling quantities - Grease ..................................... 109 Refilling quantities - Oil ............................................ 112 Refilling quantities - Others ...................................... 112 Regulating the travelling speed.................................. 71 Removing and installing the battery ......................... 120 Repair work - Safety instructions ............................. 175 Replacing the filter element...................................... 124 Replacing the filter elements.... 134; 135; 136; 137; 138

Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir)......................................... 129 Replacing the hydraulic oil return-flow filters (filter housing - cooling system) ........................... 132

S Safety instructions governing specific operational phases................................................... 6 Securing the machine ................................................ 83 Selection and qualification of personnel; basic responsibilities ................................................ 6 Service Station (tanklift) ............................................. 60 Servicing .................................................................. 169 Servicing lighting ........................................................ 29 SERVICING WORK ................................................. 117 Shutting off ........................................................... 64; 68 Signs .......................................................................... 25 Slewing and braking the superstructure..................... 78 Slewing gear neck.................................................... 150 SLEWING GEARBOX.............................................. 149 Slewing mechanism, Fault table .............................. 189 SLEWING RING....................................................... 158 Slewing ring - Checking the grease filling ................ 159 Slewing ring - Checking the screws for tightness..... 159 Slewing ring - Filling in grease ................................. 159 Slewing ring - Instructions ........................................ 158 Slip ring unit ............................................................. 125 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.......................... 7 Standard operation....................................................... 6 Stored Program Control (SPC)................................... 22 Superstructure...................................................... 21; 22 Superstructure basic position..................................... 70 Support roller fastening ............................................ 154 Support rollers.......................................................... 154 Switch-disconnector ................................................... 64

Switching on ......................................................... 64; 67 Switching the electric motor on and off ...................... 66

T Technical data .................................................. 155; 195 Tightening torques and angles, Table ...................... 191 Topping up oil........................................................... 153 Track drive, Fault table............................................. 188 Track parking brake.................................................... 74 Track roller fastening................................................ 154 Track rollers.............................................................. 153 Track tensioner......................................................... 154 Transpor ..................................................................... 75 Transport - Safety instructions ................................... 75 Transporting and recommissioning .............................. 9 Transporting the machine........................................... 75 Travel gearbox - Changing the oil ............................ 151 Travel gearbox - Checking the oil level / Topping up ........................................................... 151 TRAVEL GEARBOXES ............................................ 151 TRAVELLING ............................................................. 70 TRAVELLING - SAFETY INSTRUCTIONS ................ 69 Travelling forwards/backwards ................................... 70 Travelling over longer distances................................. 73 Travelling uphill and downhill ..................................... 71 TROUBLESHOOTING.............................................. 185 Turning ....................................................................... 71

U Unblocking a grease line.......................................... 162 Undercarriage....................................................... 21; 22 Unlocking the EMERGENCY STOP button ................ 30

V Venting bore ............................................................. 150 Venting filter ............................................. 122; 124; 163 Venting the hydraulic components ........................... 143 Venting the hydraulic system ................................... 143 Voler A.C. ................................................................... 84

W Warming up................................................................ 78 Warning and instruction signs.................................... 25 Warning und symbols................................................... 4 Warning of special dangers ......................................... 8 Warrenty....................................................................... 3 WELDING OPERATIONS ........................................ 179 Welding operations - Safety instructions.................. 179 Windscreen washer.................................................... 31 Working ...................................................................... 79 Working hydraulics, Fault table ................................ 187 WORKING OPERATION............................................ 78 WORKING OPERATIONS - SAFETY INSTRUC TIONS .................................................................... 76

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© Copyright Caterpillar Global Mining HMS GmbH 2014

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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