CAT 6090FS Hydraulic Shovel Operation & Maintenance Manual DHS90001 - DHS90002 - PDF DOWNLOAD

BI015804 October 2014

Operation and Maintenance Manual 6090FS Hydraulic Shovel

No. DHS90001, DHS90002

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OPERATING INSTRUCTIONS RH 400

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Hydraulic Excavator 6090FS DHS90002 400 Nos. DHS90001, RH No. Bucyrus HEX GmbH

Update .04, see pages 115a and 178a

Update to version .04, see pages 115a and 178a

4 BA RH400(2 731 030.03)-EN

OPERATING INSTRUCTIONS RH 400

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Published by:

Bucyrus HEX GmbH

ii

Dept. 2470 – Documentation D-44149 Dortmund, Karl-Funke-Straße 36 Tel. +49 (0) 231 922-4340 Fax +49 (0) 231 922-5340 www.bucyrus-hex.com Update to version .04, see pages 115a and 178a BA RH400(2 731 030.03)-EN

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OPERATING INSTRUCTIONS RH 400

The O&K-Mining operating manual is in 6 sections; the sections are designed for different target groups: Operating manual

Part 1 INTRODUCTION

2804050

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS 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

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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 .04, see pages 115a and 178a

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Update to version .04, see pages 115a and 178a

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PART 1 - INTRODUCTION 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 Standard operation .................................................................................................................................. 6 Special work in conjunction with utilization of the machine - maintenance and repairs during operation disposal of parts and consumables ........................................................................................................ 7 Warning of special dangers 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 Fire and Explosion Hazard .................................................................................................................... 10 NOTES...................................................................................................................................................... 11

Update to version .04, see pages 115a and 178a

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PART 2 - OPERATION Operation - Safety instructions.............................................................................................................. 15 Fire and Explosion Hazard .................................................................................................................... 17 DESCRIPTION OF THE EXCAVATOR Excavator layout .................................................................................................................................... 19 Undercarriage........................................................................................................................................ 19 Superstructure ...................................................................................................................................... 19 Loading bucket ...................................................................................................................................... 19 Undercarriage........................................................................................................................................ 20 Superstructure ...................................................................................................................................... 20 Drive ...................................................................................................................................................... 20 Hydraulic system .................................................................................................................................. 20 Pump Managing System (PMS) ............................................................................................................ 20 Stored Program Control (SPC) .............................................................................................................. 20 Electronic Hydraulic Servo-Control (EHSC) .......................................................................................... 20 Demand control / Zero-flow regulation .................................................................................................. 21 Automatic engine speed reduction ........................................................................................................ 21 Board Control System (BCS) ................................................................................................................ 21 Electrical system .................................................................................................................................. 21 Signs .................................................................................................................................................... 23 Warning and instruction signs .............................................................................................................. 23 Machine number.................................................................................................................................... 23 Engine number ...................................................................................................................................... 23 Component numbers ............................................................................................................................ 23 Entering and leaving the machine - Safety instructions ........................................................................ 24 Ramp-type ladder .................................................................................................................................. 24 Access .................................................................................................................................................. 25 Escape ladder ...................................................................................................................................... 25 Ramp lighting ........................................................................................................................................ 25 Cab interior lamp .................................................................................................................................. 26 Servicing lighting .................................................................................................................................. 27 110 V socket.......................................................................................................................................... 27 EMERGENCY STOP pushbuttons ........................................................................................................ 28 Windscreen washer .............................................................................................................................. 28 Driver’s seat .......................................................................................................................................... 29 Adjusting the backrest .......................................................................................................................... 29 Adjusting the lumbar support ................................................................................................................ 29 Adjusting the seat cushion .................................................................................................................... 29 Adjusting the armrests .......................................................................................................................... 29 Fore-and-aft adjustment ........................................................................................................................ 29 Adjusting the seat suspension .............................................................................................................. 29 Fore-and-aft adjustment of the seat plate.............................................................................................. 29 Update to version .04, see pages 115a and 178a

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Passenger seat .................................................................................................................................... 30 Adjusting the backrest .......................................................................................................................... 30 Adjusting the seat cushion .................................................................................................................... 30 Adjusting the armrests .......................................................................................................................... 30 Fore-and-aft adjustment ........................................................................................................................ 30 Adjusting the seat suspension .............................................................................................................. 30 Automatic fire-extinguishing system ...................................................................................................... 31 Manual activation .................................................................................................................................. 31 Inspection .............................................................................................................................................. 32 MONITORING, WARNING AND CONTROL ELEMENTS ...................................................................... 34 PUTTING THE MACHINE INTO OPERATION ........................................................................................ 68 Refuelling Refuelling - Safety instructions .............................................................................................................. 68 Service station (tank lift) ........................................................................................................................ 68 Lowering the service station .................................................................................................................. 69 Lifting the service station ...................................................................................................................... 69 Refilling and/or draining ........................................................................................................................ 69 Measuring devices for fluids .................................................................................................................. 70 Switching the electrical system on and off ............................................................................................ 74 Battery main switches .......................................................................................................................... 74 Starting and stopping the engines ........................................................................................................ 75 Starting the engines .............................................................................................................................. 75 Starting the engines with the cold-starting aid ...................................................................................... 76 Shutting off the engines ........................................................................................................................ 77 Emergency stop .................................................................................................................................... 77 Driving...................................................................................................................................................... 78 TRAVELLING Superstructure basic position ................................................................................................................ 79 Travelling forwards/in reverse .............................................................................................................. 79 Regulating the travelling speed ............................................................................................................ 80 Travelling uphill and downhill ................................................................................................................ 80 Cornering .............................................................................................................................................. 80 Turning .................................................................................................................................................. 80 Note ...................................................................................................................................................... 81 Travelling over longer distances ............................................................................................................ 82 Locking the superstructure .................................................................................................................... 83 Track parking brake .............................................................................................................................. 83 Transporting the machine Transport - Safety instructions .............................................................................................................. 84 Transport .............................................................................................................................................. 84 Update to version .04, see pages 115a and 178a

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WORKING OPERATION, SAFETY INSTRUCTIONS .............................................................................. 85 WORKING OPERATION Before starting work .............................................................................................................................. 87 Switching on the electronic excavator control ...................................................................................... 87 Slewing and braking the superstructure ................................................................................................ 87 Braking the superstructure .................................................................................................................... 87 Working ................................................................................................................................................ 88 Raising and lowering the boom ............................................................................................................ 88 Extending and retracting the bucket or backhoe bucket stick .............................................................. 88 Filling and emptying the bucket ............................................................................................................ 88 Opening and closing the bucket ............................................................................................................ 88 Lowering the equipment in an emergency ............................................................................................ 88 After daily operation .............................................................................................................................. 89 Parking the machine.............................................................................................................................. 89 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS Securing the machine............................................................................................................................ 92 Corrosion protection for pins and bearings (bushings and hubs) Part nos. for Voler A.C........................................................................................................................... 93 Application of Voler A.C. ...................................................................................................................... 93 NOTES...................................................................................................................................................... 95

Update to version .04, see pages 115a and 178a

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PART 3 - INSPECTION AND SERVICING Inspection and servicing - Safety instructions .................................................................................... 99 Fire and Explosion Hazard .................................................................................................................. 103 Inspection and servicing plans - Instructions Intervals .............................................................................................................................................. 105 Change of engine oil .......................................................................................................................... 105 Air-intake system ................................................................................................................................ 105 Oils / Greases...................................................................................................................................... 105 Cleaning jobs ...................................................................................................................................... 105 Plan V .................................................................................................................................................. 107 Plan N.................................................................................................................................................. 109 Plan T .................................................................................................................................................. 111 Plan W ................................................................................................................................................ 111 Plan T .................................................................................................................................................. 112 Plan W ................................................................................................................................................ 112 Plan A .................................................................................................................................................. 113 Plan B .................................................................................................................................................. 113 Plan C.................................................................................................................................................. 113 Plan D.................................................................................................................................................. 113 Plan E .................................................................................................................................................. 113 Plan A .................................................................................................................................................. 114 Plan B .................................................................................................................................................. 114 Plan C.................................................................................................................................................. 114 Plan D.................................................................................................................................................. 114 Plan E .................................................................................................................................................. 114 Plan A .................................................................................................................................................. 115 Plan B .................................................................................................................................................. 115 Plan C.................................................................................................................................................. 115 Plan D.................................................................................................................................................. 115 Plan E .................................................................................................................................................. 115 Plan A .................................................................................................................................................. 116 Plan B .................................................................................................................................................. 116 Plan C.................................................................................................................................................. 116 Plan D.................................................................................................................................................. 116 Plan E .................................................................................................................................................. 116 Plan A .................................................................................................................................................. 117 Plan B .................................................................................................................................................. 117 Plan C.................................................................................................................................................. 117 Plan D.................................................................................................................................................. 117 Plan E .................................................................................................................................................. 117 LUBRICATING CHART - GREASE (Loading bucket) Update to version .04, see pages 115a and 178a

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Lubricating chart - Grease / Loading bucket........................................................................................ 119 Filling quantities - Grease .................................................................................................................... 119 INSPECTION PLAN - OIL Inspection plan - Oil ............................................................................................................................ 121 Filling quantities - Oil .......................................................................................................................... 122 Filling quantities - other ...................................................................................................................... 122 LUBRICANTS ........................................................................................................................................ 123 Oils for combustion engines and compressors (selection) .............................................................. 123 Oils for hydraulic systems (selection) ................................................................................................ 124 Oils for gearboxes (selection).............................................................................................................. 125 Greases for bearings and slewing rings ............................................................................................ 126 SERVICING WORK Hose line for oil and coolant changes.................................................................................................. 127 ENGINE Engine - Safety instructions ................................................................................................................ 128 Checking/adjusting the V-belt tension ................................................................................................ 128 Checking/adjusting the valve clearance .............................................................................................. 128 Checking the engine oil level / Topping up .......................................................................................... 128 Checking the oil level in the engine oil reservoir / Topping up ............................................................ 129 Changing the engine oil ...................................................................................................................... 130 Drawing off engine oil with the service station .................................................................................... 130 Filling in engine oil through the service station .................................................................................... 131 Changing the oil of the engine oil reservoir ........................................................................................ 132 Drawing off engine oil .......................................................................................................................... 132 Drain off engine oil .............................................................................................................................. 132 Filling in engine oil .............................................................................................................................. 133 Eliminator filter and centrifuge ............................................................................................................ 134 Centrifuge ............................................................................................................................................ 134 Dismantling the centrifuge .................................................................................................................. 134 Cleaning the centrifuge ...................................................................................................................... 135 Assembling the centrifuge .................................................................................................................. 135 COOLING SYSTEM Temperature ........................................................................................................................................ 136 Radiators ............................................................................................................................................ 136 Coolant level........................................................................................................................................ 136 Topping up coolant .............................................................................................................................. 137 Coolant ................................................................................................................................................ 138 Drawing off coolant.............................................................................................................................. 138 Update to version .04, see pages 115a and 178a

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Filling in coolant .................................................................................................................................. 139 Testing the coolant composition .......................................................................................................... 139 Water filter .......................................................................................................................................... 140 AIR-INTAKE SYSTEM Main filter elements ............................................................................................................................ 141 Removal and installation .................................................................................................................... 141 Checking and cleaning the main filter element .................................................................................... 142 Safety filter element ............................................................................................................................ 143 Replacement ...................................................................................................................................... 143 Air-intake lines .................................................................................................................................... 144 Dust collection .................................................................................................................................... 144 FUEL SYSTEM Fuel system - Safety instructions ........................................................................................................ 145 Replacing the fuel filter ........................................................................................................................ 145 Venting the fuel system ...................................................................................................................... 146 Cleaning the fuel tanks ........................................................................................................................ 146 ELECTRICAL SYSTEM Electrical system - Safety instructions ................................................................................................ 148 Alternator - Instructions ...................................................................................................................... 148 Battery main switches§/§Main fuse .................................................................................................... 149 Batteries .............................................................................................................................................. 149 Removing and installing the batteries.................................................................................................. 149 Battery box .......................................................................................................................................... 150 Removing and installing the battery box.............................................................................................. 150 HYDRAULIC SYSTEM Hydraulic system - Safety instructions ................................................................................................ 151 Depressurizing the hydraulic system .................................................................................................. 151 Checking the hydraulic oil level / Topping up ...................................................................................... 152 Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir).................................................... 154 Bypass valves (hydraulic oil reservoir) ................................................................................................ 156 Cleaning the filter screens .................................................................................................................. 156 Replacing the hydraulic oil return-flow filters (filter housing - cooling system) .................................... 157 Bypass valves (filter housing - cooling system) .................................................................................. 158 Cleaning the filter screens .................................................................................................................. 158 Breather filters .................................................................................................................................... 159 Replacing the filter elements .............................................................................................................. 159 High-pressure filter for working hydraulics .......................................................................................... 159 Checking/cleaning the filter elements .................................................................................................. 160 Replacing the filter elements .............................................................................................................. 160 High-pressure filter for the servo circuits ............................................................................................ 161 Checking/cleaning the filter elements .................................................................................................. 161 Replacing the filter elements .............................................................................................................. 161 Update to version .04, see pages 115a and 178a

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High-pressure filters for pump-flushing circuit .................................................................................... 162 Checking/cleaning the filter elements .................................................................................................. 162 Replacing the filter elements .............................................................................................................. 162 High-pressure filters for feeding circuits/slewing gear pumps ............................................................ 163 Checking/cleaning the filter elements .................................................................................................. 163 Replacing the filter elements .............................................................................................................. 163 High-pressure filters for slewing circuit ................................................................................................ 164 Changing the hydraulic oil .................................................................................................................. 165 Drawing off the hydraulic oil ................................................................................................................ 165 Cleaning the hydraulic oil reservoir .................................................................................................... 166 Filling in hydraulic oil .......................................................................................................................... 167 Venting the hydraulic system .............................................................................................................. 168 Venting the hydraulic components ...................................................................................................... 168 Cleaning the hydraulic oil cooler.......................................................................................................... 169 Cleaning .............................................................................................................................................. 169 Pressure accumulator - Emergency lowering Pressure-accumulator inspection regulations...................................................................................... 170 Extract from the German regulations .................................................................................................. 170 Extract from the German acceptance regulations .............................................................................. 170 Checking the gas charging pressure in the pressure accumulator ...................................................... 170 PUMP TRANSFER GEARBOX Checking the gearbox oil level / Topping up........................................................................................ 171 Drawing off oil ...................................................................................................................................... 171 Filling in oil .......................................................................................................................................... 172 Gearbox venting .................................................................................................................................. 173 Pre-chamber........................................................................................................................................ 173 Checking the oil level .......................................................................................................................... 173 SLEWING GEARBOX Gearbox - Checking the oil level / Topping up .................................................................................... 174 Changing the gearbox oil .................................................................................................................... 174 Draining off oil .................................................................................................................................... 174 Filling in new oil / Topping up .............................................................................................................. 175 Gearbox venting .................................................................................................................................. 175 Venting bore ........................................................................................................................................ 175 Slewing gear neck .............................................................................................................................. 175 TRAVEL GEARBOXES Travel gearbox - Checking the oil level / Topping up .......................................................................... 176 Travel gearbox - Changing the oil ...................................................................................................... 176 Main gearbox - Draining off oil ............................................................................................................ 176 Preliminary gearbox - Draining off oil .................................................................................................. 176 Main and preliminary gearbox - Filling in oil ........................................................................................ 177 Pre-chamber - Draining off oil.............................................................................................................. 177 Update to version .04, see pages 115a and 178a

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Pre-chamber - Filling in oil .................................................................................................................. 177 CRAWLER TRACKS Cleaning .............................................................................................................................................. 178 Track rollers ........................................................................................................................................ 178 Track roller fastening .......................................................................................................................... 179 Support rollers .................................................................................................................................... 179 Support roller fastening ...................................................................................................................... 179 Track tensioner.................................................................................................................................... 179 Design ................................................................................................................................................ 179 Technical data .................................................................................................................................... 180 Function .............................................................................................................................................. 180 Pressure-accumulator inspection regulations...................................................................................... 180 Extract from the German regulations .................................................................................................. 180 Extract from the German acceptance regulations .............................................................................. 181 Checking the gas charging pressure in the pressure accumulator ...................................................... 181 Idlers.................................................................................................................................................... 182 Checking the oil level .......................................................................................................................... 182 Filling in oil .......................................................................................................................................... 182 Greasing the idler guides .................................................................................................................... 182 SLEWING RING Slewing ring - Instructions .................................................................................................................. 183 Bearing races ...................................................................................................................................... 183 Internal gearing .................................................................................................................................. 183 Slewing ring - Checking the grease filling............................................................................................ 184 Slewing ring - Filling in grease ............................................................................................................ 184 Slewing ring - Checking the screws for tightness ................................................................................ 184 CENTRAL LUBRICATING SYSTEM Design and function ............................................................................................................................ 185 Filling the grease container ................................................................................................................ 186 Breather filter ...................................................................................................................................... 186 Checking the grease pressure ............................................................................................................ 187 Unblocking a grease line .................................................................................................................... 187 Cleaning the grease sieve .................................................................................................................. 187 Cleaning .............................................................................................................................................. 187 OTHER MAINTENANCE WORK Engine ................................................................................................................................................ 188 Cleaning .............................................................................................................................................. 188 Fastenings .......................................................................................................................................... 188 Cooling system .................................................................................................................................... 188 Exhaust system .................................................................................................................................. 188 RAMP-TYPE LADDER Update to version .04, see pages 115a and 178a

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Guide pulleys and locking bolt ............................................................................................................ 189 Pressure-accumulator inspection regulations...................................................................................... 190 Extract from the German regulations .................................................................................................. 190 Extract from the German acceptance regulations .............................................................................. 190 Checking the gas charging pressure in the pressure accumulator ...................................................... 190 ON-BOARD CRANE Monitoring, warning and control elements .......................................................................................... 191 Checking the on-board crane .............................................................................................................. 191 Extract from the inspection and testing regulations ............................................................................ 191 Drive unit ............................................................................................................................................ 192 Crane engine ...................................................................................................................................... 192 Air-intake system ................................................................................................................................ 192 Hydraulic system ................................................................................................................................ 192 On-board crane .................................................................................................................................. 192 Servicing.............................................................................................................................................. 192 ALTERNATOR Monitoring, warning and control elements .......................................................................................... 193 Drive motor .......................................................................................................................................... 193 Air-intake system ................................................................................................................................ 193 Servicing.............................................................................................................................................. 194 Cleaning the prefractionator ................................................................................................................ 194 Emptying the dust trap ........................................................................................................................ 195 Main filter element .............................................................................................................................. 195 Checking and cleaning the main filter element .................................................................................... 196 Safety filter element ............................................................................................................................ 197 Replacement ...................................................................................................................................... 197 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING Putting the excavator out of operation ................................................................................................ 198 Battery storage .................................................................................................................................... 198 Recommissioning ................................................................................................................................ 198 NOTES.................................................................................................................................................... 199

Update to version .04, see pages 115a and 178a

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PART 4 - REPAIR WORK Repair work - Safety instructions ........................................................................................................ 203 Fire and Explosion Hazard .................................................................................................................. 205 ENGINE .................................................................................................................................................. 206 ELECTRICAL SYSTEM Assisted starting (with jumper cables) - Safety instructions ................................................................ 206 Assisted starting (with jumper cables) ................................................................................................ 207 Prior to assisted starting ...................................................................................................................... 207 Starting the engine with jumper cables (external batteries) ................................................................ 207 Connecting the jumper cables ............................................................................................................ 207 Starting up the engines ...................................................................................................................... 207 Disconnecting the jumper cables ........................................................................................................ 207 HYDRAULIC SYSTEM Repair .................................................................................................................................................. 208 Accumulators, safety instructions ...................................................................................................... 208 WELDING OPERATIONS ...................................................................................................................... 209 Welding operations - Safety instructions .......................................................................................... 209 NOTES.................................................................................................................................................... 211

Update to version .04, see pages 115a and 178a

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PART 5 - ANNEX TROUBLESHOOTING .......................................................................................................................... 215 Instructions on troubleshooting .......................................................................................................... 215 Layout of the fault table Fault .................................................................................................................................................... 215 Causes .................................................................................................................................................. 215 Remedial action .................................................................................................................................... 215 Section .................................................................................................................................................. 215 FAULT TABLES Combustion engine - Fault table.......................................................................................................... 216 Working hydraulics - Fault table .......................................................................................................... 217 Fahrantrieb - Fault table ...................................................................................................................... 218 Slewing mechanism, Fault table .......................................................................................................... 219 Central lubricating system - Fault table .............................................................................................. 220 Hydraulic circuit diagram Legend (loading bucket) ...................................................................................................................... 222 Tightening torques and angles - Table .............................................................................................. 223 ABBREVIATIONS .................................................................................................................................. 225 TECHNICAL DATA ................................................................................................................................ 227 NOTES.................................................................................................................................................... 229

Update to version .04, see pages 115a and 178a

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PART 6 - INDEX INDEX .................................................................................................................................................... 233

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Update to version .04, see pages 115a and 178a

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OPERATING INSTRUCTIONS RH 400

PART 1 - INTRODUCTION

Operating manual

Part 1 INTRODUCTION

2804051

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS 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

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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 .04, see pages 115a and 178a

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OPERATING INSTRUCTIONS RH 400

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OPERATING INSTRUCTIONS RH 400 Preface

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These operating instructions are designed to familiarize the operator with the machine and its designated use.

The instruction manual contains 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 instruction manual 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 operator’s cab of the machine.

The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as - operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables.

- maintenance (inspection, servicing, repair) and / or - transport.

In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed.

[1]

The operating instructions are directed to the construction-machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified O&K mechanic or by attending an O&K training course for operators or maintenance personnel.

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

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

The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the O&K 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 Owner´s Manual having been performed by the O&K Mining Service or by a workshop authorized in writing by O&K Mining to perform such work.

[1] Complies with VDMA recommendation "Operating instructions"

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OPERATING INSTRUCTIONS RH 400 FUNDAMENTAL SAFETY INSTRUCTIONS

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Complies with VDMA recommendation "Operating Instructions"

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

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

DESIGNATED USE

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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 manual, 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 manual and complying with the inspection and maintenance directives.

Using the excavator or its attachemnts 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, supports, sheet-piles 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 Organizational measures 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 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 close-fitting 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.

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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 authority/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.

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

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OPERATING INSTRUCTIONS RH 400 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 accesories 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 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.

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

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

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

Before leaving the driver’s seat always secure the machine against inadvertent movement and unauthorized use. Shut off the engines.

Special work in conjunction with utilization of the machine - maintenance and repairs during operation - disposal of parts and consumables 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.

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

In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented 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.

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 safety-oriented ladders and working platforms. Never use machine parts as a climbing aid.

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

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

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.

Warning of special dangers Electric energy 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 - drive the machine out of the hazard zone.

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 fire-fighting system.

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

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.

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

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

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

- warn others against approaching and touching the machine - have the live wire de-energized - do not leave the machine until the damaged or contacted line has been safely de-energized.

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.

Gas, dust, steam and smoke 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.

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 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 Fire and Explosion Hazard

2796684

Prior to commencing work, inform - on the national and corporate rules for 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.

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.

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

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

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

Do not store or handle any flammable substances during operation.

Do not extinguish flammable liquids with water.

Use:

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 such as turbo superchargers.

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.

- 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.

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 NOTES

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OPERATING INSTRUCTIONS RH 400

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OPERATING INSTRUCTIONS RH 400 PART 2 - OPERATION

Operating manual

Part 1 INTRODUCTION

2804052

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS 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

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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 Operation - Safety instructions

2732108

Operating instructions

Safety belt

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

For machines with a safety belt for operating personnel:

Pay special attention to: the "Fundamental Safety Instructions" and to all warnings and safety 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.

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.

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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.

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. Clearcut 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 warnings and safety instructions attached to the machine are present and legible.

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OPERATING INSTRUCTIONS RH 400

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.

16

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 Fire and Explosion Hazard

2796685

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 such as turbo superchargers.

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 DESCRIPTION OF THE EXCAVATOR

2732088

Fig. 1

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OPERATING INSTRUCTIONS RH 400 Excavator layout (Fig. 1) Undercarriage

38

- Air conditioning system

39

- Service station (tank lift)

40

- Alternator with drive

42

- On-board crane

43

- Hydraulic system (on-board crane) with drive

44

- Grease container for central lubricating system

1

- Track drive

2

- Idler

3

- Track roller

4

- Support roller

5

- Crawler track

6

- Track tensioner

7

- Slewing ring

45

- Tool cabinet

8

- Ladder

46

- Fire extinguisher (drive unit)

47

- Fire extinguisher (platform)

51

- Ramp-type ladder

52

- Ladder

53

- Ladder

54

- Emergency ladder

55

- Counterweight

Superstructure 11

- Engine

12

- Radiator (engine cooling liquid)

13

- Air-intake system

14

- Exhaust system

15

- Fuel tank

16

- Engine oil reservoir

17

- Hydraulic oil reservoir

61

- Boom

18

- Hydraulic oil cooler

62

- TriPower linkage

19

- Filter housing (cooling system)

63

- Stick

20

- Pump transfer gearbox

64

- Bottom-dump bucket

21

- Working pump

65

- Boom cylinder

22

- Slewing pump

66

- Stick cylinder

23

- Servo system pump

67

- Tipping cylinder

24

- Gearbox recirculation pump

68

- Bottom-dump cylinder

25

- Filling pump (slewing circuit)

69

- Control valves

26

- Fan drive pump (engine radiator)

70

- Quick-action valve

27

- Fan drive pump (hydraulic oil cooler)

28

- Cooling oil pump

29

- Slewing gear

30

- Travel block and rotor

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)

36

- Control cabinet with battery main switch

37

- Batteries

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Loading bucket

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OPERATING INSTRUCTIONS RH 400 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 hydraulic motors and travel gearboxes. Undercarriage and superstructure are connected by means of a slewing ring.

The SPC controls the functions - Engine Start - Engine Stop - Engine Idle - Central lubricating system

Superstructure

- Further auxiliary functions

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

Drive The drive unit comprises diesel engines, 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 overload-protected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

Pump Managing System (PMS)

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

Electronic Hydraulic Servo-Control (EHSC) 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.

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 Demand control / Zero-flow regulation

Board Control System (BCS)

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.

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.

These special features offer the following advantages: • reduced fuel consumption

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

• minimum power losses • reduced temperature of the hydraulic oil • greater service life of hydraulic pumps and diesel engines

Automatic engine speed reduction If the control pedal and control levers and thus the servovalves are not actuated for a period of 10 seconds or more (programmable), the engine speed is automatically reduced to idling. This function is a further contribution to fuel economy.

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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. Outof-limit conditions are display in the form of error messages in the driver’s cab.

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

Electrical system The electrical system operates on 24 volts.

The voltage for the floodlamps and the warmingup system is 110 V AC, 60 Hz (3-phase).

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OPERATING INSTRUCTIONS RH 400

Fig. 2

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OPERATING INSTRUCTIONS RH 400 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. 4

Fig. 2 shows the location of warning and instruction signs on the machine.

Engine number

Machine number

The identification plate (arrow, Fig. 5) with the engine number is attached to the engine.

The identification plate with the machine number is attached to the front side of the A-frame (arrow, Fig. 3 and/or 4)

Fig. 5

Component numbers Fig. 3

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 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. 6 and 8).

Fig. 7

Ramp-type ladder Retracting or extending the ramp-type ladder (Fig. 6)

Fig. 8

Retract ladder completely and engage.

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

Fig. 6

Retracting the ramp-type ladder - Actuate switch (1, Fig. 7 and/or Fig. 8).

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

24

Extending the ramp-type ladder - Press pedal (2, Fig. 7) and actuate switch (1).

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OPERATING INSTRUCTIONS RH 400 Access Ramp lighting Access to the excavator is also provided by the ladders (1 and 2, Fig. 9)..

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

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

The lighting is switched on with a pull switch (Fig. 11) and/or with the switch (1, Fig. 12).

The pull switch is located beside the ramp-type ladder and is operated with a rod (3, Fig. 11) from the ground.

Fig. 11

The switch (1, Fig. 12) is located in the driver’s cab.

Fig. 9

Escape ladder The escape ladder (1, Fig. 10) is located beside the driver’s cab.

Fig. 12

Fig. 10

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OPERATING INSTRUCTIONS RH 400 Cab interior lamp The lamp has 24 V connection voltage and is transformed internally to 208 V. The interior lamp in the driver’s cab and the amenity is switched on and off with the switch (2, Fig. 13).

Fig. 15

The interior lamp can also be switched on and off with the switch (1, Fig. 15).

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.

Fig. 13

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. 14

The interior lamp in the driver’s cab can be switched on and off separately from the amenity with the switch (82, Fig. 14).

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OPERATING INSTRUCTIONS RH 400 Servicing lighting

110 V socket

Switch on the lamps in the modules with switches (81, Fig. 16 and 3, Fig. 17).

The sockets (3, Fig. 18 and 4, Fig. 19) are located in the engine module.

Switch (81, Fig. 16) is located in the control column in the driver’s cab.

Fig. 18

Fig. 16

Switch (3, Fig. 17) is located beside the entrance door in the platform.

Fig. 19

Fig. 17

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OPERATING INSTRUCTIONS RH 400 EMERGENCY STOP pushbuttons The entire electrical system is switched off with the EMERGENCY STOP pushbuttons.

- on the righthand side of the excavator near the counterweight.

This latter one is operated with the rod (3, Fig. 22).

In an emergency, press the EMERGENCY stop button (116, Fig. 20 or 1, Fig. 21 respectively) or pull the rod (3, Fig. 22).

The EMERGENCY STOP pushbuttons are located - in the control column in the driver’s cab (116, Fig. 20)

Fig. 22

Windscreen washer The reservoir of the windscreen washing system (1, Fig. 23) is installed in the cab module. For the reservoir capacity, refer to the "Refilling quantities - Other" table.

Fig. 20

- beside the batteries (1, Fig. 21)

Fig. 23

Fig. 21

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OPERATING INSTRUCTIONS RH 400 Driver’s seat

Adjusting the seat cushion

The driver’s seat (Fig. 24) 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 The 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 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).

Fig. 24

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).

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

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OPERATING INSTRUCTIONS RH 400 Passenger seat

Adjusting the seat cushion

The passenger seat (Fig. 25) 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).

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

Lower weight - turn handwheel (2) counter-clockwise (soft springs).

Fig. 25

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).

30

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

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OPERATING INSTRUCTIONS RH 400 Automatic fire-extinguishing system

Fig. 28 shows the activating unit at the entrance to the engine module.

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. Individual extinguishing circuits, e.g. for engine 1 or 2 (left or right) can be activated manually.

Manual activation • Pull out ring (1, Fig. 26) on activating unit for corresponding extinguishing circuit.

• Strike knob (2) hard.

Fig. 28

Fig. 29 shows the activating unit in front of the distributor gearbox.

Fig. 26

Fig. 27 shows the activating unit in the cab Fig. 29

Fig. 30 shows the activating unit in front of the sealing wall to the engine compartment

Fig. 27

Fig. 30

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OPERATING INSTRUCTIONS RH 400 Fig. 31 shows one of the two extinguishing assembles with the activating units on the superstructure.

Fig. 33 shows the extinguisher with activating unit inside the platform.

Fig. 33 Fig. 31

Fig.32 shows the activating unit for the inside of the platform.

It is located beside the entrance to the superstructure.

Refill extinguishers immediately after use ready for further deployment.

The automatic fire extinguishing system prevents fire from spreading. It is, however, assumed that that the machine be 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 interests of your own safety.

Fig. 32

32

Have the extinguishing system check at the prescribed intervals by authorized testing institutes.

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OPERATING INSTRUCTIONS RH 400

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OPERATING INSTRUCTIONS RH 400 MONITORING, WARNING AND CONTROL ELEMENTS

2732084

Fig. 1

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

Function

1

BCS

Electronic measuringdata 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

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Update to version .04, see pages 115a and 178a

Symbol

35

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 2

36

Update to version .04, see pages 115a and 178a

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BI015804

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

Function

15

Pressure gauge Engine oil pressure (engine 1 left)

Indicates the oil pressure in the diesel engine lubrication circuit

16

Thermometer

Indicates the cooling-water temperature

17

Pressure gauge Engine oil pressure (Engine 2 right)

Indicates the oil pressure in the diesel engine lubrication circuit

18

Thermometer

Engine temperature (engine 2 right)

Indicates the cooling-water temperature

19

Warning lamp

Alternator (engine 1 left)

Lights up when the batteries are not being charged.

20

Warning lamp

engine oil pressure (engine 1 left)

Lights up when the engine oil pressure is too low

21

Indicator lamp

Oil level control (engine 1 left)

Flashes when one oil pump is working.

Is permanently on when both oil pumps are working.

The engine oil level is being regulated when the lamp changes from flashing to being lit up permanently.

22

Warning lamp

engine temperature (engine 1 left)

Lights up when the engine temperature is too high

23

Warning lamp

Cooling-water level (engine 1 left)

Lights up when the cooling-water level is too low

24

Warning lamp

Electronic speed control (engine 1 left) (Centry)

Flashes to indicate a Centry fault.

Engine temperature (engine 1 left)

Symbol

Shut off engine.

Stop work immediately.

Contact the O&K After-Sales Service or the engine manufacturer Lights up permanently to indicate a Centry fault.

Work must be stopped immediately.

Contact the O&K After-Sales Service or the engine manufacturer.

2 731 030.03 en

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37

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 3

38

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BI015804

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

Function

25

Warning lamp

Alternator (engine 2 right)

Lights up when the batteries are not being charged

26

Warning lamp

Engine oil pressure (engine 2 right)

Lights up when the engine oil pressure is too low

27

Indicator lamp

Oil level control (engine 2 right)

Flashes when one oil pump is working.

Is permanently on when both oil pumps are working.

The engine oil level is being regulated when the lamp changes from flashing to being lit up permanently.

28

Warning lamp

Engine temperature (engine 2 right)

Lights up when the engine temperature is too high

29

Warning lamp

Cooling-water level (engine 2 right)

Lights up when the cooling-water level is too low

30

Warning lamp

Electronic speed con- Flashes to indicate a Centry fault. trol (engine 2 right) (Centry) Shut off engine.

Stop work immediately.

Contact the O&K After-Sales Service or the engine manufacturer

Symbol

Lights up permanently to indicate a Centry fault.

Work must be stopped immediately.

Contact the O&K After-Sales Service or the engine manufacturer.

2 731 030.03 en

Update to version .04, see pages 115a and 178a

39

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 4

40

Update to version .04, see pages 115a and 178a

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BI015804

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

Function

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

2 731 030.03 en

Update to version .04, see pages 115a and 178a

Symbol

41

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 5

42

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 5) 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 7 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

2 731 030.03 en

Update to version .04, see pages 115a and 178a

Symbol

43

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 6

44

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 6) 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

Distributor gearbox 1 left contamination

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

62

Warning lamp

Distributor gearbox 2 right contaminated

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

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)

2 731 030.03 en

Update to version .04, see pages 115a and 178a

Symbol

45

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 7

46

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 7) 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.

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

2 731 030.03 en

Update to version .04, see pages 115a and 178a

Symbol

47

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 8

48

Update to version .04, see pages 115a and 178a

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BI015804

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

Function

71

Button

Cold starting (engine 1 Assisted starting for cold engine left)

72

Button

Starting (engine 1 left)

Starts the engine Hold button ca. 5 - 7 sec.

This is necessary to start and pressurize the engine’s prelubricating system.

The engine then starts up automatically.

73

Button

Stopping (engine 1 left)

Shuts off the engine

74

Switch

Idling (engine 1 left)

Shuts off the engine with 5 min. after-run

75

Switch

76

Speed adjustment

Potentiometer (engine 1 left)

Regulates the engine speed - turn CCW to limit stop: idling speed - turn CW to limit stop: full-load speed

77

Button

Centry electronic speed control (engine 1 left)

Activate after a fault indication. The BCS displays a coded fault message or the warning lamp (24) lights up in coded form.

This coding indicates the cause of the fault.

Contact the O&K After-Sales Service or the engine manufacturer.

2 731 030.03 en

Symbol

free for options

Update to version .04, see pages 115a and 178a

49

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 9

50

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 9) No. Element

Function

81

Button

Cold starting (engine 2 Assisted starting for the cold engine right)

82

Button

Starting (engine 2 right)

Starts the engine Hold button ca. 5 - 7 sec.

This is necessary to start and pressurize the engine’s prelubricating system.

The engine then starts up automatically.

83

Button

Stopping (engine 2 right)

Shuts off the engine

84

Switch

Idle (engine 2 right)

Shuts off the engine with 5 min. after-run

85

Switch

86

Speed adjustment

Potentiometer (engine 2 right)

Regulates the engine speed - turn CCW to limit stop: idling speed - turn CW to limit stop: full-load speed

87

Button

Centry electronic speed control (engine 2 right)

Activate after a fault indication. The BCS displays a coded fault message or the warning lamp (30) lights up in coded form.

This coding indicates the cause of the fault.

Contact the O&K After-Sales Service or the engine manufacturer

2 731 030.03 en

Symbol

free for options

Update to version .04, see pages 115a and 178a

51

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 10

52

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 10) 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 position and another travel function (e.g. reverse travel) is switched on, there is an automatic change to 1st gear.

92

Switch

Undercarriage holding CCW: brake CW:

93

Button

Reset

Activate after a fault in the central lubricating system

94

Switch

Slewing mechanism modem

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

95

Switch

ECO (Power Control)

Adjusts the hydraulic power (flow rate) CCW - 80% hydraulic power (flow rate) CW - 100% hydraulic power

96

Switch

Speed reset

CCW:

CW:

2 731 030.03 en

brake permanently applied.

The excavator cannot be driven.

Every time the excavator stops, the undercarriage brake is automatically applied after ca. 8 sec.

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.

normal operation. Automatic diesel engine speed reset; activated during operating intervals automatic speed reset OFF

Update to version .04, see pages 115a and 178a

53

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 11

54

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 11) No. Element 99

Function

Switch

Emergency Operation Boom/Stick

Lowers the boom and stick when actuated in an emergency.

100 Switch

Slewing ring holding brake

Disables the slewing function and brakes the superstructure Actuate switch only when the excavator is stationary.

Never use as a service brake.

101 Switch

Windscreen wiper

Activates permanent/intermittent wiping

102 Switch

Screen washer

Activates permanent/intermittent wiping

103 Switch

Floodlamps

Switches on the floodlamps on the cab

104 Switch

Floodlamps

Switches on the floodlamps on the hydraulic oil cooler

105 Switch

Floodlamps

Switches on the floodlamps on the counterweight

106 Switch

Floodlamps

Switches on the floodlamps on the platform

2 731 030.03 en

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Symbol

55

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 12

56

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 12) No. Element 107 Button

Function Test

Performance check of warning and indicator lamps

108 Switch

free for options

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

Switches the electrical system on and off

116 Button

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EMERGENCY STOP

Symbol

Switches off the entire electrical system

Update to version .04, see pages 115a and 178a

57

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 13

58

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 13) No. Element

Function

Symbol

117 Buzzer

Gives an acoustic warning signal if a fault is reported - Fault in engine system (engine 1 and/or 2; left and/or right) - Coolant level (engine 1 and/or 2; left and/or right) too low - Engine oil pressure (engine 1 and/or 2; left and/or right) too low - Engine oil temperature (engine 1 and/or 2; left and/or right) too high - Hydraulic oil level too low - Distributor 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 engine immediately if the buzzer (117) sounds and the BDS indicates a fault. The buzzer (117) continues to sound until the fault has been rectified.

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59

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 14

60

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 14) No. Element

Function

Symbol

117 Buzzer (continued)

Gives an acoustic warning signal if a fault is reported - Engine oil level (engine 1 and/or 2; left and/or right) too low - Distributor 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 - Discharge current (engine 1 and/or 2; left and/or right, option) too high - Loading current (engine 1 and/or 2; left and/or right, option) too high The buzzer (117) continues to sound until the fault has been rectified.

118 Buzzer

2 731 030.03 en

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

The warning lamp (70) also lights up.

Update to version .04, see pages 115a and 178a

61

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 15

62

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 15) No. Element

Function

121 Button

free for options

122 Button

free for options

123 Button

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

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

Symbol

141 Radio 142 Cigarette lighter

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63

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 16

64

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 16) No. Element

Function

151 Monitoring system

Bucket edge angle monitoring

152 Display

Displays the set limiting values for the bucket angle

153 Display lamp (LED)

Lights up when the bucket angle > than the max. set value.

154 Display lamp (LED)

Lights up when the bucket angle is within the set limits.

155 Display lamp (LED)

Lights up when the bucket angle < than the min. set value.

156 Mode switch

Switches on the calibrating and setting function.

Diese Function is code-protected.

157 Button

Sets the max. limit

158 Button

Sets the min. limit

159 Enter button

Switches the acoustic warning signal on and off.

When switched on, the alarm sounds continuously when the edge angle is larger or smaller than the set limits.

160 ON/OFF button

Switches the monitoring system on and off.

When this button is switched on, the monitoring system starts up with the values last set. These values are filed in a batteryoperated memory.

To switch off the monitoring system, hold the button down for 2 sec.

161 Display

Displays the actual bucket angle.

Angle < 0o: teeth pointing downwards Angle > 0o; teeth pointing upwards

162 Display

Indicates when the acoustic alarm is switched on.

2 731 030.03 en

Update to version .04, see pages 115a and 178a

Symbol

65

BI015804

OPERATING INSTRUCTIONS RH 400

Fig. 17

66

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 (Fig. 17) No. Element

Function

Symbol

171 Radio unit 172 Metering unit 173 Monitor

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67

BI015804

OPERATING INSTRUCTIONS RH 400 PUTTING THE MACHINE INTO OPERATION

Service station (tank lift) 2732085

Before daily start-up, carry out works in accordance with servicing plan T (cf. Part 3 "Inspection and servicing").

The excavator is equipped with a central service station (Fig. 1 and/or 2) for refuelling. The service station is attached to the frame and is accessible from the ground below the superstructure. Express couplings are provided for refilling various consumables (fluids).

Prior to your dailiy start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

Otherwise, increased fire and explosion hazard will exist.

Refuelling Handling chemical substances Observe safety specifications when handling chemical substances.

Fig. 1

Refuelling - Safety instructions Explosion hazard Avoid open flames and stop smoking. Fuels and fuel gases are inflammable. Risk of fire.

Fuel may cause skin injury. Wear protective gloves or use a barrier cream.

Set working equipment down on the ground.

Shut off the engines.

Fig. 2

Do not spill fuel and do not allow fuel to penetrate into the soil. Fuel pollutes the environment.

Wipe off spilt fuel immediately with cleaning rags or soak up with binding agents. Fuel and cleaning material must be disposed of without polluting the environment.

Report accidents involving fuel to the user or his representative.

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BI015804

OPERATING INSTRUCTIONS RH 400

Item Fig.3

Fluid

Express coupling for

Lowering the service station

1

Diesel fuel for lefthand and righthand fuel tank

2

Cooling fluid for left engine

filling and/or draining

Draw out control knob (21, Fig. 3) of valve (22) with rod (25). The service station is brought down to the lower position. Turn control knob (21) by 90˚ and engage.

3

Cooling fluid for right engine

filling and/or draining

Lifting the service station

4

Gearbox oil for left pump transfer gearbox

filling and/or draining

5

Gearbox oil for right pump transfer gearbox

filling and/or draining

Disengage control knob (21) of valve (22), turn by 90˚ and press in. The service station is raised to the top position.

6

Engine oil for left engine oil tank

filling and/or draining

7

Engine oil for right engine oil tank filling and/or draining

8

Engine oil for left engine

filling and/or draining

9

Engine oil for right engine

filling and/or draining

10

Hydraulic oil reservoir and filter chamber cooling

filling and/or draining

11

Grease container - central lubricating system

filling

Refilling and/or draining To fill in or drain fluids, unscrew the cap of the corresponding express coupling (Fig. 3).

Attach express coupling of filling hose from service vehicle to corresponding express coupling at service station. Fill in or drain off fuel.

Detach filling hose and refit cap on express coupling.

filling

Fig. 3

A service vehicle is needed for filling and/or draining of the fluids.

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69

BI015804

OPERATING INSTRUCTIONS RH 400 Measuring devices for fluids

Assemblies or reservoirs

Measuring device

Remarks

Fuel tank

BCS fuel indicator (Fig. 4)

Top up fuel when fuel level has dropped below 1500 l (reserve).

The BCS gives a warning signal.

Stop filling when the fuel tanks are full (service station shuts off automatically through counter-pressure).

Pump transfer gearbox

Dipstick (Fig. 5)

Top up oil when the oil level has dropped to the "min." mark.

Stop filling when the oil level reaches the "max." mark.

Fig. 4

70

Fig. 5

Update to version .04, see pages 115a and 178a

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BI015804

OPERATING INSTRUCTIONS RH 400 Measuring devices for fluids

Assemblies or reservoirs

Measuring device

Remarks

Engine

Dipstick (Fig. 6)

Top up oil when the oil level has dropped to the "min." mark.

Stop filling when the oil reaches the "max." mark.

Engine oil reservoir

BCS display (Fig. 7) Dipstick (1, Fig. 8)

Top up oil when the oil level has dropped to the "min." mark.

The BCS gives a warning signal.

Stop filling when the BCS indicates that the engine oil reservoirs are filled.

Also stop filling when the oil on the dipstick reaches the "max." mark.

Fig. 6

Fig. 8

Fig. 7

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BI015804

OPERATING INSTRUCTIONS RH 400

Assemblies or reservoirs

Measuring device

Remarks

Hydraulic oil reservoir BCS display (Fig. 9) InChecking the oil level: and filter housing spection glass (1, Fig. 10), Extend piston rods of stick and bucket cylinders halfcooling sign (2, Figs. 10 and 11) way.

Set working equipment down on the ground.

Check oil level at an oil temperature of ca. 50˚C with the engines stationary.

Top up oil when the oil level in the inspection glass has dropped below the "min." mark.

The BCS gives a warning signal.

Switch the display system on with the toggle switch (31, Fig. 12).

Stop filling when the oil level in the inspection glass reaches the "max." mark.

The indicator lamp (32) lights up.

On completion of filling, switch the display system off again with the toggle switch (31).

Fig. 9

Fig. 11

Fig. 10

Fig. 12

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BI015804

OPERATING INSTRUCTIONS RH 400

Assemblies or reservoirs

Measuring device

Remarks

Cooling system reser- Inspection glass (4, Fig. voir 13) BCS display (Fig. 14)

Top up cooling fluid when the fluid level in the inspection glass has drop to the "min." mark.

The BCS gives a warning signal.

Stop filling when the inspection glass is filled with cooling fluid.

Grease container BCS display (Fig. 14) central lubricating system

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

Switch on the display system with the toggle switch (33, Fig. 15).

Stop filling when the grease container is full.

The indicator lamp (34) lights up.

On completion of filling, switch the display system off again with the toggle switch (33).

Fig. 13

Fig. 15

Fig. 14

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73

BI015804

OPERATING INSTRUCTIONS RH 400 Switching the electrical system on and off The electrical system is switched on with the key-switch (115, Fig. 16). Insert key into keyswitch and turn to the right.

Battery main switches The battery main switches (10 and 11, Fig. 17) are installed in the control cabinet behind the hydraulic reservoir. The battery main switches disconnect the entire electrical system from the batteries. In "OFF" position, the battery main switches • prevent unauthorized starting of the engines • protect the batteries from inadvertent discharging

Fig. 16 Fig. 17

Only the automatic fire-extinguishing system remains connected to the power supply even when the switches are in "OFF" position.

The two switch positions have the following meaning: I = ON II = OFF Never set the battery main switches to "OFF" with the engines running. The resulting voltage peaks might cause irreparable damage to electrical components.

74

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BI015804

OPERATING INSTRUCTIONS RH 400 Starting and stopping the engines

2732086

Never run engines at full load until they have run for at least 3 minutes at idling speed.

Starting the engines

Repeat the procedure if one of the engines fails to start up, but not more than three or four times.

Never operate the starter for more than 10 seconds.

If, after starting, the BCS (Fig. 2) indicates a fault - in the PMS - in the engine system - because of insufficient engine oil pressure - in the alternator stop the engine concerned immediately.

Locate the cause of the fault and rectify before restarting the engine.

Fig. 1

• Turn speed control knobs (76 and 86, Fig. 1) counter-clockwise to the limit stop (idling speed).

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

Start the engines one after another.

Press button (72) for the lefthand engine.

Release button (72) as soon as the engine has started up.

Fig. 2

Press button (82) for the righthand engine.

Release button (82) as soon as the engine has started up.

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OPERATING INSTRUCTIONS RH 400 Starting the engines with the cold-starting aid • Turn speed control knobs (76 and 86, Fig. 3) counter-clockwise to the limit stop (idling speed).

If the temperature of the engine coolant is above 25 ˚C, the cold-starting system is automatically deactivated.

• Insert key into key-switch (115) and turn clockwise • Actuate the "Cold" button (71) for the lefthand engine two or three times. Each actuation injects ca. 1.5 cm3 of cold-starting fluid into the air intake line of the engine.

• Activate the "Start" button (72).

Release the button as soon as the engine has started up.

• Actuate the "Cold" button (81) for the lefthand engine two or three times. Each actuation injects ca. 1.5 cm3 of cold-starting fluid into the air intake line of the engine.

• Activate the "Start" button (82).

Release the button as soon as the engine has started up.

Never inject a greater quantity of cold-starting fluid. This would result in excessive pressures and detonations.

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OPERATING INSTRUCTIONS RH 400 Shutting off the engines

Emergency stop

During interruptions to work and after work, set the working equipment down on the ground.

In emergencies, e.g. if the buzzer (117, Fig. 4) sounds, the engines can be shut off from full load.

Never shut off the engines until the working equipment is resting on the ground.

• Turn speed control knobs (76 and 86, Fig. 3) counter-clockwise to the limit stop (idling speed).

To do so: • Depress "Stop" button (116) (the entire electrical system is switched off).

• Turn key in key-switch (115) counter-clockwise and withdraw .

Never shut off engines out of full load. The engines should be run at idling speed for another 5 minutes to bring down the temperature and to allow the lubricating oil and the coolant to dissipate the combustion heat from the combustion chamber and from bearings and shafts.

• Depress key (73) for the lefthand engine.

Fig. 4

• Depress key (83) for the righthand engine.

• Turn key in key-switch (115) counter-clockwise and withdraw (electrical system is without current).

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OPERATING INSTRUCTIONS RH 400 Driving Safety instructions

2441639

Have the attachment raised only so far as to permit the machine to be driven under overhead power lines without any risk.

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˚ 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 drive across slopes.

Take the utmost care on slippery, greasy ground.

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

- Drive the excavator in forwards approx. 50 m.

- Stop the excavator.

- Measure the temperature at each idler, track roller and support roller with an infrared thermometer. (at a temperature of approx. 100˚ C wait for idlers, track rollers and support rollers to cool down).

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

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

The engines must be at operating temperature before being subjected to full load.

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 TRAVELLING

2732087

Superstructure basic position Travel direction and sense of actuation of pedals (132 and 133, Fig. 2) are identical only when the excavator is in its BASIC POSITION (Fig. 1).

Travelling forwards/in reverse Travelling forwards Depress pedals (132 and 133) forwards The excavator moves in the direction of the idler (2, Fig. 1) Travelling in reverse 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 that expected when 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 lightly depressed to find out which way the excavator moves before initiating the full travelling movement.

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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 Regulating the travelling speed Travelling on level ground Regulate the travelling speed with • the pedals (132 and 133, Fig. 4) and • Switch (91, Fig. 5) to the right (slow gear) All forward/reverse travel movements are possible with this gear.

• Switch (91) to the left (fast gear) The excavator can be driven only parallel forwards with the fast gear.

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

Turn speed regulators (76 and 86) fully clockwise (full-throttle position).

Fig. 5

Travelling uphill and downhill Read and observe "Travelling Safety instructions".

Change speed range only when the excavator is stationary.

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 To take a righthand corner forwards depress only pedal (132) forwards Fig. 4

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 Note Change the position of the undercarriage - parallel or transverse to the working face - only by cornering forwards/in reverse (Fig. 6).

The same procedure should be adopted if the excavator is to be driven out of depressions (Fig. 7):

Fig. 7 Fig. 6

Cornering to the left from pos. 1 to pos. 2 Cornering to the right from pos. 2 to pos. 3 Cornering to the left: forward from pos. 1 to pos. 2 reverse from pos. 2 to pos. 3 forward from pos. 3 to pos. 4

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 back-wall and bucket front section are subjected to inadmissibly high stresses.

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OPERATING INSTRUCTIONS RH 400 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) to such an extent as to reach the position of the equipment Fig. 8.

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. 40o C.

Fig. 8

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OPERATING INSTRUCTIONS RH 400 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.

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

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 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

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

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

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OPERATING INSTRUCTIONS RH 400 Transporting the machine

2441641

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.

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 low-bed trailer over public roads.

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

Weights and suspensions points are marked on the modules.

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").

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OPERATING INSTRUCTIONS RH 400 WORKING OPERATION, 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.

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Running-in instructions for hydraulic cylinders Compression of an oil/air compound 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 temperatures.

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. 1/2 to 3/4(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 At low temperatures, bring the engines down to moderate speed, then activate all hydraulic functions for about 10 minutes (bring to service temperature). Further instructions are given under "Lubricants".

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.

If the BCS indicates a fault - in the engine control system - in the coolant level - in the engine oil pressure - in the engine temperature - in the hydraulic oil level - in the temperature of a distributor gearbox - in the temperature of a slewing pump - in the temperature of a slewing gearbox - in the lubricating system, lower the working equipment and shut off the engines.

Fig. 1

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OPERATING INSTRUCTIONS RH 400 WORKING OPERATION

2732089

Slewing and braking the superstructure

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.

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 the system: Run the diesel engines at ca. 2/3 full speed and perform no-load working movements for ca. 10 minutes with the excavator.

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 switch (125, Fig. 1).

Electronic excavator control activated operator is seated on driver’s seat.

Electronic excavator control deactivated driver’s seat is empty.

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OPERATING INSTRUCTIONS RH 400 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

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

Loading bucket: Close bucket completely before starting excavation.

Never level off a surface with the front shell of the bucket open.

Raising and lowering the boom To raise the boom: pull control lever (136, Fig. 3) back To lower the boom: pull control lever (136) forward To lower the boom with pressure: depress button (123) and push control lever (136) forward Extending and retracting the bucket or backhoe bucket stick

To empty the bucket by dumping/tipping: shift control lever (136) to the right Opening and closing the bucket To open the bucket: press pedal (131) forwards To close the bucket: press pedal (131) backwards

Lowering the equipment in an emergency In the event of the electronic excavator control and/or the engines failing, lower the equipment as follows: • Switch on the electrical system with the keyswitch (115, Fig. 4).

• Press switch (99).

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

To extend the stick: push control lever (135) forward To retract the stick: Push control lever (135) back

Fig. 3

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OPERATING INSTRUCTIONS RH 400 After daily operation

Excaping oil pollutes the environment.

Parking the machine • Park the machine on level and stable ground.

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

Repair leaks (or have them repaired) immediately.

Report accidents involving oil to the user of the machine.

• Set the working equipment down on the ground.

• Shut off the engines.

• Shift both control levers into 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 as well as of combustible and easily flammable substances, if possible with a stream jet (rubber parts and electric components with compressed air - refer to information label) Otherwise, the fire and explosion hazard will exist.

• 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.

• Check the drive motor (alternator) visually for leaks.

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

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

• Fill up the fuel tanks.

• 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 ASSEMBLING 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.

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

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 life-threatening situations.

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.

90

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.

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

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 Securing the machine Secure the machine as described below:

Risk of injury.

- before carrying out any fitting and modification work on the working equipment,

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.

- 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 engines.

• 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.

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 re-usable 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.

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

Other agents are not approved by O&K.

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 pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated with Voler A.C. anticorrosive 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)

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.

SN 1 438 473 - 0.5 kg tin SN 1 438 219 - 4.5 kg bucket Available from the O&K Spare-Parts Service

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OPERATING INSTRUCTIONS RH 400 >

NOTES

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OPERATING INSTRUCTIONS RH 400 PART 3 - INSPECTION AND SERVICING

Operating manual

Part 1 INTRODUCTION

2804053

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS 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

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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 Inspection and servicing - Safety instructions Operating manual No inspection and servicing work must be carried out until the operating manual has been read and understood.

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

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

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

Inspection and servicing personnel Inspection and servicing personnel must have the necessary knowhow relevant to the inspection and servicing 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 training course.

Personal protective equipment and clothing Wear closely fitting working clothing when working on the machine.

Loose, wide garments may catch on machine parts, resulting in injury.

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

2732119

Securing the working equipment Set the working equipment down 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.

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

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.

Handling chemical substances Observe the safety specifications when handling chemical substances.

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OPERATING INSTRUCTIONS RH 400 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 information label).

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

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

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

Keep solvents and cleaning agents away from 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.

Fuel and other 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 vaporize 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 new hazards.

Fastening and securing elements Check fastening and securing elements, e.g. bolts, nuts and 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 within 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.

Visible 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.

Notify the fire-fighting service.

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OPERATING INSTRUCTIONS RH 400 Relieving residual pressure in the hydraulic system Only unpressurized hydraulic systems may be opened. Even when the machine is parked on a horizontal surface with its attachments resting on the ground and its driving motors 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: (do not leave the driver’s seat) -

Set working equipment down on the ground Shut off engines Move all control levers and pedals repeatedly in all directions.

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

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

Non-polluting disposal Dispose of oils, greases, coolants, detergents, solvents and oil-containing components, such as filters, cleaning rags, replaced wearing parts and unserviceable machine parts, without polluting the environment and separately from other waste.

Never dispose of these substances together with household waste.

Dispose of these substances in the containers provided for such purposes.

Like any other oil, biodegradable, "environmentally friendly" hydraulic oil must be disposed of separately.

Never allow oils and oily waste to penetrate into the soil or into water. They are an environmental hazard.

Seals

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

Individual spares may contain asbestos. Such spares or their packaging are marked . with:

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

Never process spares containing asbestos mechanically. Inhaling asbestos dust is a health hazard.

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

Clean sealing surfaces prior to assembly.

Never repair damaged piping; always replace it.

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

Engine exhaust gases Exhaust gases are a health hazard; never inhale them.

When working on enclosed premises, draw off exhaust gases with a suction plant and ventilate the premises well.

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BI015804

OPERATING INSTRUCTIONS RH 400 Handling batteries

Selecting oils and greases

Batteries give off explosive gases.

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

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 without polluting the environment.

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 the 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&K parts must be used to ensure smooth running and a long service life of the engines and the hydraulic units.

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation, replacing 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 nipples, 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 start up the drive motors while work is being done on the machine.

Carry out performance tests with the machine.

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BI015804

OPERATING INSTRUCTIONS RH 400 Fire and Explosion Hazard

2796685

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 such as turbo superchargers.

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

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BI015804

OPERATING INSTRUCTIONS RH 400 Inspection and servicing plans - Instructions

2732090

Intervals

Air-intake system

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

The air filter must be serviced only if the BCS so indicates. Replace the filter elements after one year at the latest.

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

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 shift1).

W

.... every 60 OH or once a week1).

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.

Oils / Greases 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: 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.

1)

Whichever comes first.

OH = Bh = Operating hours

Change of engine oil The intervals stated for changing the engine oil apply to fuels with a sulphur content of < _ 0.5% and a permanent ambient temperature down to -10oC. In cases of a higher sulphur content and/or a permanent ambient temperature of below -10oC, shorter intervals are required.

If the engine oil change intervals are not reached within 6 months, the oil must be changed at least after 6 months.

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OPERATING INSTRUCTIONS RH 400

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2 731 030.03 en

BI015804

OPERATING INSTRUCTIONS RH 400

Plan V

- Once prior to initial commissioning Page 1 of 2

Location

Servicing work

Quantity/ No.

Engine Engine oil reservoir

Check oil level Check oil level

2 2

Cooling system

Check coolant level

2

Electrical system Battery Lighting

Check charge condition Check operation

8

Monitoring, warning and control elements

BCS Hydraulic system

Check function of working and travelling movements Check function of indicators Check function of monitor

Hydraulic oil reservoir Hydraulic cylinders

Check operation Check service pressure1) 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 leaks and free movement Check oil level Check for leaks and free movement Check tension Check for leaks Lubricate

2x6 2x6 2x3 2 2 2x2

Superstructure Cab - Door - Hinge

Lubricate

3x3

1

1

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

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BI015804

OPERATING INSTRUCTIONS RH 400

Plan V

- Once prior to initial commissioning Page 1 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

Check oil level (cf. "Air Conditioner" operating instructions)

1

Check oil level (cf. "Drive Motor" operating instructions) Check charge condition

1

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

4 2 5 1 1

Air conditioner Compressor Alternator Drive motor - Battery On-board crane - Bearings - Joint (column/boom) - Cylinder bearing - Slewing ring Hydraulic oil reservoir

Crane drive engine

- Battery All lines, fittings and connections

Inspect visually for leaks, wearing marks

All articulated joints and hinges

Lubricate

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1

1

2

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BI015804

OPERATING INSTRUCTIONS RH 400 Plan N

- After initial commissioning and during the running-in period

Page 1 of 2

/Location

Servicing work

After 60 OH Engine - Bearing - Fastening screws

Check for tightness

Cooling system Radiator - Bearing - Fastening screws Water filter

Check for tightness Replace

2x2

Check for tightness Replace Check/clean

2x7 2

Hydraulic system Oil cooler - Bearing - Fastening screws Reflow filter Magnetic rod Filter housing (cooling system) - Reflow filter - Magnetic rod Pressure accumulator - emergency lowering Pressure accumulator - Ramp-type ladder

Replace Check/clean Check pressure Check pressure

Slewing gearbox Fastening screws

Check for tightness (torque wrench)

Travel gearbox Fastening screws

Check for tightness

Quantity / No.

3 1 1 1

Superstructure Fastening screws especially at superstructure / Check for tightness pedestal / cab Undercarriage Diaphragm accumulator - Track tensioner Idler

Check pressure Check oil level

All lines, fittings and connections

Inspect visually for leaks, wearing marks

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2x2 2

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BI015804

OPERATING INSTRUCTIONS RH 400 Plan N

- After initial commissioning and during the running-in period

/Location

Page 2 of 2

Servicing work

Quantity / No.

Pump transfer gearbox

Change oil 2)

2

Slewing gearbox

Change oil 2)

6

Travel gearbox - Pre-chamber

Change oil 2) Change oil2)

2 2x2

Slewing ring Fastening screws (slewing ring undercarriage and superstructure)

Check tightness (torque wrench)

After 100 OH

After 250 OH Superstructure Fastening screws especially at superstructure / Check for tightness pedestal / cab After 500 OH resp. 3 month3) Slewing ring Fastening screws (slewing ring undercarriage and superstructure)

Check tightness (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

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OPERATING INSTRUCTIONS RH 400 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 1 of 2 Location

Servicing work

Quantity / No.

Plan T

Plan W

Engine Engine oil reservoir

Check oil level Check oil level

2 2

• •

• •

Cooling system Radiator

Check coolant level Check/clean

2 2

• •

Fuel system Fuel filter

Drain off water

2x2

•

Air-intake system Intake and clean-air lines

Check BCS indication Check for tightness and leaks

1

• •

Electrical system Lighting

Check operation

Monitoring, warning and con- Check operation of working and traveltrol elements ling movements Check operation of monitoring and warning elements BCS Check operation of monitor

•

•

•

•

•

•

•

•

Hydraulic system Hydraulic oil reservoir Oil cooling system Fins / fan wheel

Inspect visually 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

•

•

Travel gearbox

Check for leaks

2

•

•

Undercarriage Tracks Track roller - Expansion reservoir Support roller Idler Idler guide

Inspect track tension visually Check for leaks and free movement Check oil level Check for leaks and free movement Check for leaks Lubricate

2 2x6 2x6 2x3 2 2x2

•

• • • • • •

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•

• • • • •

•

111

BI015804

OPERATING INSTRUCTIONS RH 400 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

Central lubricating system Grease container Air conditioner Air filter - cab module

Alternator Drive motor - Fuel filter Air filter - Prefractionator - Vacuummeter On-board crane Crane drive engine - Fuel filter

Hydraulic oil reservoir - Reflow filter (contamination indicator)

Quantity / No.

Plan T

Plan W

Check pressure Check grease level (BCS)

1 1

•

• •

Clean (cf. "Air conditioner" operating instructions)

3

Check oil level Drain off water

1 1

•

• •

Check/clean Check (cf. "Drive Motor" operating instructions)

1 1

• •

• •

Check oil level4) Drain off water4) (cf. "Crane Drive Engine" operating instructions) Check oil level4) Check4)

1 1

•

• •

1 1

• •

• •

•

•

All lines, fittings and connec- Inspect visually for leaks, wearing marks tions Excavator

Overall cleaning

•

•

4) before each deployment

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OPERATING INSTRUCTIONS RH 400 Plan A

- after every 250 OH

Plan C

- after every 1000 OH

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

Plan B

- after every 500 OH

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

Plan D

- after every 5000 OH

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

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

Plan E

- after every 10000 OH (at 10000, 20000, 30000 ... OH) Page 1 of 5

Location

Servicing work

Quantity / Plan Plan Plan Plan Plan No. A B C D E

Servicing in acc. with W or T Engine - Bearing - Fastening screws - Rubber bearing - Driving belt (alternator) - Valve clearance Centrifuge - Individual parts - Seals Cooling system Water filter Radiator - Bearing - Fastening screws - Rubber bearing Coolant

•

Change oil5) Clean Check for tightness Check condition Check tension Check condition Check / adjust Check for leaks Clean Check Replace Inspect visually for leaks Replace

22)

•

•

•

•

•

• •

• •

• •

• • • • • • • •

• • • • • • • •

• • • • • • • • •

2x1

• •

• •

2x1 2x1

•

•

• •

• •

• •

• •

• •

•

• • •

• • •

•

•

• •

• •

• • • • • •

•

•

•

• •

• •

• • •

• • •

• • •

•

•

2x2

Lines Hose clamps

Check for tightness Check condition Check DCA4 concentration Replace 6) Check for leaks Check for tightness

Fuel system Fuel filter Tank breather valve

Replace Clean

2x2 2x2

Air-intake system Main filter element Safety filter element Air-intake line and clean-air line Hoses

Check/replace 7) Replace 8) Check for tightness and leaks Replace

2x3 2x3

2) Cf "Refilling quantities-oil" table 5)The maintenance interval can be prolonged if regular oil analyses are carried out and after approval

of the Diesel engine manufacturer has been obtained 6) Change coolant after not more than 2 years 7)Replace main filter element after not more than 1 year or after 3 cleaning cycles.

8)Replace safety filter element after not more than 1 year or after 3 cleaning cycles of the

main filter element.

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BI015804

OPERATING INSTRUCTIONS RH 400 Plan A

- after every 250 OH

Plan C

- after every 1000 OH

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

Plan B

- after every 500 OH

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

Plan D

- after every 5000 OH

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

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

Plan E

- after every 10000 OH (at 10000, 20000, 30000 ... OH) Page 2 of 5

Location

Servicing work

Electrical system Battery and cable connections

Check for tightness

Hydraulic system Oil cooler - Bearing - Fastening screws - Rubber bearing Reflow filter High-pressure filter Magnetic rod Bypass valve Filter housing (cooling system) - Reflow 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)

Quantity / Plan Plan Plan Plan Plan No. A B C D E

•

•

•

•

•

• • • • • • •

• • • • • • •

• • • • • • • • • •

• • • • • • • • • •

•

• • •

Check for tightness Check condition Replace Check / clean Replace Check / clean Clean filter sieve

2x7 2x4 4 2 2x4

• •

• • • •

•

•

Replace Clean filter sieve Check/clean Check/clean Replace Check/clean Replace Check/clean Replace Replace

3 3 1 2x1 2x1 2x1 2x1 2x1 2x1 2

•

•

• •

• •

•

•

•

•

Carry out oil analysis Change oil 9) Replace

1 12)

•

•

2) cf. "Refilling quantities - Oil" table 9) Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than

after 3 years

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BI015804

OPERATING INSTRUCTIONS RH 400 Plan A

- after every 250 OH

Plan C

- after every 1000 OH

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

Plan B

- after every 500 OH

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

Plan D

- after every 5000 OH

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

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

Plan E

- after every 10000 OH (at 10000, 20000, 30000 ... OH) Page 3 of 5

Location

Servicing work

Pump transfer gearbox - Pre-chamber - Breather filter

Change oil Check oil level Clean

22) 2x9 2x1

Slewing gearbox - Venting bore - Slewing gear neck

Change oil Check/clean Lubricate

62) 6 6 x 210)

Travel gearbox

Check oil level Change oil Clean Check oil level Change oil

2 22) 2x4 2x2 2x2

•

•

•

•

1

• •

2x6

- Magnetic screw - Pre-chamber Slewing ring Gearing/pinion Fastening screws (slewing ring, undercarriage and superstructure) Undercarriage Track roller - Venting valve Support roller Idler Superstructure Cab - Bearing - Fastening screws -Rubber bearing - Door - Hinge

Check grease filling Check condition Check for tightness (torque wrench)

Check for leaks and free movement Clean Check for leaks and free movement Check for leaks

Quantity / Plan Plan Plan Plan Plan No. A B C D E • • •

• • •

• • •

•

• • •

• • •

• • • • •

• • • • •

• •

• •

• • •

•

•

•

•

2x6 2x3

• •

• •

• •

• •

2

•

•

•

•

• •

• •

• •

•

•

•

Check for tightness Check condition Lubricate

3x3

•

2) cf. "Filling quantities - Oil" table 10) Lubricate bearings at least once a year

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BI015804 BA 6090FS (2 731 030.04)-EN

Inspection and Servicing

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 6 of 7 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 .04, see pages 115a and 178a































115a

BI015804

OPERATING INSTRUCTIONS RH 400 Plan A

- after every 250 OH

Plan C

- after every 1000 OH

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

Plan B

- after every 500 OH

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

Plan D

- after every 5000 OH

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

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

Plan E

- after every 10000 OH (at 10000, 20000, 30000 ... OH)

Location

Servicing work

Central lubricating system Grease sieve Check/clean Grease container - Breather filter Check/replace Ramp-type ladder - guide pulleys - locking bolt Air conditioner Air filter (cab module) Compressor

Alternator Drive motor

- Fastening screws - Fuel filter

Air filter - Main filter element - Safety filter element Battery, cable connections

Page 4 of 5 Quantity / Plan Plan Plan Plan Plan No. A B C D E

6

•

•

•

1

•

•

•

Lubricate Lubricate

3 1

• •

• •

• •

Replace Change oil (cf. "Air Conditioner" operating instructions)

3 111)

•

• • •

• • •

• • •

Clean motor Change oil Replace oil filter Check for tightness Replace cf. "Drive Motor" operating instructions

1 12) 112)

• • • • • •

• • • • • •

• • • • • •

• • • • • •

•

• • •

• • •

• • •

Clean/replace Replace Check for tightness

• • • •

112) •

112) 112) 1

•

2) cf. "Filling quantities - Oil" table.

11) Change oil at least once a year 12) Replace filter at least once a year

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BI015804

OPERATING INSTRUCTIONS RH 400 Plan A

- after every 250 OH

Plan C

- after every 1000 OH

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

Plan B

- after every 500 OH

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

Plan D

- after every 5000 OH

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

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

Plan E

- after every 10000 OH (at 10000, 20000, 30000 ... OH)

Location

On-board crane13) - Bearings - Joint (column/boom) - Cylinder bearing - Slewing ring Hydraulic system - Reflow filter - Breather filter

Crane drive engine

- Fastening screws - Air filter - Fuel pre-filter - Fuel filter - Battery cable connection

Servicing work

Lubricate Lubricate Lubricate Lubricate Öl Replace2) Replace Replace cf. "On-Board Crane" operating instructions Motor Clean Change oil2) Replace oil filter Check for tightness Replace Replace Replace Check for tightness cf. "Crane Drive Engine" operating instructions

Page 5 of 5 Quantity / Plan Plan Plan Plan Plan No. A B C D E

4 2 5 1 1 1 1

1 1 1

• • • •

• • • •

•

•

• • • •

• • • •

• •

• • • •

1 1 2

• • • • • • • •

• • • • • • • •

• • • • • • • •

• • • • • • • • •

• • • • • • • • •

• • • • • • • • •

Steel components

Carry out visual inspection

•

•

•

All articulated joints and hinges

Lubricate

•

•

•

2) cf. "Filling quantities - Oil" table 13) Do all servicing jobs at least once a year and when necessary

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BI015804

OPERATING INSTRUCTIONS RH 400 LUBRICATING CHART - GREASE (Loading bucket)

2732091

Fig. 1

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BI015804

OPERATING INSTRUCTIONS RH 400 Lubricating chart - Grease / Loading bucket (legend) No.

Greasing point

1

Central lubricating system - grease container

2

Number

Lubricant properties

Grease every .... operating hours

1

10

Idler guide

2x2

60

3

Hinge (cab door)

3x3

4

Slewing gear neck

6x2

3000

5

Ramp-type ladder - Deflection roller

3

1000

- Locking bolt

1

I

1)

1000

On-board crane2) - Bearing - Joint (column/boom) - Cylinder bearing

4 2 5

V

250 250 250

- Slewing ring

1

6

V

1)

1)

Graphite spray

1000

250

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities - Grease Greasing point, component

Lubricant properties Filling quant. in kg

Central lubricating system - grease container Internal gearing - Roller-bearing slewing ring

500

V

1)

600

1) cf. "LUBRICANTS" section.

2) at least once a year and when necessary Bh = OP = Operating hours

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BI015804

OPERATING INSTRUCTIONS RH 400 INSPECTION PLAN - OIL

2413584

Fig. 2

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BI015804

OPERATING INSTRUCTIONS RH 400 Inspection plan - Oil (legend) No.

Location

Number

Lubricant properties 1)

Check oil level every ... OH

Change oil every ... OH

I I II

10

5002)

1

Engine

2

2

Engine oil reservoir

2

3

Hydraulic system

1

4

Pump transfer gearbox

2

10 10

60002)

10

1000

III 4

- Pre-chamber

2x9

5

Slewing gearbox

3

6

Travel gearbox

2

500

III

10

3000

500

3000

500

3000

III - Pre-chamber

2x2

7

Rollers

2x6

III

10

8

Alternator 1

I

10

250

I II

10

2503)

10

10003)

- Drive motor 9

On-board crane - Crane drive motor

1

- Hydraulic oil tank

1

Bh = OP = Operating hours 1) cf. "LUBRICANTS" section.

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.

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BI015804

OPERATING INSTRUCTIONS RH 400

Filling quantities - Oil Location

Filling quantity (liters)

Öl

Engine

2 x 204

I

Engine oil reservoir

2 x 640

I

Hydraulic system - Hydraulic oil reservoir and filter housing cooling system

10000

II

Pump transfer gearbox

2 x 160

- Pre-chamber (working pumps)

8x2

- Pre-chamber (hydraulic pumps)

10 x 1

Slewing gearbox

6 x 22

Travel gearbox (main and pilot gearbox)

2 x 215

-Pre-chamber

4 x 2,5

Idler (oiled for life)

2 x 36

Track rollers (oiled for life)

12 x 45

Support rollers (oiled for life)

6 x 15

Driving motor for alternator

14

On-boaord crane - Crane driving motor

5,5

- Hydraulic oil reservoir

50

III III III III III III I I II

Filling quantities - other Location

Filling quantity (liters)

Cooling system - engine

2 x 330

Fuel tank

2 x 8000

Fuel tank, crane engine

25

Screen washer

13

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OPERATING INSTRUCTIONS RH 400 LUBRICANTS

I.

2804268

Oils for combustion engines and compressors (selection)

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II.

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Oils for hydraulic systems (selection)

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OPERATING INSTRUCTIONS RH 400

III.

Oils for gearboxes (selection)

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OPERATING INSTRUCTIONS RH 400

V.

126

Greases for bearings and slewing rings

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OPERATING INSTRUCTIONS RH 400 SERVICING WORK

2732602

Hose line for oil and coolant changes Collect escaping oil and coolant and discard without polluting the environment.

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 easily.

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

Change the oil as follows: - Place a collecting recipient for used oil under the corresponding drain valve. For the recipient capacity, refer to the "Refilling quantities - Oil" table.

- Unscrew protective cap from drain valve.

- Screw on hose line (2) to open the valve, so that the oil can flow out.

- When the oil has drained out, unscrew the hose line to allow the valve to close automatically.

- Screw protective cap back in place.

Fig. 1

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OPERATING INSTRUCTIONS RH 400 ENGINE

2732092

Engine - Safety instructions Read and observe: "Inspection and servicing - Safety instructions" and the engine operating instructions.

Risk of injury from hot or rotating parts of the engine.

Shut off engines and leave to cool down.

Checking the engine oil level / Topping up • Park machine on a horizontal surface and secure against inadvertent movement.

• Shut off engines.

• Draw out oil dipstick (1, Fig. 1).

• Wipe oil off dipstick with a clean, lint-free cleaning rag and re-insert.

Secure the machine as described under "Securing the machine".

Protect the skin from potentially harmful contact with engine oil.

Wear protective gloves and firm protective clothing.

Checking/adjusting the V-belt tension Checking/adjusting the valve clearance These and other servicing works are described in the engine manufacturer’s operating instructions.

Fig. 1

• Draw out dipstick a second time. The oil level should now be between the marks (arrows, Fig. 2).

Fig. 2

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OPERATING INSTRUCTIONS RH 400 If the oil level is at the "min" mark or below, top up with engine oil through the service station (Fig. 3) through

Checking the oil level in the engine oil reservoir / Topping up

- express coupling (8) for the lefthand engine

The engine oil level is monitored continuously by the BCS during operation.

The actual engine oil level can be displayed on the monitor (Fig. 5).

- express coupling (9) for the righthand engine.

Fig. 3

Engine oil can also be filled in through the filler tube (2, Fig. 4).

Fig. 5

• Park the machine on a horizontal surface and secure against inadvertent movement.

Fig. 4

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OPERATING INSTRUCTIONS RH 400 • Shut off engines.

Changing the engine oil

• Release and withdraw dipstick (1, Fig. 6).

• Wipe oil off dipstick with a clean, lint-free cleaning rag.

• Insert dipstick; the oil level should reach the mark.

Read and observe: "Inspection and servicing - Safety instructions".

Risk of scalding from hot engine oil.

The engines may also be hot.

Wear protective gloves and firm protective clothing.

Collect escaping oil and discard without polluting the environment.

Drawing off engine oil with the service station • Bring engine oil to operating temperature.

• Park machine on a horizontal surface and secure.

• Shut off engines.

Fig. 6

If the oil level is below the mark, fill in engine oil from the service station (Fig. 7) through - express coupling (6) for the lefthand engine oil tank - express coupling (7) for the righthand engine oil tank.

Draw off engine oil through - express coupling (8, Fig. 7) for the lefthand engine - express coupling (9) for the righthand engine.

• Unscrew cap of express coupling and connect hose line of service vehicle.

The hose line and its use are described under "Hose line for oil and coolant change".

Fig. 7

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OPERATING INSTRUCTIONS RH 400 Filling in engine oil through the service station Fill in engine oil through - express coupling (8, Fig. 8) for the lefthand engine - express coupling (9) for the righthand engine until the oil level reaches the "max" mark (Fig. 10) on the dipstick (1, Fig. 9).

Fig. 10

• Start the engines and run at idling speed for ca. 2 minutes.

• Check oil level at dipstick (1, Fig. 9) and top up with oil to the "max" mark (Fig. 10) if necessary.

• Remove the filling hose.

The express coupling closes automatically.

Fig. 8

• Unscrew cap of express coupling and connect filling hose of service vehicle.

The hose line and its use are described under "Hose line for oil and coolant change".

• Screw on protective cap.

• Engine oil can also be filled in through the filler tube (2, Fig. 9).

Fig. 9

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OPERATING INSTRUCTIONS RH 400 Changing the oil of the engine oil reservoir Read and observe: "Inspection and servicing - Safety instructions".

Drain off engine oil Engine oil can also be drained off through the plug (4, Fig. 12).

Risk of scalding from hot engine oil.

The engine oil reservoirs may also be hot.

Wear protective gloves and firm protective clothing.

Collect escaping oil and discard without polluting the environment.

Drawing off engine oil • Bring engine oil to operating temperature.

• Park the machine on a horizontal surface and secure.

Fig. 12

• Shut off the engines.

• Provide a collecting recipient for the used oil.

The required capacity is set out in the "Filling quantities - Oil" table.

Draw off engine oil with the service station (Fig. 11) through - express coupling (6) for the lefthand engine oil reservoir - express coupling (7) for the righthand engine oil reservoir.

• Connect hose line at drain plug (4).

• Unscrew plug (4) and drain off used oil.

• Tighten plug (4) again.

• Unscrew cap of express coupling and connect hose line of service vehicle.

Fig. 11

The hose line and its use are described under "Hose line for oil and coolant change".

• Remove the hose line.

The express coupling closes automatically.

• Screw on protective cap.

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OPERATING INSTRUCTIONS RH 400 Filling in engine oil

Fig. 14 Fig. 13

Fill in engine oil via the service station (Fig. 13) through - express coupling (6) for the lefthand engine oil reservoir - express coupling (7) for the righthand engine oil reservoir until the oil level on the dipstick (1, Fig. 14) reaches the mark or the BCS (Fig. 15) indicates the max. oil level.

• Start the engines and run at idling speed for ca. 2 minutes.

• Check oil level at dipstick (1, Fig. 14) and top up with oil to the mark if necessary.

• Remove the filling hose.

The express coupling closes automatically.

• Screw on protective cap.

• Unscrew cap of express coupling and connect hose line of service vehicle.

The hose line and its use are described under "Hose line for oil and coolant change".

Fig. 15

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OPERATING INSTRUCTIONS RH 400 Eliminator filter and centrifuge

Centrifuge

Read and observe: "Inspection and servicing - Safety instructions" and the Moatti Lube Oil Filter Instruction Book.

Engine oil impurities filtered out in the eliminator filters (1, Fig. 16) are transported to the centrifuge (2) where they are filtered out by centrifugal force.

Risk of injury from rotating parts in the centrifuge.

Servicing

The eliminator filter may be hot.

• Shut off engines

Wear protective gloves and firm protective clothing.

• Wait for 5 - 10 min.

Collect escaping oil and discard without polluting the environment.

Dismantling the centrifuge The rotor of the centrifuge must be stationary.

The pressure in the centrifuge must have been eliminated.

The rotor may be hot.

Wear protective gloves and firm protective clothing.

• Slacken screws (2, Fig. 17).

• Slacken hollow screw (6) and remove together with cover (1).

• Withdraw rotor housing (4) and set down on a timber base.

Fig. 16

Impurities in the engine oil are filtered out in the eliminator filter (1, Fig. 16).

• Unscrew nut (3) and remove rotor housing (4).

• Remove dirt in rotor housing by tapping lightly.

Most of the cleaned engine oil flows back to the engine after being cleaned.

A small quantity of the engine oil flows in the bypass to the centrifuge (2).

The eliminator filter is self-cleaning and maintenance-free. (cf. Moatti Lube Oil Filter Instruction Book)

Fig. 17

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OPERATING INSTRUCTIONS RH 400 • Withdraw plate assembly (12, Fig. 18) from rotor (13).

Cleaning the centrifuge • Check the inside of the rotor housing.

The plates may have sharp edges.

• Remove any dirt deposits without damaging the surface of the rotor housing.

If necessary, clean all centrifuge parts in diesel fuel. Remove all residual dirt particles with compressed air or an air/water pistol.

Adhering dirt unbalances the rotor and may damage the bearings.

Assembling the centrifuge

The plates (16, Fig. 19) have 4 possible opposing positions.

Fig. 18

• Remove clip (14, Fig. 19) and distributor plate (15).

• Remove plates (16) and end plate (17) from distributor (18) .

• Place paper filter into the rotor cap (4, Fig. 18): • Assembly is done in the reverse sequence to dismantling.

• Run engines at idling speed for a short time and check centrifuge for leaks.

• Shut off engines.

• Check oil level after ca. 10 minutes; top up if necessary.

Fig. 19

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OPERATING INSTRUCTIONS RH 400 COOLING SYSTEM

2732093

Radiators

Read and observe: Inspection and servicing - Safety instructions.

The radiators are located on the superstructure in the counterweight module.

Secure the machine as described under "Securing the machine".

Weekly checks:

Shut off engines and leave to cool down.

- Check radiator fins for dirt; clean if necessary.

Coolant level

Risk of scalding from hot coolant.

Collect escaping coolant and discard without polluting the environment.

If the coolant level is too low, this is displayed by the BCS on the monitor (Fig. 1).

Protect the skin from potentially harmful contact with coolant.

Wear protective gloves and firm protective clothing.

Temperature The coolant circuit is controlled by a thermostat.

The max. admissible temperature is ca. 100oC. At higher temperatures the BCS displays a warning on the monitor (Fig. 1).

Fig. 2

The coolant level can also be seen in the inspection glass (4, Fig. 2).

The coolant level should reach the lower edge of the filler plug; top up if necessary.

The inspection glass (4) must be full to the top.

Fig. 1

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OPERATING INSTRUCTIONS RH 400 Topping up coolant

Coolant can be filled into the cooling system through the filler plug (1, Fig 4).

Top up coolant via the service station (Fig. 3) through - express coupling (2) for the lefthand engine - express coupling (3) for the righthand engine.

Fig. 4

Never fill in cold coolant when the engine is at operating temperature.

Before refilling, leave engine to cool down to below 50 ˚C. Fig. 3

• Unscrew cap of express coupling.

Connect filling hose of service vehicle.

The hose line and its use are described under "Hose line for oil and coolant change".

The caps (1, Fig. 4) are accessible from above.

Risk of scalding from hot coolant.

Open cap with great care.

• Remove hose.

The express coupling closes automatically.

• Screw on protective cap.

• Turn cap (1) to first catch position.

• When pressure has been relieved, turn to opening position and remove.

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OPERATING INSTRUCTIONS RH 400 Use only specially prepared water to top up the cooling system.

Specially prepared water must consist of:

Coolant Read and observe: "Inspection and servicing - Safety instructions".

• calcium-free water, distilled water, rainwater

Risk of scalding from hot coolant.

• rust-proofing oil (Stir 1 % by volume of rust-proofing oil slowly into the cooling water - not vice versa).

The radiators may also be hot.

Wear protective gloves and firm protective clothing.

• antifreeze compound (The antifreeze compound / cooling water mixing ratio should be adapted to the expected temperatures but should not be less than 50/50 %).

After filling in coolant, run the engines for a short time to remove entrapped air before topping up with coolant to the lower edge of the filler plug.

Collect escaping coolant and discard without polluting the environment.

Replace coolant regularly - at least every 2 years.

Drawing off coolant

• Remove hose from express coupling.

The express coupling closes automatically.

• Screw on protective cap.

In the event of significant coolant losses, check the entire cooling system for leaks.

Check regularly: • all lines for leaks and hose clamps for tightness.

Fig. 5

Draw off coolant via the service station (Fig. 5) through - express coupling (2) for the lefthand cooling circuit - express coupling (3) for the righthand cooling circuit.

• Unscrew cap of express coupling.

Connect hose line of service vehicle.

The hose line and its use are described under "Hose line for oil and coolant change".

• Remove hose line.

The express coupling closes automatically.

• Screw on protective cap.

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OPERATING INSTRUCTIONS RH 400 Filling in coolant

Coolant can also be filled in through the filler plug (1, Fig. 7).

• Shut off engines Fill in coolant via service station (Fig. 6) through - express coupling (2) for the lefthand cooling circuit - express coupling (3) for the righthand cooling circuit.

• Unscrew cap of express coupling.

Connect filling line of service vehicle.

The hose line and its use are described under "Hose line for oil and coolant change".

• Remove hose from express coupling.

The coupling closes automatically.

• Screw on protective cap.

Fig. 7

Testing the coolant composition The engine operating instructions contain a detailed description of how to prepare and test the coolant. If there is a risk of frost, check that the factory-set antifreeze concentration is sufficient for the expected temperatures.

Check the coolant in the cooling system at regular intervals to ensure that the water filter replacement interval or the DCA4 concentration is sufficient to prevent corrosion in the respective operating conditions.

Fig. 6

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OPERATING INSTRUCTIONS RH 400 Water filter Read and observe: "Inspection and servicing - Safety instructions".

Risk of scalding from hot coolant.

The filter housings may also be hot.

Wear protective gloves and firm protective clothing.

Collect escaping coolant and discard without polluting the environment.

Fig. 8

Replace water filter are regular intervals • Close valve (2, Fig. 8).

• Unscrew water filter (1).

Tightening the filter element with a tool may damage or distort the filter head.

• Screw on new water filter until the sealing ring contacts the filter head. Then tighten the filter with another 1/2 to 3/4 turn.

• Open valve (2).

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OPERATING INSTRUCTIONS RH 400 AIR-INTAKE SYSTEM

2732094

Read and observe: "Engine - Safety instructions".

Risk of injury from rotating or hot parts of the engine.

Main filter elements Insufficient air-intake performance, resulting from contaminated main filter elements, is displayed by the BCS on the monitor (Fig. 2).

Clean or replace main filter elements only if the BCS displays a warning on the monitor (Fig. 2) when the engines are running at high idling speed.

Shut off the engines before working on the air-intake system.

Secure the machine as described under "Securing the machine".

Never start up the engines when parts of the air-intake system have been removed.

The engines can be damaged by unfiltered air.

Each of the engines has three dry-air filters (Fig. 1) consisting of main and safety filter element.

Fig. 2

Removal and installation • Unscrew nut (1, Fig. 3) and remove cover (2).

• Unscrew nut (4) and withdraw main filter element (5), taking care not to lose the washer under nut (4).

• Replace or clean main filter element (5).

Fig. 1

New or cleaned main filter elements should always be at hand to shorten excavator downtimes.

Fig. 3

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OPERATING INSTRUCTIONS RH 400

Before installing the filter elements, clean contact faces at cover (2, Fig. 4) and at filter housing.

• Put on cover (2) and tighten nut (1).

During removal of the main filter element, the safety filter element (7, Fig. 5) must remain in the filter housing.

Fig. 6

Blow filter element (Fig. 7) clean with dry compressed air from inside to outside by moving the compressed-air gun up and down.

The pressure at the nozzle must not exceed 6 bars.

Cleaning is completed when all visible dust has been blown out of the filter element.

Fig. 4

Checking and cleaning the main filter element Examine the filter paper of the element by inserting a lamp into the element (Fig. 6).

Any damage is then clearly visible.

Replaced damaged or deformed elements immediately.

Check element seal. If it is damaged, the filter element must also be replaced.

Cleaning with compressed air allows the filter element to be re-used immediately.

Fig. 7

Never clean filter element by beating against hard objects.

Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Fig. 5

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OPERATING INSTRUCTIONS RH 400 • Unscrew vacuum indicator (6, Fig. 8) and withdraw safety filter element (7).

Safety filter element Replacement Replace the safety filter elements (7, Fig. 8) after 1000 operating hours or 3 cleaning cycles of the main filter element, but not later than after one year of operation.

• Install new safety filter element and cleaned or new main filter element.

Never clean the safety filter element; always replace it.

Fig. 9

Fig. 8

• Remove main filter element (5, Fig. 9) as described above.

• Check vacuum indicator (6, Fig. 8 or arrows Fig. 10): - if the green spot is visible, the safety filter need not be replaced, - if the green spot is not visible, the safety filter must be replaced.

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OPERATING INSTRUCTIONS RH 400 Air-intake lines

Dust collection

At regular intervals:

Dust accumulating on the base of the filter housing is continuously sucked away by the exhaust system during operation.

• check intake lines for leaks and hose clamps for tightness, • replace hoses between filter housing and engine.

When doing any work on the air-intake system, ensure proper sealing to prevent unfiltered air from reaching the engines.

Non-return valve (1, Fig. 11) in the suction lines prevents engine exhaust gases from being sucked in.

At regular intervals: • check suction lines for leaks and hose clamps for tightness.

Fig. 11

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OPERATING INSTRUCTIONS RH 400 FUEL SYSTEM

2732095

Replacing the fuel filter

Fuel system - Safety instructions Read and observe: "Inspection and servicing - Safety instructions".

Read and observe: "Inspection and servicing - Safety instructions".

Collect escaping fuel and discard without polluting the environment.

When working on the fuel system: - shut off the engines - secure the machine as described under "Securing the machine".

- keep away naked flames - do not smoke

Avoid potentially harmful skin contact with diesel fuel.

Wear firm protective clothing.

Wear protective gloves or use a barrier cream.

Collect escaping fuel and discard without polluting the environment.

Avoid potentially harmful skin contact with diesel fuel.

Wear firm protective clothing.

Wear protective gloves or use a barrier cream.

Fig. 1

• Unscrew filters (5, Fig. 1).

• Fill new filters with clean fuel and screw onto filter head by hand.

• Tighten filters with another 1/2 to 3/4 turn.

Tightening the filter element with a tool may damage or distort the filter head.

The fuel filters (5) serve simultaneously as water separators.

• Open valve (6) and drain off water until fuel emerges.

• Close valve (6).

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OPERATING INSTRUCTIONS RH 400 Venting the fuel system

Cleaning the fuel tanks Explosion hazard

The fuel tanks are vented with breather valves (3, Fig. 2).

Read and observe: "Inspection and servicing - Safety instructions".

Clean breather valves at regular intervals.

Never use white spirit, paraffin oil or other solvents.

• Remove breather valve, flush with paraffin oil and blow clean with compressed air.

Use diesel fuel for flushing and cleaning.

Avoid potentially harmful skin contact with diesel fuel.

Wear firm protective clothing.

Wear protective gloves or use a barrier cream.

Fuel must be prevented from penetrating into the soil. Keep fuel for re-use or discard without polluting the environment.

• Use up as much fuel as possible.

• Check how much fuel is left in the tank and place a sufficiently large collecting recipient under the drain plugs of the tank.

• Connect hose to drain plug.

Fig. 2

• Unscrew automatic drain plug (7, Fig. 3) at fuel tank and drain off fuel.

• Flush out tank with diesel fuel.

• Screw automatic drain plug (7) back in place.

Fig. 3

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OPERATING INSTRUCTIONS RH 400 • Fill both fuel tanks with the service station (1, Fig. 4).

The filling level is displayed by the BCS on the monitor (Fig. 5).

Fig. 5 Fig. 4

• Unscrew cap of express coupling.

Connect filling hose of service vehicle.

• Remove filling hose.

The express coupling closes automatically.

• Screw on protective cap.

The hose line and its use are described under "Hose line for oil and coolant change".

Fig. 6

• Fuel can also be filled in through the sieve inset in the filler plug (2, Fig. 6).

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OPERATING INSTRUCTIONS RH 400 ELECTRICAL SYSTEM

2732096

Electrical system - Safety instructions Read and observe: "Inspection and servicing - Safety instructions".

Risk of injury from battery acids and gases.

Wear goggles, protective gloves and firm protective clothing.

Carry out voltage and continuity checks only with a test lamp of measuring instrument. Never check by "touching ground" with a bare wire. The resulting short circuit damages the alternator and the electronic modules of the PMS.

Alternator - Instructions

The electrical circuit diagrams are attached to the spare-parts list. Further information is given in the O&K leaflet "Working with circuit diagrams".

The electrical control cabinet is located behind the hydraulic reservoir. It is described in the spare-parts list together with the designation of the electrical components.

Cut off the electrical system with the battery main switch before working on the electrical system.

This prevents accidents, inadvertent starting of the engines, and short circuits.

Cables and cable lugs must not come into contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

To prevent damage to the alternators and regulators, never disconnect cables from alternators, regulators and batteries when the engine is running.

When connecting the batteries, do not interchange the cables (observe polarity).

Carry out voltage and continuity checks only with a test lamp of measuring instrument. Never check by "touching ground" with a bare wire. The resulting short circuit damages alternators and regulators.

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OPERATING INSTRUCTIONS RH 400 Battery main switches / Main fuse

Batteries

The battery main switches and the main fuse are located in the control cabinet behind the hydraulic reservoir.

Removing and installing the batteries Read and observe: "Inspection and servicing - Safety instructions".

Wear protective gloves and firm protective clothing.

Shut off the engines before removing the batteries, to prevent the alternator and regulator from being damaged.

Turn key in key-switch to position "0" and withdraw.

Set battery main switches (Fig. 1) to OFF. Disconnect and reconnect terminal clamping lugs in the prescribed order.

Fig. 1

After withdrawing 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 are, however, still under tension. These lines can be de-energized with the battery main switches. Shut off the electrical system when carrying out repair work or during prolonged excavator downtimes.

Battery main switches (10 and 11, Fig. 1):

Disconnection and reconnection in the wrong order may result in short circuits.

The batteries (1, Fig. 2) are located in the battery box (2) behind the hydraulic reservoir. The 12 V batteries are connected in series and in parallel so that the system voltage is 24 V.

- Position ON = switched on - Position OFF switched off

Fig. 2

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OPERATING INSTRUCTIONS RH 400 • Unscrew nuts (4, Fig. 3)

Battery box

• Remove battery holder (3).

• Disconnect cable lug from negative terminal of battery.

• Disconnect cable lug from positive terminal of battery.

Removing and installing the battery box If necessary, the battery box can be detached completely from the excavator.

• Disconnect first the four negative poles and then the four positive ones.

• Insulate cable lugs.

• Lift battery out of battery box.

The poles are connected to terminal strips beside the engine switch cabinets.

• Loosen the battery box and lift out of the excavator using appropriate lifting gear.

Fig. 3

Before installing new batteries, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.

• Install the new batteries.

• Connect cable lug to positive terminal of battery.

Tighten clamping screws of cable lugs but without using force, to avoid distortion.

• Connect cable lug to negative terminal of battery.

• Apply special terminal grease or acid-free Vaseline to battery terminal posts and clamping lugs.

Loose or corroded clamping lugs will lead to alternator and regulator overloading.

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OPERATING INSTRUCTIONS RH 400 HYDRAULIC SYSTEM

2732097

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 engines.

Risk of burning from hot hydraulic components (e.g. hydraulic oil reservoir, cylinders, valves) .

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 drive engines stationary, 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 pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after immobilization, the system must be depressurized.

Secure the machine as described under "Securing the machine".

Avoid potentially harmful skin contact with hydraulic oils.

Wear protective gloves and firm protective clothing.

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 Examples of system sections: 1) working hydraulics 2) precharged return-flow line

Checking the hydraulic oil level / Topping up

Depressurizing

• Bring hydraulic oil to operating temperature (ca. 50˚C).

• Park the excavator on a horizontal surface.

• Set the working equipment down on the ground.

• Shut off the drive engines.

• Switch on the electrical system.

• Park the machine on a reasonably horizontal surface.

• Move all hydraulic cylinders to their central positions.

The oil level must be between the 1/2 and 3/4marks 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 BSC. A warning is displayed on the monitor (Fig. 4) if the hydraulic oil level is too low. Shut off the engines, locate cause and rectify.

Fig. 2

Section 2: return-flow line After shutting down the engines, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

Fig. 4

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OPERATING INSTRUCTIONS RH 400

Fig. 7

Fill in hydraulic oil via the service station (Fig. 7).

• Unscrew cap of express coupling (10).

Connect filling hose of service vehicle.

Fig. 5

Set working equipment down on the ground as shown on the sign (Fig. 5) The sign (2, Fig. 6) is located beside the inspection glass. (1).

The hose line and its use are described under "Hose line for oil and coolant change".

• Fill in hydraulic oil until the oil level is between 1 /2 and 3/4of 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 Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) Read and observe: "Inspection and servicing - Safety instructions".

Shut off engines.

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.

Fig. 8

Hydraulic oil can also be filled in through the return-flow filter (Fig. 8).

Collect escaping hydraulic oil and discard without polluting the environment.

• 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 to 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 1/2 and 3/4of 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 • 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 in paraffin oil.

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OPERATING INSTRUCTIONS RH 400 Bypass valves (hydraulic oil reservoir) Read and observe: "Inspection and servicing - Safety instructions".

Shut off engines.

Risk of scalding due to hot hydraulic oil.

• Install cover (3, Fig. 13) together with sealing ring (5).

• The screens 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").

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.

Cleaning the filter screens • Remove cover (3, Fig. 13 and/or Fig. 14) together with sealing ring (5, Fig. 14).

• Unscrew screws (22).

• Remove holder (26) and screen (21).

• Clean screen (21) in white spirit or paraffin oil, or replace if necessary.

Fig. 14

• 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 screen (21) with holder (26).

Fig. 15

Fig. 13

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OPERATING INSTRUCTIONS RH 400 Replacing the hydraulic oil return-flow filters (filter housing - cooling system) Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines.

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.

Replace the return-flow filters together with the return-flow filters in the hydraulic oil reservoir.

Fig. 17

• 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 cause and rectify.

Contact the O&K Service if necessary.

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OPERATING INSTRUCTIONS RH 400 Bypass valves (filter housing - cooling system)

• Remove cover (30, Fig. 18 and/or Fig. 19) together with sealing ring (36, Fig. 19).

• Unscrew (22) screws.

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines.

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 screen (21).

• Clean screen (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 screen (21) with holder (26).

• Install cover (30) together with sealing ring (36).

Cleaning the filter screens Clean the bypass valves together with the bypass valves in the hydraulic oil reservoir.

Fig. 19

Fig. 18

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OPERATING INSTRUCTIONS RH 400 Breather filters Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines.

Risk of scalding from hot hydraulic oil.

The hydraulic oil reservoir may also be hot.

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 distributor gearboxes.

Avoid potentially harmful skin contact with hydraulic oil.

Wear protective gloves and firm protective clothing.

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 engines.

Fig. 20

• Unscrew screws (21). Remove holder (22) and withdraw filter element (20).

• Check filter element, replacing if necessary.

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.

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OPERATING INSTRUCTIONS RH 400 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 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 distributor 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 engines.

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 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 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 distributor 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 engines.

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 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 distributor gearboxes.

Checking/cleaning the filter elements • Unscrew drain plug (11, Fig. 28) and drain the hydraulic oil from the filter housing (9). (place a suitable recipient under the filter housing) • Unscrew filter housing (9).

• Withdraw filter element (15) from filter housing (9).

• Clean filter element (15) in white spirit or paraffin oil.

Replace 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), replacing if necessary.

• Reassemble the filter element in the reverse order.

• Check for leaks after putting the filter into operation.

Fig. 27

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines.

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, slightly oiled sealing rings (10 and 14).

• Check the high-pressure filter for leaks after putting it into operation.

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OPERATING INSTRUCTIONS RH 400 High-pressure filters for slewing circuit Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

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.

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. 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 Changing the hydraulic oil Read and observe: "Inspection and servicing - Safety instructions".

Drawing off the hydraulic oil Draw off the hydraulic oil with the service station (Fig. 30).

Shut off the engines.

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. 30

Never start up the drive engines when the hydraulic oil reservoir is empty. Irreparable damage can be caused to the hydraulic pumps by allowing them to run dry.

• 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 hose line and its use are described under "Hose line for oil and coolant change".

• Remove filling hose. The express coupling closes automatically.

• Screw on protective cap.

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OPERATING INSTRUCTIONS RH 400 Cleaning the hydraulic oil reservoir

Explosion hazard Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines Use no white spirit, paraffin oil or other solvents for cleaning purposes.

Use diesel fuel or special flushing oil.

• 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).

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.

• 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 Filling in hydraulic oil

• The oil level is also monitored by the BCS and displayed on the monitor (Fig 35).

Fill in hydraulic oil with the service station (Fig. 33).

• Vent the hydraulic system.

• Check the oil level in the hydraulic oil reservoir.

Top up if necessary.

• Unscrew hose line. The express coupling closes automatically.

• Screw on protective cap.

Fig. 33

• Unscrew cap of express coupling (10).

The hose line and its use are described under "Hose line for oil and coolant change".

• Connect filling hose of service vehicle.

• Fill in hydraulic oil until the oil level is between 1 /2 and 3/4of 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 1 /2 and 3/4of 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.

Top up if necessary.

• Install cover (3, Fig. 36).

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OPERATING INSTRUCTIONS RH 400 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 any hoses or lines.

Fig. 38

Venting the hydraulic components

Always admit oil first to that side of the cylinder where the piston (2) is. This is

- Hydraulic pumps and hydraulic motors (with the engines stationary).

•

the piston-side port (3) when the piston rod is retracted (1, Fig. 37)

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

•

the rod-side port (4) when the piston rod is extended (1, Fig. 38).

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.

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 the drive engines stationary).

Fig. 37

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OPERATING INSTRUCTIONS RH 400 Cleaning the hydraulic oil cooler

Cleaning

Risk of injury from rotating cooler fan blades.

The hydraulic oil coolers are located in the oil cooler module.

Shut off the engines.

Clean the hydraulic oil coolers at regular intervals.

Never start cleaning work until the cooler fan blades have stopped turning.

• Shut off the engines.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

• Remove any accumulated dirt.

Allow the hydraulic oil cooler to cool down.

• Clean the radiators with a jet of water or compressed air from outside to inside.

Wear protective gloves and firm protective clothing.

• Leave hydraulic oil coolers to dry.

• Clean the fan blades (2).

• Check the hydraulic motors (1) for free movement.

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.

In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

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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OPERATING INSTRUCTIONS RH 400 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.

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:

Checking the gas charging pressure in the pressure accumulator

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.

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 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 II p> _ l bar and p˙l < _ 200

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Inspections prior to commissioning at the factory at the place of use Pressure testing Prototype and pressure test certified by the manufacturer

Inspection certificate (Check of correctness and correct installation) issued by an expert

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Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and fluid.

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OPERATING INSTRUCTIONS RH 400 PUMP TRANSFER GEARBOX 2732098 Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines The gearbox housings may also be hot

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.

Secure the machine as described under "Securing the machine".

Avoid potentially harmful skin contact with gearbox oil.

Wear protective gloves and firm protective clothing.

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.

Fig. 2

• Unscrew cap of express coupling and connect hose line of service vehicle.

The hose line and its use are described under "Hose line for oil and coolant change".

• Screw dipstick (1) back in place.

• Remove hose when the oil has been drawn off.

The coupling closes automatically.

• Screw on protective cap.

Fig. 1

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OPERATING INSTRUCTIONS RH 400 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 hose line of service vehicle.

The hose line and its use are described under "Hose line for oil and coolant change".

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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OPERATING INSTRUCTIONS RH 400 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 overflows (3) and filling in oil through the opening until it emerges at the plug opening.

If oil leaks out of one of the overflows (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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OPERATING INSTRUCTIONS RH 400 SLEWING GEARBOX

2732099

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines.

The gearbox housings may also be hot

Changing the gearbox oil Draining off oil • Provide a collecting recipient for the used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

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. 2

• Unscrew cap from automatic drain valve.

Fig. 1

Gearbox - Checking the oil level / Topping up • Park the machine as described under "Securing the machine".

• 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 hose line and its use are described under "Hose line for oil and coolant change".

• Check the oil level visually at the expansion tanks (6, Fig. 1). The expansion tanks must be abt. 1/3 full of gearbox oil; top up if necessary.

The oil level is visible from outside (light/dark area).

The hose line (5, Figs. 1 and 2) connects the gearbox (3, Fig. 2) with the expansion tank (6, Fig. 1).

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OPERATING INSTRUCTIONS RH 400 The drain valve (9, Fig. 3) is accessible from the undercarriage.

• Remove hose. The drain valve closes automatically.

Gearbox venting The gearbox is vented through the cap (8, Fig. 4).

Venting bore

• Screw on protective cap.

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 the 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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OPERATING INSTRUCTIONS RH 400 TRAVEL GEARBOXES

2732100

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines.

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 - 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).

Travel gearbox - Checking the oil level / Topping up

• Place a collecting recipient for used oil under the main gearbox. Choose the required capacity in accordance with the "Refilling quantities Oil" table.

Park the machine as described under "Securing the machine".

• Unscrew plug (2) and drain off oil completely.

Slackening plug (3) allows the oil to run out more readily.

The oil level must be visible in the level gauge (4, Fig. 1); top up with gearbox oil if necessary.

Fig. 1

• Clean plugs (2 and 3).

• Screw in plug (2).

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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OPERATING INSTRUCTIONS RH 400 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 and 3). Fill in oil through opening in plug (3) until it flows out of opening in plug (1) or the oil level is visible in the level gauge (4, Fig. 4).

• Unscrew plugs (1, Fig. 5), clean, and screw back into place.

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

If oil emerges from the overflow (3, Fig. 5), the external sealing of the driving motor must be checked.

Fig. 4

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OPERATING INSTRUCTIONS RH 400 CRAWLER TRACKS

2732101

Cleaning Clean tracks, track and support rollers, sprockets and idlers at regular intervals and whenever necessary. Cleaning is especially important in winter to prevent

Track rollers The track rollers (2, Fig. 1) have a permanent oil filling.

Check the oil level at the expansion tanks (3, Fig. 2) at regular intervals.

• the tracks from being thrown off • oil from leaking out of track and support rollers, sprockets and idlers • excessive wear • track breakage.

Fig. 2

The oil level is visible from outside and must reach the top edge of the clamp (arrow, Fig. 2); top up if necessary.

Topping up oil

Fig. 1

To clean the tracks: • raise one side of the excavator with the working equipment and turn track; • clean side member supporting the track;

Unscrew cap (2, Fig. 2) of expansion tank (3) or protection cap of express coupling (4).

Fill oil into expansion tank (3) or through express coupling until it reaches the top edge of the clamp (arrow, Fig. 3). Close expansion tank firmly resp. screw on protection cab (4).

Cleaning

• clean track and support rollers (2 and 1, Fig. 1) thoroughly;

Check venting bore in cap (2. Fig. 2) for contamination; clean if necessary.

• clean sliding planes on idler guides.

Inspect all track rollers visually at regular intervals for leaks and free movement.

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Inspection and Servicing 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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OPERATING INSTRUCTIONS RH 400 Track roller fastening

Track tensioner

Check fastening screws (4, Fig. 3) at regular intervals for tightness:

Design

• Tighten 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 10 Stopcock 11 Check valve

Check fastening screws (3, Fig. 3) at regular intervals for tightness: • Tighten screws with a torque wrench to the prescribed tightening torque (cf. "Tightening torques" table).

Fig. 5

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OPERATING INSTRUCTIONS RH 400 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 engines have been started up. Retensioning is not required.

The tracks can be slackened for cleaning or repair work.

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.

To do so: • stop the engines • open both pressure limiting valves (7, Fig. 6) to slacken the tracks.

• When work is finished, screw down the pressure limiting valves (7) to the limit stop.

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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OPERATING INSTRUCTIONS RH 400

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:

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel

Group IV p > l bar p˙l > 1000

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".

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

Regular inspections

Preliminary inspection by an Acceptance inspection by an ex- Internal inspection: expert. pert every 10 years for nonPrototype and pressure test corroding fluids; otherwise certified by the manufacturer every 5 years. (type approval) or by an expert Pressure testing: every 10 years by an expert.

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OPERATING INSTRUCTIONS RH 400 Idlers The idlers have a permanent oil filling.

Greasing the idler guides

Inspect the idlers visually for leaks after each working shift. If leaks are detected, check oil level.

Grease the idler guides (arrow, Fig. 8) at regular intervals in accordance with the inspection plan.

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.

Fig. 7

To check the oil level, the checking plug must be ca. 30o above the horizontal axis (2 o’clock position) (Fig. 7). Unscrew checking plug. The oil level must reach the lower edge of the opening.

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.

• Press filling nozzle of grease gun onto greasing nipple.

• 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.

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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OPERATING INSTRUCTIONS RH 400 SLEWING RING

2732102

Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines Wear protective gloves and firm protective clothing.

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 central lubricating system adds the amount of greased used up during operation.

The housings have a check opening with 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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OPERATING INSTRUCTIONS RH 400 Slewing ring - Checking the grease filling Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines 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 greases 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 tightening torque (cf. table "Tightening torques and angles).

Fig. 4

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OPERATING INSTRUCTIONS RH 400 CENTRAL LUBRICATING SYSTEM 2732103

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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OPERATING INSTRUCTIONS RH 400 Filling the grease container

Breather filter

Fill grease container through service station (Fig. 4).

Check/change the breather filter at regular intervals.

The hose line and its use are described under "Hose line for oil and coolant change".

• Unscrew wing nut (1, Fig. 5).

• Switch on the display system with the toggle switch (33, Fig. 4).

• Unscrew cap of express coupling (11).

• Withdraw cover (7, Fig. 6) and filter element (8).

• Check filter element. Replace if necessary.

• 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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OPERATING INSTRUCTIONS RH 400 Checking the grease 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 a pressure intensifier.

If this is not the case, stop the engines 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 sieve at regular intervals for contamination; clean if necessary. The grease sieve 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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OPERATING INSTRUCTIONS RH 400 OTHER MAINTENANCE WORK 2732522

Engine

Cooling system

Information about maintenance can be found in the engine operating instructions.

Clean the radiators at regular intervals.

Further servicing works not described are carried out by the O&K Service or by the engine manufacturer.

• Remove any accumulated dirt.

• Shut off the engines.

• Clean the fan blades (2. Fig. 1).

Cleaning

• Clean the radiators with a jet of water or compressed air from outside to inside.

Clean the engines at regular intervals.

• Leave radiators to dry.

- If the engine is cleaned with a steam jet cleaner, make sure the jet is not directed towards electrical components.

• Check hydraulic motors (1) for free movement.

Never clean radiators with a wire brush or similar hard objects.

To remove stubborn dirt, remove radiator and clean.

- If no steam jet cleaner is available, the engines must be cleaned with suitable cleaning agents (cold cleaners).

Fastenings - Check fastening screws at regular intervals for tightness.

The seating planes of the screws must be free from paint, dirt and rust.

Fig. 1

Exhaust system Check the fastening screws at regular intervals for tightness when the exhaust system is cold.

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OPERATING INSTRUCTIONS RH 400 RAMP-TYPE LADDER

2732104

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.

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 to the locking bolt (2).

Fig. 3 Fig. 1

Fig. 2

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OPERATING INSTRUCTIONS RH 400 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.

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:

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.

Group III p> _ l bar und p˙l > _ 200 bars p˙l < _ 1000 bars

190

Inspections prior to commissioning at the factory at the place of use

Regular inspections

Preliminary testing by an exAcceptance inspection by an ex- Inspection schedule to be pert. pert. drawn up by end user, Prototype and pressure test based on experience with certified by the manufacturer or type of operation and fluby an expert id.

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OPERATING INSTRUCTIONS RH 400 ON-BOARD CRANE

2732110

Monitoring, warning and control elements (Fig. 1)

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.

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.

Fig. 1

1 2 3 4 5

The user must ensure, however, that the appointed person meets the requirements.

Monitoring lamp - alternator Warning lamp - engine oil pressure Warning lamp - engine temperature Monitoring lamp - air filter Key-switch - electrical system ON/OFF 6 Button - engine start 7 Monitoring lamp - preheating system (option) 8 Button - speed variation 9 Monitoring lamp - crane in operation 10 Warning lamp - malfunction 11 Button - EMERGENCY STOP 12 Button - emergency lowering of winch 21 Control lever - extending and retracting of boom extension 22 Control lever - folding the boom 23 Control lever - slewing the boom 24 Control lever - winch ON/OFF

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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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OPERATING INSTRUCTIONS RH 400 Air-intake system

Drive unit The drive unit comprises:

Never start up the engine when the air filter (6, Fig. 3) is removed.

- crane engine - hydraulic system

Hydraulic system

Crane engine

See crane operating instructions.

See operating instructions for the crane engine.

• 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.

• Check contamination of hydraulic oil filter regularly at contamination indicator (arrow, Fig, 2).

• Regularly, at least once a year

• 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.

- replace hydraulic oil filter (14) and breather filter (13)

On-board crane Servicing • Lubricate all bearings regularly and as required, and spray slewing ring with a graphite spray (Fig. 4) 1 - bearing, 2 - joint (column/boom), 3 - cylinder bearing, 4 - slewing ring

4 lube points 2 lube points 5 lube points

Fig. 2

Fig. 4 Fig. 3

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OPERATING INSTRUCTIONS RH 400 ALTERNATOR

2732531

Monitoring, warning and control elements

Air-intake system The air-intake system comprises: - prefractionator (13, Fig. 2)

(Fig. 1)

- dust trap (14) - main filter element (18, Fig. 3) - safety filter element (19, Fig. 4)

Fig. 1

1 2 3 4 5 6

Warning lamp - engine temperature Warning lamp - engine oil pressure Heat-up resistor Monitoring lamp - air filter Monitoring lamp - battery Key-switch - electrical system EIN/AUS Fig. 3

Drive motor See operating instructions for the drive motor.

Fig. 4

Fig. 2

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OPERATING INSTRUCTIONS RH 400 Cleaning the prefractionator

Servicing • Check engine oil level regularly with the dipstick (1, Fig. 5); top up if necessary.

Never start up the engine when parts of the air-intake system are removed.

• Unscrew wing nut (11, Fig. 6).

• Remove cover (12) and housing (13).

• Clean housing (13).

• Reassemble prefractionator.

Fig. 5

• Regularly, at least once a year - change engine oil - replace engine oil filter (2, Fig. 5) - air filter (1, Fig. 6) - check vacuum gauge (10) - clean prefractionator (13) - empty dust trap (14, Fig. 7) - clean/replace main filter element (18) - replace safety filter element (19, Fig. 8) - replace fuel prefilter (3, Fig. 5) - replace fuel filter (4) • Check battery (5) and cable connections at regular intervals.

Fig. 7

Fig. 8 Fig. 6

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OPERATING INSTRUCTIONS RH 400 Main filter element

Emptying the dust trap • Unscrew wing nut (15, Fig. 9).

Clean or replace main filter element (18, Fig. 10) only if vacuum gauge (10, Fig. 9) is at "RED" position when the engine is running.

• Remove dust trap (14, Fig. 10) together with insert (16).

• Withdraw insert (16) from dust trap (14) and empty.

• Place insert (16) in dust trap (14).

When reassembling, make sure that the opening in the insert (16) is at the top.

When installing the dust trap, watch for TOP position.

Fig. 11

• Removing the dust trap (14, Fig. 10).

• Unscrew wing nut (17).

• Withdraw main filter element (18), taking care not to lose the washer under the wing nut (17).

• Replace or clean main filter element (18).

• Refit dust trap (14).

Fig. 9

The safety filter element (20, Fig. 11) must remain in the filter housing while the main filter element (18) is removed.

Fig. 10

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OPERATING INSTRUCTIONS RH 400 Checking and cleaning the main filter element Check the filter paper of the element by inserting a lamp into the element (Fig. 12). Any damage can then be seen.

Replace damaged or distorted element immediately.

Fig. 13

Blow filter element (Fig. 13) dry with compressed air by moving the compressed-air piston up and down inside it.

The pressure at the nozzle must not exceed 6 bars.

Cleaning is completed when no more dust is seen to leave the filter element.

Fig. 12

Check element seal. If damaged, replace filter element too.

Cleaning with compressed air allows the filter element to be re-used immediately.

196

Never clean filter element by beating it against hard objects.

Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

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OPERATING INSTRUCTIONS RH 400 Safety filter element • Remove main filter element (18, Fig. 15) as described above.

Replacement Replace the safety filter element (20, Fig. 14) after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Always replace safety filter elements; never clean them.

Fig. 15 Fig. 14

• Unscrew wing nut (19, Fig. 15) and withdraw safety filter element (20).

• Install new safety filter element and cleaned or new main filter element.

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OPERATING INSTRUCTIONS RH 400 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING

2732523

Putting the excavator out of operation • Park excavator on firm and level ground.

Recommissioning

• Set working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.

• Remove covers.

• Set all control element to "0".

• Remove engine preservation in acc. with engine operating instructions.

• Clean the machine.

• 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.

• Carry out engine preservation.

• Protect all bright metal parts (e.g. piston rods) from rust and dirt.

• Check antifreeze concentration of the coolant to prevent freezing during the cold time of year.

• Fill up the fuel tanks.

• 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 - locking the cab door - securing all lockable hatches.

• Degrease/clean all protected components.

• Check fuel level in the tanks.

• Check track tension (visual inspection) • Check level and condition of coolant in cooling system.

• Check grease filling in grease container.

• Oil level

- drive engines - slewing gearbox - pump transfer gearbox - travel gearboxes - drive engine (alternator drive) - engine (on-board crane)

• Check oil level in hydraulic oil reservoir.

• Check oil in hydraulic oil reservoir (on-board crane).

• Install batteries and reconnect.

• Set battery main switch to ON.

• Cove up all openings

• Function checks:

Battery storage

- track brake - lighting system - signalling equipment

During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20oC. Observe the following maintenance points:

- superstructure holding brake

• Vent the hydraulic system.

• Clean the batteries.

• Keep the batteries clean and dry on the outside.

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OPERATING INSTRUCTIONS RH 400 NOTES

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OPERATING INSTRUCTIONS RH 400

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OPERATING INSTRUCTIONS RH 400 PART 4 - REPAIR WORK

Operating manual

Part 1 INTRODUCTION

2804054

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS 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

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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 Repair work - Safety instructions

2441963

Operating instructions

Prestressed units

Never carry out repair work without having read and understood the operating instructions.

Never open defective prestressed units but replace them as an entirety.

Pay special attention to:

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

"Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The operating manual contains no information on this point.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

Handling chemical substances

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

Repair personnel

Observe the safety specifications when handling chemical substances.

Repair personnel must have knowhow and experience relevant to repairing this or comparable machines.

Dismantling components

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from O&K.

Oils, greases, brake fluid or coolants may have a high temperature and result in burning or scalding.

Working in greater heights Always wear safety harnesses when working at greater heights.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Replace defective components in good time to prevent major damage.

Never do dismantling while the machine is at operating temperature.

Leave time for the machine to cool down.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

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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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 sound- 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 with a trial run.

Never release the machine for recommissioning until it is fully functioning.

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OPERATING INSTRUCTIONS RH 400 Fire and Explosion Hazard

2796687

Safety Instructions Prior to commencing work, inform - on the national and corporate rules for 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.

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 fire-protective blankets.

Ensure sufficient ventilation.

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

Clean the excavator before starting a job.

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

Do not store or handle any flammable substances during operation.

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

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 such as turbo superchargers.

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.

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.

Call the fire brigade.

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

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 ENGINE

2732603

Read and observe: "Repair - Safety instructions" and the engine operating instructions before working on the engines.

Risk of injury from rotating or hot parts of the engine.

Shut off the engines and leave to cool down.

Carry out repair work only if the machine has been secured as described under "Securing the machine" in these operating instructions.

Check and replace V-belts only when an engine is stationary.

ELECTRICAL SYSTEM

2441955

Assisted starting (with jumper cables) Safety instructions Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries. Battery gases are highly flammable. Explosion hazard.

Do not lean over the batteries when starting the machine from another vehicle.

Risk of injury from acid splashes and battery gases.

Never use assisted starting when the batteries are defective or frozen.

Never connect batteries (battery assemblies) unless they have the same voltage.

Use only tested jumper cables with insulated terminal clips and an adequate lead diameter.

Ensure that the bodies of the supplying and receiving machines are not in contact. Otherwise a current flow could result from connecting the positive poles. Risk of shortcircuiting.

Never use welding generators or welding transformers as a source of current.

Position the jumper cables in such a way that they cannot be caught by rotating engine components.

Read and observe: "Inspection and servicing - Safety instructions", paying particular attention to the section "Handling batteries".

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OPERATING INSTRUCTIONS RH 400 Explosion hazard When the negative terminal is connected to ground, a strong current flows through the jumper cable.

The sparks produced in the contact area can ignite the gases emanating from the discharged battery.

The negative terminal must therefore be connected to ground at a place as far away from the discarged batterı́es as possible.

Assisted starting (with jumper cables) Prior to assisted starting Read and observe the section: "Assisted starting - Safety instructions".

Starting the engine with jumper cables (external batteries) Before connecting the jumper cables (external batteries) check the own batteries for proper operation. Checking is done by switching on the excavator’s electrical system.

Do not switch on electrical consumers (e.g. floodlamps) when checking the batteries. In case of doubt, remove the batteries and have them tested.

- Assisted starting with batteries installed Connect first the positive terminal of the jumper cable to the batteries and then to the supplying unit. Connect the negative terminals in the same order. After starting, disconnect the jumper cable in reverse order, i.e. first the negative terminal and then the positive terminal.

- Assisted starting without batteries installed (only for engine trial run) Do not disconnect the starting aid when the engine is running.

After disconnecting, the alternator runs without batteries.

- Connect the jumper cable in the above order and disconnect after starting.

Fig. 1

Starting up the engines • Start up the engines of the supplying machine and run at high speed.

• Start up the engine of the receiving machine. If the engine fails to start up after 15 seconds, wait for one minute and then start again.

• When the engine has started up, continue running both machines in no-load operation for about two or three minutes with the jumper cables still connected.

Disconnecting the jumper cables • Negative pole at the receiving machine (4)

• Switch off all consumers at the receiving machine and turn the key-operated switch to "0" .

• Switch off all consumers at the supplying machine (charged batteries) and shut off the engine.

Connecting the jumper cables • Connect the red jumper cable to the positive pole of the empty battery (1, Fig. 1), then to the positive pole of the charged battery (2).

• Connect the black jumper cable first to the negative pole of the charged battery (3), then to the negative pole of the empty battery (4).

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• Negative pole at the supplying machine (3) • Positive pole at the supplying machine (2) • Positive pole at the receiving machine (1) • For machines with electronic modules: - Run engine for about half an jour at low speed. The batteries are partially charged.

- Shut off engine.

- Make all electrical connections to the modules.

- Start up engine without jumper cables.

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OPERATING INSTRUCTIONS RH 400 HYDRAULIC SYSTEM

2413504

Repair Before disconnecting hydraulic hoses: depressurize the hydraulic system.

Replace damaged or leaking hydraulic hoses by new ones.

Use original O&K 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.

Accumulators, safety instructions 2411963 Accumulators are installed in the hydraulic system. These accumulators contain nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen remains in the accumulator.

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 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".

2462901

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. distance 2 - 3 m).

The welding current must not flow via the ball or 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

Should you have any problems or queries, apply to the O&K aftersales 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".

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OPERATING INSTRUCTIONS RH 400 PART 5 - ANNEX

2804055

Operating manual

Part 1 INTRODUCTION

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS 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

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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 TROUBLESHOOTING Instructions on troubleshooting Faults are often due to the machine not being correctly operated or serviced.

For this reason, it is vital to read through the relevant section of the operating manual once again before rectifying any faults.

If you are unable to detect the cause of the fault or rectify it, apply to the O&K after-sales service.

2261173

Layout of the fault table Fault The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

Study the problem carefully, First think, then act.

Ask yourself the following questions:

Describe the fault and all accompanying circumstances as precisely as possible when calling on the O&K after-sales service. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified.

This 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.

- Which warning signals preceded the fault?

- What repair and servicing work was carried out previously?

- Has this defect already occurred?

- Is it one or several simultaneously occurring faults?

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.

Remedial action This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the operating manual. If there is no entry, the O&K after-sales service should be consulted.

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OPERATING INSTRUCTIONS RH 400 FAULT TABLES

2732105

Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts but runs unevenly or intermittently Engine gets too hot, temperature warning activated

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

Engine not working at full power Engine not working on full cylinder capacity Engine without oil pressure or oil pressure too low

1) Contact the O&K Service

Engine oil consumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly

•

•

• •

• •

Cause

Section

Oil level too low

A S Engine OI P Lubricants W Engine OI W Air-intake sys. P Fuel filter P/W P Cooler cleaning R Engine OI P/W P Battery P P P 1) Engine OI E P Engine OI P/W 1)

Oil level too high

• • •

Engine inclination too great

•

Engine oil of wrong SAE class

•

•

•

•

•

•

• •

Fuel grade not as specified •

Air filter contaminated/Turbocharger defective

• • •

Fuel filter contaminated •

Charge-air line leaking

•

Radiator/Cooling fins contaminated

•

Cooling fan or water pump defective or loose

•

Cooling air gets too hot / Heat build-up

•

Battery defective or discharged

•

Cable connections in started circuit looses or corroded

•

Starter defective or pinion not in mesh

•

•

•

• • • •

•

•

•

• • • •

Shut-off relay jamming

•

Incorrect valve setting

• •

Injection line leaking • •

Injection valve defective

•

Combustion engine blocked on output side

• •

216

•

• •

Engine oil level Engine oil level

•

PMS malfunction

1)

•

Centry coding lamp flashing/lit up

1) 1)

Centry defective (software error)

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OPERATING INSTRUCTIONS RH 400 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 Service

Uncontrolled working movements

•

Cause

Section

Electronic excavator control not activated/defective

Working

P

• • • • •

•

Malfunction of pressure-relief valve

1)

•

•

Servosystem pump(s) defective

1)

Malfunction of primary / secondary pressure-relief valves

1)

•

Speed of one engine/both engines too low

P

•

ECO power switch in 80% position

P

•

Fuel filter contaminated

Fuel filter

•

Insufficient power of one engine/both engines

Engine malfunc. 1)

•

Hydraulic oil temperature too high (warning lamp lit, PMS fault indicator lamp lit), oil cooler contaminated

Hydraulic oil cooler cleaning

•

Coolant temperature of one engine/both engines too high, warning lamp lit and PMS fault indicator lamp flashing

1)

•

Malfunction of solenoid valves

1)

•

Malfunction of control spool

1)

• • • • •

• •

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•

P/W P/R

Engine coupling(s) defective

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OPERATING INSTRUCTIONS RH 400 Fahrantrieb - Fault table Fault No forward travel and no reversing possible Max. 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 Service Cause

Section

•

•

•

Malfunction of pressure-relief valve

1)

•

•

•

Servosystem pump defective

1)

•

•

•

Malfunction of travel valve (pedal)

1)

Nominal speed of one engine/both engines too low

1)

Malfunction of control spool

1)

• •

218

•

•

ECO power switch in 80% position

Travelling

P

•

Insufficient power of one engine/both engines

Engine malfunction

1)

•

Hydraulic oil temperature too high (BCS gives a warning signal), oil cooler contaminated

Hydraulic oil cooler cleaning

P/R

•

Coolant temperature too high (BCS gives a warning signal)

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OPERATING INSTRUCTIONS RH 400 Slewing mechanism, Fault table Fault

Remedial action

No slewing possible

No righthand or lefthand slewing Slewing performance insufficient Uncontrolled slewing movement

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the O&K Service Cause

Section

•

Electronic excavator control not activated/defective

Working

P

•

Ramp-type ladder, limit switch defective / not completely retracted

Operating

P/A

•

Superstructure holding brake applied

P

Pressure-relief valve set too low / defective

1)

Servosystem pump defective

1)

•

Malfunction in feed-pressure circuit of slewing pump

1)

•

Malfunction in high-pressure circuit of slewing system

1)

•

Malfunction in moment-regulating valve

1)

•

Malfunction in slewing pump displacement cylinder

1)

Excessive leakage in slewing motor

1)

•

•

• •

•

•

• •

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OPERATING INSTRUCTIONS RH 400 Central lubricating system - Fault table Fault Grease pump not working, BCS not giving a warning signal Automatic circuit breaker on Grease pump not working, monitoring lamp lit Grease pump working but delivering no grease Greasing pressure too high or too low

Cause •

•

•

Lines between timer and hydraulic motor defective

P/W

Hydraulic motors defective

P/W

•

Grease pumps 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

•

•

220

Section P/W

• •

Check P Adjust E Replace W Top up A Reduce S Clean R Vent L 1) Contact the O&K Service

Timer defective

•

•

Remedial action

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OPERATING INSTRUCTIONS RH 400 Hydraulic circuit diagram

2732106

Legend (loading bucket) Designation

Item

No.

2 2 8 4 8 8 8 2

Diesel engine Transfer gearbox Working pump Slewing pump Pressure connection valve Stopcock Adaptor plate Slewing pump

4 2 2

Cooling oil pump Filling pump Valve block

6 1 6 2 2 6 1 1 2 2

Slewing gearbox Pressure sensor Slewing brake Gearbox recirculating pump Servopump Slewing motor Rotor with travelling valve Rotor Mobile control block Pressure-limiting valve

4 4 4 2 4 2 2 4 4 2 1 1 3 3 5 2 2 12 3 4 11 2 1

Fan motor (engine radiator) Block Displacement pump (fan drive) Distributor Valve housing Travel retarder valve Travel gearbox Travel brake Travel engine Control block Pressure-limiting valve Shuttle valve Flushing and feeding pressure valve Pressure-regulating valve with connection plate Control block Proportional control valve (moment control) Proportional control valve (pump control) Shut-off valve Flange flap Precharge valve (hydraulic reservoir) Bypass valve Filter Hydraulic reservoir

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

3 6 3 4 4 2 2 2 2 1 1 8 8 1 4 2 1 1 1 2 4 2 2 2 2 4 2 2

Filter element High-pressure filter 3/2-way valve Track tensioning cylinder Diaphragm accumulator Block Ballcock Filter High-pressure filter, complete Hydraulic track tensioner Block (leakage oil) High-pressure filter element Check valve Hose connection Mobile control block Quick-action valve Distributor with pressure-limiting and check valve Restrictor check valve Block Hatch cylinder Bottom-dump and stick cylinder Boom cylinder Check valve Pressure-limiting valve Check valve Filter Check valve Shuttle valve

16 16 2 2 7 1 2 1 2 1 1

3/2-way valve Proportional control valve Thermopressure valve Thermopressure valve Shuttle valve Hydr. bubble memory Control block Pressure accumulator (ramp-type ladder) Hydraulic motor Valve Cylinder

Item

No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Designation

(Drawing no. 2 459 305)

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OPERATING INSTRUCTIONS RH 400 Tightening torques and angles Table Bolt

2732107

Bolt size

Slewing ring Slewing ring/superstructure - tightening torque (preassembly) - joint torque - tightening torque (max.)

Checking torque Nm

120 + _4

3000

150 + _4

3000

180 + _4

15000

2500 1400 5900 M 42 x 3 x 470 / 10.9 / SW 65

Slewing gearboxM 24 x 600 / 10.9 / SW 36

960

2500 1100 5900

M 64 x 4 x 640 / 12.9 /SW 95 10000 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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Tightening angle˚

M 42 x 3x 420 / 10.9 / SW 65

Slewing ring/undercarriage - tightening torque (preassembly) - joint torque - tightening torque (max.)

Ballast - tightening torque (pre-assembly) - joint torque - tightening torque (max.)

MA Nm

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OPERATING INSTRUCTIONS RH 400 ABBREVIATIONS

2261966

A A A2 A4 abt. acc.

Ad. 1 Ah

Ampere (SI base unit of electric current) Four-wheel drive 2-point bracing (claws) 4-point bracing (claws) about according to with reference to 1 Ampere hours (SI base unit of quantity of electricity) API American Petroleum Institute approx. approximately BA bar Bh

= OI = Operating instructions unit of pressure measurement (1 bar = 14.5 psi) = OH = Operating hour

CE

Communaute Européenne = European Community CECE Committee for European Construction Equipment (Defines a measure for bucket, grab, or scoop filling) CEN European Standardization Committee cf. refer to cm centimeter (= 1/100 m) cm3/rev Cubic centimeters per revolution dB(A) dia.

DIN

Decibel (Sound intensity according to measuring method A) Diameter German Standardisation Organization

EDCV EDS eff. e.g. etc.

Electronic drive control (Grader) Electronic diagnostic system effective for example etcetera

fig.

FOPS GLR

Figure, serial number of illustration Falling objects protective structures Full-load controller (electronic module for PMS)

HD HDS hp Hydr.

Heavy duty Heavy duty small Horsepower /1 hp = 0.7457 kW) Hydraulic, Hydraulics

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i i.e.

IFN incl.

ISO kg kg/dm3 km/h kNm kW l Lb/in2 LC LDA LED l/min LpA LPS LS LS LwA

m MA mA max.

MH MHS min. min-1 mm

Transmission ratio id est = that is ISO service rating, blocked including, inclusive of International Standardisation Organisation 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) 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 Meters Tightening torque Milliampere (= 1/1000 A) maximal, maximum Mobile hydraulics (excavator) Mobile hydraulic excavator for road and rail operation minimal, minimum Revolutions per minute Millimeter (= 1/1000 m)

N N, kN NLGI

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) NLGI- Consistency - lubricant classification Klasse acc. to DIN 51 818 Nm Newtonmeter (unit of torque) No./Nos. number/numbers

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OPERATING INSTRUCTIONS RH 400 ABBREVIATIONS OH OLS op. inst.

OW O&K

Operating hour O&K load stabilization Operating Instructions Superstructure 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 Revolutions per minute (= min-1)

SAE sec.

SN SW

Society of Automotive Engineers (USA) Second Item number Width across flats

t THB TL tm typ.

Metric ton (= 1000 kg) Technical Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of slewing torque) Typical

U/min

Revolutions per minute

V VDMA

Volt (unit of electric voltage) Association of Germany Machinery and Systems Manufacturers

W

Watt (unit of electric power)

˚C ˚kW

Degrees Celsius (temperature) Degrees crank angle

> <

greater than less than

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OPERATING INSTRUCTIONS RH 400 TECHNICAL DATA

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OPERATING INSTRUCTIONS RH 400 PART 6 - INDEX

2804056

Operating manual

Part 1 INTRODUCTION

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS 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

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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

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OPERATING INSTRUCTIONS RH 400 INDEX

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Update to version .04, see pages 115a and 178a

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Before starting work ............................................ 87

1

Board Control System (BCS) .............................. 21

110 V socket ...................................................... 27

Braking the superstructure ................................ 87 Breather filter .................................................... 186

A

Breather filters .................................................. 159

ABBREVIATIONS .................................... 225, 226

Bypass valves (filter housing - cooling system) 158

Access ................................................................ 25

Bypass valves (hydraulic oil reservoir) ............ 156

Accumulators, safety instructions .................... 208 Adjusting the armrests .................................. 29, 30

C

Adjusting the backrest .................................. 29, 30

Cab interior lamp ................................................ 26

Adjusting the lumbar support .............................. 29

Causes ............................................................ 215

Adjusting the seat cushion ............................ 29, 30

CENTRAL LUBRICATING SYSTEM ................ 185

Adjusting the seat suspension ...................... 29, 30

Central lubricating system - Fault table ............ 220

After daily operation............................................ 89

Centrifuge ........................................................ 134

Air-intake lines .................................................. 144

Change of engine oil ........................................ 105

Air-intake system .............................................. 105

Changing the engine oil .................................... 130

AIR-INTAKE SYSTEM...................................... 141

Changing the gearbox oil .................................. 174

Air-intake system ...................................... 192, 193

Changing the hydraulic oil ................................ 165

ALTERNATOR ................................................ 193

Changing the oil of the engine oil reservoir ...... 132

Alternator - Instructions .................................... 148

Checking and cleaning the main filter element 142, 196

Application of Voler A.C. .................................... 93

Checking the engine oil level / Topping up ...... 128

Assembling the centrifuge ................................ 135

Checking the gas charging pressure in the pressure accumulator ...................... 170, 181, 190

ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ...................................... 90

Checking the gearbox oil level / Topping up .... 171

Assisted starting (with jumper cables) .............. 207

Checking the grease pressure .......................... 187

Assisted starting (with jumper cables) - Safety instructions ...................................................... 206

Checking the hydraulic oil level / Topping up .. 152

Automatic engine speed reduction .................... 21 Automatic fire-extinguishing system .................. 31

Checking the oil level................................ 173, 182 Checking the oil level in the engine oil reservoir / Topping up .............................................. 129 Checking the on-board crane .......................... 191

B

Checking/adjusting the V-belt tension .............. 128

Batteries .......................................................... 149

Checking/adjusting the valve clearance .......... 128

Battery box ...................................................... 150

Checking/cleaning the filter elements 160, 161, 162, 163

Battery main switches ........................................ 74

Cleaning .................................. 169, 178, 187, 188

Battery main switches§/§Main fuse .................. 149

Cleaning jobs .................................................... 105

Battery storage ................................................ 198

Cleaning the centrifuge .................................... 135

Bearing races .................................................. 183

Cleaning the filter screens ........................ 156, 158

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Cleaning the fuel tanks .................................... 146

Drive motor ...................................................... 193

Cleaning the grease sieve ................................ 187

Drive unit .......................................................... 192

Cleaning the hydraulic oil cooler ...................... 169

Driver’s seat........................................................ 29

Cleaning the hydraulic oil reservoir .................. 166

Driving ................................................................ 78

Cleaning the prefractionator ............................ 194

Dust collection .................................................. 144

Combustion engine - Fault table ...................... 216 Component numbers .......................................... 23 Connecting the jumper cables .......................... 207 Coolant ............................................................ 138 Coolant level .................................................... 136 COOLING SYSTEM ........................................ 136 Cooling system ................................................ 188 Cornering ............................................................ 80 Corrosion protection for pins and bearings (bushings and hubs) .......................................... 93

E Electric energy ...................................................... 8 Electrical system ................................................ 21 ELECTRICAL SYSTEM............................ 148, 206 Electrical system - Safety instructions .............. 148 Electronic Hydraulic Servo-Control (EHSC) ...... 20 Eliminator filter and centrifuge .......................... 134 Emergency stop.................................................. 77 EMERGENCY STOP pushbuttons .................... 28

Crane engine .................................................... 192

Emptying the dust trap ...................................... 195

CRAWLER TRACKS ........................................ 178

ENGINE ............................................................ 128 Engine .............................................................. 188

D

ENGINE ............................................................ 206

Demand control / Zero-flow regulation................ 21 Depressurizing the hydraulic system ................ 151 DESCRIPTION OF THE EXCAVATOR .............. 18

Engine - Safety instructions .............................. 128 Engine number .................................................. 23

Design .............................................................. 179

Entering and leaving the machine - Safety instructions ........................................................ 24

Design and function .......................................... 185

Escape ladder .................................................... 25

DESIGNATED USE .............................................. 4

Excavator layout ................................................ 19

Disconnecting the jumper cables ...................... 207

Exhaust system ................................................ 188

Dismantling the centrifuge ................................ 134

Extending and retracting the bucket or backhoe bucket stick .................................................. 88

Drain off engine oil ............................................ 132 Draining off oil .................................................. 174

Extract from the German acceptance regulations .................................................. 170, 181, 190

Drawing off coolant .......................................... 138

Extract from the German regulations 170, 180, 190

Drawing off engine oil ...................................... 132

Extract from the inspection and testing regulations .................................................................. 191

Drawing off engine oil with the service station .. 130 Drawing off oil .................................................. 171 Drawing off the hydraulic oil.............................. 165 Drive .................................................................. 20

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F

High-pressure filters for pump-flushing circuit .. 162

Fahrantrieb - Fault table .................................. 218

High-pressure filters for slewing circuit ............ 164

Fastenings ........................................................ 188

Hose line for oil and coolant changes .............. 127

Fault.................................................................. 215

Hydraulic and pneumatic equipment .................... 9

FAULT TABLES .............................................. 216

Hydraulic circuit diagram .................................. 222

Filling and emptying the bucket .......................... 88

Hydraulic system ................................................ 20

Filling in coolant ................................................ 139

HYDRAULIC SYSTEM .................................... 151

Filling in engine oil ............................................ 133

Hydraulic system .............................................. 192

Filling in engine oil through the service station 131

HYDRAULIC SYSTEM .................................... 208

Filling in hydraulic oil ........................................ 167

Hydraulic system - Safety instructions .............. 151

Filling in new oil / Topping up .......................... 175 Filling in oil ................................................ 172, 182 Filling quantities - Grease ................................ 119 Filling quantities - Oil ........................................ 122 Filling quantities - other .................................... 122 Filling the grease container .............................. 186 Fire and Explosion Hazard .......... 10, 17, 103, 205 Fore-and-aft adjustment .............................. 29, 30 Fore-and-aft adjustment of the seat plate .......... 29 FUEL SYSTEM ................................................ 145 Fuel system - Safety instructions ...................... 145 Function ............................................................ 180 FUNDAMENTAL SAFETY INSTRUCTIONS ........ 4

I Idlers ................................................................ 182 INDEX .............................................................. 233 Inspection .......................................................... 32 Inspection and servicing - Safety instructions .... 99 Inspection and servicing plans - Instructions .... 105 INSPECTION PLAN - OIL ................................ 120 Inspection plan - Oil .......................................... 121 Instructions on troubleshooting ........................ 215 Internal gearing ................................................ 183 Intervals ............................................................ 105

L Layout of the fault table .................................... 215

G Gas, dust, steam and smoke ................................ 8 Gearbox - Checking the oil level / Topping up .. 174 Gearbox venting ...................................... 173, 175 Greases for bearings and slewing rings .......... 126 Greasing the idler guides .................................. 182 Guide pulleys and locking bolt .......................... 189

Legend (loading bucket) .................................. 222 Lifting the service station .................................... 69 Loading bucket .................................................. 19 Locking the superstructure ................................ 83 Lowering the equipment in an emergency .......... 88 Lowering the service station .............................. 69 LUBRICANTS .................................................. 123 LUBRICATING CHART - GREASE (Loading bucket) .............................................................. 118

H High-pressure filter for the servo circuits .......... 161

Lubricating chart - Grease / Loading bucket .... 119 High-pressure filter for working hydraulics........ 159 High-pressure filters for feeding circuits/slewing gear pumps ................................ 163 Update to version .04, see pages 115a and 178a

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M

PART 5 - ANNEX ............................................ 213

Machine number ................................................ 23

PART 6 - INDEX .............................................. 231

Main and preliminary gearbox - Filling in oil .... 177

Part nos. for Voler A.C. ...................................... 93

Main filter element ............................................ 195

Passenger seat .................................................. 30

Main filter elements .......................................... 141

Plan A .............................. 113, 114, 115, 116, 117

Main gearbox - Draining off oil .......................... 176

Plan B .............................. 113, 114, 115, 116, 117

Manual activation................................................ 31

Plan C .............................. 113, 114, 115, 116, 117

Measuring devices for fluids ........................ 70, 71

Plan D .............................. 113, 114, 115, 116, 117

MONITORING, WARNING AND CONTROL ELEMENTS ........................................................ 34

Plan E .............................. 113, 114, 115, 116, 117

Monitoring, warning and control elements 191, 193

Plan N ...................................................... 109, 110 Plan T ...................................................... 111, 112 Plan V ...................................................... 107, 108

N Noise .................................................................... 9 Note .................................................................... 81 NOTES ................................ 11, 95, 199, 211, 229

Plan W ...................................................... 111, 112 Pre-chamber .................................................... 173 Pre-chamber - Draining off oil .......................... 177 Pre-chamber - Filling in oil ................................ 177

O

Preface ................................................................ 3

Oil, grease and other chemical substances .......... 9

Preliminary gearbox - Draining off oil................ 176

Oils / Greases .................................................. 105

Pressure accumulator - Emergency lowering .. 170

Oils for combustion engines and compressors (selection) ........................................................ 123

Pressure-accumulator inspection regulations 170, 180, 190

Oils for gearboxes (selection) .......................... 125 Oils for hydraulic systems (selection) .............. 124 ON-BOARD CRANE ........................................ 191 On-board crane ................................................ 192

Prior to assisted starting .................................. 207 Pump Managing System (PMS) ........................ 20 PUMP TRANSFER GEARBOX ........................ 171 Putting the excavator out of operation .............. 198

Opening and closing the bucket ........................ 88

PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING................ 198

Operation - Safety instructions .......................... 15

PUTTING THE MACHINE INTO OPERATION .. 68

Organizational measures...................................... 5 OTHER MAINTENANCE WORK ...................... 188

R Radiators .......................................................... 136

P

Raising and lowering the boom .......................... 88

Parking the machine .......................................... 89

Ramp lighting...................................................... 25

PART 1 - INTRODUCTION .................................. 1

Ramp-type ladder .............................................. 24

PART 2 - OPERATION ...................................... 13

RAMP-TYPE LADDER .................................... 189

PART 3 - INSPECTION AND SERVICING ........ 97

Recommissioning ............................................ 198

PART 4 - REPAIR WORK ................................ 201

Refilling and/or draining ...................................... 69

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Refuelling............................................................ 68

ness .................................................................. 184

Refuelling - Safety instructions .......................... 68

Slewing ring - Filling in grease .......................... 184

Regulating the travelling speed .......................... 80

Slewing ring - Instructions ................................ 183

Remedial action ................................................ 215 Removal and installation .................................. 141

Special work in conjunction with utilization of the machine - maintenance and repairs during operation - disposal of parts and consumables .... 7

Removing and installing the batteries .............. 149

Standard operation .............................................. 6

Removing and installing the battery box .......... 150

Starting and stopping the engines ...................... 75

Repair .............................................................. 208 Repair work - Safety instructions ...................... 203

Starting the engine with jumper cables (external batteries) .................................................... 207

Replacement ............................................ 143, 197

Starting the engines............................................ 75

Replacing the filter elements 159, 160, 161, 162, 163

Starting the engines with the cold-starting aid .... 76

Replacing the fuel filter .................................... 145

Starting up the engines .................................... 207

Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) .................................... 154

Stored Program Control (SPC) .......................... 20

Replacing the hydraulic oil return-flow filters (filter housing - cooling system) ........................ 157

Superstructure basic position ............................ 79

Superstructure .............................................. 19, 20

Support roller fastening .................................... 179

S

Support rollers .................................................. 179

Safety filter element .................................. 143, 197

Switching on the electronic excavator control .... 87

Safety instructions governing specific operational phases ............................................................ 6

Switching the electrical system on and off .......... 74

Section.............................................................. 215

T

Securing the machine ........................................ 92

Technical data .................................................. 180

Selection and qualification of personnel - basic responsibilities ...................................................... 6

TECHNICAL DATA .......................................... 227

Service station (tank lift) .................................... 68 Servicing .................................................. 192, 194 Servicing lighting ................................................ 27 SERVICING WORK.......................................... 127 Shutting off the engines ...................................... 77 Signs .................................................................. 23 Slewing and braking the superstructure ............ 87 Slewing gear neck ............................................ 175 SLEWING GEARBOX ...................................... 174 Slewing mechanism, Fault table ...................... 219 SLEWING RING .............................................. 183 Slewing ring - Checking the grease filling ........ 184

Temperature .................................................... 136 Testing the coolant composition ...................... 139 Tightening torques and angles - Table ............ 223 Topping up coolant .......................................... 137 Track parking brake ............................................ 83 Track roller fastening ........................................ 179 Track rollers ...................................................... 178 Track tensioner ................................................ 179 Transport ............................................................ 84 Transport - Safety instructions ............................ 84 Transporting and recommissioning ...................... 9 Transporting the machine .................................. 84 Travel gearbox - Changing the oil .................... 176

Slewing ring - Checking the screws for tightUpdate to version .04, see pages 115a and 178a

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Travel gearbox - Checking the oil level / Topping up........................................................ 176 TRAVEL GEARBOXES .................................... 176 TRAVELLING .................................................... 79 Travelling forwards/in reverse ............................ 79 Travelling over longer distances ........................ 82 Travelling uphill and downhill .............................. 80 TROUBLESHOOTING .................................... 215 Turning .............................................................. 80

U Unblocking a grease line .................................. 187 Undercarriage .............................................. 19, 20

V Venting bore .................................................... 175 Venting the fuel system .................................... 146 Venting the hydraulic components .................. 168 Venting the hydraulic system ............................ 168

W Warning and instruction signs ............................ 23 Warning of special dangers .................................. 8 Warnings and symbols ........................................ 4 Warranty .............................................................. 3 Water filter ........................................................ 140 WELDING OPERATIONS ................................ 209 Welding operations - Safety instructions .......... 209 Windscreen washer ............................................ 28 Working .............................................................. 88 Working hydraulics - Fault table ...................... 217 WORKING OPERATION .................................... 87 WORKING OPERATION, SAFETY INSTRUCTIONS ................................................................ 85

Update to version .04, see pages 115a and 178a

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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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