OPERATING INSTRUCTIONS 6015 / RH40E Inspection and servicing

Servicing Work

Hose line for oil and cooling liquid changes

Collect escaping oil and cooling liquid and discard without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more easily.

The engine, hydraulic oil reservoir, slewing gearbox and the engine cooling system are equipped with special oil drain valves (1, Fig. 3-11:).

These valves can be used for changing the oil and the coolant in clean conditions and in a nonpolluting way.

Procede as follows to change the oil or the coolant:

 Place a collecting recipient for used oil or coolant under the drain valve (capacity see "Refilling Quantities - Oil", "Refilling QuantitiesOther"

 Take the drain hose out of the the tool-box.

 Unscrew the protective cap from the drain valve.

 Screw the drain hose (2) on the valve; the valve opens and the oil / coolant drains off.

 Remove the drain hose from valve after the oil / coolant has drained off; the valve closes automatically.

 Screw the protective cap back in place.

ENGINE 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 engine and allow to cool down.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside; Do not work on the exhaust system an do not make any modifications to it.

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.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from potentially harmful contact with engine oil.

Wear protective gloves and firm working clothing.

Checking, retensioning the V-belt tension

These and other servicing works are described in the engine manufacturer's operating instructions.

Checking the engine oil level / Topping up

Fig. 3-12:

 Park the machine on a horizontal surface and protect it against rolling away.

 Shut off the engine.

 Withdraw dipstick (arrow, Fig. 3-12:).

 Wipe dipstick clean with a clean and lintfree cloth and re-insert.

 Withdraw oil dipstick once again. The oil level should now lie between the marks (arrows, Fig. 3-13:). If the oil level is at the "min" mark or below, top up with engine oil through the fillertube (arrow, Fig. 3-15:).

Changing the engine oil

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

Risk of scalding from hot engine oil. The engine may also be hot.

Wear protective gloves and firm working clothing. Collect escaping oil and discard without polluting the environment.

Draining off engine oil

 Bring engine oil to operating temperature.

 Park the machine on a horizontal surface and secure.

 Shut off the engine.

 Drain off engine oil using the oil draining hose (Fig. Fig. 3-14:).

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid changes" chapter.

After draining of the oil:

 Replace the engine oil filter.

 Remove the hose line. The automatic drain coupling closes automatically.

 Screw on protective cap.

 Fill in engine oil through the filler tube (arrow, Fig. 3-15:) until the oil level reaches the "max" mark (Fig. 3-16:).

 Start the engine and allow to run for abt. 2 minutes at idling.

 Check oil level and top up with oil up to the "max" mark, if required.

Replacing the engine oil filters

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

Risk of scalding from hot engine oil. The filter housing may also be hot. Wear protective gloves and firm working clothing. Collect escaping oil and discard with-out polluting the environment.

Replacing engine oil filters

 Unscrew the filters.

 Screw on new filters with a slightly oiled sealing ring and tighten by hand.

After replacing the engine oil filters carry out the engine oil change in compliance with the engine operating instructions. (when not done).

Fig. 3-17:

 Shut off the engine. Wait until engine has cooled down.

Risk of falling

Put on a safety harness before working on the catwalk on the right-hand side of the superstructure (1, Fig. 3-17:). Attach the safety line to the grab handles (3).

 Open the flap of the engine compartment on the right-hand side of the superstructure (2, Fig. 3-17:).

The oil filters (1, Fig. 3-18:) are then accessible.

 Let the engine run at idling for a short time and check the filters for leaks. Shut off the engine.

 Check the oil level after about 10 minutes and top up, if necessary.

Cold-starting fluid (ether) - Replacing the pressure vessel

Read and observe: "Inspection and servicingSafety instructions"

Risk of injury

Cold-starting fluid is composed mainly of ether.

Ether is toxic when the mists and vapours are inhaled. Ether is harmful to the eyes, the skin, the respiratory system and the central nervous system. Prolonged inhalation of ether can be fatal.

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

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.

Before replacing an empty pressure vessel:

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 of the surroundings.

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

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

Avoid skin contact. Wear suitable protective gloves and goggles.

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is screwed onto an electro-mechanical metering valve. At temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Replacing the pressure vessel:

 Remove the clamp around the pressure vessel.

 Unscrew the pressure vessel carefully from the metering valve.

 Remove the used seal from the metering valve.

 Insert a new seal into the valve (supplied with the new pressure vessel).

 Screw the new pressure vessel onto the metering valve and tighten by hand.

 Fasten the clamp round the pressure vessel. Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. 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 unaccessible to unauthorized persons.

 Dispose of the vessels properly.