OPERATING INSTRUCTIONS 6015 / RH40E Inspection and servicing

Handling of cold-starting fluid (ether)

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapours of escaping cold-starting fluid.

In contact with the skin, ether can cause frostbites and irritations. Avoid skin contact.

Wear suitable protective gloves and goggles. Even apparently empty pressure vessels can still contain rests of ether and therefore explode if they are damaged or heated up above 49°C. They must therefore be handled in the same way as full pressure vessels.

 Do not keep them on the machine.

 Do not damage or open the vessels.

 Do not expose the vessels to great heat or direct sunlight.

 Do not dispose of in fire.

 Keep the vessels in a place inaccessible to unauthorized persons.

 Dispose of the vessels properly.

Selecting oils and greases

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

Filters

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

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

Sealing elements

When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged. When assembling, ensure a perfect fit.

Oil-level check and oil change

Position the machine horizontally.

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

Lubricating

Clean the lubricating nipple, then lubricate as scheduled.

After servicing

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

On completing work, re-install all protective devices.

Never start up the drive motors while work is being done on the machine. Carry out performance tests with the machine.

INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD

Safety instructions

Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

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

Obtain information on the safe handling of the fire extinguishers to be used.

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

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present.

 open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel 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 hydraulic shovel.

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

If necessary, also cover the ground with fireprotective blankets.

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

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

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

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

Do not extinguish flammable liquids with water. Use:

 dry-powder, carbon-dioxide or foam extinguishing compounds.

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

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or coldstarting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

Environmentally Compatible Hydraulic Fluid

Environmentally compatible hydraulic fluid - operating instructions

The hydraulic system of this machine can be filled ex works with environmentally compatible, synthetic hydraulic fluid as an option. In this case, the machine is supplied with stickers containing the corresponding instructions.

For the initial filling, Bucyrus HEX uses only: PANOLIN HLP SYNTH 68 Bucyrus HEX (P/N: 2115005).

This synthetic hydraulic fluid has been tested by Bucyrus HEX and approved for application in Bucyrus HEX machines.

A change from mineral hydraulic oil to this synthetic hydraulic fluid can, however, be made also at a later date.

Environmentally compatible hydraulic fluid, too, must not be simply poured away but disposed of in the same way as used oil.

If hydraulic fluid seeps into the ground, the machine owner and the competent authorities must be informed. HLP SYNTH 68 is suitable only for hydraulic systems.

As HLP SYNTH 68 is not soluble in water This means that condensate may be deposited in the hydraulic oil tank. It must therefore be drained off at regular intervals and after lengthy downtimes, then disposed of in the same way as used oil.

Use only HLP SYNTH 68 for changing or topping up the hydraulic fluid.

The hydraulic fluid must not be mixed with hydraulic oils or hydraulic fluids by other manufacturers, as this affects its biodegradability.

Operating equipment and attachments driven with mineral hydraulic oil must not be mounted until thoroughly emptied, cleaned and flushed.

Analysis will show whether the hydraulic fluid can be used beyond the standard changing intervals.

See section: "Environmentally compatible hydraulic fluid, sampling".

Environmentally compatible hydraulic fluid, conversion

Read and observe: "Inspection and Servicing - Safety Instructions".

 Bring hydraulic system to operating temperature.

 Retract all hydraulic cylinders.

 Drain off hydraulic oil (see operating instructions, section 3 "Inspection and Servicing").

 Fill hydraulic oil tank with HLP SYNTH 68 up to halfway mark.

 Activate all hydraulic functions including travelling for about 30 minutes. The hydraulic system is being flushed during this time.

Then drain off the hydraulic fluid.

The fluid can be used repeatedly for flushing. Otherwise it must be properly disposed of. In this case, a disposal expert must be consulted as this is a mixture of synthetic hydraulic fluid and mineral hydraulic oil.

 Change all filters in the hydraulic system. Fill the hydraulic oil tanks with new HLP SYNTH 68.