CAT Bucyrus RH 40E Hydraulic Excavator Operating Instruction Manual 3725040 - PDF DOWNLOAD

OPERATING INSTRUCTIONS RH 40E

Hydraulic Excavator

RH 40E Bucyrus HEX GmbH

BA RH40E(3 725 040.00)-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

The Terex O&K operating manual is in 6 sections; the sections are designed for different target groups: 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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OPERATING INSTRUCTIONS 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 Ether _________________________________________________________________________ 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 Programmable Logic Controller (PLC) ________________________________________________ 2-8 Demand control / Zero-flow regulation ________________________________________________ 2-9 Automatic engine speed reduction ___________________________________________________ 2-9 Electrical system _________________________________________________________________ 2-9 Signs _________________________________________________________________________ 2-11 DRIVER'S CAB _________________________________________________________________ 2-12 Entering and leaving the machine - Safety instructions __________________________________ 2-12 Windscreen washer______________________________________________________________ 2-13 Driver's seat ___________________________________________________________________ 2-14 Fire-extinguisher ________________________________________________________________ 2-15 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-16 PUTTING THE MACHINE INTO OPERATION __________________________________________ 2-35 Refuelling _____________________________________________________________________ 2-35 Switching the electrical system on and off ____________________________________________ 2-38 Battery main switch ______________________________________________________________ 2-39

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OPERATING INSTRUCTIONS RH 40-E Table of contents STARTING AND STOPPING THE ENGINES ___________________________________________ 2-40 VENTILATION AND HEATING ______________________________________________________ 2-42 Air conditioner (optional) __________________________________________________________ 2-42 Auxiliary heating (optional) ________________________________________________________ 2-42 TRAVELLING, SAFETY INSTRUCTIONS ______________________________________________ 2-43 Running-in specifications for components of the crawler tracks ____________________________ 2-43 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 ______________________________________________ 2-54 Working _______________________________________________________________________ 2-55 After daily operation _____________________________________________________________ 2-56 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ________________________ 2-57 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 and W___________________________________________________________________ 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

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OPERATING INSTRUCTIONS RH 40-E Table of contents LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND) _______________________ 3-28 Lubricating chart – Grease / Backhoe bucket (legend) ___________________________________ 3-29 Filling quantities - Grease _________________________________________________________ 3-29 INSPECTION PLAN - OIL __________________________________________________________ 3-30 Inspection plan – Oil (legend) ) _____________________________________________________ 3-31 Filling quantities - oil _____________________________________________________________ 3-32 Filling quantities - other ___________________________________________________________ 3-32 LUBRICANTS ___________________________________________________________________ 3-33 Notes on the selection of oils and greases ____________________________________________ 3-33 I. Oils for combustion engine _____________________________________________________ 3-34 II. Oils for hydraulic system (selection) ____________________________________________ 3-35 III.a Oils for pump gearbox _____________________________________________________ 3-36 III.b Oils for swing gearbox _____________________________________________________ 3-37 III.c Oils for travel gearbox _____________________________________________________ 3-38 V. Greases for bearings and slewing rings _________________________________________ 3-39 SERVICING WORK _______________________________________________________________ 3-40 Hose line for oil and cooling liquid changes ___________________________________________ 3-40 ENGINE ________________________________________________________________________ 3-41 Engine - Safety instructions________________________________________________________ 3-41 Checking the engine oil level / Topping up ____________________________________________ 3-41 Changing the engine oil___________________________________________________________ 3-42 Replacing the engine oil filters _____________________________________________________ 3-43 Cold-starting fluid (ether) - Replacing the pressure vessel ________________________________ 3-44 COOLING SYSTEM_______________________________________________________________ 3-45 Temperature ___________________________________________________________________ 3-45 Cooler and cooling liquid __________________________________________________________ 3-45 Topping up with coolant __________________________________________________________ 3-46 Changing the coolant ____________________________________________________________ 3-46 AIR-INTAKE SYSTEM _____________________________________________________________ 3-48 Main filter elements ______________________________________________________________ 3-48 Safety filter element______________________________________________________________ 3-50 Air-intake lines__________________________________________________________________ 3-50 Dust collection __________________________________________________________________ 3-50 FUEL SYSTEM __________________________________________________________________ 3-51 Fuel system - Safety instructions ___________________________________________________ 3-51 Fuel pre-filter, Draining off water ____________________________________________________ 3-51 Fuel pre-filter, replace ____________________________________________________________ 3-52 Secondary fuel filter, replace_______________________________________________________ 3-53 Fuel tank - Venting ______________________________________________________________ 3-54 Cleaning the fuel tank ____________________________________________________________ 3-54 Refuelling station (optional)________________________________________________________ 3-55 Water trap (option) ______________________________________________________________ 3-56 ELECTRICAL SYSTEM ____________________________________________________________ 3-58 Electrical system - Safety instructions________________________________________________ 3-58 Floodlight projector, safety instructions _______________________________________________ 3-59 Floodlight projector, replacing a defective xenon bulb ___________________________________ 3-60 Battery ________________________________________________________________________ 3-61 HYDRAULIC SYSTEM_____________________________________________________________ 3-63 Hydraulic system - Safety instructions _______________________________________________ 3-63 Depressurizing the hydraulic system_________________________________________________ 3-63 Checking the hydraulic oil level _____________________________________________________ 3-64 Topping up with hydraulic oil _______________________________________________________ 3-64

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OPERATING INSTRUCTIONS RH 40-E Table of contents Changing the hydraulic oil return-flow (hydraulic oil reservoir) _____________________________ 3-65 Bypass valves (working circuit) _____________________________________________________ 3-66 Bypass valves (cooling circuit) _____________________________________________________ 3-67 Breather filter___________________________________________________________________ 3-68 High-pressure filter for working hydraulics ____________________________________________ 3-69 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump ___________ 3-70 Changing the hydraulic oil _________________________________________________________ 3-71 Venting the hydraulic system ______________________________________________________ 3-73 Cleaning the hydraulic oil cooler ____________________________________________________ 3-74 Pressure accumulator ____________________________________________________________ 3-75 PUMP TRANSFER GEARBOX ______________________________________________________ 3-76 Checking the gearbox oil level / Topping up with oil _____________________________________ 3-76 Changing the gearbox oil _________________________________________________________ 3-77 SLEWING GEARBOX _____________________________________________________________ 3-79 Gearbox - Checking the oil level / Topping up with oil ___________________________________ 3-79 Changing the gearbox oil _________________________________________________________ 3-79 Gearbox venting ________________________________________________________________ 3-80 Output pinion ___________________________________________________________________ 3-80 TRAVEL GAERBOX ______________________________________________________________ 3-81 Gearbox - Checking the oil level / Topping up with oil ___________________________________ 3-81 Travel gearbox - Changing the oil ___________________________________________________ 3-81 Gearbox venting ________________________________________________________________ 3-81 CRAWLER TRACKS ______________________________________________________________ 3-82 Track rollers, support rollers, track pads ______________________________________________ 3-82 Track tensioner _________________________________________________________________ 3-84 Track tensioner _________________________________________________________________ 3-84 Pressure-accumulator inspection regulations __________________________________________ 3-85 Checking the gas charging pressure in the pressure accumulator __________________________ 3-85 SLEWING RING__________________________________________________________________ 3-86 Slewing ring - Instructions _________________________________________________________ 3-86 Bearing races __________________________________________________________________ 3-86 CENTRAL LUBRICATING __________________________________________________________ 3-88 Design and function______________________________________________________________ 3-88 Check for each Operation: ________________________________________________________ 3-89 Malfunctions ___________________________________________________________________ 3-90 Blockade of a lub point ___________________________________________________________ 3-91 Ventilation of the lubricating pump __________________________________________________ 3-92 Cleaning the grease sieve_________________________________________________________ 3-92 Manual lubrication _______________________________________________________________ 3-93 OTHER MAINTENANCE ___________________________________________________________ 3-95 Heating and air conditioning _______________________________________________________ 3-95 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING _______________ 3-96 Putting the excavator out of operation________________________________________________ 3-96 Battery storage _________________________________________________________________ 3-96 Recommissioning _______________________________________________________________ 3-96

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OPERATING INSTRUCTIONS RH 40-E Table of contents NOTES_________________________________________________________________________ 3-97 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 – Instructions ______________________________________________________________ 4-9 Hydraulic hoses – Instructions ______________________________________________________ 4-9 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 ____________________________________________________ 5-4 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 _____________________________________________________ 5-9 ABBREVIATIONS ________________________________________________________________ 5-11 TECHNICAL DATA _______________________________________________________________ 5-13 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 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 RH40-E(3 725 040.00)-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 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 O&K operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Terex O&K will be pleased to answer.

The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex O&K aftersales 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 Terex O&K mechanic or by attending an Terex O&K training course for operators or maintenance personnel.

The Terex O&K 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 The warranty of Terex O&K presupposes among other things that the servicing works as described in the operating instructions have been performed: 

Do not operate the machine  when components / assemblies are defective or missing, 

by the Terex O&K Service

or 

in a workshop authorized in writing by Terex O&K,

and 

by using the original spare parts of Terex O&K.

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

if one or several of such components of which more than one are installed in the machine have been removed.

In cases of doubt seek advice from the Terex O&K Service.

Terex O&K refuses to assume the guaranteee for damage and consequential damage caused by an abusive utilization of the machine.

Therefore: Do not operate the machine,  when several track rollers or support rollers have been removed; 

when one or several slewing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by Terex O&K as "abusive utilization".

Why? The machines have been designed and built on the basis of detailed calculations and so that all of the components installed absorb the occurring forces and are thus loaded to an equal extent.

Example: If the machine is used for working with, for instance, one or even several track rollers removed, the forces must be absorbed by the remaining track rollers. These are then overloaded or loaded to a greater extent than calculated.

The consequences are higher wear and consequential damage to the track rollers, but also to other components of the machine: chassis, travel gearbox and crawler track.

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OPERATING INSTRUCTIONS RH 40-E Introduction FUNDAMENTAL SAFETY INSTRUCTIONS 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 lifethreatening 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 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:

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.



excavated soils,

Lifting eyes on the lower carriage



sand,

-



are settled for transporting with a crane only.

gravel,



-

blasted rock,

must not be used for towing a machine.



ore,



coal,

and other raw materials.

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

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.

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 according to 2002/44/EG.

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OPERATING INSTRUCTIONS RH 40-E Introduction ORGANIZATIONAL MEASURES The operating instructions must always be at hand at the place of use of the machine, e.g. by stowing them in the place provided for such purpose.

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

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

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

Personnel entrusted with work on the machine must have read the operating instructions and in particular the chapter on safety before beginning work. Reading the 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:



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



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



ear protectors

Observe all safety instructions and warnings attached to the machine.

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

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

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

Use only the original sparts parts of Terex O&K. 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.

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

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.

ing equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

If your machine comes into contact with a live wire  do not leave the machine  drive the machine out of the hazard zone; 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 deenergized.

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.

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.

High-voltage system

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

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.

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

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

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

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.

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 work-

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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).

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its con-

stituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

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).

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

Do not store pressure vessels with cold-starting fluid (ether) on the excavator.

Do not eat, drink or smoke when replacing pressure vessels with cold-starting fluid (ether). Observe the instructions on the pressure vessels.

Provide for sufficient ventilation (see also Part 3 "Inspection and servicing").

Hydraulic equipment

Do not open empty cold-starting fluid pressure vessels (ether). Have the vessels disposed of properly.

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

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

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.

Transporting and recommissioning

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.

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.

BA RH40-E(3 725 040.00)-EN

1-11

OPERATING INSTRUCTIONS RH 40-E Introduction FIRE AND EXPLOSION HAZARD Safety Instructions Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents.

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

Clean the excavator before starting a job.

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

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

If necessary, also cover the ground with fireprotective blankets.

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

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

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 transport flammable substances on the excavator during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the excavator carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

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

Clean rubber parts and electric components with compressed air - refer to information label.

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

Ensure sufficient ventilation.

Even battery gases can ignite in open flames or fire.

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

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

Provide for sufficient ventilation.

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

Do not extinguish flammable liquids with water.

Use: 

dry-powder,



carbon-dioxide or



foam extinguishing compounds.

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

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved

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.

1-12

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OPERATING INSTRUCTIONS RH 40-E Introduction NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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OPERATING INSTRUCTIONS RH 40-E Introduction

1-14

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation 2 OPERATION 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 RH40-E(3 725 040.00)-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

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OPERATING INSTRUCTIONS RH 40-E Operation OPERATION - SAFETY INSTRUCTIONS 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 Terex O&Kmechanic or by attending an Terex O&K operator's training course.

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

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

BA RH40-E(3 725 040.00)-EN

Safety belt 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 Terex O&K. Clear-cut data are given in the technical specification.

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

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

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

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

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

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

Clean the excavator before starting a job.

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

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

If necessary, also cover the ground with fireprotective blankets.

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

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

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 transport flammable substances on the excavator during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the excavator carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

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

Clean rubber parts and electric components with compressed air - refer to information label.

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

Ensure sufficient ventilation.

Even battery gases can ignite in open flames or fire.

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

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

Provide for sufficient ventilation.

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

Do not extinguish flammable liquids with water.

Use: 

dry-powder,



carbon-dioxide or



foam extinguishing compounds.

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

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved

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.

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2-5

OPERATING INSTRUCTIONS RH 40-E Operation DESCRIPTION OF THE EXCAVATOR

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

Pump Managing System (PMS)

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

The Pump Managing System (PMS) with overlimit regulation ensures optimum utilization of the installed or preset engine power.

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

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.

Drive The drive unit comprises diesel engines, pump transfer gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Programmable Logic Controller (PLC)

Hydraulic system

The PLC controls the functions

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.

2-8



Engine Start



Engine Stop



Engine Idle



Central lubricating system



Further auxiliary functions

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

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OPERATING INSTRUCTIONS RH 40-E Operation Demand control / Zero-flow regulation

Electrical system The electrical system operates on 24 volts

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.

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2-9

OPERATING INSTRUCTIONS RH 40-E Operation

Fig. 2-2:

2-10

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OPERATING INSTRUCTIONS RH 40-E Operation Signs Warning and instruction signs Observe the warning and instruction signs attached to the machine.

Keep the signs legible and clean.

Replace signs immediately if they have become illegible.

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

Fig. 2-4:

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

Engine number Machine number

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

The identification plate with the machine number (Fig. 2-4:) is attached to the front side of the Aframe (arrow, Fig. 2-3:).

Fig. 2-5:

Fig. 2-3:

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

On steel components, the Terex O&K 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 DRIVER'S CAB 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. 2-6:) and Fig. 2-7:.

Fig. 2-6:

Always face the machine when entering or leaving it.

Fig. 2-7:

2-12

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OPERATING INSTRUCTIONS RH 40-E Operation Cab interior lamp

Windscreen washer

The interior lamp is switched on and off with switch (1, Fig. 2-8:).

The reservoir of the windscreen washing system (1, Fig. 2-9:) is located in the behind the cover (1, Fig. 2-10:).  Remove cover (1).

For the reservoir (1, Fig. 2-9:) capacity refer to the "Refilling quantities - Other" table.

Fig. 2-8:

Switch position

0 - lamp off 1 – lamp on.

Fig. 2-9:

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

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

Fig. 2-10:

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2-13

OPERATING INSTRUCTIONS RH 40-E Operation Driver's seat

Adjusting the lumbar support

The driver's seat (Fig. 2-11:) permits adjustment of backrest inclination, height and fore-and-aft position. The air-suspension of the seat can be adapted to the driver's body weight.

An upper and a lower air chamber are integrated into the backrest.

Risk of accidents.

Do not adjust the seat while driving, because you must concentrate on the road.

Stop the machine and shift the control levers to neutral position before adjusting the seat.

Press button (3) to the „+“ side - lower air chamber is inflated.

Press button (3) to the „-“ side - lower air chamber is deflated.

Press button (4) to the „+“ side - upper air chamber is inflated.

Press button (4) to the „-“ side - lower air chamber is deflated.

Adjusting the seat cushion Adjust the seat cushion angle with lever (1).

Pull lever upwards and bring seat cushion to the desired position by leaning forward or backward.

Release lever (1).

Adjusting the seat suspension Adjust the pneumatic seat suspension with button (2).

Press button (2) to the „+“ side - air chamber is inflated.

Press button (2) to the „-“ side - air chamber is deflated.

Fig. 2-11:

Adjusting the backrest Adjust the backrest inclination with button (5).

Bring backrest to the desired position by pressing back or leaning forward. Release button (5).

Fore-and-aft adjustment The fore-and-aft position of the seat is adjusted with lever (8).

Pull lever (8) upwards, shift seat to the desired position and release lever (8).

Adjusting the armrests The armrests can be folded upwards.

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

2-14

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OPERATING INSTRUCTIONS RH 40-E Operation Fire-extinguisher

Handling

The excavator cmay be equipped with a fireextinguisher (arrow, Fig. 2-12: and Fig. 2-13:).

 Pull out safety pin (2, Fig. 2-13:).  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. 2-12:

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

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 (26.4 lb) of Glutex. This extinguishing agent is used for fighting fires of classes A, B and C. Fires are extinguished fast, perfectly and without residues.

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. 2-13:

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2-15

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

Fig. 2-14:

2-16

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OPERATING INSTRUCTIONS RH 40-E Operation (Fig. 2-14:)

No.

Element

Function Indicates different parameters on the display (E) Use push buttons (C and D) to scroll through parameter list.

Indicator lamps (A and B) lit when an active fault occurs.

Indicates the oil temperature in the pump transfer gearbox

1

Monitoring device

Engine monitoring

2

Thermometer

Engine temperature

3

Pressure gauge

Engine oil pressure

Indicates the oil pressure in the diesel engine lubricating system

4

Warning device

Engine monitoring

Gives an acoustic warning signal if a fault is reported  Engine oil pressure too low 

5

Warning lamp

PMS (PUMP MANAGING SYSTEM)

6

Warning lamp

HPI warning

Symbol

Engine temperature too high

Lower the equipment to the ground and shut off engin immediately if the warning device (4) sounds. The warning device (4) continues to sound until the fault has been retified.

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) Lamp is permanently lit  when the programmed hydraulic oil temperature of 80°C (176°F) is exceeded.

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

Contact Terex O&K after-sales service or engine manufacturer (see switch (52).

7

Warning lamp

HPI 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 O&K after-sales service or engine manufacturer (see switch (52).

8

Warning lamp

HPI 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. 2-15

2-18

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Fig. 2-15

Function

No.

Element

9

Warning lamp

10

Warning lamp

Not in use

11

Warning lamp

Not in use

12

Warning lamp

Alternator

13

Thermometer

Gearbox temperatur Indicates the temperature in the pump gearbox

Cooling-liquid level

BA RH40-E(3 725 040.00)-EN

Symbol

Lit when the cooling-liquid level is too low.

Lit when the alternator does not charge the battery.

2-19

OPERATING INSTRUCTIONS RH 40-E Operation

Fig. 2-16:

2-20

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Fig. 2-16:

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.

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

Shut off engine 20

Warning lamp

Min. fuel

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 system engine and hydraulic oil (optional)

Lit when the preheating system is switched on (switch pos. 51).

25

BA RH40-E(3 725 040.00)-EN

Free for optional equipment

2-21

OPERATING INSTRUCTIONS RH 40-E Operation

Fig. 2-17:

2-22

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OPERATING INSTRUCTIONS RH 40-E Operation Fig. 2-17: Function

No.

Element

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 system fuel (optional)

Lit when the preheating system is switched on (switch 55).

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. 2-18:

2-24

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

Element

Function

36

Buzzer

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

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.

BA RH40-E(3 725 040.00)-EN

2-25

OPERATING INSTRUCTIONS RH 40-E Operation

Fig. 2-19:

2-26

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Fig. 2-19: No.

Element

Function

51

Switch

Preheating system engine and hydraulic oil (optional)

Switch preheating system for engine and hydraulic oil ON/OFF. When switched on, indicator lamp (24) lits.

52

Momentary contact switch

Engine monitor

Diagnose ON/OFF

53

Switch

Floodlamps on working equipment (optional)

Floodlamps on the working equipment ON / OFF

54

Switch

Engine monitor

Listing of fault codes,

Symbol

see warning lamps (6 and 7) (Increment – next fault) (Decrement – previous fault) 55

Switch

56

Switch

57

Switch

Preheating system fuel (optional)

Switch preheating system for fuel ON/OFF. When switched on, indicator lamp (31) lits.

Free for optional equipment

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

Greasing system

Starts an additional greasing intervall.

Length of interval is programmed in the controller.

59

Display

Operating hours

Not in use

60

Rotary switch

Fan, air conditioner

3-stage regulation of air flow.

BA RH40-E(3 725 040.00)-EN

2-27

OPERATING INSTRUCTIONS RH 40-E Operation

Fig. 2-20:

2-28

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Fig. 2-20: 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

65

Momentary contact switch

Holding brakes in finaldrives

Applies the holding brakes of the final drives

Symbol

Actuate the switch only when the machine is stationary. The holding brake is released automatically when the driving function is activated.

66

Switch

Floodlamp

Driver's cab, instrument illumination

67

Momentary contact switch

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

BA RH40-E(3 725 040.00)-EN

Driver's cab, rear right

2-29

OPERATING INSTRUCTIONS RH 40-E Operation

Fig. 2-21:

2-30

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Fig. 2-21: 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 Not connected

71 72

Activation /De-activation of electrical system

Key-switch

Position 1: function check of indicator and warning lamps and of buzzer Position 3: starting of engine 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

78

Free for optional equipment

79

Pushbutton

Boom-floating position (only for loading shovel equipment)

When actuated: boom cylinders are pressurized when retracted.

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

80

Pushbutton

Horn

BA RH40-E(3 725 040.00)-EN

Sounding of the horn

2-31

OPERATING INSTRUCTIONS RH 40-E Operation

Fig. 2-22:

2-32

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Fig. 2-22: 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 inside Pilot control drivers seat

Activation/de-activation of pilot control

87

Control lever

Raising and lowering of bucket- or backhoe stick; slewing and braking of the superstructure

88

Control lever

Raising and lowering of boom; dumping of the bucket or back-tipping of the backhoe bucket

89

Switch

Auxiliary heating (optional)

Switches auxiliary l heating ON / OFF.

90

Indicator lamp

Auxiliary heating (optional)

Lits when auxiliary heating is switched ON.

91

Lever

Air conditioner (optional)

Controls the amount of warm air.

93

Radio

94

Control knob

95

Optional equipment Air conditioner

Controls the amount of warm air

Cigarette lighter

97

Socket

PMS diagnosis

98

Socket

Diagnosis engine electronics

99

PMS-Box (Loadlimit regulator)

Fault code display with PMS (5) warning lamp

BA RH40-E(3 725 040.00)-EN

2-33

OPERATING INSTRUCTIONS RH 40-E Operation

2-34

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation PUTTING THE MACHINE INTO OPERATION Before daily start-up, carry out works in accordance with servicing plan T (cf. Part 3 "Inspection and servicing")

Fuel level in the fuel tank Fuel level in the fuel reservoir is visible at the inspection glass (6, Fig. 2-23:).

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 Explosion hazard Fig. 2-23:

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.

Filling in fuel  Unscrew cap of filler tube (2, Fig. 2-24:).  Fill in fuel through the filter sieve in the filler tube.

Do not remove the sieve.

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.

Report fuel accidents immediately to the user or his representative.

Fig. 2-24:

BA RH40-E(3 725 040.00)-EN

2-35

OPERATING INSTRUCTIONS RH 40-E Operation Quick refuelling (optional) The express coupling (1, Fig. 2-25:) for quick refulling is located behind the step-ladder.

Refuelling with the refuelling system (optional) The refuelling system (1, Fig. 2-26:) is installed besides the step-ladder.

Fig. 2-25:

 For filling in fuel, unscrew the cap of the express coupling.  Attach express coupling of filling hose from the service vehicle to the express coupling.  Fill in fuel.

Fig. 2-26:

The refuelling system consists of an electrical pump,filling hose, switch box (2, Fig. 2-27:) and key-switch (3).

 When the fuel tank is filled, take off filling hose and refit cap on the express coupling.

Fig. 2-27:

Check before refuelling that the earthing strap (4, Fig. 2-27:) is attached to the chassis. Sparking caused by static or electric charges may set fuel on fire.

2-36

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation When using the refuelling system  Unscrew cap (16, Fig. 2-28:) from express coupling (17).  Attach filling hose (18) to express coupling (17) and introduce into the fuel barrel. The electrical pump of the refuelling system is switched on with key-switch (14).

Switch on electrical pump only after the filling hose with the micro-filter has been immersed into the fuel barrel.

Fig. 2-28:

It is recommended to use a micro-filter in the filling line.Fuel should always be filled in through a screen.

Prior to initial commissioning or after repairs on the refuelling system carry out the following works:  Loosen elbow union (12) and fill pump (11) with fuel.  Retighten elbow union (12).

BA RH40-E(3 725 040.00)-EN

2-37

OPERATING INSTRUCTIONS RH 40-E Operation Switching the electrical system on and off Key-switch (72, Fig. 2-29:) serves to switch the following functions:

P=

Not connected

0=

All electrical consumers without current.

Engine off.

1=

Electrical system on: lamp test.

All monitoring and warning lamps are activated for 5 seconds and buzzer (36, Fig. 2-30:) is activated for 1 second. Thereafter, warning lamps (9, 12, 21,26, 28) are lit.

Warning lamp (5) flashes.

2=

Not connected.

3=

Engine start. All warning and monitoring lamps must be off when engine runs.

Fig. 2-29:

Fig. 2-30:

2-38

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Battery main switch The battery main switch is located under a lockable hatch (5, Fig. 2-31:) 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.

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. 2-32: have the following meaning: I = ON II = OFF In the OFF position, the battery main switch handle can be withdrawn.

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

Fig. 2-31:

Fig. 2-32:

BA RH40-E(3 725 040.00)-EN

2-39

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

Stop the engine immediately 

if the monitoring device (1, Fig. 2-34:) shows a malfunction of the engine after starting,



if an acoustik warning sounds from the warning device (4),

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

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

and / or the warning lamp 

hydraulic system (5)



alternator (12) lits up.

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

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. 2-34:

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

Fig. 2-33:

 Turn speed control knob (70, Fig. 2-33:) 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.

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.

2-40

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

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

Ether is toxic and highly inflammable. Safety instructions and information concerning the handling of pressure vessels for cold-starting fluids (ether) can be found in the following chapters: "Fundamental safety instructions", "Inspection and servicing - Safety instructions", "Cold-starting fluid (ether) - Replacing the pressure vessel".

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Shutting off the engine

Emergency stop

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

In case of emergency, e.g. if buzzer (36, Fig. 2-36:sounds, the engine can be shut off from full load.

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

 Turn key in key-switch (72, Fig. 2-36:) to position "0" (electrical system without current).

 Turn speed control knob (70, Fig. 2-35: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).

Fig. 2-36:

Fig. 2-35:

BA RH40-E(3 725 040.00)-EN

2-41

OPERATING INSTRUCTIONS RH 40-E Operation VENTILATION AND HEATING

Air conditioner (optional)

Ventilation (fresh air)

The control elements of the air cond. are installed under the ceiling of the driver's cab (Fig. 2-39).  The desired temperature is adjusted with control knob (1).  The desired blower intensity level / amount of air is selected with control knob (2).

For more information, please refer to the air conditioner manual of the manufacturer.

Fig. 2-37:

 When the engine is stationary, turn keyoperated switch (72, Fig. 2-37:) to position 1  Slide heating control lever (91, Fig. 2-38:) backwards (heating power = 0).  Turn rotary switch (60, Fig. 2-37:) to the desired fan intensity (steps 1 - 3).

Adjusting the heating performance  Slide lever (91, Fig. 2-38:) forwards depending on the heating performance desired. The foremost position gives maximum heating power.  If greater amounts of warm air are needed, switch on the fan with rotary switch (60, Fig. 2-37:).

Fig. 2-38:

2-42

Fig. 2-39

Auxiliary heating (optional) Switch ON / OFF auxiliary heating with switch (89, ). When switched ON, indicator lamp (90) lits.

Additional information can be found in the manufacturers instruction manual.

Fig. 2-40

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation TRAVELLING, 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.

Fig. 2-42:

If the position of the superstructure in relation to the undercarriage is not exactly known, touch the accelerator.

Lightly to see which direction the machine takes, before initiating the full travelling movement.

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

Never drive across slopes.

Take the utmost care on slippery, greasy ground.

Running-in specifications for components of the crawler tracks Prior to initial commissioning and/or after repair work, run in the idlers, track rollers and support rollers as follow:

 Raise the equipment (Fig. 2-41:and Fig. 2-42:)  Drive the excavator in revers approx. 50 m (164ft).  Drive the excavator in forwards approx. 50 m (164ft).  Stop the excavator and measure the temperature at each idler, track roller and support roller with an infrared thermometer (at a temperature of approx. 100° C (212°F) wait for idlers, track rollers and support rollers to cool down).  Repeat this running-in procedure up to 10x.  Check all idlers, track rollers and support rollers for leaks.

The engine 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.

Fig. 2-41:

BA RH40-E(3 725 040.00)-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. 2-44:) are identical only when the excavator is in its BASIC POSITION (Fig. 2-43:).

 depress pedals (81 and 82) forwards.

The excavator travels in the direction of the idler (2, Fig. 2-43:).

Travelling backwards:  depress pedals (81 and 82, Fig. 2-44:) backwards.

The excavator travels in the direction of the drive sprocket (4,Fig. 2-43:).

During travelling, an acoustic warning (Travel Alarm) sounds.

Fig. 2-43:

If the superstructure is slewed out of its basic position by more than 90° (Fig. 2-45:), the excavator moves in a direction opposite to that expected when pedals (81 and 82, Fig. 2-44:) are depressed.

Fig. 2-45:

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.

Fig. 2-44:

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

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.

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 RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Regulating the travelling speed Travelling on level ground Regulate the travelling speed with

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

 pedals (81 and 82, Fig. 2-46:) and  the engine speed control (70).

 Depress pedals (81 and 82,) fully to the limit stop.  Regulate the travel speed only with the engines speed control (70).

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.

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

Fig. 2-46:

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 RH40-E(3 725 040.00)-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. 2-47:).

The same procedure should be adopted if the excavator is to be driven out of depressions (Fig. 2-48:): 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 bucket are subjected to inadmissibly high stresses.

Fig. 2-47:

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. 2-48:

2-46

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Travelling over long distances Read and observe the "Travelling – Safety instructions" chapter.

Backhoe bucket equipment (Fig. 2-50:):  Fully extend boom cylinder 1.  Retract backhoe cylinder 2.  Retract stick cylinder 3.

Travel only forwards with the excavator in its basic position.

 Extend backhoe cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment shown in Fig. 2-50:

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. 2-49: / Fig. 2-50:). For a more uniform loading of the tracks, the equipment must, howe-ver, be kept at a steep angle.

Fig. 2-50:

Lower the equipment when travelling underneath obstacles.

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

Fig. 2-49:

Loading bucket equipment (Fig. 2-49:):  Fully extend boom cylinder (1).  Extend bucket cylinder 2.  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. 2-49:).

BA RH40-E(3 725 040.00)-EN

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

If the temperature does not exceed ca. 100° C (212°F):  continue travelling.

In case of higher temperatures:  Stop travelling. Resume travelling only after the track rollers have cooled down to ca. 40° C (104°F).

2-47

OPERATING INSTRUCTIONS RH 40-E Operation Locking the superstructure The superstructure can only be locked in the BASIC POSITION.

Lock the superstructure and the undercarriage 

when travelling over longer distances (more than 1 km)



during transport.

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

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.

Locking the superstructure (Fig. 2-51:):  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. 2-52:

The brakes are controlled by means of the travel pedals (81 and 82, Fig. 2-52:). In neutral position of the pedals, the brakes are applied and the excavator is braked. During travelling, the brakes are released.

Fig. 2-51:

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

Fig. 2-53:

When the excavator is stationary, the brakes can be applied with switch (65, Fig. 2-53:).

2-48

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation TRANSPORTING THE MACHINE Transport - Safety instructions

The partly dismantled excavator can now be transported on a semi ow-bed trailer (low-bed trailer with front platform) (Fig. 2-54:).

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. 2-54:

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 bucket)



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. 2-55:).

Fig. 2-55:

BA RH40-E(3 725 040.00)-EN

2-49

OPERATING INSTRUCTIONS RH 40-E Operation

 Place solid timbers between the low-bed platform and the center part of the undercarriage (Fig. 2-57:).

 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. 2-57:).

Fig. 2-56:

Fig. 2-57:

 Lock the superstructure (Fig. 2-56:).

 Secure the excavator with suitable means (chain hoists, wire ropes, chains, turnbuckles) (Fig. 2-57:).

Unload the excavator in reverse order.

Unlock the superstructure before slewing it for the first time.

2-50

BA RH40-E(3 725 040.00)-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.

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

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 engine 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.

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 RH40-E(3 725 040.00)-EN

2-51

OPERATING INSTRUCTIONS RH 40-E Operation At low temperatures, bring the engine 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. 2-58- Fig. 2-62) Work carefully, avoiding extreme positions of this kind.

Fig. 2-60

Fig. 2-61 Fig. 2-58

Fig. 2-62 Fig. 2-59

2-52

BA RH40-E(3 725 040.00)-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.

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

Switching on the servo control The servo control is switched on and off with switch (85, Fig. 2-63:) inside the drivers seat.

Servo control activated - operator is sitting on his seat.

Servo control deactivated - driver's seat is empty.

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".  Run the diesel engine at ca. 2/3 full speed and start to perform no-load working movements for abt. 10 minutes with the excavator.

Fig. 2-63:

BA RH40-E(3 725 040.00)-EN

2-53

OPERATING INSTRUCTIONS RH 40-E Operation Slewing and braking the superstructure Slewing the superstructure

Superstructure holding brake

The superstructure can only be slewed if the superstructure holding brake is released.

The superstructure holding brake can be activated with momentary-contact switch (67, Fig. 2-65:).

 To slew the superstructure to the right: shift control lever (87, Fig. 2-64:) to the right.

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

 To slew the superstructure to the left: shift control lever (87) to the left.

Actuate switch (67) only when the superstructure is stationary.

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

The superstructure holding brake is not suited for braking the slewing movement.

Braking the superstructure The superstructure is braked onlywhen control Lever (87, Fig. 2-64:) is shifted into the direction opposite the slewing movement (countering).  To brake a slewing movement to the right: shift control lever (87) to the left.  To brake a slewing movement to the left: shift control lever (87) to the right.

Fig. 2-65:

Fig. 2-64:

2-54

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Operation Working When released, all control levers for working operation return automatically to position "0".

Raising and lowering the boom To raise the boom:

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

 pull control lever (88, Fig. 2-66:) backwards.

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

 push control lever (88) forwards.

To lower the boom:

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

Extending and retracting the bucket or backhoe bucket stick To extend the stick:  push control lever (87) forwards.

To retract the stick:  pull control lever (87) backwards.

Fig. 2-66:

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

To empty the bucket by dumping / tipping:  shift control lever (88) to the right.

Opening and closing the bottom-dump bucket To open the bucket:  press pedal (83) forwards.

To close the bucket:  press pedal (83) backwards.

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2-55

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.

2-56

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OPERATING INSTRUCTIONS RH 40-E Operation ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS 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 O&K. The operating manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

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

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

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

Wear a safety helmet, safety footwear and gloves.

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

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

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

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

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.

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

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 O&K for this type of machine.

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

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

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2-57

OPERATING INSTRUCTIONS RH 40-E Operation Securing the machine

Secure the machine as described below: 

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

The machine must not be started by unauthorized persons.



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.

 Stand the working equipment on the ground.

Risk of injury.

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.

 Shut off the engine.  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 O&K machines have been carefully purpose-coordinated. Trouble-free operation and a long service life can only be achieved with original Terex O&K spare parts.

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

2-58

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OPERATING INSTRUCTIONS RH 40-E Operation CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) Use "GLEITMO 815" anti-corrosive agent only.

Other agents are not approved by Terex O&K

All pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated with "GLEITMO 815" anticorrosive agent before fitting.

Doing so 

permits easy fitting and dismantling



protects against rust, oxidation and similar wear



prevents seizing and fretting corrosion in nonmoving parts of bearings.

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

Application of "GLEITMO 815"  Clean off grease, oil, dirt and corrosion protec-tion 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 "GLEITMO 815" on pins and all bearings using a brush or a spray can.

Pin shafts and bearings must be completely co-vered by the protective layer.

If the protective layer of a pin already treated with "GLEITMO 815" 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 "GLEITMO 815" at first only on abt. a quarter of the pin's length.

Then position pin by means of a lifting gearready for fitting.

Apply "GLEITMO 815" on the remaining length of pin shaft, fit pin and secure.

Part no. for "GLEITMO 815" is 2764305, available from Terex O&K Spare-Parts Service

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2-59

OPERATING INSTRUCTIONS RH 40-E Operation LIFTING OPERATIONS Safety instructions 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.

Switch the overload warning system on. (cf. "Technical data").

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.

Register the weight of the load. Sling only those loads not exceeding the load capacity of the lifting gear and of the machine Sling the load in such a way as to prevent it from slipping or falling while being lifted or transported.

Transporting the load 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.

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

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,

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



driving the excavator into an area with steeply sloping ground,

Slinging loads



exposure to strong wind.

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

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

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

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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. 2-67: and Fig. 2-68:) (optional equipment).

The maximum lifting capacity of the load-hook is indicated besides the hook (Fig. 2-67: and Fig. 2-68:).

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. 2-68:

Fig. 2-67:

BA RH40-E(3 725 040.00)-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.

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

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.

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.

When the warning signal sounds: - let the load down immediately - reduce the working radius or the load.

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

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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.

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

 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.  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. 2-69:

Switching on the speed reduction:  Set toggle switch to the left (57, Fig. 2-69:) Indicator lamp (27, Fig. 2-70:) lights up when the the speed reduction function is active.

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

Fig. 2-70:

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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 .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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OPERATING INSTRUCTIONS Operation

2-66

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing 3 INSPECTION AND SERVICING

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 RH40-E(3 725 040.00)-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

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing INSPECTION AND SERVICING SAFETY INSTRUCTIONS Operating manual No inspection and servicing work must be carried out until the operating manual has been read and understood.

Pay special attention to: Fundamental safety instructions" and 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 Terex O&K mechanic or by attending an Terex O&K training course.

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

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

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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.

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

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

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

Wear gloves.

Observe the instructions on the packaging.

Handling flammable liquids When handling flammable liquids: 

never smoke,



keep away from unshielded light sources and naked flames,

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

Replace any damaged parts.

Use only the original sparts parts of Terex O&K.

Handling oils and greases

Never set foot withing reach of the emerging oil jet.

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

Used oil may be harmful to the skin.

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

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

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.

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.

Notify the fire brigade.

3-4

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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:

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.

(do not leave the driver's seat)

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

 Stand working equipment on the ground

Tighten leaking screw plugs only when the system is depressurized.

 Shut off the engine

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.

Seals After replacing parts or after opening housings replace seals. Always use new seals and gaskets.

Clean sealing faces prior to assembly.

Clean sealing faces prior to assembly.

Engine exhaust gases

Do not dispose of these substances together with household wastes.

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

Fill these substances into the containers provided for such purposes.

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

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

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

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

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

Used pressure vessels for cold-starting fluid (ether) must be disposed of properly. Contact the supplier with regard to disposal / return of the vessels.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.

•Do not keep them on the machine.

•Do not damage or open the vessels.

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

•Do not dispose of in fire.

•Keep the vessels in a place inaccessible to unauthorized persons.

•Dispose of the vessels properly.

3-6

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Handling batteries Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling

Handling of cold-starting fluid (ether) Read and observe the instructions on the pressure vessels.

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

Batteries give off explosive gases.

Provide for sufficient ventilation.

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

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

Battery acid is toxic and corrosive.

Do not inhale the vapours of escaping coldstarting fluid.

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

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

Wear suitable protective gloves and goggles.

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.

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

•Do not keep them on the machine.

• Do not damage or open the vessels.

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

• Do not dispose of in fire.

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

• Dispose of the vessels properly.

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

Before working on the electrical system 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.

Disconnect first the negative and then the positive terminal.

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

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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 O&K 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 Safety Instructions Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents.

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

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

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

Even battery gases can ignite in open flames or fire.

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

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

Do not store these substances on the excavator.

If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the excavator at the end of the work.

Avoid parking the excavator in places where 

combustible substances such as coal dust or tar are present.



open or smouldering fire may occur.

If necessary, also cover the ground with fireprotective blankets.

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

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

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

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

Provide for sufficient ventilation.

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

Do not extinguish flammable liquids with water.

Use: 

dry-powder,



carbon-dioxide or



foam extinguishing compounds.

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

Call the fire brigade.

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

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.

Clean the excavator before starting a job.

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

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3-9

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

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

Environmentally compatible hydraulic fluid - operating instructions

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

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 O&K uses only: PANOLIN HLP SYNTH 68 Terex O&K (P/N: 2115005).

This synthetic hydraulic fluid has been tested by Terex O&K and approved for application in Terex O&K 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.

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.

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.

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.

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.

 Change all filters in the hydraulic system.

3-10

Fill the hydraulic oil tanks with new HLP SYNTH 68.

BA RH40-E(3 725 040.00)-EN

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.

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

Sets are available from the Terex O&K SpareParts 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.

Fig. 3-1:

 Send this sample in to the above address for analysis.

 Start up the machine. Check level in hydraulic tank according to servicing plan.

The company will then notify you of the result of the analysis.

 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.

After this, Terex O&K 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.

 Sample the hydraulic fluid after 30 - 50 operating hours and send in for analysis. (See section: "Environmentally compatible hydraulic fluid, sampling").

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 O&K Service.

BA RH40-E(3 725 040.00)-EN

3-11

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS Lubricants for bearings The machine can be lubricated with an environment-friendly grease.

Gearbox oils Environment-friendly gearbox oils are not approved by Terex O&K 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 O&K as an environmentfriendly grease.

3-12

BA RH40-E(3 725 040.00)-EN

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

Do all jobs .... once prior to initial commissioning.

N

after initial commissioning and during the running-in period.

T

every 10 OH or every working shift 2

W

every 60 OH or weekly 2

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.

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 / 14°F.

Air-intake system The air filter must be serviced only if the vacuummeter 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 a, b, c V

Oils for gearboxes 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 O&K 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 O&K shall apply.

In case of higher sulphur content and/or a permanent ambient temperature of below –10°C / 14°F, 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.

BA RH40-E(3 725 040.00)-EN

3-13

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

3-14

BA RH40-E(3 725 040.00)-EN

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

Servicing work

Quantity/ No.

Check oil level

1

Check

1

Battery

Check charge 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 (see: Technical handbook) Hydraulic oil reservoir

Check oil level

Hydraulic cylinders

Vent (see: chapter “venting hydraulic system“)

1

Pump tranfer gearbox

Check oil level

1

Check oil level

1

Slewing gearbox

Check oil level

1

Travel gearbox

Check oil level

2

Check grease filling

1

- Pre-chamber - Expansion reservoir

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 leaks and free movement

2

BA RH40-E(3 725 040.00)-EN

3-15

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

Servicing work

Quantity/ No.

Central lubricating system Grease container

Check filling level (indicator lamp)

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

BA RH40-E(3 725 040.00)-EN

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

Servicing work

Quantity/ No.

After 100 Bh Engine - Bearing - Fastening screws

Check for tightness

Cooling system Radiator - Bearing - Fastening screws

Check for tightness

Cooling liquid

Carry out analysis of cooling liquid after 500 OH (see: Operation and Maintenance Manual of the engine)

Hydraulic system Oil cooler - Bearing - Fastening screws

Check for tightness

Return-flow filter

Replace

4

Magnetic rod

Clean

3

Pressure accumulator – emergency lowering

Check function

1

Pump transfer gearbox

Change oil

13

- Pre-chamber

Change oil

33

Slewing gearbox

Change oil

13

Fastening screws

Check for tightness

Travel gearbox

Change oil

Fastening screws

Check for tightness

23

Slewing ring Fastening screws (slewing ring, undercarriage Check for tightness (see: Technical handand superstructure) book) Superstructure Fastening screws, especially at superstructure / pedestal / driver´s cab

Check for tightness

Undercarriage Fastening screws, track pads

Check for tightness (see: Technical handbook)

All lines, fittings and connections

Inspect visually for leaks, wearing marks

3

see: “Refilling quantities – Oil“ table

BA RH40-E(3 725 040.00)-EN

3-17

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

3-18

BA RH40-E(3 725 040.00)-EN

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

1





Water trap (optional)

Drain off water

1





Vacuum-meter

Check indication

2





Intake and clean-air lines

Check for tightness and leaks

Engine

Servicing work

Cooling system

Air-intake system 

Electrical system Lighting



Check operation



Switchgear cabinet - Breather filter 

- Dust trap

Check / clean

1

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 - Pre-chamber

Check oil level

1

- Expansion reservoir

Check oil level

1





Slewing gearbox

Check oil level

1





Travel gearbox

Check for leaks

2





BA RH40-E(3 725 040.00)-EN

 

 

3-19

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

Plan T - (Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working shift (whichever comes first) Page 2 of 2 Location

Servicing work

Quantity/

Plan

Plan

No.

T

W





Undercarriage Tracks

Inspect track tension visually

2x1

Track roller

Check for leaks and free movement

2x8



Support roller

Check for leaks and free movement

2x1



Idler

Check for leaks and free movement

2x1



Grease container

Check grease level (warning lamp)

1

Lubricating points

Check visually

Air conditioner (optional)

(see: “Air Conditioning manual“)

1

Fire extinguisher

Check condition

1





Automatic fire-extinguishing system (optional)

Check control module

1









Central lubricating system

All lines, fittings and connections Inspect visually for leaks, wearing marks Excavator

3-20

Overall cleaning







 



BA RH40-E(3 725 040.00)-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 of 5 Location

Servicing work

Menge / No.

Servicing acc. with W or T Engine Inspection and servicing Oil Oil Oil filter V-belt V-belt - Bearing - Fastening screws - Rubber bearing Crank case breather Groundscrew engine electronics Starter Water pump Turbo charger After 3000 OH: Crankshaft Electronic Unit Injector Engine speed sensors Engine timing sensors Engine Valve Lash Engine Valve Rotators

4

Plan Plan Plan Plan Plan A

B

C

D

E











 

 

  

  

     

     

     

 

   

   

   

















See: Operation and Mainte-

nance Manual of the engine Carry out oil analysis Change oil Clean Replace Check tension Check condition Check tightness Check condition Clean Check, clean, fasten Check Check Check

14 2

1 1

 

See: Operation and Maintenance Manual of the engine Inspect Vibration damper Inspect/Adjust Check/Clean/Adjust Check/Clean/Adjust Inspect/Adjust Inspect

see: “Refilling quantities – Oil“ table

BA RH40-E(3 725 040.00)-EN

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 of 5 Location

Servicing work

Menge / No.

Cooling system Radiator - Check tightness - Fastening screws - Rubber bearing Cooling liquid

Anti-freeze Lines Hose clamps Fuel system Fuel filter Fuel prefilter Tank breather valve Water trap (optional) Air-intake system Main filter element Safety filter element Air-intake line and clean-air line Hoses Electrical system Battery cable connections Battery

Inspect visually for leaks

Check tightness Check condition Check SCA-concentration (see: Operation and Maintenance Manual of the engine) Change Check Check for leaks Check tightness

Plan Plan Plan Plan Plan A

B

C

D

E













  

  

  





  

  

   

 

 

 







   

   

  

  

  





 

 

15

Replace Replace Clean Clean

1 1 1 1

Check / replace Replace Check for tightness and leaks

26 27

Replace Check for tightness Check fluid level

 2

5

Cooling-liquid replacement after 6000 OH at the latest

6

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

 

 

7

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

3-22

BA RH40-E(3 725 040.00)-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 of 5 Location

Servicing work

Menge / No.

Hydraulic system

Plan Plan Plan Plan Plan A

B

Check pressure (see: Technical handbook)

Oil cooler - Bearing - Fastening screw - Rubber bearing Return-flow filter High-pressure filter

C

D

E







   

      

Check for tightness Check condition Replace Check / clean Replace Magnetic rod Check / clean Bypass valve (working circuit) Clean valve

4 2 2 3 2

 

      

Bypass valve (cooling circuit)

Check / clean filter sieve

1







Change valve

1





Check for contamination and damage

1





Replace

1





Check for contamination and damage

1







Replace Replace Carry out oil analysis Change oil Check pressure (see: Technical handbook)

1 1 1

 

  

    

Filter (pilot control circuit)

Filter (slewing mechanism pump feeding-circuit) Breather filter Hydraulic oil reservoir Pressure accumulator Cylinder (seals and guide rings)

8

Replace

1

8 9

1







see: “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 RH40-E(3 725 040.00)-EN

3-23

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 4 of 5 Location

Servicing work

Menge / No.

Pump transfer gearbox

Plan Plan Plan Plan Plan A

B

C

D

E









Carry out oil analysis

1

Change oil

10 11











1

Breather filter

Clean

1



- Pre-chamber

Change oil

3 10







- Breather filter

Clean

1







Slewing gearbox

Carry out oil analysis

1







Change oil

10













1

 

Fastening screws

Check for tightness

Breather filter

Clean

1







Output-pinion bearing

Grease

1







Travel gearbox

Carry out oil analysis

2









Check oil level

2









Change oil

10









2

Breather filter

Replace

2

Slewing ring

Check grease filling

1

Gearing / pinion

Check condition

Fastening screws (slewing ring, undercarriage, superstructure)

Check for tightness (see: Technical Handbook)

Undercarriage

Check wear (see: Technical Handbook)

Diaphragm accumulator

Check pressure (see: Technical handbook) Check for tightness (see: Technical Handbook)

Track pad fastening bolts













 





see: “Refilling quantities – Oil“ table

11

In case of using TM Gear oil CLP 220 LT Terex O&K P/N 6 002 885: Oil analysis after 1000 OH; oil change after 2000 OH

 

2

10

3-24











BA RH40-E(3 725 040.00)-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 5 of 5 Location

Servicing work

Menge / No.

Plan Plan Plan Plan Plan B

C

D

E

Check function









Grease screen

Check / clean

1









Pump element

Change

1





Air conditioner resp. heating

(see „Air Conditioner Manual“)

1







- Filter mat air suction (Backside driver`s seat)

Change

3







Steel components

Visual inspection acc. to "Structural Inspection Report every 500 OH" 12























Central lubricating system

A



Inspection with dye penetrant test acc. to "Structural Inspection Report every 5000 OH" 12 Modules - Fastening screws All articulated joints and hinges

Check for tightness Grease

12

"Structural Inspection Reports" for inspections every 500 OH and every 5000 OH can be downloaded from the Terex O&K website, section "Support, Warranty".

BA RH40-E(3 725 040.00)-EN

3-25

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

Fig. 3-2:

3-26

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

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

Number

Lubricant properties

Grease every .... operating hours

1

Central lubricating system – grease container

1

V 13

10

7

Slewing gearbox output pinion

1

V 13

1000

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

Filling quantities - Grease Greasing point Central lubricating system – grease container

Lubricant properties

kg

lb

V 13

app. 10

app. 22

app. 20

app. 44

2 x app. 1.1

2 x app. 2.4

16 x app.2.5

16 x app.5.5

2 x app. 2.5

2 x app. 5.5

app. 50 cm3

app. 1.7 oz

Internal gearing – Roller-bearing slewing ring Idler (permanent grease filling) Track roller (permanent grease filling)

Tribol

Support roller (permanent grease filling)

Terex O&K P/No. 2764564

Slewing gearbox output pinion

13

V 13

Filling quant. in

see: "LUBRICANTS" section

BA RH40-E(3 725 040.00)-EN

3-27

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

Fig. 3-3:

3-28

BA RH40-E(3 725 040.00)-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

V 14

10

7

Slewing gearbox output pinion

1

V 14

1000

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

Filling quantities - Grease Greasing point Central lubricating system – grease container

Lubricant properties

kg

lb

V 14

app. 10

app. 22

app. 20

app. 44

2 x app. 1.1

2 x app. 2.4

16 x app.2.5

16 x app.5.5

2 x app. 2.5

2 x app. 5.5

app. 50 cm3

app. 1.7 oz

Internal gearing – Roller-bearing slewing ring Idler (permanent grease filling) Track roller (permanent grease filling)

Tribol

Support roller (permanent grease filling)

Terex O&K P/No. 2764564

Slewing gearbox output pinion

14

V

14

Filling quant. in

see: "LUBRICANTS" section

BA RH40-E(3 725 040.00)-EN

3-29

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

Fig. 3-4:

3-30

BA RH40-E(3 725 040.00)-EN

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

No. Location

15

Number

Lubricant properties 15

Check oil level

Change oil

every ... OH

every ... OH

1

Engine

1

I

10

250

2

Hydraulic system

1

10

10000 16

3

Pump transfer gearbox

1

60

1000

3

- pre-chamber

3

II III.a III.a

10

1000

4

Slewing gearbox

1

III.b

10

1000

5

Travel gearbox

2

III.c

500

5000

see: "LUBRICANTS" section

16

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

BA RH40-E(3 725 040.00)-EN

3-31

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

Filling quantities - oil Location

Filling quantities in litres

Oil

gal

Drive engine

I I I

- without filter change

app. 60

app. 15.85

- with filter change

app. 66

app. 17.45

Hydraulic oil system at oil change

app. 1700

app. 449

- oil reservoir

app. 1300

app. 343

Pump transfer gearbox

app. 15

app. 3.96

pre-chamber (working pumps)

2 x app. 1.4

2 x app. 0.37

pre-chamber (hydraulic pumps)

1 x app. 0.2

1 x app. 0.05

Slewing gearbox

app. 14

app. 3.7

III.b

Travel gearbox

2 x app. 18

2 x app. 4.75

III.c

II II

III.a

Filling quantities - other Location

Filling quantities in litres

gal

Cooling system - engine

app. 115

app. 30.9

Fuel tank

app. 1300

app. 343

Screen washer

app. 13

app. 3.4

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing LUBRICANTS Notes on the selection of oils and greases Original Terex O&K oils and greases

Alternative oils and greases

Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies.

The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the Terex O&K Operating Instructions.

The lubricants tables in the Terex O&K Operating Instructions contain specifications for the oils and greases that are approved for use in Terex O&K machines. These oils and greases are especially adapted to Terex O&K machines and their units and assemblies.

In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with Terex O&K specifications, Terex O&K does not assume any responsibility and does not accept any warranty claims.

Other oils and greases which do not fulfil the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies.

For this reason, Terex O&K only approves the use of the specified oils and greases.

All other qualities are not approved.

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3-33

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing I.

Oils for combustion engine

Fig. 3-5:

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

II.

Oils for hydraulic system (selection)

Fig. 3-6:

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3-35

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing III.a Oils for pump gearbox

Fig. 3-7:

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing III.b Oils for swing gearbox

Fig. 3-8:

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3-37

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing III.c Oils for travel gearbox

Fig. 3-9:

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing V.

Greases for bearings and slewing rings

Fig. 3-10:

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3-39

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing SERVICING WORK Hose line for oil and cooling liquid changes Collect escaping oil and cooling liquid and discard without polluting the environment.

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

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

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

Procede as follows to change the oil or the coolant:  Place a collecting recipient for used oil or coolant under the drain valve (capacity see "Refilling Quantities - Oil", "Refilling Quantities - Other"  Take the drain hose out of the the tool-box.  Unscrew the protective cap from the drain valve.  Screw the drain hose (2) on the valve; the valve opens and the oil / coolant drains off.  Remove the drain hose from valve after the oil / coolant has drained off; the valve closes automatically.  Screw the protective cap back in place.

Fig. 3-11:

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing ENGINE Engine - Safety instructions

Checking the engine oil level / Topping up

Read and observe: "Inspection and Servicing – Safety Instructions" and the engine operating instructions.

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

Shut off engine and allow to cool down.

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

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

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

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

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Fig. 3-12:

 Park the machine on a horizontal surface and protect it against rolling away.  Shut off the engine.  Withdraw dipstick (arrow, Fig. 3-12:).  Wipe dipstick clean with a clean and lintfree cloth and re-insert.  Withdraw oil dipstick once again. The oil level should now lie between the marks (arrows, Fig. 3-13:). If the oil level is at the "min" mark or below, top up with engine oil through the fillertube (arrow, Fig. 3-15:).

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

Protect the skin from potentially harmful contact with engine oil.

Wear protective gloves and firm working clothing.

Checking, retensioning the V-belt tension

Fig. 3-13:

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

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3-41

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Changing the engine oil Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot engine oil.

The engine may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Draining off engine oil  Bring engine oil to operating temperature.

Fig. 3-15:

 Park the machine on a horizontal surface and secure.

After draining of the oil:

 Shut off the engine.

 Replace the engine oil filter.  Remove the hose line.

The automatic drain coupling closes automatically.  Screw on protective cap.  Fill in engine oil through the filler tube (arrow, Fig. 3-15:) until the oil level reaches the "max" mark (Fig. 3-16:).  Start the engine and allow to run for abt. 2 minutes at idling.  Check oil level and top up with oil up to the "max" mark, if required.

Fig. 3-14:

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

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

Fig. 3-16:

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Replacing the engine oil filters Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot engine oil.

The filter housing may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard with-out polluting the environment.

Fig. 3-18:

Replacing engine oil filters  Unscrew the filters.  Screw on new filters with a slightly oiled sealing ring and tighten by hand.

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

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

Fig. 3-17:

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

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

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

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

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

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3-43

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Cold-starting fluid (ether) - Replacing the pressure vessel

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

Read and observe: "Inspection and servicing Safety instructions"

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

Risk of injury Cold-starting fluid is composed mainly of ether.

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

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

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C/ / 120°F) or in the event of damage.

Before replacing an empty pressure vessel: Read and observe the instructions on the pressure vessels.

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

Provide for sufficient ventilation of the surroundings.

Replacing the pressure vessel:  Remove the clamp around the pressure vessel.  Unscrew the pressure vessel carefully from the metering valve.  Remove the used seal from the metering valve.  Insert a new seal into the valve (supplied with the new pressure vessel).  Screw the new pressure vessel onto the metering valve and tighten by hand.  Fasten the clamp round the pressure vessel.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels. 

Do not keep them on the machine.



Do not damage or open the vessels.

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



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

Avoid skin contact. Wear suitable protective gloves and goggles.



Do not dispose of in fire.



Keep the vessels in a place unaccessible to unauthorized persons.



Dispose of the vessels properly.

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

3-44

The vessel is screwed onto an electro-mechanical metering valve.

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

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing COOLING SYSTEM

Cooler and cooling liquid

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

Risk of falling Put on a safety harness before working on the superstructure. Attach the safety line to eyelets or railings (arrows, Fig. 3-19:).

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.

The cooler (1, Fig. 3-19:) is located on the superstructure.

Collect escaping cooling liquid and discard without polluting the environment.

 Check the cooler fins for dirt before every workshift and clean, if necessary.

Protect the skin from contact with cooling liquid.

 Check the coolant level at the indicator (3, Fig. 3-20:). The coolant level should reach the mark on the indicator.

An insufficient coolant level is also indicated by means of a warning lamp in the control satellite.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

 Top up with coolant, if necessary.

Temperature The cooling-liquid circuit is controlled by a thermostat. The maximum admissible temperature is ca. 100° C / 212° F. In case of higher temperatures - warning lamp on satellite illuminated - locate cause and rectify.

Fig. 3-19:

Fig. 3-20:

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3-45

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Topping up with coolant

Changing the coolant Read and observe: Inspection and servicing – Safety instructions.

Risk of scalding from hot cooling liquid.The coolers may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping coolant and discard without polluting the environment.

Change the cooling agent regularly and after 6000 operating hours (OH) at the latest.

Fig. 3-21:

Risk of scalding from hot cooling liquid under pressure. Open radiator cap cautiously.  Turn the cap (2, Fig. 3-21:) into the first notch to reduce the pressure in the reservoir.  After depressurization turn the cap into the open position and remove.  Fill cooling liquid into the cooling system through the filler tube (2).

Do not add cold coolant when the engine is still at operating temperature.

Let the engine cool down to below 50 °C (122°F) before adding coolant.  Screw on the cap (2).

For topping up the cooling system use only the cooling agent CAT ELC - Terex O&K P/N 2482777 - which is specially adapted to these engines. The coolant offers frost protection down to –37°C (-34.6°F).

After topping up with coolant run the engine for a short time to remove air inclusions before filling the reservoir with coolant up to the mark on indicator (3).

Fig. 3-22:

 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, allow to cool down.

Risk of scalding from hot coolant under pressure. Open the cap of the expansion reservoir carefully.  Turn the cap (2, Fig. 3-21:) into the first notch to reduce the pressure in the reservoir..  After depressurization turn the cap into the open position and remove.

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

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

3-46

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

The drain valve for coolant is accessible under the engine compartment (arrow, Fig. 3-23:).

Testing the cooling liquid composition

 Drain off the coolant with the drain hose attached to the drain valve. (arrow, Fig. 3-23:).

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

The „Engine operating instructions“ contain a detailed description of how to prepare and test the cooling liquid composition. In case of imminent frost check that the factory-adjusted anti-freeze concentration is sufficient for the expected temperatures.

 Remove the drain hose from the valve after the oil / coolant has drained off; the valve closes automatically.  Fill the required amount of cooling agent CAT ELC, Terex O&K P/N 2482777, which is specially adapted to these engines, into the system by pouring it into the expansion reservoir (2, Fig. 3-21:). (see: "Refilling quantities Other" table.).  Check the filling level at indidicator (3, Fig. 3-22:).  After topping up with coolant run the engine for a short time to remove air inclusions before filling the system with coolant up to the mark on indicator (3).

Check the cooling liquid in the cooling system regularly to ensure that the SCA mixture is sufficiently concentrated to prevent corrosion under the corresponding operating conditions.

Checking the SCA concentration Observe the instructions of the engine manufacturer with regard to the SCA concentration (see engine manufacturer's operating instructions).

For more information see also: "Operating and servicing instructions for the engine".

Fig. 3-23:

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3-47

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing AIR-INTAKE SYSTEM Read and observe the „Inspection and maintenance, Safety instructions“ and "Engine - Safety instructions" chapters.

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

Clean or replace main filter element only if the vacuum-meter indication changes to "RED" with the engine running at high speed.

Put on your fall protection equipment before entering the superstructure.

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

Removal and installation

Shut off the engine before working on the airintake system.

 Unscrew nut (1, Fig. 3-24:) and remove cover (2).

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

 Unscrew nut (3, Fig. 3-25:) and withdraw main filter element (4). Do not loose the washer under nut (3).

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.

 Clean or renew main filter element only if the vacuummeter (8, Fig. 3-24:) 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.

The air-intake system is equipped with two dry-air filters (Fig. 3-24:) consisting of main and safety filter element.

Fig. 3-25:

Fig. 3-24:

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

 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.

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

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.

Fig. 3-26:

The pressure at the nozzle must not exceed 6 bars / 87psi.

Checking and cleaning the main filter element

Cleaning is terminated when all visible dust has been blown out of the 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. 3-29:

Never clean filter element by beating against hard objects.

Fig. 3-27:

Replace damaged or deformed elements immediately.

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

3-49

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Safety filter element Replacement

 Remove main filter element (4, Fig. 3-31:) as described above.

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.

 Unscrew nut (6, Fig. 3-30:) and withdraw safety filter element (5).

Never clean the safety filter element, but always renew.

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

Air-intake lines 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 engine.

Dust collection

Fig. 3-30:

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. 3-31:

Fig. 3-32:

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing FUEL SYSTEM

Fuel pre-filter, Draining off water

Fuel system - Safety instructions

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

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

Read and observe the "Fuel system – Safety instructions" chapter.

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

Before working on the fuel system: 

shut off the engine,



keep away naked flames,



do not smoke.

Collect escaping fuel and discard without polluting the environment.

Discard used fuel filters without polluting the environment.

Avoid skin contact with diesel fuel.

Fig. 3-33:

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel component before disconnect it.

It may be necessary to relieve residual fuel pressure from the fuel system before the fuel filter is removed. Wait for one to five minutes until the fuel pressure has lowered.

Fig. 3-34:

 Open the flap of the engine compartment (1, Fig. 3-33:). The fuel filters are now accessible.

The pre-filter (1, Fig. 3-34:) works at the same time also as a water trap:  Open valve (2) and drain off water until fuel emerges from the valve.  Close valve (2).

For further information please refer to the "Engine, Operation and Maintenance Manual".

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3-51

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Fuel pre-filter, replace Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Fuel system – Safety instructions" chapter.

 Unscrew pre-filter (1, Fig. 3-35:) completely.  Pour out fuel and discard it without polluting the environment.  Unsrew the collector (2) from the fuel pre-filter and clean it.  Clean the contact surface at the filter head.

Fig. 3-35:

 Clean and check the O-Ring of the collector.

Replace the ring, if it damaged. Dip the O-ring into clean diesel fuel.  Screw the collector (2) with the O-ring by hand to the new pre-filter (1), tighten by hand.

Using a tool for tightening of the collectorcan cause irreparable damage to the collector.  The new pre-filter can be filled with fresh and clean fuel. This helps to prevent rough running of the engine caused by excessive amounts of air in the fuel system.  Lubricate the sealing of the primary fuel filter lightly with clean fuel and screw it onto the filter base by hand. Continue to tighten filter by a further 1/2 to 3/4 turn.

Using a tool for tightening of the filter element can cause cracking or deformation of the filter head.  Start the engine and let it run for about one minute. Check that the fuel system has no leaks.

For further information please refer to the "Engine operating and servicing instructions".

3-52

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Secondary fuel filter, replace Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Fuel system – Safety instructions" chapter.

 Open the flap of the engine compartment (1, Fig. 3-36:). The fuel filters are now accessible.  Unsrew the fuel filter (3, Fig. 3-37:).  Clean the contact surface at the filter head.  Do not fill fuel into the new filter. This measure prevents unfiltered fuel from getting into the injection system.

Fig. 3-36:

 Apply a thin layer of clean diesel fuel on the seal of the new filter.  Screw the fuel filter onto the filter base by hand. Use the rotation index marks on the filter as a guide for proper tightening. Tighten the filter according to the instructions that are on the filter.

Using a tool for tightening of the filter element can cause cracking or deformation of the filter head.  Vent the fuel system, see "Engine, Operation and Maintenance Manual".

BA RH40-E(3 725 040.00)-EN

Fig. 3-37:

3-53

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Fuel tank - Venting

Cleaning the fuel tank

The fuel tank is vented with a breather valve (4, Fig. 3-38:).

Risk of explosion

Clean breather valve regularly.

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

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

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

For cleaning and flushing use diesel fuel.

Avoid skin contact.

Skin contact with diesel fuel can be a health risk.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Do not let fuel penetrate into the soil.

Keep for re-use or discard without polluting the environment.

Fig. 3-38:

Fig. 3-39:

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BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Refuelling station (optional)  Drive the machine until the fuel tank is almost empty.  Check how much fuel is left in the tank and place a recipient of sufficient capacity under the drain plugs of the tank.  Turn out the drain plug (5, Fig. 3-39:) of the fuel tank and drain off the fuel.  Flush the tank with diesel fuel.

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

Check earthing strap (equipotential bonding) (4, Fig. 3-40:) regularly for tightness.

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

 Screw the drain plug (5) back into the tank.  Fill in fuel through the strainer in the filling nozzle (2).

Fig. 3-40:

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3-55

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

Draining off water

Water contained in the fuel is removed by the water trap (Fig. 3-41:).

Carry out the following works in accordance with the servicing schedule and at regular intervals.  Loosen venting plug (9, Fig. 3-42:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

Fig. 3-41:

Fig. 3-42:

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).

3-56

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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. 3-43:) 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. 3-43:

 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.

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3-57

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing ELECTRICAL SYSTEM 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.

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

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 electronic control module.

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. The electrical circuit diagrams are annexed to thespare-parts list. Further information can be found in the Terex O&K 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.

3-58

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Floodlight projector, safety instructions The floodlight projectors use xenon technology.

The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector.

When the projector is turned on, the ballast unit generates a high-voltage pulse of more than 25000 volts to start the xenon lamp.

Warning!

This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance,  if the lamp is operated improperly, 

if the projector housing is opened in an inapropriate way or



by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp.

Allow the xenon lamp to cool off before removing it from the projector.

Wear googles and safety gloves when replacing the lamp.

Never stick your hand into the lampholder. The contacts may still be live with residual voltage.

Never switch on the projector when the xenon lamp has been removed.

There is a risk of voltage discharge and damage to the lampholder.

The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters) If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector.

If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol.

The replaced Xenon lamp must be disposed of as special waste.

Never switch on projectors when housing or electrical wiring is damaged.

Have damaged projectors be replaced by a qualified electrician as soon as possible.

BA RH40-E(3 725 040.00)-EN

3-59

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Floodlight projector, replacing a defective xenon bulb

Read and observe “Floodlight projector, safety instructions”

 Switch off the projector, shut off the engine and cut out the battery main switch.  Wait until the housing of the floodlight projector has cooled down.  Withdraw the power supply connector from the projector.  Remove four screws (1, Fig. 3-44:) and withdraw the reflector (2) from the projector housing.

Fig. 3-44:

 Remove the circlip (3, Fig. 3-45:). Turn connector (4) counter-clockwise and withdraw.  Turn lampholder (5, Fig. 3-46:) counter-clockwise and pull it out of the reflector together with lamp (6).  Remove the defective Xenon lamp (6) from the lampholder and replace by a new one. Do not touch the glass bulb of the lamp.  Reinstall the new lamp and the lampholder.

Plug the connector into the projector. Refit the circlip. Re-assemble the housing.

Fig. 3-45:

Fig. 3-46:

3-60

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing 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.

Checking battery charge The acid temperature must be 20 ° C / 68° F.  Unscrew caps of the battery  Measure the acid density of the battery using a commercial acid tester The acid density measured is in direct correlation with the battery charge.

Checking the battery fluid level

Acid density 3

(Not applicable in case of maintenance-free batteries)

kg / dm

Charge

Normal condition

Tropical conditions

 If checking inserts are provided, the battery acid must reach up to their bottom.

1,28

1,23

fully charged

1,20

1,12

half charged, recharge

 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 / 0.4 in.

1,12

1,08

discharged, recharge immediately

 Unscrew caps (Fig. 3-47:).

 If the fluid level is too low, top up with distilled water only

Fig. 3-47:

BA RH40-E(3 725 040.00)-EN

3-61

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Removing and installing the battery Read and observe the "Inspection and servicing – Safety instructions" chapter.

The batteries are located under the hatch (5, Fig. 3-48:).  Open hatch (5).

Wear protective gloves and firm working clothing.

 Unscrew battery holder (3, Fig. 3-50:).

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

 Disconnect the cable lug from the negative terminal of the battery.

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

 Disconnect the cable lug from the positive terminal of the battery.  Insulate the cable lugs.

Switch battery main switch to position II / OFF (Fig. 3-49:).

 Take out the batteries (1).

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

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.

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

 Install the new batteries.

The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

 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.  Fix battery holder (3).

Fig. 3-48:

Fig. 3-50: Fig. 3-49:

3-62

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing HYDRAULIC SYSTEM Hydraulic system - Safety instructions

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:

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 engine.

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

Fig. 3-51:

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

Avoid skin contact with hydraulic oil.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

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. 3-51:and Fig. 3-52:) and with its drive engine 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. 3-52:

 Locate the system section to be opened.  Depressurize the section to be opened. If required, the necessary measures described must be combined.  Open the depressurized system section with caution.

Examples of system sections: 1) working hydraulics 2) servo control circuit 3) precharged return-flow line Detailled information can be found in the “Technical Handbook, section 8, Hydraulic System”.

BA RH40-E(3 725 040.00)-EN

3-63

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, keep sitting on the driver’s seat.

Sections 1 and 2, servo control and working hydraulics:  Switch on electrical system (“Ignition ON”).  Shift both control levers and all pedals repeatedly into all directions (Fig. 3-53:).

Fig. 3-54:

Topping up with hydraulic oil  Remove cover (20, Fig. 3-55:) and retaining disk (23). One of the return-flow filters is now visible in the filter chamber.  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 see: "Refilling quantities - Oil").

Fig. 3-53:

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.

 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 / 122° F).  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. 3-54:).

Two sensors are monitoring the hydraulic oil level in the hydraulic oil reservoir. If the warning lamp comes on, shut off the engine. Trace out the fault and eliminate.

3-64

Fig. 3-55:

BA RH40-E(3 725 040.00)-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.

The return-flow filters must be replaced: 

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



when the "Hydraulic oil filter" warning lamp lights up when the hydraulic oil is at operating temperature. The filter elements (25, Fig. 3-56:) are then heavily contaminated.

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

Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.



after repairs on the hydraulic system;

Avoid skin contact.



in case of damage.

Skin contact with hydraulic oil may cause skin injury.

 Remove cover (20) and retaining disk (23) as described under "Topping up with hydraulic oil".

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Collect escaping hydraulic oil and discard without polluting the environment.

 Clean the magnetic rod (24).

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

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

If the filter elements are damaged, remove basket (28) and clean down with spirits or petroleum.  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. 3-56:

BA RH40-E(3 725 040.00)-EN

3-65

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. 3-57:). Remove screws (12) and take out the bypass valve.

Withdraw sieve (13) and clean in white spirit or paraffin oil. Replace, if required.

Shut off the engine.

 Check sealing ring (16) for damage and replace, if required.

Risk of scalding caused by hot hydraulic oil.

 Re-assemble the bypass valve.

The hydraulic oil reservoir itself may also be hot.

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

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

 Insert the bypass valve. Make sure the valve fits properly.  Refit cover (10) with sealing ring (15).

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-57:

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).

3-66

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Bypass valves (cooling circuit) Read and observe the "Inspection and servicing – Safety instructions" chapter.

Cleaning the valve  Remove cover (7, Fig. 3-58:).  Unscrew screws (33, Fig. 3-59:) and withdraw valve carrier (31) together with valve (32).

Shut off the engine.

 Clean valve (32) in white spirit or paraffin oil and replace, if required.

Risk of scalding caused by hot hydraulic oil.

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

The hydraulic oil reservoir itself may also be hot.

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

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-59:

Changing the valve Fig. 3-58:

 Remove bypass valve as described under "Cleaning the valve".  Remove valve (32, Fig. 3-59:) and replace by a new one.  Fasten bypass valve (31) on the hydraulic oil reservoir.  Refit cover (7, Fig. 3-58:).

BA RH40-E(3 725 040.00)-EN

3-67

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. 3-60:) 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.

Wear fall arresters before working on the hydraulic tank.

Fig. 3-60:

 Unscrew butterfly nut (50, Fig. 3-61:). 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. 3-61:

3-68

BA RH40-E(3 725 040.00)-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. 3-62:).

Checking/cleaning the filter elements  Unscrew filter housing (31, Fig. 3-62:) and pour out the oil.  Withdraw filter element (32) from housing (31).

Fig. 3-62:

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

Fig. 3-63:

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.

Wear fall arresters before working on the hydraulic tank.

Collect escaping hydraulic oil and discard without polluting the environment.

 Clean filter housing and contact faces at the filter head (35, Fig. 3-63:) 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. 3-63:) 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 RH40-E(3 725 040.00)-EN

3-69

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. 3-64:) for the servo circuit and another filter (41) for the feeding circuit of the slewing pump.

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

Check filter tell-tales (1, Fig. 3-64:) regulary - at operating temperature - for indication of contamination. If the red sector is visible through transparent cap (2), the filter element must be cleaned or changed.

 Unscrew filter housing (42, Fig. 3-65:) 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. 3-64:

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

Fig. 3-65:

Replacing the filter elements Shut off the engine.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

Avoid skin contact.

 Detach the filter elements as described under "Checking the filter elements".  Insert new assemble.

filter

element

(43)

and

re-

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

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

3-70

BA RH40-E(3 725 040.00)-EN

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

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Drawing off hydaulic oil  Bring the hydraulic oil to operating temperature (abt. 50 ° C / 122° F).  Position the machine with a slight inclination towards the drain valve (5, Fig. 3-66:).

The drain valve is located at the back of the hydraulic oil reservoir and accessible from the bottom.  Retract the hydraulic cylinders as far as possible and stand the working equipment on the ground.  Shut off the engine.  Place suitable recipients under the drain valve (5) of the hydraulic oil reservoir. For the required capacity refer to the "Refilling quantities - Oil" table.

Collect escaping oil and discard without polluting the environment.

 Connect hose (15) to drain valve (5) and drain off used oil completely. Draining is facilitated if the breather filter (6, Fig. 3-67:) is removed during the process.

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.

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid changes" section.  Remove hose. The drain valve closes automatically.

Fig. 3-66: Fig. 3-67:

BA RH40-E(3 725 040.00)-EN

3-71

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).

Shut off the engine.

Use diesel fuel or a special flushing oil.

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

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.

Wear fall arresters before working on the hydraulic tank.

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. 3-68:).

Fig. 3-68:

3-72

BA RH40-E(3 725 040.00)-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. 3-70:

Hydraulic pumps and hydraulic motors (with engine 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. 3-69:),

 Check the hydraulic system under load.



the rod-side port (4) when the piston rod is extended (1, Fig. 3-70:).

 Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions.

Hydraulic cylinder Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-69: and Fig. 3-70:) must be either completely retracted or completely extended.

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.

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. 3-69:

BA RH40-E(3 725 040.00)-EN

3-73

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

Cleaning  Remove the grid (7, Fig. 3-72:) above the cooler.  Blow the cooling fins clean with compressed air proceeding from top to bottom.

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.

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 / 140° F.

3-74

Fig. 3-71:

BA RH40-E(3 725 040.00)-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. 3-72:).

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.

Fig. 3-72:

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 RH40-E(3 725 040.00)-EN

issued by an expert

3-75

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

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

Shut off the engine.

The gearbox housings may be hot, too.

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Pre-chamber Checking oil level The oil level in the pre-chambers is visually at the inspection glas (3, Fig. 3-74) in expansion reservoir (1).

The oil level should reach up at least to the middle of the inspection glas (3). Top up with gearbox oil, if required.

Wear protective gloves and firm working clothing.

Checking the gearbox oil level / Topping up with oil  Screw out dipstick (1, Fig. 3-73:) 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.

Fig. 3-74

 Screw dipstick (1) back in place.

Fig. 3-73:

3-76

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Changing the gearbox oil

Pre-chamber

Draining off oil

Draining off oil

 Prepare a collecting recipient for used oil.

 Prepare a collecting recipient for used oil.

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

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

 Unscrew plug (3, Fig. 3-75:) and drain off oil.

 Unscrew plug (7, Fig. 3-75:) and drain off oil.

Screwing out breather filter (2) facilitates draining off the used oil. Plug (3) is accessible from the bottom.

Plug (7) is accessible from the bottom.

 Screw plug (3) back in place.

 Screw plug (7) back in place.

Filling in oil  Unscrew breather filter (2, Fig. 3-76).  Fill in new oil through opening of breather filter (2).

The oil level should reach up at least to the middle of the inspection glas (3).

Fig. 3-75:

Filling in oil  Unscrew breather filter (2, Fig. 3-75:).

Fig. 3-76

 Fill in new oil through opening of breather filter (2). After oil changes, plug (3) must be tightened beforehand.  Check oil level with dipstick (1).

Oil can also be filled in through the opening of the breather filter (2, Fig. 3-76).

BA RH40-E(3 725 040.00)-EN

3-77

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Gearbox venting

Pre-chamber

The gearbox is vented through breather filter (2, Fig. 3-77:).

The pre-chambers are vented through breather filter (2, Fig. 3-78:).

Clean breather filter in accordance with the servicing plan.

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.

 Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.

 Screw breather filter back in place.

 Screw breather filter back in place.

Fig. 3-77:

3-78

Fig. 3-78:

BA RH40-E(3 725 040.00)-EN

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

Shut off the engine

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

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

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.

Fig. 3-80:

Draining off oil  Attach hose (8, Fig. 3-80:) to drain valve (7) and drain off oil completely.

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

Fig. 3-79:

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

The drain valve (7, Fig. 3-80:) is accessible from the undercarriage.  Remove hose. The oil drain valve closes automatically. See: “Hose line for oil and cooling liquid change" section.

 Screw out dipstick (1, Fig. 3-73:) and wipe clean.  Insert dipstick (1) fully again (do not screw in) 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.

BA RH40-E(3 725 040.00)-EN

3-79

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. 3-81:).

Clean breather filter in accordance with the servicing plan.

Unscrew plug (4, Fig. 3-81:) and fill in new oil.

 Check oil level with dipstick (1, Fig. 3-81:).  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 50 cm3 / 1,7 oz grease through grease nipple (5, Fig. 3-82:) by means of a hand grease pump.

Fig. 3-81:

Fig. 3-82:

3-80

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing TRAVEL GAERBOX 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".

Travel gearbox - Changing the oil  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. 3-84:).

 Move the excavator until one of the two drain plugs (6, Fig. 3-83:) is at the bottom and screw out the upper plug.

Clean / change breather filter in accordance with the servicing plan.

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

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

Fig. 3-83: Fig. 3-84:

BA RH40-E(3 725 040.00)-EN

3-81

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing CRAWLER TRACKS Cleaning

Track roller fastening

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

Cleaning is especially important in winter to prevent

Check fastening screws (3, Fig. 3-86:) regularly for tightness:



the tracks from being thrown off



oil from leaking out of track and support rollers, sprockets and idlers



excessive wear



the track from breaking.

 Tighten screws with a torque wrench to the prescribed tightening torque (see: "Technical Handbook").

Fig. 3-86:

Support roller fastening Fig. 3-85: To clean the tracks:  raise one side of the excavator with the working equipment and allow track to turn;

Check fastening screws (4, Fig. 3-87) regularly for tightness:  Tighten screws with a torque wrench to the prescribed tightening torque (see: "Technical Handbook").

 clean the side member supporting the track;  clean track and support rollers (1 and 2 , Fig. 3-85:) thoroughly, especially at those places indicated by arrows;  clean the sliding planes on the idler guides.

Track rollers, support rollers, track pads The track rollers (1, Fig. 3-85:) and the support rollers (2) have a permanent grease filling.

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

3-82

Fig. 3-87

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Track pads Check fastening screws (5, Fig. 3-88:) regularly for tightness:  Tighten screws with a torque wrench to the prescribed tightening torque (see: "Technical Handbook").

Fig. 3-88:

BA RH40-E(3 725 040.00)-EN

3-83

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Track tensioner

Function

Design

The tensioning system is under permanent pressure of ca. 100 bar / 1450 psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engine has been started. Retensioning is not required.

The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-89:and Fig. 3-90: 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. 3-90:) to slacken the tracks.  After the work, screw down the pressure limiting valves (6) to the limit stop.

Fig. 3-89:

Pos. Function 4

Pressure accumulator

5

Pressure cylinder

6

Pressure limiting valve

9

Mini- measuring port

10

Support roller

11

Drive sprocket

12

Track roller

Fig. 3-90:

13

Crawler track

14

Idler

The pressure-limiting valves (6) are preset to a pressure of 250 bar / 3626 psi and sealed in this position. The lead seal must not be removed and the pressure setting of 250 bar / 3626 psi must not be changed.

Techncal data

The track tensioners are maintenance-free.

Track tensioning pressure

Approx. 100 bar / 1450 psi

Pressure limiting valve

250 bar / 3626 psi

Gas pressure in pressure accumulator (nitrogen filling pressure)

80 bar / 1160 psi

3-84

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Pressure-accumulator inspection regulations

Checking the gas charging pressure in the pressure accumulator

The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

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.

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".

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations]. Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Group III p ≥ l bar 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

BA RH40-E(3 725 040.00)-EN

3-85

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

Internal gearing The internal gearing and the pinion are enclosed in a housing (5, Fig. 3-92:). 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 The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing .

Fig. 3-92:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-91:). 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. 3-93:For checking, the cover must be removed.

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-91:).

Fig. 3-93:

Fig. 3-91:

3-86

BA RH40-E(3 725 040.00)-EN

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 engine.

Wear protective gloves and firm protective clothing.

At regular intervals  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 / 0.8” of grease over its whole circumference (Fig. 3-94:).

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 - 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.

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 (see: "Technical Handbook“).

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 (see: „Technical Handbook“).

Fig. 3-94:

BA RH40-E(3 725 040.00)-EN

3-87

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing CENTRAL LUBRICATING Design and function The excavator is equipped with an automatic central lubrication system. It serves for a regular lubrication of all hub joints exzerpt the one hub joint listet in the lubrication scheme.

The function of the central lubrication system is monitored by a proximity switch (7, Fig. 3-96:) which is installed at the main distributor (4).

The lubrication is effected by a central lubrication pump (1, Fig. 3-95:) with attached lubricant reservoir (2). The pump delivers the lubricant via the mainline (3) to the main distributor (4, Fig. 3-95:).

Fig. 3-96:

The pressure in the main line can be read at the manometer (8), also installed at the main distributor (4).

This also serves for monitoring the system.

Fig. 3-95:

The main distributor distributes the lubricant in the right proportion through the lines (5, Fig. 3-95: to the secondary distributors (6). Those secondary distributors deliver the lubricant to the lub points.

3-88

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Check for each Operation: 

Grease outflow at pressure relief valve



Grease level in the pump reservoir

In the case of a malfunction, stop the motor and correct it.

When there is a malfunction in the central lubrication system, the proximity switch (7, Fig. 3-97:) reports this to the control unit (see malfunctions).

The grease then comes out of the pressure relief valve (9, Fig. 3-98:).

Correct the malfunction as described under "Blockade of a lubrication point".

The grease level in the pump reservoir (2, Fig. 3-98:) can be seen from the outside.

The pump is equipped with an electronic grease level control. For this purpose, a capacitive proximity switch (10, Fig. 3-98:) has been installed into the pump reservoir (2).

When the grease level in the reservoir of the pump (2) drops below a minimum, the proximity switch (10) gives a signal to the control unit (see "Malfunctions").

Always refill the reservoir of the pump in time, as otherwise air can get into the system and cause trouble.

Fill the pump reservoir with the help of the delivered filling press (11, Fig. 3-98:). To do this, unscrew the red cap (12, Fig. 3-98:).

The pump can also be filled at the filling nipple (13, Fig. 3-98:) with the help of a customary hand lever grease press.

Please take care of utmost cleanness when filling the pump reservoir.

Fig. 3-97: Fig. 3-98:

BA RH40-E(3 725 040.00)-EN

3-89

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Malfunctions 

Blockade of one or several lubrication points



Blockade of a distributor



Interruption of the line to the main distributor



Air in the pump element of the pump



Reservoir empty

All these malfunctions are reported to the control unit by the proximity switch at the main distributor (3, Fig. 3-99:) and by the capacitive proximity switch (10, Fig. 3-100:) in the pump reservoir.

In the case of a malfunction, stop the motor and eliminate it.

Fig. 3-100:

When the line to the main distributor is interrupted or air is in the pump element (14, Fig. 3-100:) of the pump, the proximity switch (7, Fig. 3-99:) receives no longer signals and reports trouble to the control unit. 

- Renew main line



- Ventilate the pump

When the reservoir is empty 

-

Fill the reservoir

Only start to operate the excavator again, when the lubrication system operates faultless and the concerned lub points have been lubricated in unloaded condition of the of the equipment with a hand lever grease press until grease flows out visibly of the lubrication points.

Fig. 3-99:

Use for lubricating the concerned lubrication points the respective lubrication nipple (15-20, Fig. 3-99:) at the main distributor (see "Manual lubrication")

When a lub point or a distributor blocks, the grease will come out of the pressure relief valve. 

Repair the lubrication point



Clean the distributor

3-90

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Blockade of a lub point 

Switch off the ignition, take out the key



Search the secondary distributor with the blocked lubrication point with the help of the lubrication nipples (15-20, Fig. 3-102:) at the main distributor (4, Fig. 3-101: and Fig. 3-102:) To this purpose, lubricate each lubrication nipple with a hand lever grease press.

At the lubrication nipple for the distributor with the blocked lubrication point will be an almost invincible resistance.



lubrication nipple (15, Fig. 3-102:) for the distributor of the turntable and the lift cylinder below



lubrication nipple (16, Fig. 3-102:) for the distributor of the boom foot



lubrication nipple (17, Fig. 3-102:) for the distributor of the stick



lubrication nipple (18, Fig. 3-102:) for the distributor of the boom



lubrication nipple (19, Fig. 3-102:) for the distributor of the stick front



lubrication nipple (20, Fig. 3-102:) for the distributor of the connecting link (see distributor designations an the lubrication scheme)



Screw out the fitting (21, Fig. 3-103:) for the inlet line (5, Fig. 3-101: and Fig. 3-103:) at the concerned secondary distributor and replace it by a lubrication nipple.



Screw off the lines to the lubrication points (22, Fig. 3-103:) one by one and lubricate them with the hand lever grease press.

The line, at which the distributor does not block leads to the blocked lubrication point.



Repair the lubrication point



Screw on the lines at the secondary distributor again



Lubricate the concerned lubrication circle via the lubrication nipple at the main distributor until grease visibly comes out of the lubrication points

Fig. 3-101:

Fig. 3-102:

Fig. 3-103:

BA RH40-E(3 725 040.00)-EN

3-91

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Ventilation of the lubricating pump 

Refill pump reservoir



Screw off the main line (3, Fig. 3-104:) of the pump element (14, Fig. 3-104:)



Operate the lubricating pump until the lubricant comes out of the pump outlet (14) free of air inclusions



Cleaning the grease sieve Check the grease sieve (23, Fig. 3-105:) regularly for pollution and clean it, if necessary. Clean the sieve also after the blockade of a lubrication point. 

Loosen the lubrication line with the fitting (24, Fig. 3-105:)



Loosen the housing for the filter element (25, Fig. 3-105:) from the fitting for the filter element (26, Fig. 3-105:) (keep back the fitting (26) with a spanner)



Take out the filter element (27, Fig. 3-105:) and clean it in benzine or petroleum



Put the filter element (27) in again



Take care that the USIT-ring (28, Fig. 3-105:) and the 0-ring at the filter element (29, Fig. 3-105:) don't get lost



Screw the filter element housing (25) and the filter element fitting (26) with 60 Nm drawing torque together again.



Screw on the lubrication line with fitting (24) again.

Switch off the lubricating pump and close the main line again.

Fig. 3-104:

Fig. 3-105:

3-92

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing Manual lubrication Should the central lubrication system fail, there is the possibility to lubricate manually.

This also should be done in the case of extreme use.

The lubrication nippte at the pump element (30, Fig. 3-106:) can be used for lubricating the whole system when the central lubrication has failed:



Pump with a hand lever grease press grease into the central lubrication system until grease visibly comes out of all lubrication points connected to this secondary distributor



lubrication nipple (15, Fig. 3-107:) for the distributor of the turntable and the lift cylinder below



lubrication nipple (16, Fig. 3-107:) for the distributor of the boom foot



lubrication nipple (17, Fig. 3-107:) for the distributor of the stick



lubrication nipple (18, Fig. 3-107:) for the distributor of the boom



lubrication nipple (19, Fig. 3-107:) for the distributor of the stick front



lubrication nipple (20, Fig. 3-107:) for the distributor of the connecting link (see distributor designation on the lubrication scheme)

Fig. 3-106:



Take off the lubrication nipple cap



Clean the lubrication nipple



Pump with a hand lever grease press grease into the central lubrication system until grease visibly comes out of all lubrication points



Take care that the used grease is pushed out at all lubrication points. Only then the connected lubrications points have been supplied with grease



After lubricating the cap of the lubrication nipple an the lubrication nipple again.

The lubrication nipples at the main distributor can be used for lubricating individual circles. 

Remove lubrication nipple cap



Clean the lubrication nipple

BA RH40-E(3 725 040.00)-EN

Fig. 3-107:



After lubricating, put the lubrication nipple on the lubrication nipple again.

3-93

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

3-94

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing OTHER MAINTENANCE Heating and air conditioning Change the filter mats in the air suction regulary.

The filter mats are located under the driver`seat.

Fig. 3-108:

 Remove cover (1, Fig. 3-108:) Change filter mats (2)  Fasten cover (1) again.

BA RH40-E(3 725 040.00)-EN

3-95

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 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".  Clean the machine.

Battery storage During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C / 68° F. 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.

 Lock the superstructure

Recommissioning

 Carry out a visual inspection of the excavator.

 Remove the covers.

 Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.

 Degrease / clean all protected components.

 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 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.

 Remove the batteries; see: "Battery storage".

 Check grease filling in grease container.

 Secure the machine against unauthorized starting by: - withdrawing the key from the key-switch

 Oil level

- drive engine - slewing gearbox - pump transfer gearbox - travel gearboxes

- locking the cab door

 Check oil level in hydraulic oil reservoir.

- securing all lockable hatches.

 Check battery acid density and level.

 Cover up all openings

 Install batteries and reconnect.  Function checks:

- superstructure holding brake - track brake - lighting system - signalling equipmen

 Check vacuummeter  Vent the hydraulic system.

3-96

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OPERATING INSTRUCTIONS RH 40-E Inspection and servicing NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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3-97

OPERATING INSTRUCTIONS RH 40-E Inspection and servicing

3-98

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Repair work 4 REPAIR WORK

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 RH40-E(3 725 040.00)-EN

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

4-1

OPERATING INSTRUCTIONS RH 40-E Repair work

4-2

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Repair work REPAIR WORK - SAFETY INSTRUCTIONS 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 O&K. Working in greater heights Always wear safety harnesses when working at greater heights.

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

BA RH40-E(3 725 040.00)-EN

Prestressed units 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.

4-3

OPERATING INSTRUCTIONS RH 40-E Repair work Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of Terex O&K. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the drive engine 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

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Repair work FIRE AND EXPLOSION HAZARD 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.

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

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

Even battery gases can ignite in open flames or fire.

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

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

Do not store these substances on the excavator.

If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the excavator at the end of the work.

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.

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

If necessary, also cover the ground with fireprotective blankets.

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

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

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

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

Provide for sufficient ventilation.

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

Do not extinguish flammable liquids with water.

Use: 

dry-powder,



carbon-dioxide or



foam extinguishing compounds.

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

Call the fire brigade.

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

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

Clean the excavator before starting a job.

BA RH40-E(3 725 040.00)-EN

4-5

OPERATING INSTRUCTIONS RH 40-E Repair work ENGINE Read and observe the "Repair Safety instructions" chapter and the engine operating instructions before working on the engine.

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

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Risk of injury from hot or rotating parts of 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 Assisted starting (with jumper cables) – Safety instructions Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

Battery gases are highly flammable.

Explosion hazard.

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

Risk of injury from acid splashes and battery gases.

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

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

Assisted starting (with jumper cables) Prior to assisted starting Read and observe the section: "Assisted starting – Safety instructions".

Starting the engine with jumper cables (external batteries Before connecting the jumper cables (external bateries) check the own batteries for proper operation. Checking is done by switching on the excavator's electrical system.

Do not switch on electrical consumers (e.g. floodlamps) when checking the batteries. In case of doubt, remove the batteries and have them tested.

Assisted starting with batteries installed

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

 Connect first the positive terminal of the jumper cable to the batteries and then to the supplying unit.

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.

 Connect the negative terminals in the same order.

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".

 After starting, disconnect the jumper cable in reverse order, i.e. first the negative terminal and then the positive terminal.

Assisted starting without batteries installed (only for engine trial run) Do not disconnect the starting aid when the engine is running.

After disconnecting, the alternator runs without batteries.  Connect the jumper cable in the above- 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.

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4-7

OPERATING INSTRUCTIONS RH 40-E 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.

Starting up the engine  Start up the engine 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.

Fig. 4-1:

4-8

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OPERATING INSTRUCTIONS RH 40-E Repair work HYDRAULIC SYSTEM Repair – Instructions

Hydraulic hoses – Instructions

Always depressurize the hydraulic system before removing hydraulic hoses or pipes.

Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair Safety instructions".

Replace damaged and leaking hydraulic hoses as soon as possible by new ones. Use original spare parts from Terex O&K. They are adapted to the respective function.

Do not re-use old hoses.

Never repair damaged hoses.

Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years).

Check the date of manufacture on the hose or on the hose fitting regularly.

The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading.

The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multishift operation and round-the-clock work).

Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection:

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

Damage to the outer fibre reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks).



Embrittlement of the outer fibre reinforcement layer (cracks in the hose material).



Changes in the ususal shape of the hose under pressure or in pressureless condition in bends or curves such as detachment of fibre layers, formation of bubbles or bulges.



Leaks.



Non-observance of fitting requirements.



Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.



Detachment of the hose from the fitting.



Corrosion in fittings reducing the strength of the function of the fitting.

4-9

OPERATING INSTRUCTIONS RH 40-E Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS 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

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OPERATING INSTRUCTIONS RH 40-E Repair work WELDING OPERATIONS SAFETY INSTRUCTIONS 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

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".

Before beginning welding operations: Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

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

Protect the vessels against damage and high temperatures.

Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured.

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 / 2.2 – 3.2 yd).

The welding current must not flow via the ball resp. the roller bearing slewing ring, via pin couplings, articulated joints or hydraulic cylinders.

Should you have any problems or queries, apply to the Terex O&K after-sales service department.

An electric current flowing over an air gap (in an articulated joint, for instance) generates sparks that damage metallic surfaces.

If parts of the machine have to be dimantled, read and take note of the following sections:

On completion of the welding operation, restore all electrical connections.

Assembling attachments - safety instructions", "Inspection and servicing - safety instructions", "Repair - safety instructions".

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4-11

OPERATING INSTRUCTIONS RH 40-E Repair work

4-12

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OPERATING INSTRUCTIONS RH 40-E Repair work NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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4-13

OPERATING INSTRUCTIONS RH 40-E Repair work

4-14

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OPERATING INSTRUCTIONS RH 40-E Annex 5 ANNEX 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

5-1

OPERATING INSTRUCTIONS RH 40-E Annex

5-2

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OPERATING INSTRUCTIONS RH 40-E Annex TROUBLESHOOTING 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 O&K 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 O&K 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 O&K after-sales service should be consulted

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OPERATING INSTRUCTIONS RH 40-E Annex FAULT TABLES 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

• • • • •

••••

•

• •

• •• ••••

••

•

• • •

•

••

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 O&K 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)

, 5-4

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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 O&K Uncontrolled working movements Service Cause Abschnitt Servo control not activated/defective Working P • 1) • • • • • • Malfunction of pressure-relief valve 1) • • Servo system pump defective Malfunction of primary / sencondary pressure-relief valves 1) ••••• • Engine speed too low P • ECO-power switch in 80%-position P • Fuel filter contaminated Fuel filter P/W • Insufficient engine power Engine mal1) • function 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 •

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OPERATING INSTRUCTIONS RH 40-E 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

• • • •

Cause Malfunction of pressure-relief valves Servo system pump defective Malfunction of travel valve (pedal) Engine nominal speed too low Malfunction of control spool ECO-power switch in 80%-position Insufficient engine power

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the Terex O&K Service Chapter ref.

1) 1) 1) 1) 1) Travelling P 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)

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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 Terex O&K 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

• • • • • • • •

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P E W A S R

P P P 1) 1) 1) 1) 1) 1) 1)

5-7

OPERATING INSTRUCTIONS RH 40-E 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 O&Ky Service Chapter ref.

P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

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OPERATING INSTRUCTIONS RH 40-E Annex HYDRAULIC CIRCUIT DIAGRAM Detailled information can be found in the „Technical Handbook“ chapter 8 or contact Terex O&K Service.

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5-9

OPERATING INSTRUCTIONS RH 40-E Annex

5-10

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OPERATING INSTRUCTIONS RH 40-E Annex ABBREVIATIONS A abt. acc.

Ah API approx.

Ampere (SI base unit of electric current) about according to Ampere hours (SI base unit of quantity of electricity) American Petroleum Institute approximately

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 centimeter (= 1/100 m) Cubic centimeters per revolution

CECE

CEN cm cm3/rev

dia.

DIN

Decibel (sound intensity according to measuring method A) Diameter German Industrial Standard

eff. e.g. etc.

effective for example etcetera

Fig. FOPS FS ft

Figure, serial number of illustration Falling objects protective structures Face shovel (working equipment) foot

gal GLR

gallon (3.71 litres) Full-load controller (electronic module for PMS)

HD Hydr.

Heavy duty Hydraulic, Hydraulics

i i.e.

IFN

id est = that is ISO service rating, blocked

dB(A)

Transmission ratio

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Incl.

ISO

including, inclusive of International Standardization Organization

kg kg/dm3

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 Lb/in² LC LED l/min LpA LS LS LwA

Liter pound Pounds per square inch (= psi) Long crawler Light-emitting diode Liters per minute Sound pressure at workplace Limited slip Load sensing Sound power level of the machine in stationary operation

m MA MA max. min. min-1 mm

Meters Tightening torque 1 Milliampere (= /1000A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (=1/1000 m)

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 op.inst.

OW

Operating hour Operating instructions Superstructure

5-11

OPERATING INSTRUCTIONS RH 40-E Annex ABBREVIATIONS

PMS P/No. PS

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 Revolutions per minute (= min-1)

SAE sec./s.

SN SW

Society of Aotomotive Engineers (USA) Second Item number Width across flats

t THB TL tm typ.

Metric ton (= 1000 kg) Technical Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of swing torque) Typical

U/min UW

Revolutions per minute Undercarriage

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W

Watt (unit of electric power)

°C °F °kW

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) Degrees crank angle

> <

greater than less than

5-12

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OPERATING INSTRUCTIONS RH 40-E Annex TECHNICAL DATA

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OPERATING INSTRUCTIONS RH 40-E Annex

5-14

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OPERATING INSTRUCTIONS RH 40-E Annex NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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OPERATING INSTRUCTIONS RH 40-E Annex

5-16

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OPERATING INSTRUCTIONS RH 40-E Index 6 INDEX 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

6-1

OPERATING INSTRUCTIONS RH 40-E Index

6-2

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OPERATING INSTRUCTIONS RH 40-E Index

A ABBREVIATIONS ................................................... 5-11 After daily operation ................................................ 2-56 Air conditioner (optional) ......................................... 2-42 Air-intake lines......................................................... 3-50 Air-intake system .............................................. 3-13 AIR-INTAKE SYSTEM ............................................ 3-48 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ................................................. 2-57 Assisted starting (with jumper cables) ....................... 4-7 Assisted starting (with jumper cables) – Safety instructions ............................................................ 4-7 Automatic engine speed reduction ............................ 2-9 Auxiliary heating (optional) ...................................... 2-42

B Battery..................................................................... 3-61 Battery main switch ................................................. 2-39 Battery storage........................................................ 3-96 Bearing races .......................................................... 3-86 Before starting work ................................................ 2-53 Breather filter........................................................... 3-68 Bypass valves (cooling circuit) ................................ 3-67 Bypass valves (working circuit) ............................... 3-66

C CENTRAL LUBRICATING ...................................... 3-88 Central lubricating system – Fault table .................... 5-8 Change of engine oil ............................................... 3-13 Changing the coolant .............................................. 3-46 Changing the engine oil........................................... 3-42 Changing the gearbox oil ............................... 3-77, 3-79 Changing the hydraulic oil ....................................... 3-71 Changing the hydraulic oil return-flow (hydraulic oil reservoir .............................................................. 3-65 Checking the engine oil level / Topping up.............. 3-41 Checking the gas charging pressure in the pressure accumulator......................................................... 3-85 Checking the gearbox oil level / Topping up with oil 3-76 Checking the hydraulic oil level ............................... 3-64 Cleaning jobs .......................................................... 3-13 Cleaning the fuel tank.............................................. 3-54 Cleaning the hydraulic oil cooler.............................. 3-74 Cold-starting fluid (ether) - Replacing the pressure vessel .................................................................. 3-44 Combustion engine - Fault table................................ 5-4 Components............................................................ 3-13 Cooler and cooling liquid ......................................... 3-45 COOLING SYSTEM................................................ 3-45 Corrosion protection for pins and bearings (bushings and hubs) ............................................................ 2-59 CRAWLER TRACKS............................................... 3-82

D Demand control / Zero-flow regulation ...................... 2-9 Depressurizing the hydraulic system ....................... 3-63 DESCRIPTION OF THE EXCAVATOR .................... 2-6

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Design and function................................................. 3-88 Designated use.......................................................... 1-6 Drive .......................................................................... 2-8 DRIVER'S CAB ....................................................... 2-12 Driver's seat............................................................. 2-14 Dust collection ......................................................... 3-50

E Electrical system........................................................ 2-9 ELECTRICAL SYSTEM....................................3-58, 4-7 Electrical system - Safety instructions ..................... 3-58 ENGINE................................................................... 3-41 ENGINE..................................................................... 4-6 Engine - Safety instructions ..................................... 3-41 Entering and leaving the machine - Safety instructions212 Environmentally compatible hydraulic fluid .............. 3-10 Environmentally compatible hydraulic fluid - operating instructions .......................................................... 3-10 Environmentally compatible hydraulic fluid - Sampling 311 Environmentally compatible hydraulic fluid, conversion ............................................................................ 3-10 Environment-friendly lubricants and gearbox oils .... 3-12 Ether........................................................................ 1-11 Excavator layout ........................................................ 2-7

F FAULT TABLES ........................................................ 5-4 Filling quantities - Grease...............................3-27, 3-29 Filling quantities - oil ................................................ 3-32 Filling quantities - other ........................................... 3-32 Fire and explosion hazard .........................1-12, 2-5, 3-9 Fire and Explosion Hazard ........................................ 4-5 Fire-extinguisher...................................................... 2-15 Floodlight projector, replacing a defective xenon bulb . 360 Floodlight projector, safety instructions ................... 3-59 Fuel pre-filter, Draining off water ............................. 3-51 Fuel pre-filter, replace.............................................. 3-52 FUEL SYSTEM ....................................................... 3-51 Fuel system - Safety instructions............................. 3-51 Fuel tank - Venting .................................................. 3-54

G Gas, dust, steam and smoke................................... 1-11 Gearbox - Checking the oil level / Topping up with oil . 379, 3-81 Gearbox oils ............................................................ 3-12 Gearbox venting .............................................3-80, 3-81 Greases for bearings and slewing rings................... 3-39

H Heating and air conditioning .................................... 3-95 High-pressure filter for working hydraulics............... 3-69 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump...................... 3-70 Hose line for oil and cooling liquid changes............. 3-40

6-3

OPERATING INSTRUCTIONS RH 40-E Index

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

Plan N...................................................................... 3-17 Plan T and W........................................................... 3-19 Plan V...................................................................... 3-15 Possible causes......................................................... 5-3 Preface ...................................................................... 1-3 Pressure accumulator.............................................. 3-75 PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS ................................................. 4-10 Pressure-accumulator inspection regulations .......... 3-85 Programmable Logic Controller (PLC)....................... 2-8 Pump Managing System (PMS) ................................ 2-8 PUMP TRANSFER GEARBOX ............................... 3-76 Putting the excavator out of operation ..................... 3-96 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ................................. 3-96 PUTTING THE MACHINE INTO OPERATION ....... 2-35

L

R

Layout of the fault table ............................................. 5-3 LIFTING OPERATIONS.......................................... 2-60 Load-hooks on backhoe buckets)............................ 2-61 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)327

Recommissioning .................................................... 3-96 Refuelling ................................................................ 2-35 Refuelling station (optional) ..................................... 3-55 Repair – Instructions.................................................. 4-9 Repair work - Safety instructions ............................... 4-3 Replacing the engine oil filters................................. 3-43

HYDRAULIC CIRCUIT DIAGRAM ............................ 5-9 Hydraulic equipment................................................ 1-11 Hydraulic hoses – Instructions................................... 4-9 Hydraulic system ....................................................... 2-8 HYDRAULIC SYSTEM............................................ 3-63 HYDRAULIC SYSTEM.............................................. 4-9 Hydraulic system - Safety instructions..................... 3-63

I

M Main filter elements ................................................. 3-48 Measures .................................................................. 5-3 MONITORING, WARNING AND CONTROL ELEMENTS......................................................... 2-16

N Noise ....................................................................... 1-11 NOTES.........................................1-13, 2-65, 3-97, 4-13 NOTES................................................................ 5-15 Notes on the selection of oils and greases.............. 3-33

O Oil, grease and other chemical substances............. 1-11 Oils / Greases ......................................................... 3-13 Oils for combustion engine...................................... 3-34 Oils for hydraulic system (selection)........................ 3-35 Oils for pump gearbox ............................................. 3-36 Oils for swing gearbox............................................. 3-37 Oils for travel gearbox ............................................. 3-38 Operation - Safety instructions .................................. 2-3 Organizational measures .......................................... 1-7 OTHER MAINTENANCE ........................................ 3-95 Output pinion........................................................... 3-80

P Plan A - E ................................................................ 3-21

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S Safety filter element................................................. 3-50 Safety instructions ................................................... 2-60 SAFETY INSTRUCTIONS ...................................... 2-51 Safety instructions governing specific operational phases................................................................... 1-8 Secondary fuel filter, replace ................................... 3-53 Section ...................................................................... 5-3 Securing the machine.............................................. 2-58 Selection and qualification of personnel; basic responsibilities ....................................................... 1-8 SERVICING WORK ................................................ 3-40 Signs ....................................................................... 2-11 Slewing and braking the superstructure................... 2-54 SLEWING GEARBOX ............................................. 3-79 Slewing mechnism – Fault table ................................ 5-7 SLEWING RING...................................................... 3-86 Slewing ring - Instructions........................................ 3-86 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 ........................... 2-40 Starting the engine with jumper cables (external batteries................................................................. 4-7 Superstructure........................................................... 2-8 Switching the electrical system on and off ............... 2-38

T TECHNICAL DATA ................................................. 5-13 Topping up with coolant........................................... 3-46 Topping up with hydraulic oil ................................... 3-64 Track drive – Fault table ............................................ 5-6 Track parking brake................................................. 2-48 Track rollers, support rollers, track pads.................. 3-82 Track tensioner........................................................ 3-84 Transport - Safety instructions................................. 2-49 Transporting and recommissioning.......................... 1-11

BA RH40-E(3 725 040.00)-EN

OPERATING INSTRUCTIONS RH 40-E Index Transporting the machine........................................ 2-49 TRAVEL GEARBOX ............................................... 3-81 Travel gearbox - Changing the oil ........................... 3-81 TRAVELLING.......................................................... 2-44 TRAVELLING, SAFETY INSTRUCTIONS .............. 2-43 TROUBLESHOOTING .............................................. 5-3

U Undercarriage ........................................................... 2-8

V

Venting the hydraulic system................................... 3-73

W Warning of special dangers ..................................... 1-10 Warnings and symbols .............................................. 1-5 Warranty.................................................................... 1-4 Water trap (option)................................................... 3-56 Welding operations - Safety instructions ................. 4-11 Windscreen washer ................................................. 2-13 Working ................................................................... 2-55 Working hydraulics – Fault table................................ 5-5 Working operation ................................................... 2-51

Ventilation and heating............................................ 2-42

BA RH40-E(3 725 040.00)-EN

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OPERATING INSTRUCTIONS RH 40-E Index

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BA RH40-E(3 725 040.00)-EN