Cat Bucyrus Hydraulic Excavator RH 40E Operating Instructions Manual BI651491

OPERATING INSTRUCTIONS RH 40E

Hydraulic Excavator

RH 40E Bucyrus HEX GmbH

BA RH40E(3 664 930.00)-EN

No.

OPERATING INSTRUCTIONS RH 40E

Published by:

Bucyrus HEX GmbH 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

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OPERATING INSTRUCTIONS RH 40 E

Die O&K Mining operating manual is in 6 sections; the sections are designed for different target groups: 2804051

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Part 4 REPAIR WORK

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

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

Part 5 ANNEX

Part 6 INDEX

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

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OPERATING INSTRUCTIONS RH 40 E

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BETRIEBSANLEITUNG RH 40 E Table of contents TABLE OF CONTENTS 1 INTRODUCTION ___________________________________________________________________ 1-1 PREFACE ________________________________________________________________________ 1-3 WARRANTY ______________________________________________________________________ 1-4 FUNDAMENTAL SAFETY INSTRUCTIONS______________________________________________ 1-5 Warnings and symbols _____________________________________________________________ 1-5 DESIGNATED USE _________________________________________________________________ 1-6 ORGANIZATIONAL MEASURES ______________________________________________________ 1-7 Selection and qualification of personnel; basic responsibilities ______________________________ 1-8 Safety instructions governing specific operational phases __________________________________ 1-8 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ____________________________ 1-9 Warning of special dangers ________________________________________________________ 1-10 Gas, dust, steam and smoke _______________________________________________________ 1-11 Hydraulic equipment ______________________________________________________________ 1-11 Noise__________________________________________________________________________ 1-11 Oil, grease and other chemical substances ____________________________________________ 1-11 Transporting and recommissioning __________________________________________________ 1-11 FIRE AND EXPLOSION HAZARD ____________________________________________________ 1-12 NOTES _________________________________________________________________________ 1-13 2 OPERATION ______________________________________________________________________ 2-1 OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3 FIRE AND EXPLOSION HAZARD _____________________________________________________ 2-5 DESCRIPTION OF THE EXCAVATOR__________________________________________________ 2-6 Excavator layout __________________________________________________________________ 2-7 Undercarriage ____________________________________________________________________ 2-8 Superstructure ___________________________________________________________________ 2-8 Drive ___________________________________________________________________________ 2-8 Hydraulic system__________________________________________________________________ 2-8 Pump Managing System (PMS) ______________________________________________________ 2-8 Demand control / Zero-flow regulation _________________________________________________ 2-8 Automatic engine speed reduction ____________________________________________________ 2-8 Electrical system __________________________________________________________________ 2-8 Sign___________________________________________________________________________ 2-11 Fire-extinguisher _________________________________________________________________ 2-12 DRIVER'S CAB ___________________________________________________________________ 2-13 Entering and leaving the machine - Safety instructions ___________________________________ 2-13 Driver's seat ____________________________________________________________________ 2-14 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-16 PUTTING THE MACHINE INTO OPERATION ___________________________________________ 2-35 Refuelling ______________________________________________________________________ 2-35 Service Station (optional equipment) _________________________________________________ 2-36 Switching the electrical system on and off _____________________________________________ 2-37 Battery main switch_______________________________________________________________ 2-38

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OPERATING INSTRUCTIONS RH 40 E Table of contents STARTING AND STOPPING THE ENGINES____________________________________________ 2-39 VENTILATION AND HEATING _______________________________________________________ 2-41 DRIVING ________________________________________________________________________ 2-42 SAFETY INSTRUCTIONS _________________________________________________________ 2-42 TRAVELLING ___________________________________________________________________ 2-44 Locking the superstructure _________________________________________________________ 2-48 Track parking brake ______________________________________________________________ 2-48 TRANSPORTING THE MACHINE ____________________________________________________ 2-49 Transport - Safety instructions ______________________________________________________ 2-49 WORKING OPERATION____________________________________________________________ 2-51 SAFETY INSTRUCTIONS _________________________________________________________ 2-51 Before starting work ______________________________________________________________ 2-53 Slewing and braking the superstructure _______________________________________________ 2-53 Working _______________________________________________________________________ 2-54 After daily operation ______________________________________________________________ 2-55 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS_________________________ 2-56 Securing the machine _____________________________________________________________ 2-58 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ____________ 2-59 LIFTING OPERATIONS ____________________________________________________________ 2-60 Safety instructions________________________________________________________________ 2-60 Load-hooks on backhoe buckets.____________________________________________________ 2-61 NOTES _________________________________________________________________________ 2-65 3 INSPECTION AND SERVICING _______________________________________________________ 3-1 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ________________________________ 3-3 FIRE AND EXPLOSION HAZARD _____________________________________________________ 3-9 ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID _________________________________ 3-10 Environmentally compatible hydraulic fluid - operating instructions __________________________ 3-10 Environmentally compatible hydraulic fluid, conversion ___________________________________ 3-10 Environmentally compatible hydraulic fluid - Sampling____________________________________ 3-11 ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS___________________________ 3-12 Lubricants for bearings ____________________________________________________________ 3-12 Gearbox oils ____________________________________________________________________ 3-12 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ________________________________ 3-13 Intervals _______________________________________________________________________ 3-13 Change of engine oil l _____________________________________________________________ 3-13 Oils / Greases ___________________________________________________________________ 3-13 Cleaning jobs ___________________________________________________________________ 3-13 Components ____________________________________________________________________ 3-13 Plan V _________________________________________________________________________ 3-15 Plan N _________________________________________________________________________ 3-17 Plan T _________________________________________________________________________ 3-19 Plan A – E ______________________________________________________________________ 3-21 LUBRICATING CHART – GREASE (LOADING BUCKET)__________________________________ 3-26 Lubricating chart – Grease / Loading bucket (legend) ____________________________________ 3-27 Filling quantities - Grease __________________________________________________________ 3-27 LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND) ________________________ 3-28 Lubricating chart – Grease / Backhoe bucket (legend) ___________________________________ 3-29 vi

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BETRIEBSANLEITUNG RH 40 E Table of contents Filling quantities - Grease __________________________________________________________ 3-29 INSPECTION PLAN - OIL ___________________________________________________________ 3-30 Inspection plan – Oil (legend) ) ______________________________________________________ 3-31 Filling quantities - oil ______________________________________________________________ 3-31 Filling quantities - other____________________________________________________________ 3-32 LUBRICANTS ____________________________________________________________________ 3-33 I. Oils for combustion engines and compressors (selection) _____________________________ 3-33 II. Oils for hydraulic system (selection)_______________________________________________ 3-34 III. Oils for gearboxes (selection)__________________________________________________ 3-35 V. Greases for bearings and slewing rings ____________________________________________ 3-36 SERVICING WORK________________________________________________________________ 3-37 Hose line for oil and cooling liquid changes ____________________________________________ 3-37 ENGINE _________________________________________________________________________ 3-38 Engine - Safety instructions ________________________________________________________ 3-38 Checking the V-belt tension ________________________________________________________ 3-38 Retensioning the alternator/fan belt __________________________________________________ 3-38 Checking and adjusting the valve clearance ___________________________________________ 3-38 Checking the engine oil level / Topping up _____________________________________________ 3-38 Changing the engine oil ___________________________________________________________ 3-39 Replacing the oil filter _____________________________________________________________ 3-40 Centrifuge (optional) ______________________________________________________________ 3-41 COOLING SYSTEM _______________________________________________________________ 3-42 Radiators_______________________________________________________________________ 3-42 Cooling liquid ___________________________________________________________________ 3-43 Water filter _____________________________________________________________________ 3-44 AIR-INTAKE SYSTEM______________________________________________________________ 3-45 Main filter elements_______________________________________________________________ 3-45 Safety filter element ______________________________________________________________ 3-47 Air-intake lines __________________________________________________________________ 3-47 Dust collection___________________________________________________________________ 3-47 FUEL SYSTEM ___________________________________________________________________ 3-48 Fuel system - Safety instructions ____________________________________________________ 3-48 Replacing the fuel filter ____________________________________________________________ 3-49 Venting the fuel system____________________________________________________________ 3-49 Cleaning the fuel tanks ____________________________________________________________ 3-50 Refuelling station (optional) ________________________________________________________ 3-50 Water trap (option) _______________________________________________________________ 3-51 ELECTRICAL SYSTEM_____________________________________________________________ 3-53 Electrical system - Safety instructions ________________________________________________ 3-53 Alternator - Instructions____________________________________________________________ 3-53 Battery main switch / Main fuse _____________________________________________________ 3-54 Battery_________________________________________________________________________ 3-54 HYDRAULIC SYSTEM _____________________________________________________________ 3-57 Hydraulic system - Safety instructions ________________________________________________ 3-57 Depressurizing the hydraulic system _________________________________________________ 3-57 Checking the hydraulic oil level______________________________________________________ 3-58 Topping up with hydraulic oil________________________________________________________ 3-58 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ______________________________ 3-59 Bypass valves (working circuit)______________________________________________________ 3-60 Bypass valves (cooling circuit) ______________________________________________________ 3-61 Breather filter ___________________________________________________________________ 3-62 High-pressure filter for working hydraulics _____________________________________________ 3-63 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump____________ 3-64

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OPERATING INSTRUCTIONS RH 40 E Table of contents Changing the hydraulic oil__________________________________________________________ 3-65 Venting the hydraulic system _______________________________________________________ 3-67 Cleaning the hydraulic oil cooler _____________________________________________________ 3-68 Pressure accumulator_____________________________________________________________ 3-69 PUMP TRANSFER GEARBOX _______________________________________________________ 3-70 Checking the gearbox oil level / Topping up with oil ______________________________________ 3-70 Changing the gearbox oil __________________________________________________________ 3-70 SLEWING GEARBOX ______________________________ FEHLER! TEXTMARKE NICHT DEFINIERT. Gearbox - Checking the oil level / Topping up with oil ____________Fehler! Textmarke nicht definiert.

Changing the gearbox oil __________________________________Fehler! Textmarke nicht definiert.

Gearbox venting _________________________________________Fehler! Textmarke nicht definiert.

TRAVEL GAERBOX _______________________________________________________________ 3-74 Gearbox - Checking the oil level / Topping up with oil ____________________________________ 3-74 Travel gearbox - Changing the oil____________________________________________________ 3-74 Gearbox venting _________________________________________________________________ 3-74 CRAWLER TRACKS _______________________________________________________________ 3-75 Track rollers, support rollers, track pads ______________________________________________ 3-75 Track tensioner __________________________________________________________________ 3-77 Pressure-accumulator inspection regulations___________________________________________ 3-78 Checking the gas charging pressure in the pressure accumulator___________________________ 3-78 Idlers __________________________________________________________________________ 3-79 SLEWING RING __________________________________________________________________ 3-80 Slewing ring - Instructions__________________________________________________________ 3-80 Bearing races ___________________________________________________________________ 3-80 CENTRAL LUBRICATING___________________________________________________________ 3-82 Design and function ______________________________________________________________ 3-82 Greasing cycle __________________________________________________________________ 3-84 Venting the grease pump __________________________________________________________ 3-86 Venting the grease lines ___________________________________________________________ 3-86 Unblocking a grease line __________________________________________________________ 3-86 Cleaning the grease sieves_________________________________________________________ 3-87 Lubricating the grease distributor of the working equipment _______________________________ 3-87 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING _______________ 3-88 Putting the excavator out of operation ________________________________________________ 3-88 Battery storage __________________________________________________________________ 3-88 Recommissioning ________________________________________________________________ 3-89 NOTES _________________________________________________________________________ 3-90 4 REPAIR WORK____________________________________________________________________ 4-1 REPAIR WORK - SAFETY INSTRUCTIONS _____________________________________________ 4-3 FIRE AND EXPLOSION HAZARD _____________________________________________________ 4-5 ENGINE __________________________________________________________________________ 4-6 ELECTRICAL SYSTEM______________________________________________________________ 4-7 Assisted starting (with jumper cables) – Safety instructions_________________________________ 4-7 Assisted starting (with jumper cables) _________________________________________________ 4-7 Starting the engine with jumper cables (external batteries __________________________________ 4-7 HYDRAULIC SYSTEM ______________________________________________________________ 4-9 Repair __________________________________________________________________________ 4-9

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BETRIEBSANLEITUNG RH 40 E Table of contents PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS _______________________________ 4-10 WELDING OPERATIONS - SAFETY INSTRUCTIONS ____________________________________ 4-11 NOTES _________________________________________________________________________ 4-13 5 ANNEX __________________________________________________________________________ 5-1 TROUBLESHOOTING ______________________________________________________________ 5-3 Instructions on troubleshooting_______________________________________________________ 5-3 Layout of the fault table_____________________________________________________________ 5-3 Possible causes __________________________________________________________________ 5-3 Measures _______________________________________________________________________ 5-3 Section _________________________________________________________________________ 5-3 FAULT TABLES____________________________________________________________________ 5-4 Combustion engine - Fault table______________________________________________________ 5-4 Working hydraulics – Fault table______________________________________________________ 5-5 Track drive – Fault table ____________________________________________________________ 5-6 Slewing mechnism – Fault table ______________________________________________________ 5-7 Central lubricating system – Fault table ________________________________________________ 5-8 HYDRAULIC CIRCUIT DIAGRAM_____________________________________________________ 5-10 ABBREVIATIONS _________________________________________________________________ 5-13 TECHNICAL DATA ________________________________________________________________ 5-15 6 INDEX ___________________________________________________________________________ 6-1

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OPERATING INSTRUCTIONS RH 40 E Table of contents

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OPERATING INSTRUCTIONS RH 40 E Introduction 1 INTRODUCTION 2804051

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Part 4 REPAIR WORK

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

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

Part 5 ANNEX

Part 6 INDEX

BA RH40E(3 664 930.00)-EN

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

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OPERATING INSTRUCTIONS RH 40 E Introduction

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OPERATING INSTRUCTIONS RH 40 E Introduction PREFACE 2804199

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

The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.

The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

The operating instructions must always be available in the driver's cab of the machine.

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

The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex Germany 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.

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 1 for safe and proper working must be observed 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 GERMANY Germany mechanic or by attending an Terex-Germany training course for operators or maintenance personnel.

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

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Complies with VDMA recommendation "Operating instructions"

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OPERATING INSTRUCTIONS RH 40 E Introduction WARRANTY 2732604

The warranty of Terex-Germany presupposes among other things that the servicing works as described in the operating instructions have been performed: !

by the Terex-Germany Service

or !

in a workshop authorized in writing by TerexGermany,

and !

by using the original spare parts of TerexGermany.

The proper execution of the servicing works must be documented on the Terex Germany Service checklists.

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OPERATING INSTRUCTIONS RH 40 E Introduction FUNDAMENTAL SAFETY INSTRUCTIONS 2261165

Complies with VDMA recommendation "Operating Instructions"

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

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

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OPERATING INSTRUCTIONS RH 40 E Introduction DESIGNATED USE 2413494

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 (acceptable risk) An acceptable risk is present, e.g.: loose material or material to be loaded may drop out of the bukket or backhoe while the working equipment is being swivelled.

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

The excavator with backhoe or loading bucket attachment is designed solely for excavating and loading: !

excavated soils,

!

sand,

!

gravel,

!

blasted rock,

!

ore,

!

coal,

and other raw materials.

Fitted with other attachments, the excavator can also be used as a special-purpose machine, e.g. with a hydraulic hammer. Further detailed information can be found in the Technical Specifications.

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

Using the excavator or its attachments for purposes other than or extending beyond those stated above, e.g.: ! for lifting or transporting persons, !

as a working platform,

!

for lifting crane loads without the equipment being approved for this purpose,

!

for driving in posts, sheetpiles supports, etc. without the equipment being approved for this purpose,

is considered contrary to the designated use.

Improper use may involve a life-threatening 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) fulfill the requirements of protecting the driver against wholebody vibration.

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OPERATING INSTRUCTIONS RH 40 E Introduction !

fall arresters

!

protective suit

!

helmet

!

goggles - e. g. for cleaning work - or for welding work

!

protective gloves - e.g. for work on hot units - for grinding and welding work

!

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

protective working gloves - e.g. for fitting work - for grinding and welding work

!

ear protectors

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.

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

ORGANIZATIONAL MEASURES 2413495

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.

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

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

For reasons of security, long hair must be tied back or otherwise secured, garments must be 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.

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

Personal protective equipment and the working clothing Depending on the cleaning, servicing and/or repair activities to be performed, the personal protective equipment and the working clothing may consist of the following items:

Observe all safety instructions and warnings attached to the machine.

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.

Use only the original sparts parts of TerexGermany.

They are the only ones to fulfill the technical specifications of the machine.

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

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

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

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

Observe all fire-warning and fire-fighting procedures.

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OPERATING INSTRUCTIONS RH 40 E Introduction Selection and qualification of personnel; basic responsibilities

Safety instructions governing specific operational phases

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

Standard operation

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

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

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

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

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

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

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

Avoid any operational mode that might be prejudicial to safety.

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

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

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

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

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

Start the machine from the driver's seat only.

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

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

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

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

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

Persons accopanying 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.

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OPERATING INSTRUCTIONS RH 40 E Introduction 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 and maintenance and repairs as well as troubleshooting during work; 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 safetyoriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the operating instructions and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

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

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

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

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

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

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OPERATING INSTRUCTIONS RH 40 E Introduction Wear a safety harness when carrying out maintenance work at heights above 1 m.

Caution, danger! Check out the prescribed safety distances.

Wear an approved harness equipped with fall arresters and safety lines.

If your machine comes into contact with a live wire

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.

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

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.

" do not leave the machine " drive the machine out of the hazard zone; 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.

High-voltage system Floodlamps equipped with gaz discharge lamps require a high-voltage supply (ca. 25 kV).

The high voltage is generated by a ballast unit.

Switch off the electrical system of the excavator before touching the lamp or the ballast unit.

Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling

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.

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.

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OPERATING INSTRUCTIONS RH 40 E Introduction Gas, dust, steam and smoke

Noise

Always start and operate the engine in a wellvented area;

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

If in an enclosed area, vent the exhaust to the outside;

Always wear the prescribed ear protectors.

Do not modify or tamper with the exhaust system Diesel engine exhaust and some of its constituents are known to cause cancer, birth defects, and other reproductive harm Operate fuel-operated 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).

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).

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 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) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Hydraulic 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.

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OPERATING INSTRUCTIONS RH 40 E Introduction FIRE AND EXPLOSION HAZARD 2796684

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

Pay particular attention to hazards caused by combustible and easily flammable substances.on the safe handling of the fire extinguishers to be used.

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

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

If necessary, also cover the ground with fireprotective blankets.

Ensure sufficient ventilation.

Clean the excavator before starting a job.

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

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

Do not extinguish flammable liquids with water.

Use:

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

!

dry-powder,

!

carbon-dioxide or

Do not store or handle any flammable substances during operation.

!

foam extinguishing compounds.

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.

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

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

1-12

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OPERATING INSTRUCTIONS RH 40 E Introduction NOTES 2804180

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1-13

OPERATING INSTRUCTIONS RH 40 E Introduction

1-14

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OPERATING INSTRUCTIONS RH 40 E Operation 2 OPERATION 2804052

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Part 4 REPAIR WORK

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

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

Part 5 ANNEX

Part 6 INDEX

BA RH40E(3 664 930.00)-EN

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

2-1

OPERATING INSTRUCTIONS RH 40 E Operation

2-2

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Safety belt

OPERATION - SAFETY INSTRUCTIONS 2804201

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

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

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

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

Keep the operating instructions with the machine at all times.

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 TerexGermany mechanic or by attending an TerexGermany 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

BA RH40E(3 664 930.00)-EN

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

Apply the safety belt before starting work.

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 TerexGermany. Clear-cut data are given in the technical specification.

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

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

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

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

Entering and leaving the machine Always face the machine when entering or leaving it.

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.

2-3

OPERATING INSTRUCTIONS RH 40 E Operation Hazard range The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its equipment and attachments or of swinging loads.

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

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

Marshallers The marshaller must keep outside the hazard zone.

Have a marshaller to assist you: !

when you have no clear overview over the hazard zone of the machine,

!

when reversing,

!

when shunting.

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

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

Keep in constant contact with the marshaller.

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

Securing the machine Secure the machine as described under "Securing the machine" before:

2-4

!

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 40 E Operation 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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2-5

OPERATING INSTRUCTIONS RH 40 E Operation DESCRIPTION OF THE EXCAVATOR 2804413

Fig. 2-1:

2-6

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OPERATING INSTRUCTIONS RH 40 E Operation Excavator layout

Loading bucket

Fig. 2-1:

29 – Boom

Undercarriage 1 - Track drive 2 – Idler 3 - Track roller 4 - support roller 5 - Crawler track 6 - Track tensioner 7 - Slewing ring

Superstructure 8 – Hydraulic oil reservoir 9 – Radiator (engine cooling liquid) 10 - Fuel tank 11 - Engine 12 - Pump transfer gearbox 13 – Hydraulic pumps (main pumps) 14 – Hydraulic pump (fan drive) 15 - Slewing pump 16 – Pilot control pump 17 - Cooling oil pump

30 - TriPower linkage 31 – Stick 32 - Bottom-dump bucket 33 - Boom cylinder 34 - Stick cylinder 35 - Tipping cylinder 36 - Bottom-dump cylinder 42 - Control valves 43 - Bottom-dump control valve 44 - Quick-action valve

Backhoe bucket 31 - Stick 33 - Boom cylinder 34 - Stick cylinder 37 - Monoblock boom 38 - Backhoe bucket 39 - Backhoe cylinder 40 - Toggle link 41 - Toggle lever 42 - Control valves

18 – Hydraulic oil cooler 19 – Slewing gear 20 – Batteries and battery main switch 21 – Driver`s cab with air conditioner 22 – Control panel 23 – Counterweight 24 – Grease container for central lubricating system 25 – Travel control block and rotor 26 – Air-intake system with vacuum-meter 27 – Exhaust system 28 - Ladder

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2-7

OPERATING INSTRUCTIONS RH 40 E Operation Undercarriage The undercarriage of the hydraulic excavator serves as a stable base and for travelling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and superstructure are connected by means of a slewing ring.

Superstructure 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 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) 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.

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

This means that during the 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 zeroflow.

These special features offer the following advantages:

!

reduced fuel consumption

!

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 pedals and control levers and thus the Servovalves are not actuated for a period of 10 seconds or more (programable), the speed of the engines is automatically reduced to idling. Thisfunction is a further contribution to fuel economy.

Electrical system The electrical system operates on 24 volts

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

2-8

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OPERATING INSTRUCTIONS RH 40 E Operation

BA RH40E(3 664 930.00)-EN

2-9

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-2:

2-10

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Sign 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 Terex-Germany Spare Parts Service.

The ordering part numbers are set out in the spare-parts list of the machine.

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

Fig. 2-4:

Engine number The serial number plate (Fig. 2-5:) for the diesel engine is located on the diesel engine.

Machine number The identification plate with the machine number is attached to the front side of the A-frame (arrow, Fig. 2-3:and/or Fig. 2-4:)

Fig. 2-5:

Component numbers

Fig. 2-3:

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

On steel components, the Terex-Germany part number or the serial number may be stamped into the metal at a clearly visible place.

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2-11

OPERATING INSTRUCTIONS RH 40 E Operation Fire-extinguisher

Handling

(optional equipment)

" Pull out safety pin (2, Fig. 2-7:).

The excavator cmay be equipped with a fireextinguisher (arrow, Fig. 2-6: and Fig. 2-7:).

" Press down button (3) firmly and release. " Operate the extinguishing gun.

After fire-fighting, the extinguisher must be refilled Immediately and prepared ready for use.

Inspection Have fire-extinguishers inspected regulary by an expert. This is required by the authorities and the insurance companies, but also for your own safety.

Fig. 2-6:

The excavator driver and the maintenance personnel must inform themselves about how to handle the fire-extinguisher in order to be able to act fast and efficiently in case of beginning fires.

Such instruction should be given by a qualified instructor.

Extinguishing agent Each filre-extinguisher is filled with 12 kg of Glutex. This extinguishing agent is used for fighting fires of classes A, B and C. Fires are extinguished fast, perfectly and without residues.

Have the fire-extinguisher checked at the prescribed intervals by authorized testing institutes.

Fire extinguishing system (optional)

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.

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

Fig. 2-7:

2-12

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation DRIVER'S CAB 2804265

Entering and leaving the machine - Safety instructions Clean off oil, grease, soil, mud, snow, ice and other substances from shoes, grab handles and steps.

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

Risk of injury due to slipping.

For entering and leaving use only the steps, platforms and grab handles provided (see Fig. 2-8:).

Always face the machine when entering or leaving it.

BA RH40E(3 664 930.00)-EN

Fig. 2-8:

2-13

OPERATING INSTRUCTIONS RH 40 E Operation Driver's seat

Adjusting the lumbar support

The driver's seat (Fig. 2-9:) can be adjusted in inclination, height and fore-and-aft position. The seat suspension can be adapted to the driver's weight.

The backrest is equipped with an upper and a lower air chamber.

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"

Pull knob (7) upwards - the lower chamber is inflated with air Pull knob (3) upwards - the upper chamber is inflated with air Push knobs (3 and 7) downwards - the air chambers are deflated

Adjusting the seat cushion Adjust the inclination of the seat cushion with handle (4). Bring the seat cushion into the desired position by moving the body forwards or backwards. Release handle (4).

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

To adjust the armrest inclination, turn knobs (6) to the right or left.

Fore-and-aft position The fore-and-aft position of the seat can be adjusted with lever (1).

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

Adjusting the seat suspension Fig. 2-9:

Adjusting the backrest Adjust the inclination of the backrest with handle (5) verstellen. Lean against the backrest or move your body forwards to bring the backrest into the desired position. Release handle (5).

The seat suspension can be steplessly adjusted with lever (2).

Higher weight - Pull knob (2) upwards (hard springs).

Lower weight - Push knob (2) downwards (soft springs) Optimal setting +/- 50 mm swing.

2-14

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OPERATING INSTRUCTIONS RH 40 E Operation

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2-15

OPERATING INSTRUCTIONS RH 40 E Operation MONITORING, WARNING AND CONTROL ELEMENTS 3659024

Fig. 2-10:

2-16

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OPERATING INSTRUCTIONS RH 40 E Operation (Fig. 2-10:)

No.

Element

Function

1

Clock

2

Thermometer

Pump transfer gearbox temperature

Indicates the oil temperature in the pump transfer gearbox

3

Pressure gauge

Engine oil pressure

Indicates the oil pressure in the diesel engine lubricating system

4

Thermometer

Diesel engine temperature

Indicates the temperature of the cooling liquid

5

Warning lamp

PMS (PUMP MANAGING SYSTEM)

Lamp flashes: !

when the electrical system is on (engine stationary)

!

in the event of a fault (engine running) short-circuit, cable break or defective componenent (magnetic pick-up, termperature probe for load-sensing or proportional valve)

Symbol

Lamp is permanently lit !

6

Warning lamp

CELECT warning

when the programmed hydraulic oil temperature of 80°C is exceeded.

Lamp is lit up in the event of an HPI fault The lamp moreover indicates the fault code.

Contact Terex Germany after-sales service or engine manufacturer (see switch (52).

7

Warning lamp

CELECT warning

Lamp is lit up in the event of an HPI fault The lamp moreover indicates the fault code.

Shut off engine Stop working.

Contact Terex Germany after-sales service or engine manufacturer (see switch (52).

8

Warning lamp

CELECT warning

Lamp is lit up (e. g.): ! when the engine oil pressure is too low !

when the cooling water temperature is too high

Shut off engine

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2-17

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-11

2-18

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Fig. 2-11

No.

Element

9

Warning lamp

Cooling-liquid level

Lit when the cooling-liquid level is too low.

10

Warning lamp

Cooling-liquid temperature

Lit when the temperature is too high

Engine oil pressure

Lit when the engine oil pressure is too low

11

Warning lamp

Function

Symbol

Shut off engine

Shut off engine 12

Warning lamp

Alternator

Lit when the alternator does not charge the battery.

13

Speedometer

(optional equipment)

Indicates the engine revolutions

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2-19

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-12:

2-20

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Fig. 2-12:

No.

Element

Function

14

Thermometer

Hydraulic oil tempe- Indicates the temperature of the oil in the hydraulic reservoir. rature

15

Warning lamp

Slewing pump contamination

Lit when the slewing pump is contaminated with metallic particles.

16

Warning lamp

Slewing pump temperature

Lit when the temperature of the slewing pump is too high.

17

Indicator lamp

Preheating, travel motors (optional)

Lit when the preheating system is switched on.

Free for optional equipment.

18 19

Symbol

Warning lamp

Min. hydraulic oil level

Lit when the hydraulic oil level is below limit value.

Shut off engine

20

Warning lamp

Min. fuel

Lit when the fuel has been used up, so that there is only the fuel reserve (abt. 115 l) left

21

Indicator lamp

Track parking brake

Lit when the parking brake is applied. ! The parking brake is automatically applied when the machine is stationary. !

The parking brake is automatically released when the "Travel" function is active.

22

Warning lamp

Main pump I contamination

Lit when the hydraulic pump I is contaminated with metallic particles

23

Warning lamp

Main pump II contamination

Lit when the hydraulic pump II is contaminated with metallic particles

24

Indicator lamp

Preheating, cooling fluid, hydraulic oil (optional)

Lit when the preheating system is switched on.

25

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Free for optional equipment

2-21

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-13:

2-22

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Fig. 2-13: No.

Element

Function

26

Warning lamp

Hydraulic oil filter

Lit when the flow resistance in the hydraulic return-flow filters is too high.

Replace filter elements when this warning lamp does not go out with the oil at operating temperature

27

Indicator lamp

Idle-Auto

Lit when the automatic speed reduction function is activated (speed reduced to idling when the pilot control valves remain inactivated for abt. 10 seconds).

28

Warning lamp

Superstructure holding brake

Lit when the holding brake is applied. ! The holding brake is automatically applied when the superstructure is stationary. !

Symbol

The holding brake is automatically released when the "Slewing" function is active.

Free for optional equipment

29 30

Indicator lamp

Lubrication ON

Lit when the lubricating system is on and in the event of a malfunction (see "Central lubricating system")

31

Indicator lamp

Preheating, fuel (optional)

Lit when the preheating system is switched on.

32

Warning lamp

Hydraulic reservoir

Lit when the shut-off valve at the hydraulic reservoir is closed.

The engine cannot be started when the shut-off valve is closed.

Closing the valve while the engine is running stops the engine.

33

Indicator lamp

Pilot control

Lit when the pilot control is active. see also pushbutton (85)

34

Free for optional equipment

35

Free for optional equipment

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2-23

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-14:

2-24

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Fig. 2-14: No.

Element

Function

36

Buzzer

Sounds an acoustic warning when a malfunctionis reported continuous tone together with warning lamps 9,10,11,19

Symbol

Intermittent tone with warning lamps 15,16,22,23 Shut off the engine immediately and lower the working equipment to the ground when buzzer (36) sounds continuously and when one of the warning lamps indicates a fault. The buzzer continues to sound until the fault has been rectified.

In the event of pump contamination or excessive slewing pump temperature, buzzer (36) sounds intermittently. The corresponding warning lamp lights up. The buzzer continues to sound until the fault has been rectified.

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2-25

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-15:

2-26

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Fig. 2-15: No.

Element

Function

51

Switch

Preheating, cooling fluid, hydraulic oil (optional)

Switched on the preheating system

52

Momentary contact switch

Engine monitor

Diagnose ON/OFF

53

Switch

Hammer operation (optional)

Switched on operation with hydraulic hammer

54

Switch

Engine monitor

Listing of fault codes

Symbol

see warning lamps (6 and 7) Increment) Decrement) 55

Switch

Preheating, fuel (optional)

Switched on the preheating system

56

Switch

Preheating, travel motors (optional)

Switched on the preheating system

57

Switch

Speed reduction

to the left: normal operation of automatic speed reduction of diesel engine; activated during working pauses to the right: automatic speed reduction off

58

Switch

Free for optional equipment

59

Operating-hours meter

Sums up the operating hours of the machine; servicing work must be carried out accordingly.

60

Rotary switch

Fan, air conditioner

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3-stage regulation of air flow

2-27

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-16:

2-28

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Fig. 2-16: No.

Element

Function

61

Switch

Windscreen wiper

Permanent / intermittent wiping

62

Switch

Floodlamp

Front of superstructure on the right

63

Momentary contact switch

Windscreen washer

Wipe/wash operation

64

Switch

Floodlamp

Counterweight Free for optional equipment

65 66

Symbol

Switch

67

Floodlamp

Driver's cab, instrument illumination

Superstructure holding brake

Applies the holding brake of the superstructure Actuate the switch only when the superstructure is stationary. The holding brake is released automatically when the superstructure slewing function is activated.

68

Switch

Floodlamp

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Driver's cab, rear right

2-29

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-17:

2-30

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OPERATING INSTRUCTIONS RH 40 E Operation Fig. 2-17: No.

Element

70

Speed control

(Potentiometer)$<

Function Controls the engine speed -

Symbol

turn counter-clockwise to the limit stop: idling speed

- turn clockwise to the limit stop: full speed 71 72

(

Not connected Activation /De-activation of electrical system

Key-switch

Position 1: function check of indicator and warning lamps in satellites I and II and of buzzer Position 3: starting of engine Hold key approx. 5 - 7 sec. This is necessary to start and pressurize the engine`s prelub system.

After then the engine starts automatically.

73

Free for optional equipment

74

Free for optional equipment

75

Free for optional equipment

76

Free for optional equipment

77

Free for optional equipment Free for optional equipment

78 79

Pushbutton

Boom-floating position (only for loading shovel equipment)

When actuated: boom cylinders are pressurized when when retracted.

Depress button (79) only when control lever (88) is in position "0" 80

Pushbutton

Horn

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Sounding of the horn

2-31

OPERATING INSTRUCTIONS RH 40 E Operation

Fig. 2-18:

2-32

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Fig. 2-18: No.

Element

81

Pedal

Travelling, right track

forwards / backwards

82

Pedal

Travelling, left

forwards / backwards

Pedal

track Bottom dump

Opens/closes the bucket bottom

83

Function

Symbol

(only for loading shovel equipment) 85

Pushbutton

Pilot control

Activation/de-activation of pilot control

86

Lever

Raising left control console

Locks and unlocks the control console

87

Control lever

Raising and lowering of bucket- or backhoe stick slewing and braking of the superstructure Raising and lowering of boom; dumping of the bucket or back-tipping of the backhoe bucket

88

Control lever

91

Lever

93

Radio

94

Control knob

97

Socket

PMS diagnosis

98

Socket

CELECT diagnosis

99

PMS-Box (Loadlimit regulator)

Fault code display with PMS (5) warning lamp

Air conditioner

Controls the amount of warm air optional equipment

Air conditioner

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Controls the amount of warm air

2-33

OPERATING INSTRUCTIONS RH 40 E Operation

2-34

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OPERATING INSTRUCTIONS RH 40 E Operation PUTTING THE MACHINE INTO OPERATION 2804416

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

Filling in fuel " Unscrew cap of filler tube (2, Fig. 2-19:). " Fill in fuel through the filter sieve in the filler tube.

Do not remove the sieve.

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 Refuelling - Safety instructions Fig. 2-19:

Explosion hazard

Refuelling with the refuelling system (optional equipment) The refuelling system (1, Fig. 2-20:) is installed besides the step-ladder.

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.

Stand working equipment on the ground.

Shut off the engines.

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.

Fig. 2-20:

Report fuel accidents immediately to the user or his representative.

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2-35

OPERATING INSTRUCTIONS RH 40 E Operation The refuelling system consists of an electrical pump,filling hose, switch box (2, Fig. 2-21:) and key-switch (3).

Service Station (optional equipment) Refilling and draining For filling in or for draining fluids, unscrew the cap of the corresponding express coupling (Fig. 2-22:).

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

Take off filling hose and refit cap on the express coupling.

Fig. 2-21:

Check before refuelling that the earthing strap (4, Fig. 2-21:) is attached to the chassis. Sparking caused by static or electric charges may set fuel on fire.

Fig. 2-22:

Item Fig.4

2-36

Fluid

Express coupling

1

Diesel fuel

filling

2

Cooling liquid

filling resp. draining

3

Engine oil

filling resp. draining

4

Hydraulic oil reservoir

filling resp. draining

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OPERATING INSTRUCTIONS RH 40 E Operation

Switching the electrical system on and off

P=

Not connected

0=

All electrical consumers without current.

Engine off.

1=

Electrical system on: lamp test. All

Switching the electrical system on and off Key-switch (72, Fig. 2-23:) serves to switch the following functions:

Monitoring and warning lamps are activated for 5 seconds and buzzer (36, Fig. 2-24:) is activated for 1 second. Thereafter, warning lamps (5, 9, 10, 21,26, 28, 30) are lit. Warning lamp (5) flashes.

2=

Not connected.

3=

Engine start. All warning and monitoring lamps

Fig. 2-23:

Fig. 2-24:

BA RH40E(3 664 930.00)-EN

2-37

OPERATING INSTRUCTIONS RH 40 E Operation Battery main switch The battery main switch is located under a lockable hatch (arrow, Fig. 2-25:) beside the batteries and the tool box. The battery main switch disconnects the whole electrical system from the batteries. In the OFF position, the battery main switch protects !

the machine against unauthorized starting of the engine

!

the batteries against inadvertent discharge

Fig. 2-25:

Only the automatic fire-extinguishing system (optional equipment) remains connected to the power supply even when the switch is in the OFF position.

The two switch positions shown in Fig. 2-26: have the following meaning: I = ON II = OFF In the OFF position, the battery main switch handle can be withdrawn.

Fig. 2-26:

Never set battery main switch to OFF when the engine is running to avoid destruction of electrical components by voltage peaks.

2-38

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation STARTING AND STOPPING THE ENGINES 3659014

Repeat the starting procedure if the engine does not fire. Repeat starting procedure not more often than 3 to 4 times. Do not operate the starter for more than 10 seconds.

If warning lamps (5, 11, 12, Fig. 2-28:) do not go out when the engine is running, shut off engine immediately.

Starting the engines

Start and operate combustion engines only on well-ventilated premises; Locate cause of the fault and rectify before restarting the engine.

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

Fig. 2-28:

Shutting off the engine During interruptions of the work and after the work, stand working equipment on the ground.

Do not shut off engine before the working equipment rests on the ground.

Fig. 2-27:

" Turn speed control knob (70, Fig. 2-27:) counter-clockwise to the limit stop (idling). " Insert key into key-switch (72) and turn right to position 3. " Release key after the engine has fired.

Allow engine to run at idling for at least 5 minutes before running it at full load

" Turn speed control knob (70, Fig. 2-27:) counter-clockwise to the limit stop (idling).

Do not shut off the engine out of full load. The engine should be run at idling for another 5 minutes to allow the lubricating oil and the cooling liquid to dissipate the combustion heat from the combustion chamber and from bearings and shafts.

" Turn key in key-switch (72) to position "0" (electrical system without current).

BA RH40E(3 664 930.00)-EN

2-39

OPERATING INSTRUCTIONS RH 40 E Operation Emergency stop In case of emergency, e.g. if buzzer (36, Fig. 2-29:) sounds, the engine can be shut off from full load.

Fig. 2-29:

" turn key in key-switch (72, Fig. 2-30:) to position "0" (electrical system without current).

Fig. 2-30:

2-40

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Adjusting the heating performance

VENTILATION AND HEATING 2804412

Ventilation

" Slide lever (91, Fig. 2-32:) forwards depending on the heating performance desired. The foremost position gives maximum heating power.

(fresh air) " If greater amounts of warm air are needed, switch on the fan with rotary switch (60, Fig. 2-31:).

Fig. 2-31:

" When the engine is stationary, turn keyoperated switch (72, Fig. 2-31:) to position 1

Fig. 2-32:

" Slide heating control lever (91, Fig. 2-32:) backwards (heating power = 0). " Turn rotary switch (60, Fig. 2-31:) to the desired fan intensity (steps 1 - 3).

BA RH40E(3 664 930.00)-EN

2-41

OPERATING INSTRUCTIONS RH 40 E Operation DRIVING SAFETY INSTRUCTIONS 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.

Fig. 2-34:

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. 2-33:and Fig. 2-34:) " Drive the excavator in revers approx. 50 m. " Drive the excavator in forwards approx. 50 m. " Stop the excavator. " Measure the temperature at each dler, 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.

Fig. 2-33:

2-42

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation

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.

Do not travel uphill or downhill with the excavator if the gradient is greater than 20°.

In this case, the engine may be insufficiently lubricated.

BA RH40E(3 664 930.00)-EN

2-43

OPERATING INSTRUCTIONS RH 40 E Operation TRAVELLING

Travelling forwards/backwards

Superstructure basic position

Travelling forwards:

Travel direction and sense of actuation of pedals (81 and 82, Fig. 2-36:) are identical only when the excavator is in its BASIC POSITION (Fig. 2-35:).

depress pedals (81 and 82) forwards.

The excavator travels in the direction of the idler (2, Fig. 2-35:).

Travelling backwards: depress pedals (81 and 82, Fig. 2-36:) backwards.

The excavator travels in the direction of the drive sprocket (4,Fig. 2-35:).

Fig. 2-35:

If the superstructure is slewed out of its basic position by more than 90° (Fig. 2-37:), the excavator moves in a direction opposite to that expected when pedals (81 and 82, Fig. 2-36:) are depressed.

Fig. 2-37:

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

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

Do not 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. 2-36:

If the operator is not completely sure of the position of the superstructure with regard to the undercarriage, pedals (81 and 82) should be depressed slightly in order to find out which way the excavator moves before initiating the full travelling movement.

2-44

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.

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Regulating the travelling speed

Travelling uphill and downhill

Travelling on level ground Regulate the travelling speed with " pedals (81 and 82, Fig. 2-38:) and

Read and observe the "Travelling Safety instructions" chapter.

" the engine speed control. " Depress padals (81 and 82,) fully to the limit stop. " Regulate the travel speed only with the engines speed control.

When travelling downhill, the travel retarder valve acts as a speed limiter.

The travel retarder valve works correctly if pedals (81 and 82) are fully depressed down to the limit stop.

Fig. 2-38:

Should the travelling speed become too high when travelling downhill release pedals (81 and 82) to stop the excavator.

Cornering To take a right-hand corner forwards " depress only peda l (82,) forwards To take a lefthand corner forwards " depress only pedal (81) forwards -

Turning To turn to the right " depress pedal (82) forwards and pedal (81) backwards To turn to the left " depress pedal (81) forwards and pedal (82) backwards.

BA RH40E(3 664 930.00)-EN

2-45

OPERATING INSTRUCTIONS RH 40 E Operation Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-39:).

The same procedure should be adopted if the excavator is to be driven out of depressions (Fig. 2-40:): Cornering to the left

from pos. 1 to pos. 2

Cornering to the right

from pos. 2 to pos. 3

Never use the working equipment to raise one side of the undercarriage and then turn the undercarriage by initiating the slewing and/or the travelling function.

This way of working is contrary to the excavator'sdesignated use.

There is a risk of accident. Moreover, the tracks, slewing gear, roller bearing slewing ring, backhoe or bucket back-wall and the front part of the bukket are subjected to inadmissibly high stresses.

Fig. 2-39:

Cornering to the left: forwards

from pos. 1 to pos. 2

backwards

from pos. 2 to pos. 3

forwards

from pos. 3 to pos. 4

Fig. 2-40:

2-46

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Travelling over long distances

Backhoe bucket equipment (Fig. 2-42:) " Fully extend boom cylinder 1.

Read and observe the "Travelling – Safety instructions" chapter.

Travel only forwards with the excavator in its basic

" Retract backhoe cylinder 2. " Retract stick cylinder 3. " Extend backhoe cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment shown in Fig. 2-42:

position.

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

Keep the loading or the backhoe bucket close to the ground (Fig. 2-41: / Fig. 2-42:). For a more uniform loading of the tracks, the equipment must, howe-ver, be kept at a steep angle.

Fig. 2-42:

Lower the equipment when travelling underneath obstacles.

If the equipment position must be changed: " stop the excavator " change the position " continue to travel.

Fig. 2-41:

After travelling for 15 minutes without interruption, stop the excavator and check the temperatureof the track rollers.

Loading bucket equipment (Fig. 2-41:)

If the temperature does not exceed ca. 100° C:

" Fully extend boom cylinder (1).

" continue travelling.

" Extend bucket cylinder 2.

In case of higher temperatures:

" Extend stick cylinder 3. " Retract bucket cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment (Fig. 2-41:).

BA RH40E(3 664 930.00)-EN

" Stop travelling. Resume travelling only after the track rollers have cooled down to ca. 40° C.

2-47

OPERATING INSTRUCTIONS RH 40 E Operation Locking the superstructure

Track parking brake The excavator is equipped with two track brakes integrated in the track drives.

The superstructure can only be locked in the BASIC POSITION.

The track brakes are parking brakes which relieve the hydro-static travel drives during working operation and which protect the excavator against rolling forwards and backwards.

Lock the superstructure and the undercarriage !

when travelling over longer distances (more than 1 km)

!

during transport.

Locking the superstructure (Fig. 2-43:) " Take locking bar (18) out of the tool box. " Slew superstructure slowly until the hole in superstructure is in alignment with with lugs (16). " Push locking pin (18) and recure with screws.

Fig. 2-44:

The brakes are controlled by means of the travel pedals (81 and 82, Fig. 2-44:). In neutral position of the pedals, the brakes are applied and the excavator is braked. During travelling, the brakes are released.

Fig. 2-43:

After travelling or after transport, " remove locking pin and place back into the tool box.

Fig. 2-45:

The brakes are operated by means of the travel pedals (81 and 82, Fig. 10). In the neutral position of the travel pedals, the brakes are applied and the excavator is braked. During travelling the brakes are released.

When the excavator is stationary, the brakes can be applied with switch (65, Fig. 2-45:).

2-48

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation TRANSPORTING THE MACHINE 2804419

The partly dismantled excavator can now be transported on a semi ow-bed trailer (low-bed trailer with front platform) (Fig. 2-46:).

Transport - Safety instructions The machine must be loaded and transported only after all safety regulations have been observed and complied with.

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

The responsability 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.

Fig. 2-46:

Secure the transport vehicle against rolling away.

The dismantled components and modules must be transported on vehicles or low-bed trailers of sufficient size and carrying capacity.

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

Loading the excavator:

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: !

counterweight

!

driver's cab

!

excavating tool (loading bucket, backhoe bukket)

!

stick

!

boom

" Lower the front platform of the low-bed trailer down to the ground. " Uncouple the front part of the low-bed trailer and pull it away with the truck tractor. " Drive the excavator (without counterweight) from the front over the lowered platform with the tracks straddling the low-bed trailer. Align the machine properly in the longitudinal and the transverse direction (Fig. 2-47:).

Fig. 2-47:

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2-49

OPERATING INSTRUCTIONS RH 40 E Operation " Lock the superstructure (Fig. 2-48:). " Place solid timbers between the low-bed platform and the center part of the undercarriage (Fig. 2-49:).

" Couple the tractor to the low-bed trailer and raise the platform. The excavator is raised at the same time by the supporting timbers, so that the crawler tracks are clear of the ground (Fig. 2-49:).

Fig. 2-48:

Fig. 2-49:

" Secure the excavator with suitable means (chain hoists, wire ropes, chains, turn-buckles) (Fig. 2-49:).

Unload the excavator in reverse order.

Unlock the superstructure before slewing it for the first time.

2-50

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation WORKING OPERATION Running-in instructions for hydraulic cylinders

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.

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 speed.

The pressure-limiting valve in the hydraulic system must not respond

!

In the first two working cycles, retract and extend the pistons of the hydraulic cylinders to max. ½ to ¾ (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.

Sound the horn 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.

BA RH40E(3 664 930.00)-EN

2-51

OPERATING INSTRUCTIONS RH 40 E Operation At low temperatures, bring the engines down to moderate speed, then activate all hydraulic functions for about 10 minutes (bring to service temperature). For further instructions, see section "Lubricants".

If the warning lamps for engine temperature, engine oilpressure, coolant level, alternator or hydraulic oil filter control (with hydraulic oil at service temperature) light up: Lower the working equipment and shut off engine.

Parts of the attachment may damage the machine if they are moved into extreme positions (see illustration Fig. 2-50- Fig. 2-54) Work carefully, avoiding extreme positions of this kind.

Fig. 2-50

Fig. 2-51

2-52

Fig. 2-52

Fig. 2-53

Fig. 2-54

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Before starting work

Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded equipment for abt. 5 minutes.

Slewing and braking the superstructure To slew the superstructure to the right " shift control lever (87, Fig. 2-55:) to the right.

To slew the superstructure to the left This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts.

Warming up At low outside 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. also "Oils for hydraulic systems".

" shift control lever (87) to the left.

After releasing, the control lever returns automatically to position "0".

Switch on the "hold" function of the superstructure slewing brake with push button (67, Fig. 2-56:)

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

Fig. 2-56:

Depress button (67) only when the superstructure is stationary.

The slewing brake is released automatically when the "superstructure slewing" function is activated.

Fig. 2-55:

Switching on the servo control The servo control is switched on and off with switch (105, Fig. 2-55:).

Servo control activated - operator is sitting on his seat.

Servo control deactivated - driver's seat is empty.

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2-53

OPERATING INSTRUCTIONS RH 40 E Operation Raising and lowering the boom To raise the boom " pull control lever (88, Fig. 2-57:) backwards.

To lower the boom " push control lever (88) forwards.

To lower the boom with pressure " depress button (79) and " push control lever (88) forwards.

Extending and retracting the bucket or backhoe bucket stick

Fig. 2-57:

The superstructure is braked when control Lever (87, Fig. 2-57:) is shifted into the opposite direction (countering).

To extend the stick " push control lever (87) forwards.

To retract the stick

To brake a slewing movement to the right " shift control lever (87) to the left.

To brake a slewing movement to the left

" pull control lever (87) backwards.

Filling and emptying the bucket or the backhoe To fill/tip back the bucket " shift control lever (88) to the left.

" shift control lever (87) to the right.

To empty the bucket by dumping/tipping

Working

" shift control lever (88) to the right.

When released, all control levers for working operation return automatically to position "0".

Opening and closing the bottom-dump bucket

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

To open the bucket " press pedal (83) forwards.

To close the bucket

Loading bucket: Close bucket completely before beginning to dig. Do not level off a surface with the front shell of the bucket open.

2-54

" press pedal (83) backwards.

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation After daily operation Parking the machine " Park the machine on level and stable ground. This is particularly important in winter to avoid freezing of the tracks. " Stand the working equipment on the ground. " Shut off the engine. " Shift both control levers into all directions todepressurize the hydraulic cylinders. " Withdraw the key from the electrical system key-switch. " Close the cab window.

Escaping oil pollutes the environment.

Repair leaks immediately (or have them repaired). Report oil accidents to the user of the machine. " Check the superstructure, undercarriage and the working equipment for damage and all steel components for cracks or fractures. " Report detected damage immediately to the user. " Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler.

" 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. " Fill up the fuel tank. " Inspect the engine, the hydraulic system, the track rollers, support rollers, idlers and gearboxes visually for leaks.

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2-55

OPERATING INSTRUCTIONS RH 40 E Operation Tools and auxiliaries

ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS

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

2804209

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

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from Terex-GERMANY. 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.

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.

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.

2-56

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OPERATING INSTRUCTIONS RH 40 E Operation Securing the machine

Protective roof against falling objects

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

The machine is equipped with an integrated cabprotection roof (FOPS).

Securing the machine 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 Terex-GERMANY for this type of machine.

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

BA RH40E(3 664 930.00)-EN

2-57

OPERATING INSTRUCTIONS RH 40 E Operation Securing the machine Risk of injury.

The machine must not be started by unauthorized persons.

Secure the machine as described below: !

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

!

before carrying out any servicing and repair work on the machine.

Therefore, secure the machine.

" Park the machine on level and stable ground.

Observe the accident prevention regulations.

" Lock the superstructure.

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

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

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

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

" 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, set battery main switch to position "OFF". " Insulate the connecting terminals and plugs properly.

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 Terex-GERMANY machines have been carefully purpose-coordinated. Troublefree operation and a long service life can only be achieved with original Terex-GERMANY spare parts.

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

2-58

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2281259

Use Voler A.C. anti-corrosive agent only.

Other agents are not approved by Terex

All pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated Voler A.C. anti-corrosive agent before fitting.

Voler A.C.: !

permits easy fitting and dismantling

!

protects against rust, oxidation and similar wear

!

prevents seizing and fretting corrosion in nonmoving parts of bearings.

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

Rust patches must be thoroughly removed, if any.

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 gearready for fitting.

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

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 (CSC free) SN 1 438 473 - 0,5 kg tin SN 1 438 219 - 4,5 kg bucket Available from Terex–Germany Spare-Parts Service

BA RH40E(3 664 930.00)-EN

2-59

OPERATING INSTRUCTIONS RH 40 E Operation LIFTING OPERATIONS

Register the weight of the load. Sling only those loads not exceeding the load capacity of the lifting gear and of the machine

Safety instructions

Sling the load in such a way as to prevent it from slipping or falling while being lifted or transported.

Transporting the load Never use the machine for liftinggear operation unless it is equipped and approved for this purpose, i.e. the machine must be equipped with an overload warning system and a pipe break protection.

Read the sections "Fundamental safety instructions" and "Operation - safety instructions" with care and observe the instructions contained in them.

Never move the load above persons. Keep the load as close as possible to the ground. Prevent the load from swinging The machine must never be driven with a slung load unless the road surface is even and the roadway is clearly visible.

Roadway visibility can be improved by adjusting the boom and slewing the superstructure to the right.

Switch the overload warning system on.

The built-in overload warning device cannot totally exclude accidents due to incorrect operation. This applies in particular to:

(cf. "Technical data").

!

inadequate hooking of the load or the loadcarrying device,

!

excessive deceleration or acceleration forces (hard braking or strong slewing with the load to be moved),

!

loads dropping into the cable,

!

oblique pull,

!

driving the excavator into an area with steeply sloping ground,

!

exposure to strong wind.

Room for slingers Slingers must approach the working gear from the side when the load is slung.

During the lifting and transporting of loads, slingers or other assistant personnel must stand in a safe position or go beside the machine to ensure that they are outside the hazard zone.

Ensure that slingers and other assistant personnel are always in sight.

Avoid these risks by handling the machine carefully and with discretion.

Slinging loads Use only tested and efficient lifting gear with an adequate load capacity.

Hoist the load only from the hooks provided for that purpose.

Never use the the teeth of backhoe buckets, shovels or grabs.

Cable lugs, thimbles or U-bolts may slip from the teeth, putting the load out of control.

2-60

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Load-hooks on backhoe buckets.

Lifting capacity of the load hook

In order to be able to use the excavator with backhoe attachment also for short lifting operations, the backhoe buckets are available with welded load-hooks (Fig. 2-58: and Fig. 2-59:) (optional equipment).

The maximum lifting capacity of the load-hook is indicated besides the hook (Fig. 2-58: and Fig. 2-59:).

Read and observe "Lifting-gear operation - Safety instructions".

Lifting capacity of the excavator The admissible lifting capacity as a function of the working range is set out in the load table, see "Technical Data".

Switch on your overload warning system.

Fig. 2-59:

Fig. 2-58:

BA RH40E(3 664 930.00)-EN

2-61

OPERATING INSTRUCTIONS RH 40 E Operation Overload warning system

Checking the overload warning system

Hydraulic excavators that are used as lifting gear or for the transport of loads must be equipped with an overload warning system.

Check the overload warning system for safe operation before beginning to work with the loadhook.

The overload warning system consists mainly of an electro-hydraulic switching unit which gives an optical and an acoustic warning signal before the maximum admissible load moment is reached.

Do not switch off the overload warning system when the warning signal sounds.

The overload warning system must be on during lifting-gear operation.

The overload warning system only gives warning signals.

It cannot avert the danger of overturning. ! When the warning signal sounds: !

let the load down immediately

!

reduce the working radius or the load.

In case of malfunctions have the overload warning system immediately checked and repaired by Terex Germany.

Do not make re-adjustments or repairs of the overload warning system.

Re-adjustments or repairs might lead to incorrect operation or failure of the system.

Putting the overload warning system out of operation Shut off the overload warning system if the machine is to be used exclusively for digging.

In spite of the overload warning system, the operator must assure himself beforehand that the load to be lifted does not exceed the excavator's lifting capacity.

The admissible load moment is exceeded if too big a load is being lifted with a large working radius of the equipment (lifting capacity cf. the "Lifting capacity of the excavator" section).

2-62

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Operation Pipe burst protection

Speed reduction function

The pipe burst protection prevents uncontrolled lowering of the working equipment if a hydraulic line to the boom cylinder bursts.

Do not activate the speed reduction function when the machine is used for lifting operations and during travelling.

The hydraulic port on the rod-side of the boom cylinder is blocked off so that the hydraulic oil in the cylinder can flow out only if the "boom lowering" function is activated.

The speed reduction function can cause the hydraulic output to drop off suddenly.

When a hydraulic line has broken: " Warn persons in the vicinity of the machine by sounding the signal horn.

Stop working. " Secure the area within reach of the working equipment and the attached load.

Persons must be prevented from entering the hazard zone under the working equipment or the suspended load.

The speed reduction sets the drive engine back to idling speed if the working equipment remains inactivated during more than 10 seconds.

" Replace the broken hydraulic line or have it replaced before continuing the work. " Absorb spilt hydraulic oil and dispose of oilsoaked cleaning rags, binding agents, etc. without polluting the environment.

Fig. 2-60:

Switching on the speed reduction: " Set toggle switch to the left (57, Fig. 2-60:) Indicator lamp (27, Fig. 2-61:) lights up when the the speed reduction function is active.

Switching off the speed reduction: " Set toggle switch (57) to the left.

Fig. 2-61:

BA RH40E(3 664 930.00)-EN

2-63

OPERATING INSTRUCTIONS RH 40 E Operation Hydraulic hammer Working with the hydraulic hammer - Safety instructions Nobody must stand in the hazard range of the hammer.

Risk of injury by splintering stones.

Stop the work immediately if persons enter the hazard range of the hammer or the machine.

Close the front window of the machine before putting the hammer into operation.

Mount a protective grid as a splinter protection.

Wear ear protectors.

Operate the hammer only when sitting in the driver's seat.

The power of the machine and that of the hydraulic hammer must be adapted to each other. In case of doubt, contact the Terex Germany Service.

Do not change the setting of the pressure-relief valves without approval and do not remove lead seals.

Observe the operating instructions of the hammer manufacturer.

Stop the work immediately when oil losse are detected. Collect escaping oil and discard without polluting the environment.

Report oil accidents immediately to the user or his representative.

Repair leaks and damage immediately or have them repaired.

2-64

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OPERATING INSTRUCTIONS RH 40 E Operation NOTES 2804180

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2-65

OPERATING INSTRUCTIONS RH 40 E Operation

2-66

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing 3 INSPECTION AND SERVICING 2804053 Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Part 4 REPAIR WORK

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

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

Part 5 ANNEX

Part 6 INDEX

BA RH40E(3 664 930.00)-EN

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

3-1

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

3-2

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing INSPECTION AND SERVICING SAFETY INSTRUCTIONS 2804211

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 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 know-how on the inspection and servicing of this or comparable machines.

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

Personal protective equipment and working clothing

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

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

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

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

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

Always face the machine when climbing on and off.

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

Select the right tool for the job.

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

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

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

BA RH40E(3 664 930.00)-EN

3-3

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Cleaning jobs

Fastening and securing elements

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).

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

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

Spare parts

Cleaning agents and solvents may give off harmful, readily flammable vapours. Never work with such agents except on well ventilated premises; never inhale the vapours and never smoke.

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

Wear gloves.

Observe the instructions on the packaging.

Handling flammable liquids

Replace any damaged parts.

Use only the original sparts parts of TerexGermany.

They are the only ones to fulfill the technical specifications of the machine.

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

Never set foot withing reach of the emerging oil jet.

When handling flammable liquids:

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

!

never smoke,

Used oil may be harmful to the skin.

!

keep away from unshielded light sources and naked flames,

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

Fuel and other consumables often have low flash points and are readily ignited. Never attempt to extinguish burning liquids with water.

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

Use: !

dry powder,

!

carbon dioxide or

!

foam extinguishers.

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

Notify the fire brigade.

3-4

Visisble oil losses Have any visible leakage repaired immediately.

Escaping oil is an environmental hazard.

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

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

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Relieving residual pressure in the hydraulic system Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with ist attachments supported on the ground and its driving motor 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 depressurzized: (do not leave the driver's seat) " Stand ground

working

equipment

on

the

" Shut off the engine

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

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

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

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

Never repair damaged piping; always replace them.

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

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

" Move all control levers and pedals repeatedly into all ndirections.

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3-5

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

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

Do not dispose of these substances together with household wastes.

Fill these substances into the containers provided for such purposes.

Seals Individual spares may contain asbestos. Such spares or their packaging are marked with: Never process spares containing asbestos mechanically. Inhaling asbestos dust is a health hazard.

Clean sealing faces prior to assembly.

Engine exhaust gases Start and operate combustion engines only on well-ventilated premises;

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

In closed rooms, exhaust gases must be evacuated to the outside;

Do not allow oils and oily wastes to penetrate into the soil or into water. They are an environmental hazard

Do not work on the exhaust system an do not make any modifications to it;.

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

3-6

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

Handling batteries

Before working on the electrical system

Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling

Before performing work on the electrical system where tools, spare parts, etc. can come into contact with electrical conductors or contacts, the battery must be disconnected.

Batteries give off explosive gases.

Disconnect first the negative and then the positive terminal.

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

Battery acid is toxic and corrosive.

After the work: Reconnect first the positive and then the negative terminal.

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 watchstraps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

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

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3-7

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

Selecting oils and greases Use the recommended qualities only, matching viscosities with the temperature level.

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

Filters

On completing work, re-install all protective devices.

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

Never start up the drive motors while work is being done on the machine.

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

Carry out performance tests with the machine.

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.

3-8

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing FIRE AND EXPLOSION HAZARD 2796686

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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3-9

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID 2804212

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, Terex Germany uses only: PANOLIN HLP SYNTH 68 Terex Germany (P/N: 2115005).

This synthetic hydraulic fluid has been tested by Terex Germany and approved for application in Terex Germany 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.

3-10

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.

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Fix an instruction sticker (Fig. 3-1:): !

in the cab,

!

on the hydraulic oil tank and

!

on hydraulically-operated attachment.

Fig. 3-1:

" Start up the machine. Check level in hydraulic tank according to servicing plan. " The hydraulic fluid may dissolve deposits in the hydraulic system.

So change all filters 30 - 50 operating hours after making the change.

Make further filter changes according to servicing plan. " Sample the hydraulic fluid after 30 - 50 operating hours and send in for analysis. (See section: "Environmentally compatible hydraulic fluid, sampling").

BA RH40E(3 664 930.00)-EN

Environmentally compatible hydraulic fluid - Sampling Complete sets are compiled for hydraulic fluid analysis. They contain all necessary parts. !

Sets are available from the Terex Germany Spare-Parts Service: Part-No. 1 465 077.

!

Hydraulic fluid analyses are performed by: WEARCHECK GmbH Bahnhofstraße 75 D-83098 Brannenburg

!

After 30 - 50 operating hours with environmentally compatible hydraulic fluid, take a sample of the hydraulic fluid.

Send this sample in to the above address for analysis. The company will then notify you of the result of the analysis.

!

After this, Terex Germany recommends sending in a sample for analysis every 1000 operating hours or once a year.

It is essential that the hydraulic fluid should be analysed not later than after 3000 operating hours.

!

The results of the analysis show whether the hydraulic fluid is still serviceable and the changing interval can be extended.

In case of questions contact the Terex Germany Service.

3-11

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS

Gearbox oils

2804246

Lubricants for bearings The machine can be lubricated with an environment-friendly grease.

Environment-friendly gearbox oils are not approved by O&K-Mining for use in the travelling, slewing and pump transfers gearboxes.

Environment-friendly grease can be used in the central lubricating system, in all other bearings and in the roller-bearing slewing ring.

BP Biogrease E2 is approved by Terex Germany as an environmentfriendly grease.

3-12

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing INSPECTION AND SERVICING PLANS - INSTRUCTIONS 3659025

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

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 sServicing 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 shift 1)

W

...every 60 OH or weekly .

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.

2

OH = Bh = Operating hours

Change of engine oil l 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 –10° C.

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

Oils / Greases For the specification of oils and greases to be used refer to the "Lubricants" section.

The numerals mentioned in the "Oil / Grease" column in the inspection and sServicing 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..

Components The maintenance intervals for components, e.g. engine and gearbox, are listed in the following Terex Germany maintenance schedules.

It is possible that the manufacturer's documentation for these components states intervals deviating from the above-mentioned intervals.

In such case, only the maintenance intervals specified by Terex Germany shall apply.

In case of higher sulphur content and/or a permanent ambient temperature of below –10° C, 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.

2

Whichever comes first.

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3-13

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

3-14

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Plan V Plan V - Once prior to initial commissioning Page 1 von 2 Location

Servicing work

Quantity/ No.

Check oil level

1

Check

1

Battery

Check liquid level

2

Lighting

Check operation

Monitoring, warning and control elements

Check function of monitoring, warning and control elements

Engine Cooling system Cooling liquid Electrical system

Fuel system Refuelling station (option) - Earthing strap (equipotential bonding)$

Check tightness

Hydraulic system

Check function of working and travelling movement

1

Check pressure (cf. Technical handbook) Hydraulic oil reservoir

Check oil level

Hydraulic cylinders

Vent (cf. chapter “venting hydraulic system“)

1

Pump tranfer gearbox

Check oil level

1

Slewing gearbox

Check oil level

1

Travel gearbox

Check oil level

2

Grease

11

Check grease filling

1

Working equipment Backhoe-bucket bearing Slewing ring Internal gearing Undercarriage Track roller

Check for leaks and free movement

2x8

Support roller

Check for leaks and free movement

2x1

Track

Check pressure

2

Idler

Check oil level

2

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3-15

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Plan – V Once prior to initial commissioning Page 2 von 2 Location

Servicing work

Quantity/ No.

Central lubricating system Grease container

Check filling level

1

Compressor

Check oil level

1

All lines, fittings and connections

Inspect visually for leaks, wearing marks

All articutated joints and hinges

Grease

Air conditioner (optional)

3-16

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Plan N Plan N – After initial commissioning and during the running-in period Page 1 von 1 Location

Servicing work

Quantity/ No.

After 100 Bh Engine - Bearing - Fastening screws

Check for tightness

Cooling system Water filter

Replace

1

Radiator - Bearing - Fastening screws

Check for tightness

Hydraulic system Oil cooler - Bearing - Fastening screws

Check for tightness

Return-flow filter

Replace

Magnetic rod

Clean

3

Pressure accumulator – emergency lowering

Check function

1

Pump transfer gearbox

Change oil

1

3

Slewing gearbox

Change oil

1

3

Fastening screws

Check for tightness

Travel gearbox

Change oil

2

3

Fastening screws

Check for tightness

4

Slewing ring Fastening screws (slewing ring, undercarriage Check for tightness (cf. Technical handbook) and superstructure) Superstructure Fastening screws, especially at superstructure Check for tightness / pedestal / driver´s cab Undercarriage Fastening screws, track pads

Check for tightness (cf. Technical handbook)

All lines, fittings and connections

Inspect visually for leaks, wearing marks

3

cf. “Refilling quantities – Oil“ table

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

3-18

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Plan T (Every 10 OH or every working shift (whichever comes first) Every 60 OH or every working shift (whichever comes first) Page 1 von 2 Location

Quantity/

Plan

Plan

No.

T

W

Check oil level

1

#

#

Cooling fluid level

Check

1

#

#

Radiator

Check / clean

1

#

#

Fuel system Fuel filter

Drain off water

2

#

#

Water trap (optional)

Drain off water

1

#

#

Check indication

2

#

Engine

Servicing work

Cooling system

Air-intake system Vacuum-meter Intake and clean-air lines

# #

Check for tightness and leaks

Electrical system Lighting

Check operation

#

#

Monitoring, warning and control elements

Check function of monitoring, warning and control elements

#

#

Hydraulic system

Check function of working and travelling movement

#

# #

Inspect visually for leaks #

#

Hydraulic oil reservoir

Check oil level

1

Oil cooler

Check / clean

1

Fan wheel

Check condition

1

Pump transfer gearbox

Check oil level

1

Expansion reservoir

Check oil level

1

#

#

Travel gearbox

Check for leaks

2

#

#

Tracks

Inspect track tension visually

2

#

#

Track roller

Check for leaks and free movement

2x8

#

Support roller

Check for leaks and free movement

2x1

#

Idler

Check for leaks

2

#

Grease

11

# #

# #

Slewing gearbox

Undercarriage

Working equipment Backhoe bucket

BA RH40E(3 664 930.00)-EN

#

#

3-19

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing (Every 10 OH or every working shift (whichever comes first) Every 60 OH or every working shift (whichever comes first) Page 2 von 2 Location

Servicing work

Quantity/

Plan

Plan

No.

T

W

Central lubricating system Grease container

Check grease level

1

#

#

Overpressure valve

Check for escaping grease

2

#

#

Lubricating points

Check visually

#

#

Air conditioner (optional)

(cf. “Air Conditioning manual)

1

Fire extinguisher

Check condition

2

#

#

Automatic fire-extinguishing system (optional)

Check control module

1

#

#

All lines, fittings and connections

Inspect visually for leaks, wearing marks

#

#

Excavator

Overall cleaning

3-20

#

#

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Plan A – E 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)

Page 1 von 4 Location

Servicing work

Menge / No.

Servicing acc. with W or T Engine - Bearing - Fastening screws - Rubber bearing Oil filter V-belt Inspection and servicing Engine with centifuge (optional)

Change oil Clean Check tightness Check condition Replace Check tension Check condition (cf. Operating and maintenance manual for engine)

Centrifuge - Rotor seal - Casing seal Inspection and servicing

4

2

1

Carry out oil analysis Change oil Clean

- Bearing - Fastening screws - Rubber bearing Oil filter V-belt

1

4

Check tightness Check condition Replace Check tension Check condition Clean Replace Check /replace (cf. Operating and maintenance manual for engine)

1

Plan Plan Plan Plan Plan B A C D E #

#

#

#

#

#

#

# #

# #

# #

# # # # # #

# # # # # #

# # # #

# # # #

# # # # # #

#

#

#

#

#

#

# #

# #

# #

# # # # # # # # #

# # # # # # # # #

# # # # # # # # #

4

2

1 1 1 1

# # #

# # # #

#

#

cf. “Refilling quantities – Oil“ table

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3-21

OPERATING INSTRUCTIONS RH 40 E 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) Page 2 von 4 Location Cooling system Water filter Radiator - Check tightness - Fastening screws - Rubber bearing Cooling liquid Anti-freeze Lines Hose clamps Fuel system Fuel filter Tank breather valve Water trap (optional) Air-intake system Main filter element

Servicing work Inspect visually for leaks Replace

No.

Plan Plan Plan Plan Plan B A C D E

1

# #

# #

# #

# #

# #

#

# # #

# # #

#

#

# # #

# # #

# # # # # # #

#

#

#

#

#

#

# # #

# # #

Check tightness Check condition Check DCA4-concentration Change Check Check for leaks Check tightness

1

Replace Clean Clean

2 1 1

Check / replace

2

6

#

#

#

2

7

#

#

#

#

#

#

#

#

# #

# #

Safety filter element

Replace

Air-intake line and clean-air line Hoses

Check for tightness and leaks Replace

Electrical system Battery cable connections

Check for tightness

Battery

Check fluid level

5

Menge /

5

# 2

# #

# #

Cooling-liquid replacement after 2 years at the latest

6

Replacement of safety filter element after one year resp. after 3 cleaning cycles of the main filter element at the latest.

7

Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

3-22

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E 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) Page 3 von 4 Location

Servicing work

Menge / No.

Plan Plan Plan Plan Plan B A C D E

Check pressure (cf. Technical handbook)

#

#

#

- Fastening screw

Check for tightness

#

#

#

- Rubber bearing

Check condition

#

#

#

Return-flow filter

Replace

#

#

#

Hydraulic system Oil cooler - Bearing

High-pressure filter Magnetic rod

4

Check / clean

2

Replace

2

Check / clean

3

#

# #

#

#

#

#

#

#

#

#

#

Bypass valve (working circuit) Clean valve

2

#

Bypass valve (cooling circuit)

1

#

Check / clean filter sieve

#

#

#

#

#

#

#

#

#

#

#

#

#

#

#

#

#

#

Change valve

1

Check for contamination and damage

1

Replace

1

Check for contamination and damage

1

Replace

1

Breather filter

Replace

1

Hydraulic oil reservoir

Carry out oil analysis

1

Change oil

8 9

#

1

#

Filter (pilot control circuit)

Filter (slewing mechanism pump feeding-circuit)

1

Pressure accumulator

Check pressure (cf. Technical handbook)

Cylinder (seals and guide rings)

Replace

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

8

#

#

#

#

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

cf. “Refilling quantities – Oil“ table

9

Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

BA RH40E(3 664 930.00)-EN

3-23

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing 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) Page 4 von 4 Location

Servicing work

Menge / No.

Plan Plan Plan Plan Plan B A C D E

Carry out oil analysis

1

#

#

#

Change oil

1

10

#

#

#

Breather filter

Clean

1

#

#

#

Slewing gearbox

Carry out oil analysis

1

#

#

#

Change oil

10

#

#

#

#

#

#

#

#

#

Pump transfer gearbox

1

#

# #

Fastening screws

Check for tightness

Breather filter

Clean

1

Output-pinion bearing

Grease

1

#

#

#

#

#

#

#

Carry out oil analysis

2

#

Check oil level

2

#

#

#

Change oil

2

10

#

#

Breather filter

Replace

2

#

#

Slewing ring

Check grease filling

1

Gearing / pinion

Check condition

Fastening screws (slewing ring, undercarriage and superstructure)

Check for tightness (cf. Technical Handbook)

Undercarriage

Check wear (cf. Technical Handbook)

Diaphragm accumulator

Check pressure (cf. Technical handbook) Check for tightness

Travel gearbox

Track pad fastening bolts

#

#

#

#

#

#

#

# #

#

#

# #

2 #

#

#

#

#

#

#

#

#

#

#

#

#

#

(cf. Technical Handbook) Central lubricating system

Check function

Grease screen

Check / clean

Pumpenelement

Change

Air conditioner

Cf. Technical Information

#

#

#

Steel components

Carry oput visual inspection

#

#

#

Check for tightness Grease

#

#

#

#

#

#

3

Modules - Fastening screws All articulated joints and hinges

10

cf. “Refilling quantities – Oil“ table

3-24

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

BA RH40E(3 664 930.00)-EN

3-25

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing LUBRICATING CHART – GREASE (LOADING BUCKET) 3659155

Fig. 3-2:

3-26

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

Lubricating chart – Grease / Loading bucket (legend) No. Greasing point

Number

1

Central lubricating system – grease container

1

7

Slewing gearbox output pinion

1

Lubricant properties

Grease every .... operating hours 10

V 11

1000

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

Filling quantities - Grease Greasing point

Lubricant properties

Central lubricating system – grease container Internal gearing – Roller-bearing slewing ring Idler (permanent grease filling) (from machine no. 40 139 onwards)

Filling quant. in kg 5

V 11

Tribol

20 2 x 1.3

Terex Germany P/No. 2764564

11

cf. "LUBRICANTS" section

BA RH40E(3 664 930.00)-EN

3-27

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND)

Fig. 3-3:

3-28

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Lubricating chart – Grease / Backhoe bucket (legend)

No. Greasing point

Number

Lubricant properties

Grease every .... operating hours

1

Central lubricating system – grease container

1

10

2

Cylinder/toggle link bearing

1

10

3

Toggle link/toggle lever bearing

2

4

Stick/toggle lever bearing

2

10

5

Stick/backhoe bucket bearing

2x 2

10

6

Toggle link/toggle lever bearing

2

10

7

Slewing gearbox output pinion

1

10000

V 12

10

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

Filling quantities - Grease Greasing point

Lubricant properties

Central lubricating system – grease container Internal gearing – Roller-bearing slewing ring Idler (permanent grease filling)

Filling quant. in kg 5

V 11

Tribol

20 2 x 1.3

Terex Germany P/No. 2764564

12

cf. "LUBRICANTS" section

BA RH40E(3 664 930.00)-EN

3-29

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-4:

3-30

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Inspection plan – Oil (legend) )

No. Location

Number

Lubricant 13 properties

Check oil level

Change oil

every ... OH

every ... OH

1

Engine

1

I

10

250

2

Hydraulic system

1

10

10000

3

Pump transfer gearbox

1

II III

60

1000

14

API SAE 80 (synthetic oil for gearboxes) 4

Slewing gearbox

1

III

10

1000

5

Travel gearbox

2

III

500

5000

Filling quantity

Oil

Filling quantities - oil Location

(litres) Drive engine - without filter change

60

- with filter change

66

Hydraulic oil system at oil change

Approx. 1700

- oil reservoir

Approx. 1300

Pump transfer gearbox

Approx. 15

I I I II II III API SAE 80 (synthetic oil for gearboxes)

Slewing gearbox

Approx. 21.5

III

Travel gearbox

2 x approx. 18

III

Track rollers (permanent oil filling)

16 x 1.5

III

Support rollers (permanent oil filling)

2 x 1.5

III

13

cf. "LUBRICANTS" section

14

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

BA RH40E(3 664 930.00)-EN

3-31

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

Filling quantities - other

Location

Filling quantity (litres)

Cooling system - engine

170

Fuel tank

1300

Screen washer

13

3-32

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing LUBRICANTS 2804268

I.

Oils for combustion engines and compressors (selection)

Fig. 3-5:

BA RH40E(3 664 930.00)-EN

3-33

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

II.

Oils for hydraulic system (selection)

Fig. 3-6:

3-34

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing III.

Oils for gearboxes (selection)

Fig. 3-7:

BA RH40E(3 664 930.00)-EN

3-35

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing V.

Greases for bearings and slewing rings

Fig. 3-8:

3-36

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Carry out oil changes as follows:

SERVICING WORK 2413586

Hose line for oil and cooling liquid changes

" Place a recipient for waste oil under the drain opening (choose the capacity of the recipient in acc. with the "Refilling quantities - Oil" table). " Choose the proper draining hose from the tool kit.

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.

" Unscrew protective cap from oil drain valve. " Screw on draining hose (2); the valve opens and the oil drains away. " After the oil has drained away unscrew draining hose; the valve closes automatically. " Screw protective cap back in place.

The engine, hydraulic oil reservoir and the slewing gearbox are equipped with special oil drain valves (1, Fig. 3-9:).

These plugs permit to carry out oil changes in a clean and non-polluting way.

Fig. 3-9:

BA RH40E(3 664 930.00)-EN

3-37

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing ENGINE 3659026

Checking the engine oil level / Topping up

Engine - Safety instructions

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

Fig. 3-10:

" Park the machine on a horizontal surface and protect it against rolling away. " Shut off the engine.

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 allow to cool down.

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.

" Withdraw dipstick (1, Fig. 3-10:). " 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. 3-11:). If the oil level is at the "min" mark or below, top up with engine oil through the fillertube (2, Fig. 3-10:).

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

3-38

Fig. 3-11:

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Changing the engine oil

After draining of the oil: " Replace the engine oil filter.

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

" Remove the hose line.

The automatic drain coupling closes automatically. " Screw on protective cap.

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. " Bring engine oil to operating temperature.

" Fill in engine oil through the filler tube (2, Fig. 3-12:) until the oil level reaches the "max" mark (Fig. 3-13:). " 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.

" Park the machine on a horizontal surface and secure. " Shut off the engine. " Drain off engine oil using the oil draining hose.

The use of the oil draining hose is described in the "Draining hose for oil changes" chapter.

After the engine oil has drained away:

Fig. 3-13:

Fig. 3-12:

BA RH40E(3 664 930.00)-EN

3-39

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Replacing the oil filter

Carry out servicing of the oil filters (1, Fig. 3-15:) in accordance with the engine operating instructions.

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.

Fig. 3-15:

Renewing of filters Collect escaping oil and discard with-out polluting the environment

" Shut off the engine. " Unscrew filters. " Install new filter with slightly oiled sealing ring and tighten by hand.

After renewing the oil filters, the oil of the engine must be changed in accordance with the engine operating instructions.

Then

Fig. 3-14:

" Open hatch I (Fig. 3-14:).

" allow engine to run at idling for a short time and check filters for leaks, shut off engine; " check oil level after abt. 10 minutes and top up with oil, if required.

The oil filters are now accessible.

3-40

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Centrifuge (optional)

Fig. 3-17:

Fig. 3-16:

The centrifuge (Fig. 3-16:) filters out engine oil impurities in the bypass line by centrifugal forces.

Adhering dirt causes the rotor to run unbalanced. Any unbalance may damage the bearings.

Servicing " Shut off the engines " Wait 5 minutes The rotor of the centrifuge must be stationary.

The pressure in the centrifuge must have disappeared.

" Replace seal (6) inserting it slightly smeared with oil. " Check nozzle (7) for free passage.

If necessary, open up nozzle with a wire or with compresse air. " Place paper filter into the rotor cap.

The paper filter must adhere uniformly to the rotor casing.

The centrifuge may also be hot.

Wear protective gloves and firm working clothing. " Loosen clamp (2, Fig. 3-17:) and withdraw housing (1). " Check housing seal (8) and replace, if required. " Unscrew knurled nut (3) and draw off rotor cap (4).

Thereafter " Allow engines to run for short while and check centrifuge for tightness and leaks before shutting off the engines. " Check oil level after abt. 10 minutes and to up, if required.

" Remove dirt from the rotor cap by tapping lightly against the cap. " Clean rotor cap (4) and vertical tube (5) thoroughly with white spirit and dry.

BA RH40E(3 664 930.00)-EN

3-41

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing If the cooling-liquid level is too low, a warning lamp on satellite I lights up.

COOLING SYSTEM 2804424

The cap (2) is accessible from above.

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

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

Shut off the engine and allow to cool down.

Risk of scalding from hot cooling liquid.

Collect escaping cooling liquid and discard without polluting the environment.

Risk of scalding from hot cooling liquid. Open radiator cap cautiously.

" Turn radiator cap (1) back to the first notch. " When the pressure has been released turn cap into the "open" position and remove.

The cooling-liquid level should reach up to the lower edge of the filler tube. Top up with cooling liquid, if required.

Protect the skin from contact with cooling liquid.

Skin contact with cooling liquid is a potential health hazard.

Fill cooling liquid into the cooling system through the filler tube.

Do not fill in cold cooling liquid when the engine is at operating temperature.

Wear protective gloves and firm working clothing.

Temperature The cooling-liquid circuit is controlled by a thermostat. The maximum admissible temperature is ca.

100° C. In case of higher temperatures - warning lamp on satellite I illuminated - locate cause and rectify.

Before refilling, allow engine to cool down to below 50° C

For topping up of the cooling system use specially prepared water only.

Specially prepared water must consist of: !

calcium-free water, distilled water, rain water

!

anti-freeze compound The mixing ratio of anti-freeze / cooling water must be at least 50 % : 50 % (anti-freeze protection down to -40 °C).

!

For use at lower temperatures, the amount of anti-freeze must be increased accordingly.

" After filling in cooling liquid allow the engine to run for short period to eliminate air voids before topping up with cooling liquid to the lower edge of the filler tube.

Fig. 3-18:

Radiators The radiator (1, Fig. 1) is located on the superstructure. " After each working shift: examine radiator fins for dirt and clean, if required.

3-42

" In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks.

Check regularly:

" all lines for leaks and all hose clamps for tightness.

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Cooling liquid

Read and observe: Inspection and servicing – Safety instructions.

The engine operating instructions describe in detail how to prepare cooling water and how to check the cooling liquid. Check in case of imminent frost whether the concentration of the anti-freeze compound added to the cooling liquid at the factory is sufficient for the temperatures to be expected.

Risk of scalding from hot cooling liquid.The radiators may also be hot. Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

The cooling liquid must be changed regularly and after two years at the latest.

Fig. 3-20:

Checking the cooling liquid Check the cooling liquid in the cooling system regularly to ensure that the water-filter change interval resp. the DCA4-concentration is sufficient to prevent corrosion under the existing operating conditions.

Fig. 3-19:

To do so: " Prepare a collecting recipient for used cooling liquid. Choose the required recipient capacity in accordance with the "Refilling quantities Other" table. " Shut off the engine. " Open hatch II (Fig. 3-19:). " Unscrew plug (arrow, Fig. 3-20:) and drain off cooling liquid completely. " Fill in cooling liquid after having re-inserted the plug with a new sealing ring.

BA RH40E(3 664 930.00)-EN

3-43

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Water filter

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

Risk of scalding from hot cooling liquid.

The filter housings may be hot, too.

Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

Replace water filter regularly. " Open hatch II (Fig. 3-21:). " Close valve (2).

Fig. 3-22:

Tightening the filter element with a tool can damage or deform the filter head.

" Unscrew water filter (3, Fig. 3-22:). " Screw on new water filter until the sealing ring contacts the filter head. Continue to tighten the filter by another ½ to ¾ turn.

" Open valve (2).

Fig. 3-21:

3-44

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing AIR-INTAKE SYSTEM Clean or renew main filter element only if the vacuum-meter nindication changes to "RED" with the engine running at high speed.

2804425

Read and observe the "Engine Safety instructions" chapter.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine before working on the airintake system.

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

Do not start the engine when parts of the air-intake system have been detached.

Engine damage may occur if the engine is allowed to draw in unfiltered air.

The air-intake system is equipped with two dry-air filter (Fig. 3-23:) consisting of main and safety filter element.

Fig. 3-24:

Removal and installation " Unscrew nut (1, Fig. 3-23:) and remove cover (2). " Unscrew nut (3, Fig. 3-25:) and withdraw main filter element (4). Do not loose the washer under nut (3). " Clean or renew main filter element only if the vacuummeter indication changes to "RED" with the engine running at high speed.

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

Fig. 3-23:

Main filter elements An insufficient air-intake performance, caused by a contaminated main filter element, is indicated by the vacuum-meter (8, Fig. 3-24:).

Fig. 3-25:

BA RH40E(3 664 930.00)-EN

3-45

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing " Before installing the filter element, clean contact faces at cover (2, Fig. 3-26:) and at filter housing.

Replace damaged or deformed elements immediately.

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

During the removal of the main filter element, the safety element (5, Fig. 3-27:) must remain in the filter housing.

Check element seal. When the seal is damaged, the filter element must be replaced, too.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.

Fig. 3-26:

Checking and cleaning the main filter element Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 3-28:). Any damage is then clearly visible.

Fig. 3-28:

Blow filter element (Fig. 3-29:) clean with dry compressed air from the inside by moving the compressed-air gun up and down.

The pressure at the nozzle must not exceed 6 bars.

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

Fig. 3-27:

Fig. 3-29:

3-46

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

Never clean filter element by beating against hard objects.

" Remove main filter element (4, Fig. 3-31:) as described above. " Unscrew nut (6, Fig. 3-30:) and withdraw safety filter element (5).

Replace the main filter element after 1000 operating hours or 3 cleaning cycles; and, after one year of operation at the latest.

" Install the new safety filter element and a cleaned or a new main filter element.

Safety filter element

Air-intake lines

Replacement Replace the safety filter elements (5, Fig. 3-30:) after 1000 operating hours or 3 cleaning cycles; after one year of operation at the latest.

Never clean the safety filter element, but always renew.

At regular intervals: " check intake lines for leaks and hose clamps for tightness; " replace hoses between filter housing and engine.

During all works on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engines.

Dust collection Dust accumulating on the filter-housing bottom is constantly sucked away by the exhaust system during operation.

The non-return valves (7, Fig. 3-32:) in the suction lines prevent engine exhaust gases from being sucked in.

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

Fig. 3-30:

Fig. 3-32: Fig. 3-31:

BA RH40E(3 664 930.00)-EN

3-47

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Prior to initial commissioning or after repairs on the refuelling system carry out the following works:

FUEL SYSTEM 2804426

Fuel system - Safety instructions

" Loosen elbow union (12, Fig. 3-33:) and fill pump (11) with fuel. " Retighten elbow union (12).

Read and observe the "Inspection and servicing – Safety instructions" chapter.

When working on the fuel system: shut off the engines secure the machine as described in the "Securing the machine" section keep away naked flames

Fig. 3-33:

do not smoke.

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

3-48

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Replacing the fuel filter

The fuel filters (3) serve at the same time as water

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Fig. 3-35:

" Open valve (4) and drain off water until fuel emerges. " Close valve (4).

Venting the fuel system The fuel tanks are vented with breather valves (4, Fig. 3-36:).

Clean breather valves regularly. " Remove breather valve, flush with paraffin oil and blow clean with compressed air.

Fig. 3-34:

" Open hatch I (Fig. 3-34:) to gain access to the filters. " Unscrew filters (3, Fig. 3-35:). " Fill new filter with clean fuel and screw it onto the filter head by hand. " Continue to tighten filter by a further 1/2 to 3/4 turn.

Fig. 3-36:

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

BA RH40E(3 664 930.00)-EN

3-49

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Cleaning the fuel tanks " Use up as much fuel as possible.

Explosion hazard.

Read and observe the "Inspection and servicing.

Safety instructions" chapter.

Do not use white spirit, paraffin oil or other solvents.

For flushing and cleaning use diesel fuel.

Avoid skin contact.

Skin contact with diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier ccream.

" Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plugs of the tanks. " Loosen drain plug (5, Fig. 3-37:) at fuel the tank and drain off fuel. " Flush tank with diesel fuel. " Screw drain plug (5) back in place. " Fill in fuel through the filter sieve in the filler tube (2).

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

Fig. 3-38:

Refuelling station (optional)

Sparking caused by static or electric charges may set fuel on fire.

Fig. 3-37:

Check earthing strap (equipotential bonding) (4, Fig. 3-38:) regularly for tightness.

Only a perfectly connected earthing strap can remove static or electric charges and thus avoid the risk of fire during refuelling.

3-50

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Water trap (option)

Servicing

Water contained in the fuel is removed by the water trap (Fig. 3-39:).

Draining off water Carry out the following works in accordance with the servicing schedule and at regular intervals: " Loosen venting plug (9, Fig. 3-40:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

Fig. 3-39:

Fig. 3-40:

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

The liquid flowing out of the valve flushes and cleans the filter element(6) von from top to bottom. " Close drain valve (3) and tighten venting plug (9).

BA RH40E(3 664 930.00)-EN

3-51

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Checking / cleaning the filter element

" Clean recipient (1) and filter housing (4). " Loosen flange (2).

Replace filter element (6, Fig. 3-41:) only when the suction resistance is too high.

" Take off recipient (1) and clean with diesel fuel " Check cover sealing and replace, if necessary. " Attach recipient (1) with flange (2) at filter housing (4).

Check for proper sealing.

Fig. 3-41:

" Loosen venting plug (9) and leave drain valve (3) open until the reservoir is completely empty.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment. " " Remove cover (5). " Remove spring holder (7) and filter element (6) from filter housing (4). " Check / replace filter element (6) " Clean filter housing (4) using diesel fuel. " Check cover sealing and replace,if necessary. " Insert filter element (6) and spring housing (7) into filter housing (4). " Fasten cover (5) on filter housing (4).

Check for proper sealing.

3-52

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing ELECTRICAL SYSTEM 3659028

Electrical system - Safety instructions

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Risk of injury caused by battery acid and gases.

Wear goggles, working gloves and firm working clothing.

The electrical circuit diagrams are annexed to thespare-parts list. Further information can be found in the Terex - Germany booklet "Working with circuit diagrams".

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

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

If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Gas-discharge lamps (optional) are operated with high voltage.

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the electronic modules of the PMS.

Alternator - Instructions Never disconnect cables from the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator.

Do not interchange the cables when connecting the battery (observe polarity).

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the regulator.

BA RH40E(3 664 930.00)-EN

3-53

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Battery main switch / Main fuse

Battery

The battery main switch and the main fuse are located under a lockable hatch (arrow, Fig. 3-42:) beside the batteries and the tool box.

Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling

Checking the battery fluid level (Not applicable in case of maintenance-free batteries) " Unscrew caps (Fig. 3-44:).

Fig. 3-42:

After withdrawing the key from the key-switch (control panel in driver's cab), the electrical lines from the key-switch to the consumers are deenergized. The lines from the battery to the keyswitch are, however, still under tension. These lines can be de-energized with the battery main switch. Shut off the electrical system with the battery main switch when carrying out repair work or during prolonged downtimes of the excavator.

" If checking inserts are provided, the battery acid must reach up to their bottom. " If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm. " If the fluid level is too low, top up with distilled water only

Battery main switch (Fig. 3-43:): Position I - ON Position II - OFF In position II, the battery main switch handle can be withdrawn.

Fig. 3-44:

Fig. 3-43:

3-54

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Removing and installing the battery

Removing and installing the battery

The acid temperature must be 20 ° C. Read and observe the "Inspection and servicing – Safety instructions" chapter.

" Unscrew caps of the battery (Fig. 3-45: " Measure the acid density of the battery using a commercial acid tester (Fig. 3-45: The acid density measured is in direct correlation with the battery charge.

Wear protective gloves and firm working clothing.

Shut off the engines before removing the batteries to avoid damaging the alternator and the regulator.

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

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

The batteries (1, Fig. 3-46:) are located behind the hydraulic reservoir. The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

Fig. 3-45:

Acid density kg / dm3

Charge

Normal condition

Tropical conditions

1,28

1,23

fully charged

1,20

1,12

half charged, recharge

1,12

1,08

discharged, recharge immediately

Fig. 3-46:

BA RH40E(3 664 930.00)-EN

3-55

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing The batteries are located under the lockable hatch (arrow, Fig. 3-48:). The two 12-volt batteries are connected in series, so that the system voltage is 24 volts.

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

Fig. 3-48: Fig. 3-47:

" Unscrew battery holder (6, Fig. 3-48:). " Disconnect the cable lug from the negative terminal of the battery. " Disconnect the cable lug from the positive terminal of the battery. Insulate the cable lugs.

Install the new battery. " Connect the cable lug to the positive terminal of the battery. " Tighten the clamping screw of the cable lug.

Do not use too much force to avoid deformations. " Connect the cable lug to the negative terminal of the battery. " Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs.

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

3-56

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing HYDRAULIC SYSTEM 2804228

Residual pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be freed from pressure, i.e. depressurized:

Hydraulic system - Safety instructions

Read and observe the "Inspection and servicing – Safety instructions" chapter.

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.

Fig. 3-49:

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

" Locate the system section to be opened.

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

" Depressurize the section to be opened. If required, the necessary measures described must be combined

Avoid skin contact with hydraulic oil.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

" Open the depressurized system section with caution.

Depressurizing the hydraulic system Hydraulic systems may only be opened if they are completely depressurized. Even when an excavator is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-49:and Fig. 3-50:) and with its drive engines stationary, there may still be a considerable amount of residual pressure in parts of the hydraulic system, as e.g. the primary pressure resulting from the last hydraulic movements before the immobilization.

Fig. 3-50:

Examples of system sections: 1) working hydraulics 2) servo control circuit 3) precharged return-flow line

BA RH40E(3 664 930.00)-EN

3-57

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Depressurizing " Park the excavator on a horizontal surface. " Set the working equipment on the ground. " Shut off the drive engine.

Sections 1 and 2: servo control and working hydraulics - Shift both control levers repeatedly into all dIrections (Fig. 3-51:).

Fig. 3-52:

Topping up with hydraulic oil " Remove cover (20, Fig. 3-53:) and retaining disk (23). " One of the return-flow filters is now visible in the filter chamber.

Fig. 3-51:

Section 3: return-flow line After shutting down the engine, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

" Fill in hydraulic oil through this return-flow filter until the oil level lies between the ½ and ¾ marks of the inspection glass (oil grade cf.

"Refilling quantities - Oil"). " Before fitting retaining disk (23) and cover (20), check sealing ring (26) and replace if damaged. " Fit cover together with sealing ring.

Checking the hydraulic oil level " Bring hydraulic oil to operating temperature (abt. 50 °C). " Park the machine on a horizontal surface. " Move all hydraulic cylinders to their central positions.

The oil level must lie between the ½ and ¾ marks of the inspection glass (1, Fig. 3-52:).

Fig. 3-53:

3-58

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Changing the hydraulic oil return-flow (hydraulic oil reservoir)

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

!

when the "Hydraulic oil filter" warning lamp (satellite II) lights up when the hydraulic oil is at operating temperature. The filter elements (25, Fig. 3-54:) are then heavily contaminated.

(The warning can be disregarded if the lamp lights up only shortly during starting of the engine);

!

after repairs on the hydraulic system;

!

in case of damage.

" Remove cover (20) and retaining disk (23) as described under "Topping up with hydraulic oil". " Clean the magnetic rod (24).

If abraded metal and metal filings adhere to the magnetic rod, locate the cause or contact the O&KMining Service.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

" Withdraw filter element (25) together with sealing ring (22).

The return-flow filters must be replaced:

If the filter elements are damaged, remove basket (28) and clean down with spirits or petroleum.

!

when servicing works in accordance with the servicing plan are carried out;

" Lower basket (28) into tank. " Insert new filter element (25) together with sealing ring (22). " Fit retaining disk (23) with sealing ring (27). " Refit cover (20) with sealing ring (26).

Proceed in the same way to replace the other filter elements (25).

Fig. 3-54:

BA RH40E(3 664 930.00)-EN

3-59

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Bypass valves (working circuit)

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Cleaning the filter screens " Remove cover (10, Fig. 3-55:). Remove screws (12) and take out the bypass valve.

Withdraw sieve (13) and clean in white spirit or paraffin oil. Replace, if required. " Check sealing ring (16) for damage and replace, if required.

Shut off the engine.

" Re-assemble the bypass valve.

Risk of scalding caused by hot hydraulic oil.

" Check sealing rings (14 and 15) for damage and replace, if required.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

" Insert the bypass valve. Make sure the valve fits properly.

Skin contact with hydraulic oil may cause skin injury.

" Refit cover (10) with sealing ring (15).

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-55:

Replacing the bypass valves and the sealing rings " Remove the bypass valve as described under "Cleaning the sieve". " Re-assemble new bypass valve with sieve (13) and new sealing ring (16). " Insert bypass valve with new sealing ring (14). " Refit cover (10) with new sealing ring (15).

3-60

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Bypass valves (cooling circuit)

Cleaning the valve " Remove cover (7, Fig. 3-56:).

Read and observe the "Inspection and servicing – Safety instructions" chapter.

" Unscrew screws (33, Fig. 3-57:) and withdraw valve carrier (31) together with valve (32). " Clean valve (32) in white spirit or paraffin oil and replace, if required.

Shut off the engine.

" Insert valve (32) into valve carrier (31).

Risk of scalding caused by hot hydraulic oil.

" Fasten valve carrier (31) with screws (33) in the hydraulic oil reservoir. Refit cover (7, Fig. 8) with a new sealing ring.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-57:

Changing the valve Fig. 3-56:

" Remove bypass valve as described under "Cleaning". " Remove valve (32, Fig. 3-57:) and replace by a new one. " Fasten bypass valve (31) on the hydraulic oil reservoir. " Refit cover (7, Fig. 3-56:).

BA RH40E(3 664 930.00)-EN

3-61

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Breather filter

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Replacing the filter elements The breather filters (20, Fig. 3-58:) ensure venting of the hydraulic oil reservoir at varying hydraulic oil levels.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 3-58:

" Unscrew butterfly nut (50, Fig. 3-59:).

Withdraw hood (51) and withdraw filter element (52) from the holding rod. " Insert new sealing ring (53) and new filter element and secure hood (51) with nut (50).

Fig. 3-59:

3-62

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing High-pressure filter for working hydraulics To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with two high-pressure filters (30, Fig. 3-60:).

Checking/cleaning the filter elements " Unscrew filter housing (31, Fig. 3-60:) and pour out the oil. " Withdraw filter element (32) from housing (31).

Fig. 3-60:

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Fig. 3-61:

Checking/changing the filter elements Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

" Clean filter housing and contact faces at the filter head (35, Fig. 3-61:) with white spirit or paraffin oil and replace, if required. " Insert filter element into housing (31, Fig. 11) and attach to the filter head (35) with new, slightly oiled sealing rings (33 and 34) and a new retaining ring (36).

Check high-pressure filter for leaks after the system has been put into operation.

Replacing the filter elements " Detach the filter element as described under "Checking the filter elements". " Clean filter housing (9, Fig. 3-61:) and the sealing faces at the filter head with white spirit or paraffin oil. " Insert new filter element into filter housing (9) and refit to the filter head with new, lightly oiled sealing rings (10 and 14) and a new retaining ring (13).

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

BA RH40E(3 664 930.00)-EN

3-63

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing High-pressure filters for the servo circuit and the feeding circuit of the slewing pump

Checking/cleaning the filter elements

The excavator is equipped with a high-pressure filter (40, Fig. 3-62:) for the servo circuit and §another filter (41) for the feeding circuit of the slewing pump.

" Withdraw filter element (43) from housing (42).

" Unscrew filter housing (42, Fig. 3-63:) and pour out the oil.

" Clean filter housing and contact faces at the filter head with white spirit or paraffin oil. " Insert filter element into housing (42) and attach to the filter head with a new, slightly oiled sealing ring (46). " Check the high-pressure filter for leaks after thesystem has been put into operation.

Fig. 3-62:

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

Shut off the engine.

Fig. 3-63:

Risk of scalding from hot hydraulic oil.

Replacing the filter elements The filter housings may also be hot.

Avoid skin contact.

" Detach the filter elements as described under "Checking the filter elements".

Skin contact with hydraulic oil may cause skin injury.

" Insert new assemble.

Wear protective clothing.

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

gloves

and

firm

protective

filter

element

(43)

and

re-

Collect escaping hydraulic oil and discard without polluting the environment.

3-64

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Changing the hydraulic oil

Drawing off hydaulic oil " Bring the hydraulic oil to operating temperature (abt. 50 ° C).

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engine.

" Position the machine with a slight inclination towards the drain valve (5, Fig. 3-64:).

The drain valve is located at the back of the hydraulic oil reservoir and accessible from the bottom.

The hydraulic oil reservoir itself may also be hot.

" Retract the hydraulic cylinders as far as possible and stand the working equipment on the ground.

Avoid skin contact.

" Shut off the engine.

Skin contact with hydraulic oil may cause skin injury.

" Place suitable recipients under the drain valve (5) of the hydraulic oil reservoir. For the required capacity refer to the "Refilling quantities Oil" table.

Risk of scalding caused by hot hydraulic oil.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Do not start up the drive engine when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry.

" Connect hose (15) to drain valve (5) and drain off used oil completely. Draining is facilitated if the breather filter (6, Fig. 3-65:) is removed during the process.

The use of the oil draining hose is described in the "Draining hose for oil changes" section. " Remove hose. The drain valve closes automatically.

Fig. 3-64: Fig. 3-65:

BA RH40E(3 664 930.00)-EN

3-65

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Cleaning the hydraulic oil reservoir

Explosion hazard.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

" Place a collecting recipient for the flushing oil under the hydraulic oil reservoir. " Clean the inside of the hydraulic oil reservoir with diesel fuel or flushing oil.

Remove all sediments and also the residues of the cleaning agent thoroughly " Refit cap (7).

Filling in hydraulic oil Shut off the engine.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Use diesel fuel or a special flushing oil.

Avoid skin contact.

Fill in hydraulic oil as described under "Topping up with hydraulic oil". " Vent the hydraulic system. " Check the oil level in the hydraulic oil reservoir and top up with oil, if required.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste. " Drain off hydraulic oil as described under "Draining off the hydraulic oil". " Remove cap (7, Fig. 3-66:).

Fig. 3-66:

3-66

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Venting the hydraulic system Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented !

after assembly on site and prior to initial commissioning,

!

before each recommissioning of the excavator, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes,

!

after each hydraulic oil change,

!

after replacement of hoses or lines.

Venting the hydraulic components !

Fig. 3-68:

Hydraulic pumps and hydraulic motors (with electric motors shut off).

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

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

• the piston-side port (3) when the piston rod is retracted (1, Fig. 3-67:), • the rod-side port (4) when the piston rod is extended (1, Fig. 3-68:).

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. !

If, for assembly reasons, the piston rod is inmiddle 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.

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, Fig. 3-67: and Fig. 3-68:) must be either completely retracted or completely extended.

The screws/nozzles of the following components must be opened until oil emerges bubble-free from the opening: Always vent only the system section that has been opened.

!

the travel brake valve at the venting screw,

!

the oil cooler manifold at the mini-measuring ports,

!

the servo system at the venting screws of the control blocks (under the servo caps),

!

the intake line at the venting screw (with drive motors stationary).

Fig. 3-67:

BA RH40E(3 664 930.00)-EN

3-67

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Cleaning the hydraulic oil cooler

Cleaning " Remove the grid (7, Fig. 3-70:) above the cooler.

Risk of injury from rotating cooler fan blades.

Shut off the engine.

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

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

Allow the hydraulic oil cooler to cool down.

Wear protective gloves and firm protective clothing.

" Blow the cooling fins clean with compressed air proceeding from top to bottom.

Loose dirt drops through the cooler down to the ground.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan.

The speeds of the fan motors are thermostatcontrolled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca.

60°C.

3-68

Fig. 3-69:

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Extract from the German acceptance regulations

Pressure accumulator To permit lowering of the working equipment in case of emergency, the machine is equipped with a pressure accumulator (1, Fig. 3-70:).

The pressure accumulator (1) is located under the superstructure baseplate.

The following regulations are applicable only in the Federal Republic of Germany. Please observe the corresponding regulations in your own country.

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

Fig. 3-70:

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 released

Group

Inspections prior to commissioning

Regular

at the factory

at the place of use

inspections

II

Pressure testing

Inspection certificate

p ≥ l bar

Prototype and pressure test certified by the manufacturer

(Check of correctness and correct installation)

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

and p·x l ≤ 200

BA RH40E(3 664 930.00)-EN

issued by an expert

3-69

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing PUMP TRANSFER GEARBOX

Changing the gearbox oil 2804429

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

Draining off oil " Prepare a collecting recipient for used oil.

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

Read and observe: "Inspection and servicing Safety instructions.

Shut off the engine The gearbox housings may be hot, too.

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

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

" Unscrew plug (3, Fig. 3-72:) and drain off oil.

Screwing out breather filter (2, Fig. 3-71:) facilitates draining off the used oil. Plug (3, Fig. 3-72:) is accessible from the bottom. " Screw plug (3) back in place.

Checking the gearbox oil level / Topping up with oil Park the machine as described in the "Securing the machine" section. " Screw out dipstick (1, Fig. 3-71:) and wipe clean. " Insert dipstick (1) fully again and withdraw a second time.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required. " Screw dipstick (1) back in place.

Fig. 3-72:

Filling in oil " Unscrew breather filter (2, Fig. 3-71:). " Fill in new oil through opening of breather filter (2). After oil changes, plug (3, Fig. 3-72:) must be tightened beforehand. " Check oil level with dipstick (1, Fig. 3-71:).

Fig. 3-71:

3-70

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Gearbox venting The gearbox is vented through breather filter (2, Fig. 3-73:).

Clean breather filter in accordance with the servicing plan. " Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air. " Screw breather filter back in place.

Fig. 3-73:

BA RH40E(3 664 930.00)-EN

3-71

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing SLEWING GEARBOX Read and observe: "Inspection and servicing - Safety instructions.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required. " Screw dipstick (1) back in place.

Changing the gearbox oil " Prepare a collecting recipient for used oil.

Shut off the engine The gearbox housings may be hot, too.

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

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

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Fig. 3-75:

Draining off oil " Attach hose (8, Fig. 3-75:) to drain valve (7) and drain off oil completely.

The use of the oil draining hose is described in the "Draining hose for oil changes" chapter.

Fig. 3-74:

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

The drain valve (7, Fig. 3-75:) is accessible from the undercarriage. " Remove hose. The oil drain valve closes automatically.for oil and cooling liquid change" section.

" Screw out dipstick (1, Fig. 3-71:) and wipe clean. " Insert dipstick (1) fully again (do not screw in) and withdraw a second time.

3-72

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Filling in new oil / Topping up

Gearbox venting

"

The gearbox is vented through breather filter (2, Fig. 3-76:).

Clean breather filter in accordance with the servicing plan.

Unscrew plug (4, Fig. 3-76:) and fill in new oil.

" Check oil level with dipstick (1, Fig. 3-76:). " Screw in plug (4) again.

" Unscrew breather filter (2), clean in white spirit or paraffin oil and blow dry with compressed air. " Screw breather filter (2) back in place.

Output pinion Grease bearing regulary. " Fill in approximate 20 g. grease (4 – 5 strokes) through grease nipple (5, ) by means of a hand grease pump.

Fig. 3-76:

Fig. 3-77:

BA RH40E(3 664 930.00)-EN

3-73

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing TRAVEL GEARBOX

Travel gearbox - Changing the oil 2413595

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

Shut off the engine The gearbox housings may be hot, too.

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

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Gearbox - Checking the oil level / Topping up with oil " Park the machine as described under "Securing the machine". " Move the excavator until one of the two drain plugs (6, Fig. 3-78:) is at the bottom and screw out the upper plug.

" Park the machine as described under "Securing the machine". " Place a collecting recipient for used oil under the travel gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table. " Unscrew lower plug (6) and drain off oil completely. Screwing out the upper plug facilitates draining off the used oil.

Before filling in new oil, screw lower plug (6) back in place.

Filling in new oil / Topping up " Unscrew upper plug (6) and fill in new oil through the borehole until the oil level reaches up to the lower edge of the opening.

Gearbox venting The gearbox is vented through breather filter (2, Fig. 3-79:).

Clean / change breather filter in accordance with the servicing plan. " Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

" Screw breather filter back in place.

Fig. 3-78:

Fig. 3-79:

3-74

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing CRAWLER TRACKS 2413697

Track rollers, support rollers, track pads

Cleaning

The track rollers (1, Fig. 3-81:) and the support rollers (2, Fig. 3-82:) have a permanent oil filling.

Clean tracks, track and support rollers, sprockets and idlers regularly and whenever required.

Cleaning is especially important in winter to prevent

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

!

the tracks from being thrown off

!

oil from leaking out of track and support rollers, sprockets and idlers

!

excessive wear

!

the track from breaking.

Fig. 3-80:

Track roller fastening Check fastening screws (3, Fig. 3-81:) regularly for tightness: " Tighten screws with a torque wrench to the prescribed tightening torque (cf. table "Tightening torques").

Fig. 3-81:

To clean the tracks: " raise one side of the excavator with the working equipment and allow track to turn; " clean the side member supporting the track; " clean track and support rollers (1 and 2 , Fig. 3-80:) thoroughly, especially at those places indicated by arrows; " clean the sliding planes on the idler guides.

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3-75

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Support roller fastening

Track pads

Check fastening screws (4, Fig. 3-82:) regularly for tightness:

Check fastening screws (5, Fig. 3-83:) regularly for tightness:

" Tighten screws with a torque wrench to the prescribed tightening torque (cf. table "Tightening torques").

" Tighten screws with a torque wrench to the prescribed tightening torque (cf. table "Tightening torques").

Fig. 3-82:

Fig. 3-83:

3-76

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Track tensioner

Function

Design

The tensioning system is under permanent pressure of ca. 100 bars which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engines have been started.

Retensioning is not required.

The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-84:and Fig. 3-85: show parts of the tracks and the tensioner:

For cleaning and servicing work, the tracks can be slackened.

To do so: " stop the engine " open both pressure limiting valves (6, Fig. 3-85:) to slacken the tracks. " After the work, screw down the pressure limiting valves (6) to the limit stop.

Fig. 3-84:

4

Pressure accumulator

5

Pressure cylinder

6

Pressure limiting valve

9

Mini- measuring port

10

Idler

11

Drive sprocket

12

Track roller

13

Crawler track

Fig. 3-85:

14

Support roller

The pressure-limiting valves (6) are preset to a pressure of 250 bars and sealed in this position.

The lead seal must not be removed and the pressure setting of 250 bars must not be changed.

Techncal data

The track tensioners are maintenance-free.

Track tensioning pressure

ca. 100 bars

Pressure limiting valve

250 bars

Gas pressure in pressure accumulator (nitrogen filling pressure)

80 bars

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3-77

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Pressure-accumulator inspection regulations

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

The 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:

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner.

They are no substitute for the inspections as required by 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. under "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.

Tab. 3-1

Group III p ≥ l bar p·x l ≥ 200 and

Inspections prior to commissioning

Regular

at the factory

at the place of use

inspections

Preliminary inspection by an expert

Acceptance inspection by an expert

Test programme to be drawn up by end user based upon experience with the type of operation and fluid.

Prototype and pressure test certified by the manufacturer (type approval) or the expert

p x l ≤ 1000

3-78

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Idlers The idlers have a permanent oil resp. grease filling.

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

Checking the oil level The checking plug (arrow, Fig. 3-86:) is located on the inside of the idler.

To check the oil level, the checking plug must be ca. 30° above the horizontal axis (2 o'clock position) (Fig. 3-86:). Unscrew the 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.

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.

Fig. 3-86:

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3-79

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Internal gearing

SLEWING RING 2413596

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

The internal gearing and the pinion are enclosed in a housing (5, Fig. 3-88:). The housing forms a grease-filled trough in which the pinion of the slewing mechanism moves.

Shut off the engine.

Wear protective gloves and firm protective clothing.

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.

Bearing races

Fig. 3-88:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-87:). The amount of grease used up during operation is replenished by the central lubricating system.

The housings have a check opening which is closed with a cover (6, Fig. 3-89:For checking, the cover must be removed.

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. 3-87:).

Fig. 3-89:

Fig. 3-87:

3-80

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Slewing ring - Checking the grease filling

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

Shut off the engines Wear protective gloves clothing.

and

firm

protective

At regular intervals

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

!

old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never slew the superstructure when refilling grease.

" check internal gearing and teeth of slewing mechanism pinion for condition " 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. 3-90:).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued slewing movements.

Slewing ring - Checking the screws for tightness The fastening screws of the slewing ring in the superstructure and the undercarriage are tightened with their respective check torque (cf. "Tightening torques" table).

When these values are reached, the fastening screws are perfectly tight.

Loosen slack screws before tightening them with a torque wrench to the prescribed torque (cf. table "Tightening torques and angles).

Fig. 3-90:

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3-81

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing CENTRAL LUBRICATING 2486213

Design and function The excavator is equipped with an automatic central lubricating system ensuring regular the regular supply of grease to all greasing points except those mentioned in the "Lubricating chart - Grease" for the backhoe bucket.

All lubricating points connected to the system are greased at regular intervals. During the greasing cycle, indicator lamp (24, Fig. 3-91:) is lit up.

A grease pump (5, Fig. 3-93:) with attached grease container (6) pumps the grease through lines (7) to the main distributors (17 and 18, Fig. 3-93: and Fig. 3-94:).

Fig. 3-93:

There is no main distributor (18) if the excavator is equipped with a backhoe bucket.

Fig. 3-91:

When the electrical system is switched on with the key-switch, the indicator lamp (23, Fig. 3-91:) lights up and the lubricating system is activated.

The indicator lamp (23) is visible after removing cover (20, Fig. 3-92:).

Fig. 3-94:

Fig. 3-92:

3-82

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

In the case of trouble-free operation, two control pins in the main distributors must always move up and down when the pertaining pistons in the main distributors are being switched over.

Control pin movement is monitored by means of sensors. Indicator lamp (24, Fig. 3-95:) flashes on and off in the event of a fault.

See fault indication table.

In the event of trouble, shut off engine and rectify.

Check during every working shift !

that no grease escapes from the pressurerelief valves (9, Fig. 3-96:) and

!

that the grease container contains a sufficient amount of grease.

Fig. 3-96:

Always refill the grease container in time to avoid malfunctions caused by air penetrating into the lubricating system.

The grease container (6) can also be filled by hand.

Switch off the electrical system and withdraw key from the key-switch.

Fig. 3-95:

The level of grease in the container is visible from outside.

If grease escapes from the pressure valves (9), the line system is clogged. In this case, rectifiy the fault as described under "Unblocking a grease line".

Unscrew cover (8)of the grease container and fill in grease manually.

Screw cover (8) back in place.

If the amount of grease left in the container is insufficient, refill container through greasing nipple (10, Fig. 3-96:) with a manual grease gun or with a mobile service station. The filling pressure must be ca. 5 - 8 bars.

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3-83

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Greasing cycle The greasing cycle is initiated by a electronic unit.

The duration of a single cycle is controlled by the check-back signal from the sensors in the greasing circuit.

Presetting the pause duration The pause duration is preset with jumper (21, Fig. 3-97:) and rotary switch (22).

Jumper (21) placed over contact pins on the left and in the middle: presetting of minutes.

Do not change the setting

The optimal adjustment of the pause duration is attained when an increasing ring of grease forms at the greasing (friction) points. If one of the greasing points shows a different behaviour, it is not being supplied with sufficient grease. In this case, the pause duration must be adapted accordingly.

Indicators Diode (23, Fig. 7) lights up when the power supply in on.

Diode (24) lights up in the event of malfunctions (code flashing sequence see table in Fig. 8).

The control panel indicator "Lubrication" in the driver›s cab flashes in the same sequence.

A = Drive motor defective

Rotary switch (22) is used to preset 15 time ranges 1 thru and A thru F.

B = Malfunction of lubricating circuit 1 C = Malfunction of lubricating circuit 2 D = Malfunction of lubricating circuits 1 and 2 E = Container empty (Optional) F = Pump running indicator extinguished during greasing pauses

Fig. 3-97:

Rotary switch (22) is set to range "1". The corresponding pause duration is the 4 minutes.

If rotorary switch (22) is set to range "2", the pause duration will 8 minutes. In range "3", the duration is 12 minutes.

Increasing the range by one step of the switch prolongs the pause duration by another 4 minutes.

Set the pause duration at first to 4 minutes.

If required, the pause can be prolonged later on.

3-84

Fig. 3-98

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Malfunctions

The malfunctions mentioned above prevent the pistons in the monitored distributor from moving up and down. Lamp (24) will then indicate the corresponding fault by flashing on and off in the following intervals:

!

greasing point(s) blocked up

!

distributor (s) blocked up

!

main line to distributor with piston movement sensor interrupted

Malfunction of lubricating circuit 1

!

air in greasing system

B = 0,5 seconds - "ON" - 1 second "OFF"

!

container empty

Malfunction of lubricating circuit 2

Reset button C = 1 second - "ON" - 0,5 seconds "OFF" (25, Fig. 3-99:) Depressing reset button (25) for more than 2 seconds initiates an additional greasing cycle.

After having rectified a malfunction, reset button (25) must be depressed shortly (1 second) to cancel the fault message.

Malfunction of lubricating circuit 1 and 2 D = 2 seconds - "ON" - 2 seconds "OFF" Container empty (option) Indicator lamp (24) flashes in the following intervals E = 0,5 seconds - "ON" - 0,5 seconds " OFF" The "container empty" signal starts flashing only after 6 revolutions of the motor.

In the event of malfunction, the piston sensor (initiator) can no longer detect piston movements and therefore not switch off the motor.

Fig. 3-99:

The monitoring timer of the control unit operating in parallel switches off the pump after the monitoring time has elapsed.

The system indicates a fault.

Indicator lamp (24) flashes on and off.

The pump does not restart automatically.

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3-85

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Venting the grease pump

Venting the grease lines

" Refill grease container (6, Fig. 3-100:). " Unscrew lines (7) from connections (12).

If air has penetrated into the line system - e.g. when lines are being replaced - the lubricating system must be vented.

" Start up grease pump (5) until grease emerges from connections (12).

" Disconnect lines (7, Fig. 3-100:) from the distributors.

" Switch off grease pump and reconnect lines (7).

" Start up grease pump (5) until grease emerges from lines (7). " Switch off grease pump (5) and reconnect lines (7) to the distributors. " Disconnect all other lines one after the other from the distributors, start up grease pump (5) and wait until grease emerges from the respective connection. " Repeat these procedures at all other distributors.

Unblocking a grease line Proceed as described under "Venting the line system".

Fig. 3-100:

Put the excavator back into operation only after the lubricating system works properly and after activating the unloaded working equipment for abt. 5 minutes. This is required to supply sufficient grease to the cylinder bearings.

3-86

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Cleaning the grease sieves Check the grease sieves (13, Fig. 3-101:) for contamination and clean, if required. The grease sieves must also be cleaned after a blockage in one of the grease lines has been removed

Cleaning " Loosen nut (12) by holding union (16) in place with a wrench. " Unscrew disk (14).

Lubricating the grease distributor of the working equipment " Withdraw protective cap from greasing nipple. " Clean greasing nipple. " Press nozzle of the grease gun onto the greasing nipple. " Inject grease until the fresh grease squeezes the used grease out of the bearing joints.

" Remove sieve (13) and clean with white spirit or paraffin oil.

Make sure that used grease emerges from all greasing points connected to the distributor.

" Refit (13) and fasten with disk (14).

Only then have all greasing points connected to the grease distributor been properly greased.

" Screw nut (12) onto the union.

" Wipe off used grease with cleaning rags. " After greasing, place protective cap back on the greasing nipple.

Dispose of cleaning rags without polluting the environment.

Fig. 3-101:

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3-87

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 2413688

Putting the excavator out of operation " Park the excavator on firm and level ground. " Set the working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible. " Set all control element to "0".

Battery storage During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C. Observe the following points with regard to maintenance: " Clean the batteries. " Check the acid density and the electrolyte level of the battery every two weeks. " Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³. " Keep the batteries clean and dry on the outside.

" Clean the machine. " Lock the superstructure " Carry out a visual inspection of the excavator. " Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler. " Carry out engine preservation " Protect all bright metal parts (e.g. piston rods) from rust and dirt. " Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season. " Fill up the fuel tank. " 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 and withdrawing the key handle - locking the cab door - securing all lockable hatches. " Cover up all openings

3-88

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing Recommissioning " Remove the covers. " Degrease / clean all protected components. " Remove engine preservation in acc. with the engine operationg anstructions " Unlock the superstructure " Check the fuel level in tank " Check track tension (visual inspection) " Check level and condition of the cooling liquid in the cooling system. " Check grease filling in grease container. " Oil level

- drive engine - slewing gearbox - pump transfer gearbox - travel gearboxes

" Check oil level in hydraulic oil reservoir. " Check battery acid density and level. " Install batteries and reconnect. " Set the battery main switch to ON " Function checks:

- superstructure holding brake - track brake - lighting system - signalling equipment

" Vent the hydraulic system.

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3-89

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing NOTES 2804180

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3-90

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OPERATING INSTRUCTIONS RH 40 E Inspection and servicing

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3-91

OPERATING INSTRUCTIONS RH 40 E Repair work 4 REPAIR WORK 28040534 Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Part 4 REPAIR WORK

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

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

Part 5 ANNEX

Part 6 INDEX

BA RH40E(3 664 930.00)-EN

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

4-1

OPERATING INSTRUCTIONS Repair work

4-2

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Repair work Prestressed units

REPAIR WORK - SAFETY INSTRUCTIONS 2804243

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

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

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

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

Repair personnel Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

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

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

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

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

The operating manual contains no information on this point.

Dismantling components Never do dismantling while the machine is at operating temperature.

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

Leave time for the machine to cool down.

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

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate 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.

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

BA RH40E(3 664 930.00)-EN

4-3

OPERATING INSTRUCTIONS Repair work Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of Terex.

Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the drive engines while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

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

4-4

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OPERATING INSTRUCTIONS RH 40 E Repair work 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.

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

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.

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

Do not store or handle any flammable substances during operation.

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

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

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.

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4-5

OPERATING INSTRUCTIONS Repair work ENGINE 2413690

Read and observe the "Repair Safety instructions" chapter and the engine operating instructions before working on the engine.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine and allow to cool down.

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

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

4-6

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OPERATING INSTRUCTIONS RH 40 E Repair work 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.

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

Risk of injury from acid splashes and battery gases.

Before connecting the jumper cables (external bateries) check the own batteries for proper operation. Checking is done by switching on the excavator's electrical system.

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

Do not switch on electrical consumers (e.g. floodlamps) when checking the batteries. In case of doubt, remove the batteries and have them tested.

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

!

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)

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 short-circuiting.

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".

BA RH40E(3 664 930.00)-EN

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- described order and disconnect after starting.

" 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.

4-7

OPERATING INSTRUCTIONS Repair work Connecting the jumper cables " Connect the red jumper cable to the positive pole of the empty battery (1,Fig. 4-1:), 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).

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 batteríes as possible.

Fig. 4-1:

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 thenstart 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) " 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.

4-8

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Repair work HYDRAULIC SYSTEM 2804218

Repair

Always depressurize the hydraulic system before disconnecting any hydraulic hoses.

Replace damaged or leaking hydraulic hoses by new ones. Use original Terex-Germany 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.

BA RH40E(3 664 930.00)-EN

4-9

OPERATING INSTRUCTIONS Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS 2411963

The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So: " Never handle accumulators mechanically, never weld or solder. " Testing and servicing work must be carried out by experts only. " Prior to any testing and servicing work, depressurize the hydraulic part of the system. " To dismantle the accumulator, always wear goggles and working gloves. " Fill accumulator with nitrogen only, never with compressed air or oxygen. " Report any defects or damage to the machine owner without delay. " Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately

4-10

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Repair work WELDING OPERATIONS SAFETY INSTRUCTIONS 3657352

Never perform welding operations unless you are qualified to do so.

Observe the accident prevention regulations.

Wear protective clothing !

protective suit

!

protective gloves

!

face protection

Protect the disconnected terminals and plugs from short-circuiting and soiling by covering them with foil or adhesive tape.

Attach the welding-current pincers close to the welding zone (max. 2 - 3 m).

The welding current must not flow via the ball resp. the roller bearing slewing ring, via pin couplings, articulated joints or hydraulic cylinders.

An electric current flowing over an air gap (in an articulated joint, for instance) generates sparks that damage metallic surfaces.

On completion of the welding operation, restore all electrical connections.

Any work on receptacles that contain or have contained substances !

which are combustible or which encourage combustion,

!

which are susceptible to explosion,

!

or which may develop health-hazardous gases, vapours, mist or dust

during welding operations must be carried out only under expert supervision and only by experienced persons authorized to do such work.

Detailed information on the correct execution of welding operations is given in the technical manual "Welding for maintenance and repair".

Should you have any problems or queries, apply to the Terex Germany after-sales service department.

If parts of the machine have to be dimantled, read and take note of the following sections: Assembling attachments - safety instructions", "Inspection and servicing - safety instructions", "Repair - safety instructions".

BA RH40E(3 664 930.00)-EN

4-11

OPERATING INSTRUCTIONS Repair work

4-12

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Repair work NOTES 2804180

.............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

BA RH40E(3 664 930.00)-EN

4-13

OPERATING INSTRUCTIONS Repair work

4-14

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex 5 ANNEX 2804052

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Part 4 REPAIR WORK

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

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

Part 5 ANNEX

Part 6 INDEX

BA RH40E(3 664 930.00)-EN

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

5-1

OPERATING INSTRUCTIONS Annex

5-2

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex TROUBLESHOOTING 3657368

Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

Fault

For this reason, it is vital to read through the relevant section of the operating instructions once again before rectifying any faults.

The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

If you are unable to detect the cause of the fault or to rectify it, apply to the Terex Germany after-sales service.

Study the problem carefully. First think, then act.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the Terex Germany after-sales service. Exact data allow for fast troubleshooting.

!

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?

Never do any jobs for which you are not qualified.

The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

Ask yourself the following questions:

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the operating instructions. If there is no entry, the Terex Germany after-sales service should be consulted

BA RH40E(3 664 930.00)-EN

5-3

OPERATING INSTRUCTIONS Annex FAULT TABLES 3659434

Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts, but runs enevenly or intermittently Engine gets too hot, temperature warning activated Engine not working at full power Engine not working on full cylinder papacity Engine without oil pressure or oil pressure too low Engine oil comsumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly Cause Oil level too low •

• ••

••

Oil level too high

••• • •

•

•

•

•

• • •• •

Engine inclination too big Engine oil of wrong SAE-class Fuel quality not corresponding to specification

• •

•

Air filter contaminated / turbo-charger 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 buid-up Battery defective or discharged Cable connections in starter circuit loose or corroded Starter defective or pinion not in mesh Shut-off relay jamming Incorrect valve setting

• • • • •

••••

•

• •

• •• ••••

••

• • •

5-4

•

••

•

Injection line leaking Injection valve defective Combustion engine blocked on output side • PMS malfunction • Celect coding lamp flashing/lit Celect defective (software error)

Remedial action Check P Adjust E Replace W Top up A Reduce S Clean R

1) Contact the Terex-Germany Service

Chapter ref.

Engine oil level Engine oil level Engine Op. Instr.

Lubricants Engine Op. Instr.

Air intake syst.

Fuel filter Cooler ning Engine Instr.

Battery

Engine Instr.

Engine Instr.

A S P W W P

P/W P clea- R Op. P/W P P P P 1) Op. E P Op. P/W 1) 1) 1) 1)

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex Working hydraulics – Fault table

Fault

Remedial action

Working and slewing functions not operational No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the Terex-Germany Uncontrolled working movements Service Cause Abschnitt Servo control not activated/defective Working P • 1) • • • • • • Malfunction of pressure-relief valve 1) • • Servo system pump defective 1) • • • • • • Malfunction of primary / sencondary pressure-relief valves Engine speed too low P • ECO-power switch in 80%-position P • Fuel filter contaminated Fuel filter P/W • Insufficient engine power Engine 1) • malfunction Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R • lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS fault 1) • indicator lamp flashing) 1) • Malfunction of solenoid valves 1) • • Malfunction of control spool Engine coupling defective •

BA RH40E(3 664 930.00)-EN

5-5

OPERATING INSTRUCTIONS Annex Track drive – Fault table

Fault

Remedial action

No forward travel and no reversing travel Maximum travel speed cannot be reached Insufficient traction power

• • •

• • • • • • • • •

5-6

• • • •

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the Terex-Germany Service Cause Chapter ref.

Malfunction of pressure-relief valves 1) Servo system pump defective 1) Malfunction of travel valve (pedal) 1) Engine nominal speed too low 1) Malfunction of control spool 1) ECO-power switch in 80%-position Travelling P Insufficient engine power Engine mal- 1) fuction Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil P/R cator lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS 1) fault indicator lamp flashing)

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex Slewing mechnism – Fault table

Fault

Remedial action

No slewing possible Check Adjust Replace Slewing performance insufficient Top up Reduce Uncontrolled slewing movement Clean 1) Contact the TerexGermany Service Cause Chapter ref.

Servo control not activated / defective Working Endschalter Aufstiegleiter (Option) defekt, nicht vollständig einge- Operation fahren Superstructure holding brake applied Pressure-relief valve adjusted too low level / defective • Servo system pump defective Malfunction in feed-pressure circuit of slewing pump • Malfunction in high-pressure circuit of slewing system • Malfuction of moment-regulating valve • • Malfunction in slewing pump displacement cylinder Excessive leakage in slewing motor •

No righthand or lefthand slewing

• • • • • • • •

BA RH40E(3 664 930.00)-EN

P E W A S R

P P P 1) 1) 1) 1) 1) 1) 1)

5-7

OPERATING INSTRUCTIONS Annex Central lubricating system – Fault table

Fault

Remedial action

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

• • • •

• • •

•

• • • •

5-8

• • •

•

Cause Timer defective Lines between timer and hydraulic motor defective Hydraulikmotor defektive Grease pump defective Grease sieve clogged Distributor defective Grease container empty Grease pump does not suck grease Leaky lines Non-return valve defective Pressure switch defective

Check P Adjust E Replace W Top up A Reduce S Clean R Vent L 1) Contact the Terex-Germany Service Chapter ref.

P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex

BA RH40E(3 664 930.00)-EN

5-9

OPERATING INSTRUCTIONS Annex HYDRAULIC CIRCUIT DIAGRAM 2731685

Legend (loading bucket)

Pos. Stück Benennung

Pos. Stück Benennung

1

1

Diesel engine

55

2

Track tensioner

2

1

Pump tansfer gearbox

56

2

Diaphragm accumulator

4

2

Variable displacement pump

57

2

Track tensioner cylinder

5

1

Coupling

58

2

Pressure limiting valve (250 bars)

6

1

Coupling

59

2

Travel gearbox, complete

7

1

Slewing pump

60

2

Travel motor

8

1

Cooling oil pump

61

2

Track brake

9

1

Servo pump

63

1

Triple control block (working equipment)

10

1

Variable displacement pump (fan drive)

64

6

Pressure/anti-cavitation valve

11

1

Filter

65

1

Single control block (bottom dump)

12

2

Pressure limiting valve (55 bars)

66

2

Pressure/anti-cavitation valve

13

1

Pressure limiting valve (35 bars)

67

1

Float valve (boom)

14

1

Filter

69

2

Boom cylinder

16

1

Proportional valve , complete

70

2

Stick cylinder

17

1

Torque control valve

71

2

Bucket tipping cylinder

18

3

Test point

72

2

Bottom-dump cylinder

19

1

Pressure limiting valve

75

2

Servo valve, left

20

1

Hydraulic oil reservoir, complete

76

3

Pedal valve (travelling, bottom dump)

21

4

Return-flow filter

77

1

Pedal valve (dump/lift limiter

22

2

Bypass valve

81

1

One-way restrictor

23

2

Tank-line precharging valve

82

2

Distributor strip (servo control)

24

1

Shut-off cock

83

1

Pressure accumulator

25

1

Breather filter

84

1

Non-return valve

26

1

Shut off cock

85

1

Shut off block

27

2

High-pressure filter with pressure relief

86

1

Solenoid valve

28

2

Hight pressure filter

88

9

Shuttle valve

29

2

Pressure limiting valve (330 bars)

89

5

Shuttle valve

30

1

Distributor

91

1

Load sensing sensor

31

1

Fan motor

92

2

Pressure switch (3,5 bars, DSF + DS)

32

1

Fan wheel

93

1

Pressure switch (DSL)

33

1

Cooler for hydraulic oil

94

3

Protective cap

34

1

By-pass valve

95

3

Connecting piece

35

1

Thermostat valve

97

3

Solenoid valve Port plate

36

1

Thermostat and safety valve

98

3

37

1

Non-return valve

99

1

Test point

39

1

Slewing gearbox complete

100

1

Microprocessor (PMS box) Magnetic-Pickup

40

1

Slewing motor

101

1

41

1

Superstructure holding brake

104

1

Strip

46

1

Travel block, complete

105

2

Cover plate

47

1

Rotor

111

4

Flange

48

1

Valve (travelling right)

113

1

Housing (cooling oil pump)

49

1

Valve (travelling left)

114

1

Block (control spool)

50

1

Valve (travel brake right)

115

1

Block (control spool)

51

1

Valve (travel brake left)

116

1

Coupling (dump spool)

52

4

Anti-cavitation valve

117

2

Distributor (bucket tipping)

53

4

Cover plate

118

1

T-flange (control spool/dump spool)

119

1

Disk (control spool)

(drgw.-no. 2 762 218)

5-10

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex

BA RH40E(3 664 930.00)-EN

5-11

OPERATING INSTRUCTIONS Annex Legend (backhoe configuration)

Pos. Stück Benennung

Pos. Stück Benennung

1

1

Diesel engine

2

1

Pump tansfer gearbox

53

4

Cover plate

Variable displacement pump

55

2

Track tensioner

Coupling

56

2

Diaphragm accumulator

Coupling

57

2

Track tensioner cylinder

2

Pressure limiting valve (250 bars)

4 5 6

2 1 1

7

1

Slewing pump

58

8

1

Cooling oil pump

59

2

Travel gearbox, complete

Servo pump

60

2

Travel motor

Variable displacement pump

61

2

Track brake

Filter

63

1

Triple control block (working equipment)

6

Pressure/anti-cavitation valve

9 10 11

1 1 1

12

2

Pressure limiting valve (55 bars)

64

13

1

Pressure limiting valve (35 bars)

69

1

Boom cylinder

Filter

70

2

Stick cylinder

2

Backhoe cylinder Servo valve, left

14

1

15

2

Non-return valve

71

16

1

Proportional valve , complete

75

2

17

1

Moment pressure regulating valve

76

3

Pedal valve (travelling, bottom dump)

18

3

Messuring port

82

2

Distributor strip (servo control)

19

1

Pressure limiting valve

83

1

Pressure accumulator

1

Non-return valve Valve block

20

1

Hydraulic oil reservoir, complete

84

21

3

Return-flow filter

85

1

Bypass valve

86

1

Control blocl

9

Shuttle valve Shuttle valve

22

2

23

2

Tank-line precharging valve

88

24

1

Intermediate shut-off cock

89

5

Filter

91

1

Pressure pick-up

2

Pressure switch (3,5 bars)

25

1

27

2

High-pressure filter with pressure relief

92

28

2

Line filter

93

1

Pressure switch

Pressure limiting valve (330 bars)

94

3

Protective cap

Fan motor

95

3

Connecting piece

2

Solenoid valve

29 31

2 1

32

1

Fan wheel

97

33

1

Cooler for hydraulic oil

98

2

Port plate

1

Measuring port

35

1

Thermostat valve

99

36

1

Thermostat valve

100

1

Microprocessor

37

1

Non-return valve

101

1

Magnetic-Pickup

39

1

Slewing gearbox complete

104

1

Strip

40

1

Slewing motor

105

3

Cover plate

41

1

Superstructure holding brake

110

1

Distributor

4

Flange (travel block/travel spool)

46

1

Travel block, complete

111

47

1

Rotor

114

1

Block (control spool)

Valve (travelling right)

117

1

Distributor (bucket tipping)

Valve (travelling left)

118

1

T-flange (control spool/dump spool)

Valve (travel brake right)

119

1

Disk (control spool)

Valve (travel brake left)

121

1

Distributor (boom)

Anti-cavitation valve

122

1

Distributor (bottom dump)

48 49 50 51 52

1 1 1 1 4

(drgw-no. 2 455 702)

5-12

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex ABBREVIATIONS 2804493

A A A2 A4 abt.

ABE acc.

Ah AOT API approx.

AUT

Four-wheel drive Ampere (SI base unit of electric current) 2-point bracing (claws) 4-point bracing (claws) about General Operating Permit [Germany] according to Ampere hours (SI base unit of quantity of electricity) Upper part of boom American Petroleum Institute approximately Lower part of boom

BA Bh

= OI = Operating instructions = OH = Operating hour

CE

Communauté Européenne = European community Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee 1 centimeter (= /100 m) Cubic centimeters per revolution

CECE

CEN cm 3 cm /rev

dia.

DIN

Decibel (sound intensity according to measuring method A) Diameter German Industrial Standard

EDS eff. e.g. etc.

Electronic diagnostic system effective for example etcetera

Fig. FOPS FS

Figure, serial number of illustration Falling objects protective structures Rock shovel (working equipment)

GLR

Full-load controller (electronic module for PMS)

HD HDS Hydr.

Heavy duty Heavy duty small Hydraulic, Hydraulics

i i.e.

IFN

id est = that is ISO service rating, blocked

dB(A)

Transmission ratio

BA RH40E(3 664 930.00)-EN

incl.

ISO

including, inclusive of International Standardization Organization

kg 3 kg/dm

Kilogram (unit of weight) Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

km/h kNm kW l Lb/in² LC LDA LED l/min LpA LPS LS LS LwA

Liter Pounds per square inch (= psi) Long crawler Charge pressure-dependent full-load limiter Light-emitting diode Liters per minute Sound pressure at workplace Load-sensing Power System Limited slip Load sensing Sound power level of the machine in stationary operation

min.

-1 min mm MONO

Meters Tightening torque 1 Milliampere (= /1000A) maximal, maximum Mobile hydraulics (excavator) Mobile hydraulic excavator for road and rail operation minimal, minimum Revolutions per minute Millimeter (=1/1000 m) Monoblock boom

N N, kN NLGI NLGI-Klasse Nm No.

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency - lubricant classification acc. to DIN 51 818 Newtonmeter (unit of torque) Number

OH OLS op.inst.

OW

Operating hour Terex load stabilization Operating instructions Superstructure

m MA MA max.

MH MHS

5-13

OPERATING INSTRUCTIONS Annex ABBREVIATIONS

PLA PMS P/No. PS

bulldozer blade Pump Managing System Part number (Terex) Metric horsepower (1 PS = 0.74 kW)

Qty.

Quantity

R, r resp.

RH ROPS rpm

Radius Respectively Crawler hydraulics (excavator) Roll-over protective structures -1 Revolutions per minute (= min )

SAE sec./s.

SN StVO StVZO

Society of Aotomotive Engineers (USA) Second Item number German Road Traffic Regulations German regulations authorizing the use of vehicles for road traffic Width across flats

SW

typ.

Metric ton (= 1000 kg) Civil Engineering Employer's Liability Insurance Association Technical Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of slewing torque) Typical

U/min UW

Revolutions per minute Undercarriage

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

t TBG THB TL tm

W

Watt (unit of electric power)

°C °kW

Degrees Celsius (temperature) Degrees crank angle

> <

greater than less than

5-14

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex TECHNICAL DATA 2462197

BA RH40E(3 664 930.00)-EN

5-15

OPERATING INSTRUCTIONS Annex

5-16

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Annex NOTES

2804180

.............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

BA RH40E(3 664 930.00)-EN

5-17

OPERATING INSTRUCTIONS Annex

5-18

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Index 6 INDEX 2804053&

Operating instructions

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Part 2 OPERATION

Target group

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Part 4 REPAIR WORK

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

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

Part 5 ANNEX

Part 6 INDEX

BA RH40E(3 664 930.00)-EN

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

6-1

OPERATING INSTRUCTIONS Index

6-2

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Index

A

D

ABBREVIATIONS 5-14 ABBREVIATIONS 5-13 After daily operation 2-55 Air-intake lines 3-49

Demand control / Zero-flow regulation 2-8 Depressurizing the hydraulic system 3-59 DESCRIPTION OF THE EXCAVATOR 2-6 Design and function 3-84 Designated use 1-6 Drive 2-8 DRIVER'S CAB 2-13 Driver's seat 2-14 DRIVING 2-42 Dust collection 3-49

Air-intake system 3-13 AIR-INTAKE SYSTEM 3-47 Alternator - Instructions 3-55 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS 2-56 Assisted starting (with jumper cables) 4-7 Assisted starting (with jumper cables) – Safety instructions 4-7 Automatic engine speed reduction 2-8

B Battery 3-56 Battery main switch 2-38 Battery main switch / Main fuse 3-56 Battery storage 3-90 Bearing races 3-82 Before starting work 2-53 Breather filter 3-64 Bypass valves (cooling circuit) 3-63 Bypass valves (working circuit) 3-62

C CENTRAL LUBRICATING 3-84 Central lubricating system – Fault table 5-8 Centrifuge (optional) 3-43 Change of engine oil 3-13 Changing the engine oil 3-41 Changing the gearbox oil 3-72, 3-74 Changing the hydraulic oil 3-67 Changing the hydraulic oil return-flow (hydraulic oil reservoir 3-61 Checking and adjusting the valve clearance 3-40 Checking the engine oil level / Topping up 3-40 Checking the gas charging pressure in the pressure accumulator 3-80 Checking the gearbox oil level / Topping up with oil 372 Checking the hydraulic oil level 3-60 Checking the oil level 3-81 Checking the V-belt tension 3-40 Cleaning jobs 3-13 Cleaning the fuel tanks 3-52 Cleaning the grease sieves 3-89 Cleaning the hydraulic oil cooler 3-70 Combustion engine - Fault table 5-4 Components 3-13 Cooling liquid 3-45 COOLING SYSTEM 3-44 Corrosion protection for pins and bearings (bushings and hubs) 2-1 CRAWLER TRACKS 3-77

BA RH40E(3 664 930.00)-EN

E Electrical system 2-8 ELECTRICAL SYSTEM 3-55, 4-7 Electrical system - Safety instructions 3-55 ENGINE 3-40 ENGINE 4-6 Engine - Safety instructions 3-40 Entering and leaving the machine - Safety instructions 2-13 Environmentally compatible hydraulic fluid 3-10 Environmentally compatible hydraulic fluid - operating instructions 3-10 Environmentally compatible hydraulic fluid - Sampling 3-11 Environmentally compatible hydraulic fluid, conversion 3-10 Environment-friendly lubricants and gearbox oils 3-12 Excavator layout 2-7

F FAULT TABLES 5-4 Filling quantities - Grease 3-27, 3-29 Filling quantities - oil 3-31 Filling quantities - other 3-32 Fire and explosion hazard 1-12, 2-5 Fire and Explosion Hazard 3-9, 4-5 Fire-extinguisher 2-12 FUEL SYSTEM 3-50 Fuel system - Safety instructions 3-50

G Gas, dust, steam and smoke 1-11 Gearbox - Checking the oil level / Topping up with oil 3-74, 3-76 Gearbox oils 3-12 Gearbox venting 3-75, 3-76 Greases for bearings and slewing rings 3-38 Greasing cycle 3-86

H High-pressure filter for working hydraulics 3-65 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump 3-66 Hose line for oil and cooling liquid changes 3-39 HYDRAULIC CIRCUIT DIAGRAM 5-10

6-3

OPERATING INSTRUCTIONS Index Hydraulic equipment 1-11 Hydraulic system 2-8 HYDRAULIC SYSTEM 3-59 HYDRAULIC SYSTEM 4-9 Hydraulic system - Safety instructions 3-59

I Idlers 3-81 Inspection and servicing - Safety instructions 3-3 Inspection and Servicing plans - Instructions 3-13 INSPECTION PLAN - OIL 3-30 Inspection plan – Oil (Legend) 3-31 Instructions on troubleshooting 5-3 Intervals 3-13

L Layout of the fault table 5-3 LIFTING OPERATIONS 2-2 Load-hooks on backhoe buckets). 2-3 Locking the superstructure 2-48 LUBRICANTS 3-33 Lubricants for bearings 3-12 LUBRICATING CHART – GREASE (LOADING BUCKET) 3-26 Lubricating chart – Grease / Backhoe bucket (legende) 3-29 Lubricating chart – Grease / BACKHOE bucket (legende) 3-28 Lubricating chart – Grease / Loading bucket (legende) 3-27 Lubricating the grease distributor of the working equipment 3-89

M Main filter elements 3-47 Measures 5-3 MONITORING, WARNING ELEMENTS 2-16

AND

CONTROL

N Noise 1-11 NOTES 1-13, 2-8, 3-3, 4-13 NOTES 5-17

O Oil, grease and other chemical substances 1-11 Oils / Greases 3-13 Oils for combustion engines and compressors (selection) 3-33 Oils for gearboxes (selection 3-37 Oils for hydraulic system (selection) 3-34 Operation - Safety instructions 2-3 Organizational measures 1-7

P Plan A - E 3-21 Plan N 3-17 Plan T 3-19 Plan V 3-15 Possible causes 5-3

6-4

Preface 1-3 Pressure accumulator 3-71 PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS 4-10 Pressure-accumulator inspection regulations 3-80 Pump Managing System (PMS) 2-8 PUMP TRANSFER GEARBOX 3-72 Putting the excavator out of operation 3-90 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-90 PUTTING THE MACHINE INTO OPERATION 2-35

R Radiators 3-44 Recommissioning 3-1 Refuelling 2-35 Refuelling station (optional) 3-52 Repair 4-9 Repair work - Safety instructions 4-3 Replacing the fuel filter 3-51 Replacing the oil filter 3-42 Retensioning the alternator/fan belt 3-40

S Safety filter element 3-49 Safety instructions 2-2 SAFETY INSTRUCTIONS 2-42, 2-51 Safety instructions governing specific operational phases 1-8 Section 5-3 Securing the machine 2-58 Selection and qualification of personnel; basic responsibilities 1-8 Service Station (optional equipment) 2-36 SERVICING WORK 3-39 Sign 2-11 Slewing and braking the superstructure 2-53 SLEWING GEARBOX 3-74 Slewing mechnism – Fault table 5-7 SLEWING RING 3-82 Slewing ring - Instructions 3-82 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables 1-9 Starting and stopping the engines 2-39 Starting the engine with jumper cables (external batteries 4-7 Superstructure 2-8 Switching the electrical system on and off 2-37

T TECHNICAL DATA 5-15 Topping up with hydraulic oil 3-60 Track drive – Fault table 5-6 Track parking brake 2-48 Track rollers, support rollers, track pads 3-77 Track tensioner 3-79 Transport - Safety instructions 2-49 Transporting and recommissioning 1-11 Transporting the machine 2-49 TRAVEL GEARBOX 3-76 Travel gearbox - Changing the oil 3-76 TRAVELLING 2-44

BA RH40E(3 664 930.00)-EN

OPERATING INSTRUCTIONS RH 40 E Index TROUBLESHOOTING 5-3

W

U

Warning of special dangers 1-10 Warnings and symbols 1-5 Warranty 1-4 Water filter 3-46 Water trap (option) 3-53 Welding operations - Safety instructions 4-11 Working 2-54 Working hydraulics – Fault table 5-5 Working operation 2-51

Unblocking a grease line 3-88 Undercarriage 2-8

V Ventilation and heating 2-41 Venting the fuel system 3-51 Venting the grease lines 3-88 Venting the grease pump 3-88 Venting the hydraulic system 3-69

BA RH40E(3 664 930.00)-EN

6-5

OPERATING INSTRUCTIONS Index

6-6

BA RH40E(3 664 930.00)-EN