Cat Bucyrus RH 40E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651527

OPERATING INSTRUCTIONS RH 40E

Hydraulic Excavator

RH 40E Bucyrus HEX GmbH

BA RH40E(2 804 411.00)-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

ii

BA RH40E(2 804 411.00)-EN

OPERATING INSTRUCTIONS RH 40 E

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

Part 1 INTRODUCTION

2804050

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

2 804 411.00 en

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

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

PART 1 - INTRODUCTION Preface ...................................................................................................................................................... 3 Warranty .................................................................................................................................................... 3 FUNDAMENTAL SAFETY INSTRUCTIONS ............................................................................................ 4 Warnings and symbols ............................................................................................................................ 4 DESIGNATED USE .................................................................................................................................... 4 Organizational measures ........................................................................................................................ 5 Selection and qualification of personnel - basic responsibilities ........................................................ 6 Safety instructions governing specific operational phases Standard operation .................................................................................................................................. 6 Special work in conjunction with utilization of the machine - maintenance and repairs during operation disposal of parts and consumables ........................................................................................................ 7 Warning of special dangers Electric energy ........................................................................................................................................ 8 Gas, dust, steam and smoke .................................................................................................................. 8 Hydraulic equipment................................................................................................................................ 9 Noise ...................................................................................................................................................... 9 Oil, grease and other chemical substances ............................................................................................ 9 Transporting and recommissioning ........................................................................................................ 9 Fire and Explosion Hazard .................................................................................................................... 10 NOTES...................................................................................................................................................... 11

PART 2 - OPERATION Operation - Safety instructions.............................................................................................................. 15 Fire and Explosion Hazard .................................................................................................................... 17 DESCRIPTION OF THE EXCAVATOR Excavator layout .................................................................................................................................... 19 Undercarriage........................................................................................................................................ 19 Superstructure ...................................................................................................................................... 19 Loading bucket ...................................................................................................................................... 19 Backhoe bucket .................................................................................................................................... 19 Undercarriage........................................................................................................................................ 19 Superstructure ...................................................................................................................................... 19 Drive unit .............................................................................................................................................. 19 Hydraulic system .................................................................................................................................. 20 Pump-Managing-System ...................................................................................................................... 20 Load-Sensing control / Zero-flow regulation .......................................................................................... 20 Automatic engine speed reduction ........................................................................................................ 20 Electrical system .................................................................................................................................. 20 Signs .................................................................................................................................................... 23 Warning and instructions signs ............................................................................................................ 23 Machine number.................................................................................................................................... 23 Engine number ...................................................................................................................................... 23 Component numbers ............................................................................................................................ 23 Fire-extinguisher.................................................................................................................................... 24 Extinguishing agent .............................................................................................................................. 24 Handling ................................................................................................................................................ 24 Inspection .............................................................................................................................................. 24 Fire extinguishing system (optional) ...................................................................................................... 24 Inspection .............................................................................................................................................. 24 DRIVER’S CAB Entering and leaving the machine - Safety instructions ........................................................................ 25 Driver’s seat .......................................................................................................................................... 26 Adjusting the backrest .......................................................................................................................... 26 Adjusting the lumbar support ................................................................................................................ 26 Adjusting the seat cushion .................................................................................................................... 26 Adjusting the armrests .......................................................................................................................... 26 Fore-and-aft position ............................................................................................................................ 26 Adjusting the seat suspension .............................................................................................................. 26 Cab interior lighting .............................................................................................................................. 27 Screen-washer ...................................................................................................................................... 27 MONITORING, WARNING AND CONTROL ELEMENTS ...................................................................... 28

PUTTING THE MACHINE INTO OPERATION ........................................................................................ 46 Refuelling Refuelling - Safety instructions .............................................................................................................. 46 Filling in fuel .......................................................................................................................................... 46 Refuelling with the refuelling system (optional equipment).................................................................... 46 Using the refuelling system .................................................................................................................. 47 Service station (optional equipment) .................................................................................................... 48 Refilling and draining ............................................................................................................................ 48 Switching the electrical system on and off ............................................................................................ 48 Battery main switch .............................................................................................................................. 49 Starting and stopping the engine .......................................................................................................... 50 Starting the engine ................................................................................................................................ 50 Using the cold-starting aid for starting .................................................................................................. 50 Shutting off the engine .......................................................................................................................... 51 Emergency stop .................................................................................................................................... 51 Ventilation and heating .......................................................................................................................... 52 Ventilation.............................................................................................................................................. 52 Adjusting the heating performance ........................................................................................................ 52 Driving - Safety instructions .................................................................................................................. 53 TRAVELLING Superstructure basic position ................................................................................................................ 54 Travelling forwards/backwards .............................................................................................................. 54 Regulating the travel speed .................................................................................................................. 55 Travelling downhill ................................................................................................................................ 55 Cornering .............................................................................................................................................. 55 Turning .................................................................................................................................................. 55 Note ...................................................................................................................................................... 56 Travelling over long distances .............................................................................................................. 57 Superstructure lock .............................................................................................................................. 58 Track parking brake .............................................................................................................................. 58 Transporting the machine Transport - Safety instructions .............................................................................................................. 59 Transport .............................................................................................................................................. 59 Working operation - Safety instructions .............................................................................................. 61 WORKING OPERATION Before starting work .............................................................................................................................. 63 Switching on the pump servo system .................................................................................................... 63 Activating and de-activating the pump servo control ............................................................................ 63 Slewing and braking the superstructure ................................................................................................ 63 Working ................................................................................................................................................ 64

Raising and lowering the boom ............................................................................................................ 64 Extending and retracting the bucket or backhoe bucket stick .............................................................. 64 Filling and emptying bucket ot backhoe bucket .................................................................................... 64 Opening and closing the bottom-dump bucket ...................................................................................... 64 After daily operation .............................................................................................................................. 65 Parking the machine.............................................................................................................................. 65 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS Securing the machine............................................................................................................................ 68 Corrosion protection for pins and bearings (bushings and hubs) Part nos. for Voler A.C........................................................................................................................... 69 Application of Voler A.C. ...................................................................................................................... 69 Lifting-gear operation - Safety instructions ........................................................................................ 70 LIFTING-GEAR OPERATION Load-hooks on backhoe buckets .......................................................................................................... 71 Lifting capacity of the load-hook ............................................................................................................ 71 Lifting capacity of the excavator ............................................................................................................ 71 Overload warning system ...................................................................................................................... 71 Checking the overload warning system ................................................................................................ 71 Putting the overload warning system out of operation .......................................................................... 71 Pipe break protection ............................................................................................................................ 72 Speed-reduction function ...................................................................................................................... 72 Hydraulic hammer ................................................................................................................................ 73 Working with the hydraulic hammer - Safety instructions ...................................................................... 73 NOTES...................................................................................................................................................... 75

PART 3 - INSPECTION AND SERVICING Inspection and servicing - Safety instructions .................................................................................... 79 Fire and Explosion Hazard .................................................................................................................... 83 Environmentally compatible hydraulic fluid Environmentally compatible hydraulic fluid - operating instructions ...................................................... 84 Environmentally compatible hydraulic fluid, conversion ........................................................................ 84 Environmentally compatible hydraulic fluid - Sampling ........................................................................ 85 Environment-friendly lubricants and gearbox oils Lubricants for bearings .......................................................................................................................... 86 Gearbox oils .......................................................................................................................................... 86 Inspection and servicing plans - Instructions Intervals ................................................................................................................................................ 87 Change of engine oil ............................................................................................................................ 87 Air-intake system .................................................................................................................................. 87 Oils / Greases........................................................................................................................................ 87 Cleaning jobs ........................................................................................................................................ 87 Plan V .................................................................................................................................................... 89 Plan N.................................................................................................................................................... 91 Plan T .................................................................................................................................................... 93 Plan W .................................................................................................................................................. 93 Plan T .................................................................................................................................................... 94 Plan W .................................................................................................................................................. 94 Plan A .................................................................................................................................................... 95 Plan B .................................................................................................................................................... 95 Plan C.................................................................................................................................................... 95 Plan D.................................................................................................................................................... 95 Plan E .................................................................................................................................................... 95 Plan A .................................................................................................................................................... 96 Plan B .................................................................................................................................................... 96 Plan C.................................................................................................................................................... 96 Plan D.................................................................................................................................................... 96 Plan E .................................................................................................................................................... 96 Plan A .................................................................................................................................................... 97 Plan B .................................................................................................................................................... 97 Plan C.................................................................................................................................................... 97 Plan D.................................................................................................................................................... 97 Plan E .................................................................................................................................................... 97 Plan A .................................................................................................................................................... 98 Plan B .................................................................................................................................................... 98 Plan C.................................................................................................................................................... 98 Plan D.................................................................................................................................................... 98

Plan E .................................................................................................................................................... 98 LUBRICATING CHART - GREASE (Loading Bucket) Lubricating chart - Grease / Loading Bucket ...................................................................................... 101 Refilling quantities - Grease ................................................................................................................ 101 LUBRICATING CHART - GREASE (Backhoe Bucket) Lubricating chart - Grease / Backhoe Bucket ...................................................................................... 103 Refilling quantities - Grease ................................................................................................................ 103 INSPECTION PLAN - OIL Inspection plan - Oil ............................................................................................................................ 105 Refilling quantities - Oil ........................................................................................................................ 105 Refilling quantities - Other .................................................................................................................. 106 LUBRICANTS ........................................................................................................................................ 107 Oils for combustion engines and compressors (selection) .............................................................. 107 Oils for hydraulic systems (selection) ................................................................................................ 108 Oils for gearboxes (selection).............................................................................................................. 109 Greases for bearings and slewing rings ............................................................................................ 110 SERVICING WORK Draining hose for oil changes .............................................................................................................. 111 ENGINE Engine - Safety instructions ................................................................................................................ 112 Checking the V-belt tension ................................................................................................................ 112 Retensioning the alternator/fan belt .................................................................................................... 112 Retensioning the fan belt .................................................................................................................... 112 Checking and adjusting the valve clearance ...................................................................................... 112 Checking the engine oil level / Topping up with oil .............................................................................. 112 Changing the engine oil ...................................................................................................................... 113 Changing the engine oil filter .............................................................................................................. 114 Centrifuge (optional) ............................................................................................................................ 115 COOLING SYSTEM Temperature ........................................................................................................................................ 116 Radiator .............................................................................................................................................. 116 Cooling liquid ...................................................................................................................................... 117 Checking the cooling liquid .................................................................................................................. 117 Water filter .......................................................................................................................................... 118 AIR-INTAKE SYSTEM Main filter element .............................................................................................................................. 119

Removal and installation .................................................................................................................... 119 Checking and cleaning the main filter element .................................................................................... 120 Safety filter element ............................................................................................................................ 121 Replacement ...................................................................................................................................... 121 Air-intake line ...................................................................................................................................... 121 Dust collection .................................................................................................................................... 121 FUEL SYSTEM Fuel system - Safety instructions ........................................................................................................ 122 Changing the fuel filter ........................................................................................................................ 123 Venting the fuel system ...................................................................................................................... 123 Cleaning the fuel tank .......................................................................................................................... 124 Refuelling station (optional) ................................................................................................................ 124 Water trap (option) .............................................................................................................................. 125 Servicing.............................................................................................................................................. 125 Draining off water ................................................................................................................................ 125 ELECTRICAL SYSTEM Electrical system - Safety instructions ................................................................................................ 126 Alternator - Instructions ...................................................................................................................... 126 Battery main switch / Main fuse .......................................................................................................... 127 Battery ................................................................................................................................................ 127 Checking the battery fluid level............................................................................................................ 127 Checking the battery charge .............................................................................................................. 128 Removing and installing the battery .................................................................................................... 128 HYDRAULIC SYSTEM Hydraulic system - Safety instructions ................................................................................................ 130 Depressurizing the hydraulic system .................................................................................................. 130 Checking the hydraulic oil level .......................................................................................................... 131 Topping up with hydraulic oil .............................................................................................................. 131 Changing the hydraulic oil return-flow filters........................................................................................ 132 Bypass valves (working circuit) .......................................................................................................... 133 Cleaning the sieve .............................................................................................................................. 133 Replacing the bypass valves and the sealing rings ............................................................................ 133 Bypass valve (cooling circuit) .............................................................................................................. 134 Cleaning the valve .............................................................................................................................. 134 Changing the valve.............................................................................................................................. 134 Breather filter ...................................................................................................................................... 135 Replacing the filter element ................................................................................................................ 135 High-pressure filter for working hydraulics .......................................................................................... 136 Checking/changing the filter elements ................................................................................................ 136 Replacing the filter element ................................................................................................................ 136 High-pressure filter for the servo circuit and the feeding circuit of the slewing pump .......................... 137 Checking the filter element .................................................................................................................. 137

Replacing the filter element ................................................................................................................ 137 Changing the hydraulic oil .................................................................................................................. 138 Draining off the hydraulic oil ................................................................................................................ 138 Cleaning the hydraulic oil reservoir .................................................................................................... 139 Filling in hydraulic oil .......................................................................................................................... 139 Venting the hydraulic system .............................................................................................................. 140 Venting the hydraulic components ...................................................................................................... 140 Cleaning the hydraulic oil cooler.......................................................................................................... 141 Cleaning .............................................................................................................................................. 141 Pressure accumulator ........................................................................................................................ 142 Pressure-accumulator inspection regulations...................................................................................... 142 Excerpt from the German regulations.................................................................................................. 142 Excerpt from the acceptance regulations ............................................................................................ 142 Checking the gas charging pressure in the pressure accumulator ...................................................... 142 PUMP TRANSFER GEARBOX Checking the gearbox oil level / Topping up with oil............................................................................ 144 Changing the gearbox oil .................................................................................................................... 144 Draining off oil .................................................................................................................................... 144 Filling oil .............................................................................................................................................. 144 Gearbox venting .................................................................................................................................. 144 SLEWING GEARBOX Gearbox - Checking the oil level / Topping up with oil ........................................................................ 145 Changing the gearbox oil .................................................................................................................... 145 Draining off oil .................................................................................................................................... 145 Filling in new oil / Topping up .............................................................................................................. 145 Gearbox venting .................................................................................................................................. 145 Venting bore ........................................................................................................................................ 145 TRAVEL GEARBOXES Gearbox - Checking the oil level / Topping up with oil ........................................................................ 146 Travel gearbox - Changing the oil ...................................................................................................... 146 Filling in new oil / Topping up .............................................................................................................. 146 Gearbox venting .................................................................................................................................. 146 CRAWLER TRACKS Cleaning .............................................................................................................................................. 147 Track rollers, support rollers, track pads ............................................................................................ 147 Track roller fastening .......................................................................................................................... 147 Support roller fastening ...................................................................................................................... 147 Track pads .......................................................................................................................................... 148 Track tensioner.................................................................................................................................... 148 System configuration .......................................................................................................................... 148 Technical data .................................................................................................................................... 148 Function .............................................................................................................................................. 148

Pressure-accumulator inspection regulations...................................................................................... 149 Excerpt from the German regulations.................................................................................................. 149 Excerpt from the acceptance regulations ............................................................................................ 149 Checking the gas charging pressure in the diaphragm accumulator .................................................. 149 Idlers.................................................................................................................................................... 150 Checking the oil level .......................................................................................................................... 150 Filling in oil .......................................................................................................................................... 150 SLEWING RING Slewing ring - Instructions .................................................................................................................. 151 Bearing races ...................................................................................................................................... 151 Internal gearing .................................................................................................................................. 151 Slewing ring - Checking the grease filling............................................................................................ 152 Slewing ring - Filling in grease ............................................................................................................ 152 Slewing ring - Checking the screws for tightness ................................................................................ 152 CENTRAL LUBRICATING SYSTEM Design and function ............................................................................................................................ 153 Greasing cycle .................................................................................................................................... 155 Presetting the pause duration ............................................................................................................ 155 Indicators ............................................................................................................................................ 155 Venting the grease pump .................................................................................................................... 156 Venting the grease lines ...................................................................................................................... 156 Unblocking a grease line .................................................................................................................... 156 Cleaning the grease sieves ................................................................................................................ 157 Cleaning .............................................................................................................................................. 157 Lubricating the grease distributor of the working equipment .............................................................. 157 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING Putting the excavator out of operation ................................................................................................ 158 Battery storage .................................................................................................................................... 158 Recommissioning ................................................................................................................................ 158 NOTES.................................................................................................................................................... 159

PART 4 - REPAIR WORK Repair work - Safety instructions ........................................................................................................ 163 Fire and Explosion Hazard .................................................................................................................. 165 ENGINE .................................................................................................................................................. 166 ELECTRICAL SYSTEM Assisted starting (with jumper cables) - Safety instructions ................................................................ 166 Assisted starting (with jumpercables) .................................................................................................. 166 Prior to assisted starting ...................................................................................................................... 166 Starting the engine with jumper cables (external batteries) ................................................................ 166 Connecting the jumper cables ............................................................................................................ 167 Starting up the engines ...................................................................................................................... 167 Disconnecting the jumper cables ........................................................................................................ 167 HYDRAULIC SYSTEM Repair .................................................................................................................................................. 168 Accumulators, safety instructions ...................................................................................................... 168 WELDING OPERATIONS ...................................................................................................................... 169 Welding operations - Safety instructions .......................................................................................... 169 NOTES.................................................................................................................................................... 171

PART 5 - ANNEX TROUBLESHOOTING .......................................................................................................................... 175 Instructions on troubleshooting .......................................................................................................... 175 Layout of the fault table Fault .................................................................................................................................................... 175 Possible causes .................................................................................................................................... 175 Measure ................................................................................................................................................ 175 Section .................................................................................................................................................. 175 FAULT TABLES Combustion engine - Fault table.......................................................................................................... 176 Working hydraulics - Fault table .......................................................................................................... 177 Track drive - Fault table ...................................................................................................................... 178 Slewing mechanism - Fault table ........................................................................................................ 179 Central lubricating system - Fault table .............................................................................................. 180 Hydraulic plan Legend (loading bucket) ...................................................................................................................... 182 Legend (backhoe configuration) .......................................................................................................... 184 Tightening torques and -angles .......................................................................................................... 185 ABBREVIATIONS .................................................................................................................................. 187 TECHNICAL DATA ................................................................................................................................ 189 NOTES.................................................................................................................................................... 191

PART 6 - INDEX INDEX .................................................................................................................................................... 195

OPERATING INSTRUCTIONS RH 40 E

PART 1 - INTRODUCTION

Operating manual

Part 1 INTRODUCTION

2804051

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

2 804 411.00 en

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

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

1

OPERATING INSTRUCTIONS RH 40 E

2

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Preface These operating instructions are designed to familiarize the operator with the machine and its designated use.

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

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

The operating instructions must always be available in the operator’s cab of the machine.

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

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

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

[1]

2804199

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

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

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

The operating instructions are not working instructions for carrying out major repairs. Such work is willingly done for you by the O&K-Mining 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.

Warranty

2732604

O&K-Mining’s warrenty is subject among other things to the maintenance works described in the Owner’s Manual having been performed by the O&K-Mining Service or by a workshop authorized in writing by O&K-Mining to perform such work.

[1] Complies with VDMA recommendation "Operating instructions"

2 804 411.00 en

3

OPERATING INSTRUCTIONS RH 40 E FUNDAMENTAL SAFETY INSTRUCTIONS

2261165

Complies with VDMA recommendation "Operating Instructions"

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

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

DESIGNATED USE

2413494

The machine has been built in accordance with state-of-the-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property.

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

The excavator with backhoe or loading bucket attachment is designed solely for excavating and loading: - excavated soils, - sand, - gravel, - blasted rock, - ore, - coal, and other raw materials.

4

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

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

Using the excavator or its 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, supports, sheet-piles etc. without the equipment being approved for this purpose, is considered contrary to the designated use.

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

The manufacturer/supplier cannot be held liable for any damage resulting from other than the designated use. The risk involved in such misuse lies with the user.

Noise emission specification in acc. with the 3rd Ordinance of the Machine Safety Act of 18th January 1991 resp. with EC Machine Directive, Annex I, para. 1.7.4 f.

If the earth-moving machine is operated in accordance with the designated use, the installation of driver´s seats complying with ISO 7096 ensures that the considered vibration accelerations azw (measured as per ISO 2631, Part 1) fulfil the requirements of protecting the driver against wholebody vibration.

2 804 411.00 en

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

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

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

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

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

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

For reasons of security, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewellery, such as rings, may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts.

2413495

Observe all safety instructions and warnings attached to the machine.

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

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

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

Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturers can be relied on to do so.

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

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

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

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

Observe all fire-warning and fire-fighting procedures.

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

2 804 411.00 en

5

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

Safety instructions governing specific operational phases

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

Standard operation

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

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

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

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

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

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

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

Avoid any operational mode that might be prejudicial to safety.

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

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

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

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

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

Start the machine from the driver’s seat only.

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

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

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

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

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

6

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Persons accompanying the driver must be seated on the passenger seat provided for this purpose.

When crossing underpasses and bridges or when passing under overhead lines always make sure that there is sufficient clearance.

Always keep a distance from the working face and from slopes.

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

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

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

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

Special work in conjunction with utilization of the machine - maintenance and repairs during operation - disposal of parts and consumables Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

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

In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the operating instructions and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

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

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

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

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

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

2 804 411.00 en

7

OPERATING INSTRUCTIONS RH 40 E Wear a safety harness when carrying out maintenance work at greater heights.

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

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use aggressive detergents.

Use lint-free cleaning rags.

Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switch-gear cabinets.

Warning of special dangers Electric energy Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

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

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

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

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

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

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

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

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

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

Gas, dust, steam and smoke Operate internal combustion engines and fueloperated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.

Observe the regulations in force at the respective site.

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

8

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Hydraulic equipment Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immmediately. Splashed oil may cause injury and fire.

Depressurize all system sections and pressure pipes (hydraulic system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Transporting and recommissioning The machine must be loaded and transported only in accordance with the operating instructions.

Use only appropriate means of transport and lifting gear of adequate capacity.

The recommisioning procedure must be strictly in accordance with the operating instructions.

Hydraulic lines must be laid and fitted properly.

Ensure that no connections are interchanged.

The fittings, lenghts and quality of the hoses must comply with the technical requirements.

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

Always wear the prescribed ear protectors.

Oil, grease and other chemical substances When handling oil, grease or other chemical substances, observe the product-related safety regulations.

Be careful when handling hot consumables (risk of burning or scalding).

2 804 411.00 en

9

OPERATING INSTRUCTIONS RH 40 E Fire and Explosion Hazard

2796684

Prior to commencing work, inform - on the national and corporate rules for prevention of accidents. Pay particular attention to hazards caused by combustible and easily flammable substances.

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

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

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

Do not store or handle any flammable substances during operation.

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

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

If necessary, also cover the ground with fireprotective blankets.

Ensure sufficient ventilation.

Clean the excavator before starting a job.

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

Do not extinguish flammable liquids with water.

Use: - dry-powder, - carbon-dioxide or

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

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

Even battery gases can ignite in open flames or fire.

- foam extinguishing compounds.

Avoid parking the excavator in places where

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

- combustible substances such as coal dust or tar are present.

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.

- open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

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

10

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E NOTES

2 804 411.00 en

2804180

11

OPERATING INSTRUCTIONS RH 40 E

12

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E PART 2 - OPERATION

Operating manual

Part 1 INTRODUCTION

2804052

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

2 804 411.00 en

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

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

13

OPERATING INSTRUCTIONS RH 40 E

14

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Operation - Safety instructions

2804201

Operating Instructions

Safety belt

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

For machines with a safety belt for operating personnel:

Pay special attention to: the "Fundamental Safety Instructions" and all warnings and safety instructions 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 O&K-Mining mechanic or by attending an O&K-Mining operators’ 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.

2 804 411.00 en

Check the safety belt attached to the driver’s seat. In the event of damage or after an accident, have it replaced immediately.

Apply safety belt before starting work.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the equipment and component combinations approved by O&K-Mining.

Clear-cut data are given in the technical specification.

Never install and commission other equipment and component combinations without O&K-Mining 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 up the machine.

Check that all warnings and safety instructions attached to the machine are present and legible.

15

OPERATING INSTRUCTIONS RH 40 E

Entering and leaving the machine Use only the steps, platforms and handrails provided when entering and leaving the machine.

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

Hazard range The hazard range is that zone around the machine in which persons are within reach of falling loads or falling attachments due to operational movements by the machine, to its equipment and attachments or to swinging loads.

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

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

16

Marshallers The marshaller must keep outside the hazard zone.

Have a marshaller to assist you: - when you have no clear overview over the hazard zone of the machine, - when reversing, - when shunting.

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie / camera). Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller.

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

Securing the machine Secure the machine as described in the section "Securing the Machine" before: - mounting or dismantling the attachment, - parking the machine after daily operation, - carrying out any servicing or repair work.

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Fire and Explosion Hazard

2796685

Safety Instructions Avoid smoking and open fire on, next to and below the machine.

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

Do not store such substances on the excavator.

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

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

Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where - combustible substances such as coal dust or tar are present.

- open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks may cause fire on the ground that can spread to the excavator.

2 804 411.00 en

17

OPERATING INSTRUCTIONS RH 40 E DESCRIPTION OF THE EXCAVATOR

2804413

Fig. 1

18

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Excavator layout (Fig. 1) Undercarriage

Loading bucket

1

- Track drive

2

- Idler

3

- Track rollers

4 5 6 7

-

29 30 31 32 33 34 35 36 42 43 44

Support rollers Crawler track Track tensioner Slewing ring

Superstructure 8 9 10 11 12 13 14 15 16

-

Hydraulic oil reservoir Radiator (engine cooling liquid) Fuel tank Engine Pump transfer gearbox Hydraulic pumps (main pumps) Hydraulic pump (fan drive) Slewing pump Pilot control pump

17 18 19 20 21 22 23 24

-

25 26 27 28

-

Cooling pump Cooler (hydraulic oil) Slewing mechanism Batteries and battery main switch Driver’s cab with air conditioner Control panel Counterweight Grease container for central lubricating system Travel control block and rotor Air-intake system with vacuum-meter Exhaust system Ladder

-

Boom TriPower-linkage Stick Bottom-dump bucket Boom cylinder Stick cylinder Bucket tipping cylinder Bottom-dump cylinder Working equipment control valves Bottom-dump control valve Quick-motion valve

Backhoe bucket 31

- Stick

33

- Boom cylinder

34

- Stick cylinder

37

- Monoblock boom

38

- Backhoe bucket

39

- Backhoe bucket cylinder

40

- Toggle link

41

- Toggle lever

42

- Working equipment control valve

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

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

Drive unit The drive unit comprises the diesel engine, the pump transfer gearbox, the hydraulic pumps, hydraulic cylinders and hydraulic motors.

2 804 411.00 en

19

OPERATING INSTRUCTIONS RH 40 E Hydraulic system All working and travelling movements are performed hydraulically. The movements are controlled by servo-valves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the superstructure to the undercarriage is ensured by the rotor. The hydraulic system is overload-protected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

Pump-Managing-System The Pump-Managing-System (PMS) with a loadlimit regulation ensures optimum utilization of the installed or preset engine power. The electronic pump load-sensing control prevents the machine from demanding more hydraulic power than the diesel engine can furnish. A micro-processor ensures that the hydraulic output power of the pump is optimally suited to the actual working conditions.

The PMS Box (load-limit regulator) is located in the driver’s cab (behind the control center).

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

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 engine.

Automatic engine speed reduction If the control pedals and control levers and thus the servovalves remain without actuation for a period of 10 seconds or more, the engine speed is automatically reduced to idling. This function is a further contribution to fuel economy.

Electrical system The electrical system operates on 24 volts.

20

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

2 804 411.00 en

21

OPERATING INSTRUCTIONS RH 40 E

Fig. 2

22

2 804 411.00 en

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

Keep the signs legible and clean.

Replace the signs immediately if they have become illegible.

New warning and instruction signs can be ordered from the O&K-Mining pare-Parts Service.

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

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

Fig. 4

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

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

Fig. 5

Component numbers

Fig. 3

Also the other larger units have identification lates indicating, among other things, their serial number.

On steel components, the O&K-Mining part number or the serial number may be stamped into the metal at a clearly visible place.

2 804 411.00 en

23

OPERATING INSTRUCTIONS RH 40 E Fire-extinguisher (optional equipment)

Handling

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

• Pull out safety pin (2, Fig. 7).

• Press down button (3) firmly and release.

• Operate the extinguishing gun.

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

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

Fig. 6

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

Such instruction should be given by a qualified instructor.

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

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

Fire extinguishing system (optional) The automatic fire extinguishing system prevents fire from spreading. It is, however, assumed that that the machine be thoroughly cleaned of combustible and easily flammable substances.

Inspection Have the extinguishing system inspected regularly by an expert. This is required by authorities and insurance companies and is in the interests of your own safety.

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

Fig. 7

24

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E DRIVER’S CAB

2804414

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. 1).

Always face the machine when entering or leaving it.

2 804 411.00 en

Fig. 1

25

OPERATING INSTRUCTIONS RH 40 E Driver’s seat

Adjusting the seat cushion

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

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

Never adjust the seat while driving.

Concentrate on the road to avoid accidents.

Before carrying out any seat adjustments: - stop the machine - set the control lever to "0"

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

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

Fore-and-aft position The fore-and-aft position of the seat can be adjusted with lever (1). Pull lever (1) upwards, slide seat to the desired position and allow lever (1) to engage.

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

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

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

Fig. 2

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

Adjusting the lumbar support The backrest is equipped with an upper and a lower air chamber.

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

26

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Cab interior lighting

Screen-washer

The cab lighting is switched on and off with switch (1, Fig. 3).

The reservoir (1, Fig. 4) for the screen-washer is located in the platform under the driver ’s cab.

The power supply to the lamp is not interrupted even after the electrical system has been shut off.

• Open flap (2).

The batteries may be discharged if the interior lighting remains on for prolonged periods.

• Depending on the season, fill reservoir (1) either with water or with water and an antifreeze compound.

Therefore, shut off the interior lighting when leaving the machine.

Fig. 4

Fig. 3

2 804 411.00 en

27

OPERATING INSTRUCTIONS RH 40 E MONITORING, WARNING AND CONTROL ELEMENTS

2804415

Fig. 1

28

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 1) No. Element

Function

1

Clock

2

Thermometer

3

Pressure gauge Engine oil pressure

4

Thermometer

Diesel engine tempera- Indicates the temperature of the cooling ture liquid

5

Warning lamp

PMS (PUMP MANAGING SYSTEM)

Symbol

Pump transfer gearbox Indicates the oil temperature in the pump temperature transfer gearbox Indicates the oil pressure in the diesel engine lubricating system

Lamp flashes:

- when the electrical system is on (engine stationary) - in the event of a fault (engine running) short-circuit, cable break or defective componenent (magnetic pick-up, termperature probe for load-sensing or proportional valve) Lamp is permanently lit - when the programmed hydraulic oil temperature of 80˚C is exceeded.

6

Warning lamp

CELECT warning

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

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

7

Warning lamp

CELECT warning

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

Shut off engine Stop working.

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

8

Warning lamp

CELECT warning

Lamp is lit up (e.g.): - when the engine oil pressure is too low - when the cooling water temperature is too high Shut off engine

2 804 411.00 en

29

OPERATING INSTRUCTIONS RH 40 E

Fig. 2

30

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 2) No. Element

Function

9

Warning lamp

Cooling-liquid level

Lit when the cooling-liquid level is too low.

Shut off engine

10

Warning lamp

Cooling-liquid temperature

Lit when the temperature is too high Shut off engine

11

Warning lamp

Engine oil pressure

Lit when the engine oil pressure is too low Shut off engine

12

Warning lamp

Alternator

Lit when the alternator does not charge the battery.

13

Speedometer

(optional equipment)

Indicates the engine revolutions

2 804 411.00 en

Symbol

31

OPERATING INSTRUCTIONS RH 40 E

Fig. 3

32

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 3) No. Designation

Function

14

Thermometer

Hydraulic oil temperature

Indicates the temperature of the oil in the hydraulic reservoir.

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

Free for optional equipment

18

Free for optional equipment

19

Warning lamp

Min. hydraulic oil level Lit when the hydraulic oil level is below limit value.

Shut off engine

20

Warning lamp

Min. fuel

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

21

Indicator lamp

Track parking brake

Lit when the parking brake is applied.

- The parking brake is automatically applied when the machine is stationary.

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

22

Warning lamp

Main pump I contamination

Lit when the hydraulic pump I is contaminated with metallic particles

23

Warning lamp

Main pump II contami- Lit when the hydraulic pump II is contamination nated with metallic particles

24

Free for optional equipment

25

Free for optional equipment

2 804 411.00 en

Symbol

33

OPERATING INSTRUCTIONS RH 40 E

Fig. 4

34

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 4) No. Element

Function

26

Warning lamp

Hydraulic oil filter

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

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

27

Indicator lamp

Idle-Auto

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

28

Warning lamp

Superstructure holding brake

Lit when the holding brake is applied.

Symbol

- The holding brake is automatically applied when the superstructure is stationary.

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

29 30

Free for optional equipment Indicator lamp

Lubrication ON

31

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

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

2 804 411.00 en

35

OPERATING INSTRUCTIONS RH 40 E

Fig. 5

36

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 4) No. Element

Function

36

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

Buzzer

Symbol

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.

2 804 411.00 en

37

OPERATING INSTRUCTIONS RH 40 E

Fig. 6

38

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 6) No. Element

Function

51

Momentary contact switch

Cold

Starting aid for cold engine

52

Momentary contact switch

Engine monitor

Diagnosis ON/OFF

53

Momentary contact switch

Stop

Shuts off the engine

54

Switch

Engine monitor

Listing of fault codes see warning lamps (6 and 7) (Increment) (Decrement)

55

Free for optional equipment

56

Free for optional equipment

57

Switch

Speed reduction

58

Symbol

to the left:

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

Free for optional equipment

59

Operating-hours meter

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

60

Rotary switch

3-stage regulation of air flow

2 804 411.00 en

Fan, air conditioner

39

OPERATING INSTRUCTIONS RH 40 E

Fig. 7

40

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 7) 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

Track parking brake

Applies the track parking brake Actuate switch only when the machine is stationary.

The track parking brake is released automatically when the "Travel" 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

Driver’s cab, rear right

2 804 411.00 en

Symbol

41

OPERATING INSTRUCTIONS RH 40 E

Fig. 8

42

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 8) No. Element 70

Speed control

Function (Potentiometer)

71 72

Symbol

Controls the engine speed - turn counter-clockwise to the limit stop: idling speed - turn clockwise to the limit stop: full speed not in use

Key-switch

Activation /De-activation of electrical system Position 1: function check of indicator and warning lamps in satellites I and II 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 (with shovel equipment)

When actuated: boom cylinders are pressurized when when retracted. (only for loading shovel equipment) Depress button (79) only when control lever (88) is in position "0"

80

Pushbutton

Horn

Sounding of the horn

81

Pedal

Travelling, right track

forwards / backwards

82

Pedal

Travelling, left track

forwards / backwards

82

Pedal

Bottom dump

Opens/closes the bucket bottom

2 804 411.00 en

43

OPERATING INSTRUCTIONS RH 40 E

Fig. 9

44

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E (Fig. 9) No. Element

Function

85

Pushbutton

87

Control lever

Raising and lowering of the bucket / backhoe bucket stick slewing and braking of the superstructure

88

Lever

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

91

Control lever

Air conditioner

93

Radio

(optional equipment)

97

Socket

PMS diagnosis

98

Socket

CELECT diagnosis

99

PMS-Box (Load-limit regulator)

Fault code display with PMS (5) warning lamp

2 804 411.00 en

Pilot control

Symbol

Activation/de-activation of pilot control

Controls the amount of warm air

45

OPERATING INSTRUCTIONS RH 40 E PUTTING THE MACHINE INTO OPERATION

Filling in fuel 2804416

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

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

Fig. 1

• Unscrew cap of filler tube (2, Fig. 1).

Refuelling - Safety instructions Explosion hazard.

Do not smoke and avoid open fire.

Fuels and fuel gases are inflammable. Risk of fire.

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

• Fill in fuel through the screen in the filler tube.

Do not remove screen.

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

Stand working equipment on the ground.

Shut off engine.

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.

Fuel accidents must be reported immediately to the user or his representative.

46

Fig. 2

2 804 411.00 en

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

Using the refuelling system • Unscrew cap (16, Fig. 4) 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. 3

Check before refuelling that the earthing strap (4, Fig. 3) is attached to the chassis. Sparking caused by static or electric charges may set fuel on fire.

Fig. 4

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

2 804 411.00 en

47

OPERATING INSTRUCTIONS RH 40 E Service station (optional equipment) Refilling and draining For filling in or for draining fluids, unscrew the cap of the corresponding express coupling (Fig. 5).

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

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

Switching the electrical system on and off Key-switch (72, Fig. 6) serves to switch the following functions:

Fig. 6

P = Not connected.

0 = All electrical consumers without current.

Engine off.

Fig. 5

Pos. Fig.4

Fluid

Express coupling for

1 = Electrical system on: lamp test. All monitoring and warning lamps are activated for 5 seconds and buzzer (36, Fig. 7) is activated for 1 second. Thereafter, warning lamps (5, 9, 10, 21,26, 28, 30) are lit. Warning lamp (5) flashes.

1

Diesel fuel

filling

2

Cooling liquid

filling resp. draining

2 = Not connected.

3

Engine oil

filling resp. draining

4

Hydraulic oil reservoir

filling resp. draining

3 = Engine start. All warning and monitoring lamps must go out when the engine is running.

Fig. 7

48

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Battery main switch The battery main switch is located under a lockable hatch (arrow, Fig. 8) 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. 9 have the following meaning: I = ON II = OFF In the OFF position, the battery main switch handle can be withdrawn.

Fig. 8 Fig. 9

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

2 804 411.00 en

49

OPERATING INSTRUCTIONS RH 40 E Starting and stopping the engine

2804205

Starting the engine

Fig. 2

Using the cold-starting aid for starting • Turn speed control knob (70, Fig. 1) counterclockwise to the limit stop (idling).

Fig. 1

• Turn speed control knob (70, Fig. 1) counterclockwise 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 3 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.

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

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

50

• Insert key into key-switch (72) and turn clockwise to position 1.

• Actuate the "Cold" switch (51) 2 to 3 times.

Each actuation injects ca. 1.5 cm3 of cold-starting liquid into the air-intake line of the engine.

• Turn key to position 3.

Release key after the engine has fired.

Do not inject a greater amount of cold-starting liquid to avoid excessive pressures and deflagrations.

If the temperature of the engine cooling liquid is above 25˚C, the cold-starting system is automatically de-activated.

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E 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. 4) sounds, the engine can be shut off from full load.

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

• Turn speed control knob (70, Fig. 3) counterclockwise to the limit stop (idling).

To do so: • actuate stop-button (53, Fig. 3) and hold in this position until the engine has come to a standstill; • turn key in key-switch (72) to position "0" (electrical system without current).

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. 4

Fig. 3

2 804 411.00 en

51

OPERATING INSTRUCTIONS RH 40 E Ventilation and heating

2804412

Ventilation (fresh air) Adjusting the heating performance • Slide lever (94, Fig. 2) 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. 1).

Fig. 1

• When the engine is stationary, turn key-operated switch (72, Fig. 1) to position 1 • Slide heating control lever (94, Fig. 2) backwards (heating power = 0) • Turn rotary switch (60, Fig. 1) to the desired fan intensity (steps 1 - 3).

52

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Driving - Safety instructions 2804417

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

Close the cab door.

If the machine is fitted with a safety belt for the operator, fasten the belt.

If the superstructure is turned by more than 90˚ from the BASIC POSITION, the excavator travels in the opposite direction to that selected.

If the position of the superstructure in relation to the undercarriage is not exactly known, touch the accelerator lightly to see which direction the machine takes, before initiating the full travelling movement.

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

Never drive across slopes.

Take the utmost care on slippery, greasy ground.

Fig. 2

Running-in specifications for components of the crawler tracks Prior to initial commissioning and/or after repair work, run in the idlers, track rollers and support rollers as follow: - Raise the equipment (Fig. 1 and 2) - Drive the excavator in reverse approx. 50 m.

- Drive the excavator in forwards approx. 50 m.

- Stop the excavator.

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

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

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

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

Fig. 1

2 804 411.00 en

If the machine is to be driven a longer distance, the superstructure must be secured against turning by means of the locking bolts and the holding brake. The machine is then in its basic position.

53

OPERATING INSTRUCTIONS RH 40 E TRAVELLING

2804418

Superstructure basic position Travel direction and sense of actuation of pedals (81 and 82, Fig. 2) are identical only when the excavator is in its BASIC POSITION (Fig. 1).

Travelling forwards/backwards Travelling forwards: Depress pedals (81 and 82) forwards travelling in the direction of the idler (2, Fig. 1).

Travelling backwards: Depress pedals (81 and 82, Fig. 2) backwards travelling in the direction of the drive sprocket (4, Fig. 1).

Fig. 1

If the superstructure is slewed out of its basic position by more than 90˚ (Fig. 3), the excavator moves in a direction opposite to that expected when pedals (81 and 82, Fig. 2) are depressed.

Fig. 3

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

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

Do not travel across slopes.

When travelling uphill or downhill, the travel drive must always be at the rear. Travel only in the basic position of the excavator and only forwards.

Be extremely careful on slippery and greasy ground.

Fig. 2

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

54

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.

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Regulating the travel speed

Travelling downhill

Travelling on level ground or uphill:

Read and observe the "Travelling Safety instructions" chapter.

Regulate the travel speed with • pedals (81 and 82, Fig. 4) and/or • the engine speed control.

• Always depress pedals (81 and 82) to the limit stop.

• Regulate the travel speed only with the engine speed control.

When travelling downhill, the travel retarder valve acts as a speed limiter. The travel retarder valve works correctly only if pedals (81 and 82) are fully depressed down to the limit stops.

Should the travel speed nevertheless become too high, release pedals (81 and 82) to stop the excavator.

Cornering

Fig. 4

Taking a righthand corner forwards depress only pedal (82) forwards.

Taking a lefthand corner forwards depress only pedal (81) forwards.

Turning Turning to the right depress pedal (82) forwards and pedal (81) backwards.

Turning to the left depress pedal (81) forwards and pedal (82) backwards.

2 804 411.00 en

55

OPERATING INSTRUCTIONS RH 40 E Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 5): 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 The same procedure should be adopted if the excavator is to be driven out of depressions (Fig. 6):

This way of working is contrary to the excavator’s designated use.

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

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.

Fig. 5

Fig. 6

56

2 804 411.00 en

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

Travel only forwards with the excavator in its basic position.

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

Keep the loading bucket or backhoe bucket near the ground (Fig. 7 and 8). For a more uniform loading of the tracks, the equipment must, however, be kept at a steep angle.

Fig. 8

Backhoe bucket equipment (Fig. 8) 5) Fully extend boom cylinder 1.

6) Retract backhoe cylinder 2.

7) Retract stick cylinder 3.

8) Extend backhoe cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment shown in Fig. 8.

Lower the equipment when travelling underneath obstacles.

If the equipment position must be changed: • stop the excavator • change the position Fig. 7

Loading bucket equipment (Fig. 7) 1) Fully extend boom cylinder 1.

2) Extend bucket cylinder 2.

3) Extend stick cylinder 3.

4) Retract bucket cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment Fig. 7.

2 804 411.00 en

• continue to travel After travelling for 15 minutes without interruption, stop the excavator and check the temperature of the track rollers.

If the temperature does not exceed ca. 100˚ C: continue travelling.

In case of higher temperatures: Stop travelling. Resume travelling only after the track rollers have cooled down to ca. 40o C.

57

OPERATING INSTRUCTIONS RH 40 E Superstructure lock 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)

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

The track parking brakes are holding brakes which serve to relieve the hydrostatic track drives and to protect the excavator against rolling forwards and backwards.

• during transport.

Locking the superstructure (Fig. 9) • 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. 10

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

Fig. 9

When the excavator is stationary, the brakes can be applied with switch (65, Fig. 11).

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

Fig. 11

58

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Transporting the machine

2804419

Transport - Safety instructions

The partly dismantled excavator can now be transported on a semi low-bed trailer (low-bed trailer with front platform) (Fig. 1).

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 responsibility for loading and transporting lies with the transport company or their representative.

Remove oil, grease, soil, mud, snow, ice and other materials from the excavator’s crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Secure the transport vehicle against rolling away.

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

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.

Fig. 1

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

Loading the excavator: • 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)

Therefore, the following components and modules must be dismantled beforehand: • counterweight • driver’s cab • excavating tool (loading bucket, backhoe bucket) • stick • boom Fig. 2

2 804 411.00 en

59

OPERATING INSTRUCTIONS RH 40 E • Lock the superstructure (Fig. 3).

• Place solid timbers between the low-bed platform and the center part of the undercarriage (Fig. 4).

• 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. 5).

Fig. 3 Fig. 4

• Secure the excavator with suitable means (chain hoists, wire ropes, chains, turn-buckles) (Fig. 4).

Unload the excavator in reverse order.

Unlock the superstructure before slewing it for the first time.

60

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Working operation - Safety instructions Read the sections "Fundamental safety instructions" and "Operation, safety instructions" carefully and observe the instructions given in them.

Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life!

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements.

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

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk.

Ensure that the attachment has adequate clearance below overhead power lines and structures.

Trenches and working faces may give way. Keep well clear of them.

2 804 411.00 en

2413577

Running-in instructions for hydraulic cylinders Compression of an oil/air compound in a hydraulic cylinder may result in detonations which might damage pistons and sealing rings.

Prior to initial commissioning and/or after repairs, run in the hydraulic cylinders as follows: - Start up the engines and run at low temperatures.

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

- In the first two working cycles, retract and extend the pistons of the hydraulic cylinders to max. 1/2 to 3/4(not to the limit stop).

Never change direction suddenly.

The waiting time between changes of direction must be at least 4 seconds.

- In the next eight working cycles, retract and extend the pistons of the hydraulic cylinders to the limit stop. The waiting time between changes of direction must be at least 4 seconds.

- When all hydraulic cylinders have been run in, the excavator can operate at a higher engine speed.

61

OPERATING INSTRUCTIONS RH 40 E

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".

Parts of the attachment may damage the machine if they are moved into extreme positions (see illustration 1 and 2).

Work carefully, avoiding extreme positions of this kind.

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

Fig. 1

Fig. 2

62

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E WORKING OPERATION

2804420

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 bearing when the works starts.

Slewing and braking the superstructure To slew the superstructure to the right shift control lever (87, Fig. 1) to the right.

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

The control lever returns automatically to neutral position when released and the superstructure is braked in accordance with the braking valve setting.

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").

To warm up the system, run the engine at approximately 2/3 of full speed before performing for abt. 10 minutes working movements with the unloaded excavator.

Fig. 2

Switch on the "hold" function of the superstructure slewing brake with push-button (65, Fig. 2) The slewing brake is released automatically when the "superstructure slewing" function is activated.

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

Fig. 1

Switching on the pump servo system Activating and de-activating the pump servo control The hydraulic pump servo control is activated by means of button switch (85, Fig. 1).

Servo control activated The driver is sitting in his seat.

Servo control de-activated The driver’s seat is empty.

2 804 411.00 en

63

OPERATING INSTRUCTIONS RH 40 E Working After releasing, all control levers for working operation return automatically to their neutral position.

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

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

Fig. 3

Raising and lowering the boom The superstructure is braked when control lever (87, Fig. 3) is shifted into the opposite direction (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.

To raise the boom pull control lever (88) backwards.

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

To lower the boom with pressure (only for loading shovel equipment) Press 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.

Filling and emptying bucket ot backhoe bucket To fill/tip 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.

64

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E 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.

Escaping oil pollutes the environment.

Repair leaks immediately.

Report oil accidents to the user of the machine.

• Stand the working equipment on the ground.

• Shut off the engine.

• Shift both control levers into all directions to depressurize the hydraulic cylinders.

• Withdraw the key from the electrical system key-switch.

• Close the cab window.

• 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 hydraulic system, engine, track rollers, support rollers, idlers and gearboxes visually for leaks.

2 804 411.00 en

65

OPERATING INSTRUCTIONS RH 40 E ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS 2804209

Personnel

Tools and auxiliaries

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

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

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from O&K-Mining.

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.

66

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.

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

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

Protective roof against falling objects The machine is equipped with an integrated cab-roof protection structure (FOPS).

Selecting the attachments The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by O&K-Mining for this type of machine.

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

2 804 411.00 en

67

OPERATING INSTRUCTIONS RH 40 E Securing the machine Secure the machine as described below:

Risk of injury.

The machine must not be started by unauthorized persons.

Therefore, secure the machine.

Observe the accident prevention regulations.

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

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

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

- Before carrying out any fitting and modification work on the working equipment, - Before carrying out any servicing and repair work on the machine.

• park the machine on level and stable ground.

• lock the superstructure.

• stand the working equipment on the ground.

• shut off the 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.

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

Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of non re-usable oils without polluting the environment.

All components of O&K-Mining machines are carefully purpose-coordinated. Trouble-free operation and a long service life can only be achieved with original O&K-Mining spare parts.

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

68

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Corrosion protection for pins and bearings (bushings and hubs) Use Voler A.C. anti-corrosive agent only.

Other agents are not approved by O&K. All pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated with Voler A.C. anticorrosive agent before fitting.

Voler A.C.: • permits easy fitting and dismantling • protects against rust, oxidation and similar wear • prevents seizing and fretting corrosion in nonmoving parts of bearings.

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

Part nos. for Voler A.C. SN 0 271 554 - 0,5 l spray can (CFC-free)

2281259

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

Rust patches must be thoroughly removed, if any.

All parts must present a dry, bright metal surface.

• Apply a thin layer of Voler A.C. on pins and all bearings using a brush or a spray can. Pin shafts and bearings must be completely covered by the protective layer.

If the protective layer of a pin already treated with Voler A.C. is damaged, these areas must be touched up before fitting the part.

• Fitting and securing of pins If the pin is too heavy to be fitted manually, apply Voler A.C. at first only on abt. a quarter of the pin’s length Then position pin by means of a lifting gear ready for fitting.

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

SN 1 438 473 - 0,5 kg tin SN 1 438 219 - 4,5 kg bucket Available from the O&K Spare-Parts Service

2 804 411.00 en

69

OPERATING INSTRUCTIONS RH 40 E Lifting-gear operation - Safety instructions

2413547

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.

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

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.

Never move the load above persons. Keep the load as close as possible to the ground.

Prevent the load from swinging

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

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

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

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

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

Transporting the load

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 load-carrying device, - excessive deceleration or acceleration forces (hard braking or strong slewing with the load to be moved), - loads dropping into the cable, - oblique pull, - driving the excavator into an area with steeply sloping ground, - exposure to strong wind.

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

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.

Register the weight of the load.

Sling only those loads not exceeding the load capacity of the lifting gear and of the machine (cf. "Technical data").

70

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E LIFTING-GEAR OPERATION

2804430

Load-hooks on backhoe buckets 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 (Figs. 1 and 2) (optional equipment).

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

Switch on the overload warning system

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.

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

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

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

The overload warning system only gives warning signals. It cannot avert the danger of overturning.

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

In 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.

Fig. 1

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).

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

In case of malfunctions have the overload warning system immediately checked and repaired by O&K Mining.

Fig. 2

Lifting capacity of the load-hook The maximum lifting capacity of the load-hook is indicated besides the hook (Figs. 1 and 2).

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.

Lifting capacity of the excavator

Putting the overload warning system out of operation

The admissible lifting capacity as a function of the working radius is set out in the load table; cf.

"Technical data".

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

2 804 411.00 en

71

OPERATING INSTRUCTIONS RH 40 E Pipe break protection

Speed-reduction function

The pipe break protection prevents the working equipment from lowering if a hydraulic line to the boom cylinder breaks.

Do not activate the speed-reduction function when the machine is used for lifting-gear operation and for travelling.

The hydraulic connection on the rod side of the boom cylinder is blocked, so that the hydraulic oil can flow out only if the "Boom lowering" function is initiated.

The speed-reduction function can cause the hydraulic output to decrease suddenly.

If a hydraulic line has broken: • Warn persons in the vicinity of the excavator by sounding the horn.

Stop working.

The speed-reduction function reduces the drive engine revolutions to idling if the working equipment remains inactivated during 10 seconds.

• Secure the working equipment with the attached load.

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

• Replace the broken hydraulic line (or have it replaced) before continuing the work.

• Collect escaping hydraulic oil. Dispose of oily cleaning rags, oil binding agents, etc. without polluting the environment.

Fig. 3

To switch on the speed-reduction function: - Press toggle switch (57, Fig. 3) to the left.

Monitoring lamp (23, Fig. 4) lights up when the speed-reduction function is activated.

To switch off the speed-reduction function: - Press toggle switch (57) to the right.

Fig. 4

72

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E 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.

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 losses are detected. Collect escaping oil and dispose of it without polluting the environment.

Wear ear protectors.

Report oil accidents immediately to the user or his representative.

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

Repair leaks and damage immediately.

The power of the machine and that of the hydraulic hammer must be adapted to each other. In case of doubt, contact the O&K Mining Service.

2 804 411.00 en

73

OPERATING INSTRUCTIONS RH 40 E

74

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E NOTES

2 804 411.00 en

2804180

75

OPERATING INSTRUCTIONS RH 40 E

76

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E PART 3 - INSPECTION AND SERVICING

Operating manual

Part 1 INTRODUCTION

2804053

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

2 804 411.00 en

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

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

77

OPERATING INSTRUCTIONS RH 40 E

78

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E 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 knowhow on the inspection and servicing of this or comparable machines.

The necessary know-how can be aquired in a several days’ instruction, e.g. by an O&K-Mining mechanic or by attending an O&K-Mining 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.

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

2 804 411.00 en

2804211

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

Always keep 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.

79

OPERATING INSTRUCTIONS RH 40 E Cleaning jobs Prior to commencing work, clean your working area, if necessary and possible, with a stream jet (rubber parts and electric components with compressed air - refer to information label).

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

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

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

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

Wear gloves.

Observe the instructions on the packaging.

Handling flammable liquids 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.

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

Replace any damaged parts.

Spare parts Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturers can be relied on to do so.

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

Never set foot within reach of the emerging oil jet.

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

Used oil may be harmful to the skin.

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

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

Never attempt to extinguish burning liquids with water. 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 new hazards.

Visible loss of oil 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.

80

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E 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 its 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 depressurized: (do not leave the driver’s seat) -

Stand working equipment on the ground Shut off the engine Move all control levers and pedals repeatedly into all directions.

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

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

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

Do not dispose of these substances together with household wastes.

Fill these substances into the containers provided for such purpose.

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

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

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

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

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

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

Clean sealing faces prior to assembly.

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

Engine exhaust gases

Never repair damaged piping; always replace them.

Exhaust gases from engines are a health hazard: never inhale them.

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

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

2 804 411.00 en

81

OPERATING INSTRUCTIONS RH 40 E Handling batteries

Selecting oils and greases

Batteries give off explosive gases.

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

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

Battery acid is toxic and corrosive.

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

Wear gloves, firm protective clothing and goggles when handling batteries.

If the skin is spashed with acid, rinse thoroughly with running water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short-circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watch-straps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

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

Prior to work on the electrical system Prior to any work on the electrical system involving tools, spares etc. coming into contact with electric cables or contacts, disconnect the battery.

Disconnect first the negative pole, then the positive pole.

After work: Connect first the positive pole, then the negative pole.

Filters Replace all filter elements or filter cartridges within the specified periods.

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

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature.

Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

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

On completing work, re-install all protective devices.

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

Carry out performance tests with the machine.

82

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Fire and Explosion Hazard

2796685

Safety Instructions Avoid smoking and open fire on, next to and below the machine.

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

Do not store such substances on the excavator.

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

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

Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where - combustible substances such as coal dust or tar are present.

- open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks may cause fire on the ground that can spread to the excavator.

2 804 411.00 en

83

OPERATING INSTRUCTIONS RH 40 E Environmentally compatible hydraulic fluid Environmentally compatible hydraulic fluid - operating instructions The hydraulic system of this machine can be filled ex works with environmentally compatible, synthetic hydraulic fluid as an option. In this case, the machine is supplied with stickers containing the corresponding instructions.

For the initial filling, O&K-Mining uses only: PANOLIN HLP SYNTH 68 O&K-Mining (P/N: 2115005).

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

2804212

Environmentally compatible hydraulic fluid, conversion Read and observe: "Inspection and Servicing - Safety Instructions".

- Bring hydraulic system to operating temperature.

- Retract all hydraulic cylinders.

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

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

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

- Then drain off the hydraulic fluid.

The fluid can be used repeatedly for flushing.

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

- Change all filters in the hydraulic system.

- Fill the hydraulic oil tanks with new HLP SYNTH 68.

As HLP SYNTH 68 is not soluble in water This means that condensate may be deposited in the hydraulic oil tank.

It must therefore be drained off at regular intervals and after lengthy downtimes, then disposed of in the same way as used oil.

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

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

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

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

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

84

Fig. 1

Fix an instruction sticker (Fig. 1): - in the cab, - on the hydraulic oil tank and - on hydraulically-operated attachment.

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E - Start up the machine. Check level in hydraulic tank according to servicing plan.

Environmentally compatible hydraulic fluid - Sampling

- 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.

Complete sets are compiled for hydraulic fluid analysis. They contain all necessary parts.

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

- Hydraulic fluid analyses are performed by:

- Sets are available from the O&K Mining SpareParts Service: Part-No. 1 465 077.

WEARCHECK GmbH Bahnhofstraße 75 D-83098 Brannenburg - After 30 - 50 operating hours with environmentally compatible hydraulic fluid, take a sample of the hydraulic fluid.

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

- After this, O&K Mining recommends sending in a sample for analysis every 1000 operating hours or once a year.

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

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

In case of questions contact the O&K Mining Service.

2 804 411.00 en

85

OPERATING INSTRUCTIONS RH 40 E Environment-friendly lubricants and gearbox oils

2804246

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

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 O&K-Mining as an environmentfriendly grease.

Gearbox oils

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

86

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Inspection and servicing plans - Instructions

2804421

Intervals

Air-intake system

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

The air filter must be serviced only if the vacuummeter so indicates.

The individual inspection and servicing plans are marked with letters providing a link between the operating hours (OH) recorded by the hours-run meter of the machine and the inspection and servicing plans.

Oils / Greases

Plan

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 servicing plans have the following meaning:

Do all jobs ....

V

.... once prior to initial commissioning.

I

Oils for combustion engines and compressors

N

.... after initial commissioning and during the running-in period.

II

Oils for hydraulic systems

T

.... every 10 OH or every working shift1).

III

Oils for gearboxes

W

.... every 60 OH or weekly1).

V

Greases for bearings and slewing rings

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.

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

1)

Whichever comes first.

OH = Bh = Operating hours

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

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

2 804 411.00 en

87

OPERATING INSTRUCTIONS RH 40 E

88

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

Plan V

- Once prior to initial commissioning Page 1 of 1

Location

Servicing work

Quantity/ No.

Engine

Check oil level

1

Cooling system Cooling liquid

Check level

1

Electrical system Battery Lighting

Check charge condition Check operation

2

Monitoring, warning and control elements

Check operation

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

Check tightness

1

Hydraulic system Hydraulic oil reservoir Hydraulic cylinders

Check pressure 1) Check oil level Bleed systems

1

Pump transfer gearbox

Check oil level

1

Slewing gearbox Expansion reservoir

Check oil level

1

Travel gearbox

Check oil level

2

Working equipment Backhoe bucket bearing

Grease

11

Slewing ring Internal gearing

Check grease filling

1

Undercarriage Track roller Support roller Track Idler

Check for leaks and free movement Check for leaks and free movement Check tension Check for leaks

16 4 2 2

Central lubricating system Grease container

Check filling level

1

Air conditioner Compressor

Check oil level

1

Central lubricating system Grease container

Check filling level

1

All lines, fittings and connections

Inspect visually for leaks, wearing marks

All articulated joints and hinges

Lubricate

1)Contact the O&K-Mining Service

2 804 411.00 en

89

OPERATING INSTRUCTIONS RH 40 E

90

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Plan N

- After initial commissioning and during the running-in period

/Location

Servicing work

Page 1 of 2

Quantity / No.

After 60 OH Engine - Bearing - Fastening bolts Centrifuge (optional)

Check for tightness Clean

1

Cooling system Radiator - Bearing - Fastening bolts Water filter

Check for tightness Replace

1

Hydraulic system Oil cooler - Bearing - Fastening bolts Return-flow filter Magnetic rod Pressure accumulator

Check for tightness Replace Clean Check pressure

4 4 1

Slewing gearbox Fastening bolts

Check for tightness (torque wrench)

Travel gearbox Fastening bolts

Check for tightness

Superstructure Fastening bolts, especially at superstructure / pedestal / driver’s cab

Check for tightness

Undercarriage Fastening bolts - track pads Diaphragm accumulator - track tensioner Idler

Check for tightness (torque wrench) Check pressure Check oil level

All lines, fittings and connections

Inspect visually for leaks, wearing marks

2 804 411.00 en

2 2

91

OPERATING INSTRUCTIONS RH 40 E Plan N

- After initial commissioning and during the running-in period

Page 2 of 2

/Location

Servicing work

Quantity / No.

After 100 OH Pump transfer gearbox

Change oil

12)

Slewing gearbox

Change oil

12)

Travel gearbox

Change oil

22)

Slewing ring Fastening bolts (slewing ring undercarriage and Check tightness (torque wrench) superstructure) After 250 OH Superstructure Fastening bolts, especially at superstructure / pedestal / driver’s cab Undercarriage Modul crawler/undercarriage

Check for tightness

Check tightness

After 500 OH resp. 3 month3) Slewing ring Fastening bolts (slewing ring undercarriage and Check tightness (torque wrench) superstructure) 2) Cf. "Refilling quantities - Oil" table.

3) When a lost of preload of the bolts is found in the course of the check, checking shall be carried out

after 500 OH resp. 3 month.

92

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Plan T

- Every 10 OH or every working shift (whichever comes first)

Plan W - Every 60 OH or weekly (whichever comes first) Page 1 of 2 Location

Servicing work

Quantity / No.

Plan T

Plan W

Engine

Check oil level

1

•

•

Cooling system Cooling liquid Radiator

Check level Check contamination/clean

1

• •

• •

Drain off water

2

•

•

Fuel system Fuel filter Refuelling station (option) - Earthing strap (equipotential bonding) Water trap (optional)

Check tightness

1

•

•

Drain off water

1

•

•

Air-intake system Vacuum-meter Intake and clean airlines

Check indication Check for tightness and leaks

1

•

• •

Electrical system Lighting

Check operation

•

•

Monitoring, warning and con- Check operation trol elements BCS Check operation

•

•

•

•

Hydraulic system Hydraulic oil reservoir Oil cooler Fins /fan wheel

Inspect visually for leaks Check oil level Check / clean Remove contamination, ice and snow

1 1

•

• • • •

Pump transfer gearbox

Check oil level

1

•

•

Slewing gearbox Expansion reservoir Venting bore

Check oil level Check / clean

1 1

•

• •

Travel gearbox

Check for leaks

2

•

•

Working equipment Backhoe bucket

Grease

11

•

•

Undercarriage Tracks Track roller Support roller Idler

Inspect track tension visually Check for leaks and free movement Check for leaks and free movement Check for leaks

2 16 4 2

• • • •

• • • •

2 804 411.00 en

•

93

OPERATING INSTRUCTIONS RH 40 E Plan T

- Every 10 OH or every working shift (whichever comes first)

Plan W - Every 60 OH Or weekly (whichever comes first) Page 2 of 2 Location

Servicing work

Central lubricating system Grease container Overpressure valve

Check grease level Check for escaping grease

All lines, connections Excavator

94

fittings

a n d Inspect visually for leaks, wearing marks Carry out overall cleaning

Quantity / No.

Plan T

Plan W

1 2

• •

• •

•

• •

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Plan A

- After every 250 OH

Plan C

- After every 1000 OH

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

Plan B

- After every 500 OH

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

Plan D

- After every 5000 OH

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

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

Plan E

- After every 10000 OH (at 10000, 20000, 30000 .... OH) Page 1 of 4

Location

Servicing work

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

Servicing in acc. with W or T Engine - Bearing - Fastening bolts - Rubber bearing Oil filter V-belt V-belt Valve clearance

Change oil 4) Clean Check tightness Check condition Replace Check tension Check condition Check / adjust

Engine with engine oil cen- Change oil 4) trifuge (optional) Clean - Bearing - Fastening bolts Check tightness - Rubber bearing Check condition Oil filter Replace Centrifuge Clean - Rotor seal Replace - Casing seal Check / replace V-belt Check tension V-belt Check condition Valve clearance Check / adjust Cooling system Radiator - Bearing - Fastening bolts - Rubber bearing Water filter Cooling liquid Lines Hose clamps

1 3)

•

•

•

•

•

•

• •

• •

• •

• • • • • •

• • • • • •

• • • • • •

•

•

•

•

•

•

• • • • • • • • •

• • • • • • • • •

• • • • • • • • •

2

• • •

• • •

1 3)

•

•

2 1 1 1

Inspect visually for leaks

Check tightness Check condition Replace Check DCA4-concentration Change5) Check for leaks Check for tightness

•

1

• • • • • •

• • • • • •

•

•

•

•

•

•

• •

• • • •

• • • •

•

•

• •

• •

• • • • • • •

2) Cf. "Refilling quantities - Oil" table.

4) The maintenance interval can be prolonged if regular oil alalyses are carried out and after approval

of the Diesel engine manufacturer has been obtained.

5) Cooling-liquid replacement at the latest after 2 years.

2 804 411.00 en

95

OPERATING INSTRUCTIONS RH 40 E Plan A

- After every 250 OH

Plan C

- After every 1000 OH

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

Plan B

- After every 500 OH

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

Plan D

- After every 5000 OH

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

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

Plan E

- After every 10000 OH (at 10000, 20000, 30000 .... OH) Page 2 of 4

Location

Servicing work

Fuel system Fuel filter Tank breather valve Water trap (optional)

Replace Clean Clean

2 1 1

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

Replace 6) Replace 7) Check for tightness and leaks Replace

2 2

Electrical system Battery and cable connections

Check for tightness

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

•

•

•

•

•

•

•

•

• • •

• • •

• • •

• • •

• • •

•

•

•

•

•

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

7) Replacement of safety filter element after one year resp. after 3 cleaning cycles

of the main filter element at the latest.

96

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Plan A

- After every 250 OH

Plan C

- After every 1000 OH

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

Plan B

- After every 500 OH

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

Plan D

- After every 5000 OH

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

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

Plan E

- After every 10000 OH (at 10000, 20000, 30000 .... OH) Page 3 of 4

Location

Hydraulic system Oil cooler - Bearing - Fastening bolts - Rubber bearing Return-flow filter High-pressure filter

Servicing work

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

Magnetic rod Bypass valve (working circuit) Bypass valve (cooling circuit) Clean valve Replace valve Filter (pilot control circuit) Check for contamination and damage Replace Filter (slewing mechanism Check for contamination and pump feeding-circuit) damage Replace Hydraulic oil reservoir brea- Replace ther-filter Hydraulic oil reservoir Carry out oil analysis Change oil8) Cylinder (seals and guide Replace rings)

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

4 2 2 4 1

• •

• • • •

• •

• •

1

•

•

1

•

•

• • •

1 1

•

•

• •

• •

• •

• •

•

• • •

1 1 1 1 2)

•

•

•

• • • • • • •

• • • • • • • • • •

2) Cf. "Refilling quantities - Oil" table.

8) Change the hydraulic oil after 2 years at the latest.

2 804 411.00 en

97

OPERATING INSTRUCTIONS RH 40 E Plan A

- After every 250 OH

Plan C

- After every 1000 OH

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

Plan B

- After every 500 OH

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

Plan D

- After every 5000 OH

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

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

Plan E

- After every 10000 OH (at 10000, 20000, 30000 .... OH) Page 4 of 4

Location

Servicing work

Pump transfer gearbox

Carry out oil analysis Change oil Clean

1 1 2) 1

•

•

• • •

• • •

• • •

Slewing gearbox

Carry out oil analysis Change oil

1 1 2)

•

•

•

• •

• •

Travel gearbox Travel gearbox

Carry out oil analysis Check oil level Change oil Clean Change

2 2 2 2) 2 2

•

• •

• •

• • • • •

• • • • •

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

1

• •

• •

• •

• • •

Check for leaks and free movement Check for leaks and free movement Check for leaks Check for tightness (torque wrench)

16

•

•

•

•

2

•

•

•

•

2

• •

• •

• •

• •

•

•

•

Breather filter

Breather filter Slewing ring Gearing pinion Fastening screw (slewing ring, superstructure and undercarriage) Undercarriage Track roller Support roller Idler Track pad fastening bolts

Central lubricating system Grease screen Check / clean

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

3

•

Steel components

Carry out visual inspection

•

•

•

All articulated joints and hinges

Lubricate

•

•

•

2) Cf. "Refilling quantities - Oil" table.

98

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

2 804 411.00 en

99

OPERATING INSTRUCTIONS RH 40 E LUBRICATING CHART - GREASE (Loading Bucket)

2804422

Fig. 1

100

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Lubricating chart - Grease / Loading Bucket (legend) Pos.

Greasing location

Number

Lubricant properties

Grease every ... operating hours

V

10

1

Central lubricating system - grease container

1

2

Hinge (cab door)

3

1)

1000

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

Refilling quantities - Grease Greasing location, component Central lubricating system - grease container

Lubricant properties Filling quantity in kg

V

5

1)

Internal gearing - roller-bearing slewing ring

28

1) Cf. section "Lubricants" Bh = OH = Operating hours

2 804 411.00 en

101

OPERATING INSTRUCTIONS RH 40 E LUBRICATING CHART - GREASE (Backhoe Bucket)

Fig. 2

102

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Lubricating chart - Grease / Backhoe Bucket (legend) Pos.

Greasing point

Number

Lubricant properties

Grease every .... operating hours

1

Central lubricating system - grease container

1

10

2

Cylinder/toggle link bearing

1

10

3

Toggle link/toggle lever bearing

2

4

Stick/toggle lever bearing

2

10

5

Stick/backhoe bucket bearing

2x2

10

6

Toggle link/toggle lever bearing

2

10

7

Hinge (cab door)

3

1000

V

1)

10

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

Refilling quantities - Grease Greasing point, component

Lubricant properties Filling quantities in kg

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

5

V

1)

28

1) Cf. section "Lubricants" Bh = OH = Operating hours

2 804 411.00 en

103

OPERATING INSTRUCTIONS RH 40 E INSPECTION PLAN - OIL

Fig. 3

104

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Inspection plan - Oil (legend) Pos.

Location

Number

Lubricant properties 1)

Check oil level every .... OH

Change oil every .... OH

I II III

10

2502)

10

100003)

10

1000

10

5000

500

5000

1

Engine

1

2

Hydraulic system

1

3

Pump transfer gearbox

1

API SAE 80, (synthetic oils for gearboxes) 4

Slewing gearbox

1

5

Travel gearbox

2

III III

Bh = OH = Operating hours 1) Cf. section "Lubricants" of the Diesel engine manufacturer has been obtained.

2) The maintenance interval can be prolonged if regular oil alalyses are carried out and after approval of the Diesel engine manufacturer has been obtained.

3) Unless it is regulary analyzed, the hydraulic oil must be changed every 3000 OH or after 3 years at the latest

Refilling quantities - Oil Location

Filling quantity (liters)

Oil

Drive engine -without filter change

60

-with filter change

66

I I II II

Hydraulic system at oil change

ca. 1700

-Oil reservoir

ca. 1300

Pump transfer gearbox

ca. 15

III API SAE 80 (synthetic oils for gearboxes)

Slewing gearbox

ca. 24

Travel gearbox

2 x ca. 18

Idler (permanent oil filling) P/N 1 596 579

2 x 1,1

Track rollers (permanent oil filling)

16 x 1.5

Support rollers (permanent oil filling)

2 x 1.5

2 804 411.00 en

III III III III III

105

OPERATING INSTRUCTIONS RH 40 E Refilling quantities - Other Location

Filling quantity (liters)

Engine cooling liquid

170

Fuel reservoir

1300

Windscreen washer

13

106

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E LUBRICANTS

I.

2804268

Oils for combustion engines and compressors (selection)

2 804 411.00 en

107

OPERATING INSTRUCTIONS RH 40 E

II. Oils for hydraulic systems (selection)

108

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

III. Oils for gearboxes (selection)

2 804 411.00 en

109

OPERATING INSTRUCTIONS RH 40 E

V. Greases for bearings and slewing rings

110

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E SERVICING WORK

2413586

Draining hose for oil changes Collect escaping oil and discard without polluting the environment.

Carry out oil changes as follows:

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

- Choose the proper draining hose from the tool kit.

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

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

- Place a recipient for waste oil under the drain opening (choose the capacity of the recipient in acc. with the "Refilling quantities - Oil" table).

- Unscrew protective cap from oil drain valve.

- Screw on draining hose (2); the valve opens and the oil drains away.

- After the oil has drained away unscrew draining hose; the valve closes automatically.

- Screw protective cap back in place.

Fig. 1

2 804 411.00 en

111

OPERATING INSTRUCTIONS RH 40 E ENGINE

2804423

Engine - Safety instructions

Checking the engine oil level / Topping up with oil

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

Risk of injury due to rotating or hot parts of the engine.

Shut off engine and allow to cool down.

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

Avoid skin contact with engine oil.

Fig. 1

Skin contact with engine oil is a health hazard.

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

Wear protective gloves and firm working clothing.

• Shut off the engine.

• Withdraw dipstick (1, Fig. 1).

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

Checking the V-belt tension Retensioning the alternator/fan belt

• Withdraw oil dipstick once again. The oil level should now lie between the marks (arrows, Fig. 2). If the oil level is at the "min" mark or below, top up with engine oil through the filler tube (2, Fig. 1).

Retensioning the fan belt Checking and adjusting the valve clearance These and other servicing works are described in the engine manufacturer’s operating instructions.

Fig. 2

112

2 804 411.00 en

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

Risk of scalding caused by hot engine oil.

• Replace engine oil filter.

• Unscrew draining hose to allow oil drain plug to close automatically.

• Screw protective cap back in place.

The engine itself may be hot, too.

• Fill in engine oil through the filler tube (2, Fig. 3) until the oil level reaches the "max" mark (Fig. 4).

Wear protective gloves and firm working clothing.

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

Collect escaping oil and discard without polluting the environment.

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

• Bring engine oil to operating temperature.

• Park the machine on a horizontal surface and secure.

• Shut off the engine.

• Drain off engine oil using the oil draining hose.

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

After the engine oil has drained away:

Fig. 4

Fig. 3

2 804 411.00 en

113

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

Risk of scalding due to hot engine oil.

Renewing of filters • Shut off the engine.

• Unscrew filters.

• Install new filter with slightly oiled sealing ring and tighten by hand.

The filter housing itself may also be hot too.

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

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

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

Fig. 5

Open hatch I (Fig. 5). The oil filters are now accessible.

Carry out servicing of the oil filters (1, Fig. 6) in accordance with the engine operating instructions.

Fig. 6

114

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Centrifuge (optional)

Fig. 8 Fig. 7

The centrifuge (Fig. 7) filters out engine oil impurities in the bypass line by centrifugal forces.

Servicing • Shut off the engine • Wait 5 minutes The rotor of the centrifuge must be stationary.

The pressure in the centrifuge must have disappeared.

• Loosen clamp (2, Fig. 8) and withdraw housing (1).

• Check housing seal (8) and replace, if required.

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

• Replace seal (6) inserting it slightly smeared with oil.

• Check nozzle (7) for free passage.

If necessary, open up nozzle with a wire or with compressed air.

• Place paper filter into the rotor cap.

The paper filter must adhere uniformly to the rotor casing.

Thereafter

• Unscrew knurled nut (3) and draw off rotor cap (4).

• Allow engine to run for short while and check centrifuge for tightness and leaks before shutting off the engine.

• Remove dirt from the rotor cap by tapping lightly against the cap.

• Check oil level after abt. 10 minutes and to up, if required.

• Clean rotor cap (4) and vertical tube (5) thoroughly with white spirit and dry.

2 804 411.00 en

115

OPERATING INSTRUCTIONS RH 40 E COOLING SYSTEM

2804424

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

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

Shut off engine and allow to cool down.

Risk of scalding due to hot cooling liquid.

Collect escaping cooling liquid and discard without polluting the environment.

Avoid skin contact with cooling liquid.

Skin contact with cooling liquid is a health hazard.

Wear protective gloves and firm working clothing.

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

Radiator

The cap (2) is accessible from above.

Risk of scalding due to high cooling liquid. Open cap cautiously.

• Turn cap (2) back to the first catch.

• When the pressure has been reliesed, turn cap to the "open" position and remove.

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

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

Do not top up with cold cooling liquid when the engine is at operating temperature.

Allow engine to cool down to below 50˚ C before topping up.

To top up the cooling system, use only specially prepared water.

Specially prepared water must consist of: • calcium-free water, distilled water, rain water • anti-freeze compound (the anti-freeze compound / cooling water mixing ratio must be adapted to the temperatures to be expected).

After each working shift:

After topping up the radiator, allow engine to run for a short time to eliminate air pockets before filling up cooling liquid up to the lower edge of the filling tube.

- examine radiator fins for dirt and clean, if required.

In case of significant cooling-liquid losses, check the whole cooling system for leaks.

If the cooling-liquid level is too low, a warning lamp on satellite I lights up.

At regular intervals:

The radiator (1, Fig. 1) is located on the superstructure.

• check lines for leaks and hose clamps for tightness.

Fig. 1

116

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Cooling liquid Read and observe the "Inspection and servicing - Safety instructions" chapter.

Risk of scalding caused by hot cooling liquid.

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

The cooler itself may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

Change the cooling liquid regularly and after 2 years at the latest.

Fig. 3

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

Fig. 2

To do so: • Prepare a collecting recipient for used cooling liquid. Choose the required recipient capacity in accordance with the "Refilling quantities - Other" table.

• Shut off the engine.

• Open hatch II (Fig. 2).

• Unscrew plug (arrow, Fig. 3) and drain off cooling liquid completely.

• Fill in cooling liquid after having re-inserted the plug with a new sealing ring.

2 804 411.00 en

117

OPERATING INSTRUCTIONS RH 40 E Water filter Read and observe the "Inspection and servicing - Safety instructions" chapter.

Risk of scalding caused by hot cooling liquid.

The filter housing itself may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

Replace the water filter regularly.

• Open hatch II (Fig. 4).

Fig. 5

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

• Unscrew the water filter (3, Fig. 5).

• Screw on new water filter until the sealing ring contacts the filter head. Continue to tighten the filter by a further 1/2 to 3/4 turn.

Fig. 4

118

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E AIR-INTAKE SYSTEM

2804425

Read and observe "Engine - Safety instructions".

Wear a safety harness.

Main filter element An insufficient air-intake performance, caused by a contaminated main filter element, is indicated by the vacuum-meter (8, Fig. 2).

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

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

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

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

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

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

The air-intake system is equipped with two dry-air filter (Fig. 1) consisting of main and safety filter element.

Fig. 2

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

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

• Replace or clean main filter element. The vacuum-meter (arrow, Fig. 2) must now show a green segment.

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

Fig. 1

Fig. 3

2 804 411.00 en

119

OPERATING INSTRUCTIONS RH 40 E

Replace damaged or deformed elements immediately.

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

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

Fig. 4

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

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

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

Fig. 6

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

The pressure at the nozzle must not exceed 6 bars.

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

Fig. 5

Checking and cleaning the main filter element Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 6). Any damage is then clearly visible.

Fig. 7

120

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

Never clean filter element by beating against hard objects.

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

Safety filter element Replacement Replace the safety filter element (5, Fig. 8) after 1000 operating hours or 3 cleaning cycles of the main filter element, at the latest, however, after one year of operation.

Never clean the safety filter element, but always renew.

Fig. 9

Air-intake line At regular intervals: • check intake line 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 Dust accumulating on the filter-housing bottom is constantly being sucked away by the exhaust system during operation.

Fig. 8

• Remove main filter element (4, Fig. 9) as described above.

• Unscrew nut (6, Fig. 8) and withdraw safety filter element (5).

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

A non-return valve (7, Fig. 10) in the suction line prevents engine exhaust gases from being sucked in.

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

Fig. 10

2 804 411.00 en

121

OPERATING INSTRUCTIONS RH 40 E FUEL SYSTEM

2804426

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

When working on the fuel system: - shut off the engine - secure the machine as described in the "Securing the machine" section - keep away naked flames - do not smoke.

Prior to initial commissioning or after repairs on the refuelling system carry out the following works: • Loosen elbow union (12, Fig. 1) and fill pump (11) with fuel.

• Retighten elbow union (12).

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

122

Fig. 1

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Changing the fuel filter Read and observe the "Inspection and servicing - Safety instructions" chapter.

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Fig. 3

The fuel filter (3) serves at the same time as a water separator.

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

• Close valve (4).

Venting the fuel system If the fuel tank is completely emptied in operation, the fuel system must ebe vented. Cf. engine operating instructions.

Fig. 2

• Open hatch I (Fig. 2) to gain access to the filters.

• Unscrew filters (3, Fig. 3).

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

The fuel tank is vented with breather valve (4, Fig. 4).

Clean breather valve regularly.

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

• Continue to tighten filter by a further 1/2 to 3/4 turn.

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

Fig. 4

2 804 411.00 en

123

OPERATING INSTRUCTIONS RH 40 E Cleaning the fuel tank Explosion hazard.

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

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

• Use up as much fuel as possible.

• Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plug of the tank.

• Unscrew drain plug (5, Fig. 5) at fuel tank and drain off fuel.

• Flush tank with diesel fuel.

For flushing and cleaning use diesel fuel.

• Screw drain plug back in place.

Avoid skin contact.

• Fill in fuel through the filter sieve in the filler tube (2).

Skin contact with diesel fuel can cause skin injury.

Refuelling station (optional)

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

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

Check earthing strap (equipotential bonding) (4, Fig. 6) regularly for tightness.

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

Fig. 5

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

Fig. 6

124

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Water trap (option)

Checking / cleaning the filter element

Water contained in the fuel is removed by the water trap (Fig. 7).

Replace filter element (6) only when the suction resistance is too high.

• 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)

Fig. 7

• Clean filter housing (4) using diesel fuel.

Servicing

• Check cover sealing and replace,if necessary.

Draining off water

• Insert filter element (6) and spring housing (7) into filter housing (4).

Carry out the following works in accordance with the servicing schedule and at regular intervals: • Loosen venting plug (9, Fig. 8) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

• Fasten cover (5) on filter housing (4).

Check for proper sealing.

Clean recipient (1) and filter housing (4).

• Loosen flange (2).

• 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. 8

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).

2 804 411.00 en

125

OPERATING INSTRUCTIONS RH 40 E ELECTRICAL SYSTEM

2804245

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

Risk of injury caused 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.

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

Alternator - Instructions

Never disconnect electrical connections at the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator.

The electrical circuit diagrams are annexed to the spare-parts list. Further information can be found in the O&K-Mining booklet "Working with circuit diagrams".

The electrical system switch-cabinet is located in the driver’s cab below the control panel. The cabinet is described in the spare-parts list together with the designation of the electrical components.

Cut off the electrical system with the battery main switch before carrying out work on the electrical system. This prevents accidents, unauthorized starting of the engine and short-circuits.

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.

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

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

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

126

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Battery main switch / Main fuse The battery main switch and the main fuse are located under a lockable hatch (arrow, Fig. 1) beside the batteries and the tool box.

Fig. 2

Battery Checking the battery fluid level

Fig. 1

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

Battery main switch (Fig. 2):

(Not applicable in case of maintenance-free batteries) • Unscrew caps (Fig. 3).

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

• If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm.

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

- Position I ON - Position II OFF In position II, the battery main switch handle can be withdrawn.

Fig. 3

2 804 411.00 en

127

OPERATING INSTRUCTIONS RH 40 E Checking the battery charge

Removing and installing the battery

The acid temperature must be 20˚C.

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

• Unscrew caps of the battery (Fig. 4).

• Measure the acid density of the battery using a commercial acid tester (Fig. 4).

Wear protective gloves and firm working clothing.

The acid density measured is in direct correlation with the battery charge.

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

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

Set battery main switch (Fig. 5) to position II "OFF".

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

Disconnecting and connecting in the wrong order may cause shortcircuits.

Fig. 4

Acid density in kg / dm3

Charge

Normal conditions

Tropical conditions

1.28

1.23

fully charged

1.20

1.12

half charged, recharge

1.12

1.08

discharged, recharge immediately

128

Fig. 5

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

The batteries are located under the lockable hatch (arrow, Fig. 6). The two 12-volt batteries are connected in series, so that the system voltage is 24 volts.

Fig. 7

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

Fig. 6

• Unscrew battery holder (6, Fig. 7).

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

• Disconnect the cable lug from the positive terminal of the battery.

• Insulate the cable lugs.

• Lift battery out of battery box.

2 804 411.00 en

• Install the new battery.

• Connect the cable lug to the positive terminal of the battery.

Tighten the clamping screw of the cable lug.

Do not use too much force to avoid deformations.

• Connect the cable lug to the negative terminal of the battery.

• Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs.

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

129

OPERATING INSTRUCTIONS RH 40 E HYDRAULIC SYSTEM

2413592

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

Before working on the hydraulic system, make sure that the system is without pressure and that also the residual pressures have been eliminated.

Shut off the engine.

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

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 (Figs. 1 and 2) and with the drive engine stationary, there may still be a considerable residual pressure in parts of the hydraulic system, e.g. the primary pressure resulting from the last hydraulic movements before stopping the machine.

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:

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

Avoid skin contact with hydraulic oils.

Contact with hydraulic oils can cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 1

• 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.

Fig. 2

130

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Examples for system sections: 1) servo control circuit 2) working hydraulics 3) precharged return-flow line Depressurizing • Park the excavator on a horizontal surface.

• Stand working equipment on the ground.

• Shut off the drive engine.

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

Fig. 4

Topping up with hydraulic oil

Fig. 3

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.

Checking the hydraulic oil level

Fig. 5

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

• Remove cover (20, Fig. 5) and retaining disk (23).

• Park the machine on a horizontal surface.

• One of the return-flow filters is now visible in the filter chamber.

• Move all hydraulic cylinders to their central positions.

The oil level must lie between the 1/2 and 3/4marks of the inspection glass (4, Fig. 4).

The hydraulic oil level in the hydraulic reservoir is monitored by two initiators. If the warning lamp in control panel II lights up, shut off the engine, locate defect and rectify.

2 804 411.00 en

• Fill in hydraulic oil through this return-flow filter until the oil level lies between the 1/2 and 3 /4marks of the inspection glass (oil grade cf.

"Refilling quantities - Oil").

• Before fitting retaining disk (23) and cover (20), check sealing ring (26) and replace if damaged.

• Fit cover together with sealing ring.

131

OPERATING INSTRUCTIONS RH 40 E

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

- when the "Hydraulic oil filter" warning lamp (satellite II) lights up when the hydraulic oil is at operating temperature. The filter elements (25, Fig. 6) 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.

- after repairs on the hydraulic system;

Risk of scalding caused by hot hydraulic oil.

- in case of damage.

The hydraulic oil reservoir itself may also be hot.

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

Avoid skin contact.

• Clean the magnetic rod (24).

Changing the hydraulic oil return-flow filters

Skin contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

The return-flow filters must be replaced: - when servicing works in accordance with the servicing plan are carried out;

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

• Withdraw filter element (25) together with centering ring (22).

• Insert new filter element (25) together with sealing ring (22) on the centering device.

• 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. 6

132

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Bypass valves (working circuit)

Cleaning the sieve

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

Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The hydraulic reservoir itself may also be hot.

Avoid skin contact.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 7

• Remove cover (10, Fig. 7). Remove screws (12) and take out the bypass valve. Withdraw sieve (13) and clean in white spirit or paraffin oil. Replace, if required.

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

• Re-assemble the bypass valve.

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

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

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

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).

2 804 411.00 en

133

OPERATING INSTRUCTIONS RH 40 E Bypass valve (cooling circuit)

Cleaning the valve

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

Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The hydraulic reservoir itself may also be hot.

Avoid skin contact.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 9

• Remove cover (7, Fig. 8).

• Unscrew screws (33, Fig. 9) and withdraw valve carrier (31) together with valve (32).

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

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

• Fasten valve carrier (31) with screws (33) in the hydraulic oil reservoir.

• Refit cover (7, Fig. 8) with a new sealing ring.

Fig. 8

Changing the valve Remove bypass valve as described under "Cleaning".

• Remove valve (32, Fig. 9) and replace by a new one.

• Fasten bypass valve (31) on the hydraulic oil reservoir.

• Refit cover (7, Fig. 8).

134

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Breather filter Read and observe the "Inspection and servicing - Safety instructions" chapter.

Replacing the filter element The breather filter (6, Fig. 10) ensures 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 reservoir itself may also be hot.

Avoid skin contact.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 10

• Unscrew butterfly nut (50, Fig. 11). 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. 11

2 804 411.00 en

135

OPERATING INSTRUCTIONS RH 40 E High-pressure filter for working hydraulics

• Unscrew filter housing (31, Fig. 13) and pour out the oil.

• Withdraw filter element (32) from housing (31).

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. 12).

Fig. 12

Checking/changing the filter elements Read and observe the "Inspection and servicing - Safety instructions" chapter.

Fig. 13

• Clean filter housing and contact faces at the filter head (35, Fig. 12) with white spirit or paraffin oil and replace, if required.

Risk of scalding caused by hot hydraulic oil.

• Insert filter element into housing (31, Fig. 13) and attach to the filter head (35) with new, slightly oiled sealing rings (33 and 34) and a new retaining ring (36).

The filter housing itself may also be hot.

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

Shut off the engine.

Avoid skin contact.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

136

Replacing the filter element • Remove the filter element as described under "Checking the filter element".

• Insert new filter element (32) and re-assemble.

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

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E High-pressure filter for the servo circuit and the feeding circuit of the slewing pump The excavator is equipped with a high-pressure filter (40, Fig. 14) for the servo circuit and another filter (41) for the feeding circuit of the slewing pump. Both filters are located beside the hydraulic oil reservoir and accessible from the bottom.

• Unscrew filter housing (42, Fig. 15) and pour out the oil.

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

• Clean filter housing and contact faces at the filter head (47, Fig. 14) with white spirit or paraffin oil.

• Insert filter element into housing (42, Fig. 15) and attach to the filter head with a new, slightly oiled sealing ring (46).

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

Fig. 14

Checking the filter element Fig. 15

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

Replacing the filter element

Shut off the engine.

• Remove filter element as described under "Checking the filter element".

Risk of scalding caused by hot hydraulic oil.

• Insert new filter element (43) and re-assemble.

The filter housing itself may also be hot.

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

Avoid skin contact.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

2 804 411.00 en

137

OPERATING INSTRUCTIONS RH 40 E 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 reservoir itself may also be hot.

Draining off the hydraulic oil • Bring the hydraulic oil to operating temperature (abt. 50˚C).

• Position the machine with a slight inclination towards the drain valve (5, Fig. 16).

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

Avoid skin contact.

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

Contact with hydraulic oil can cause skin injury.

• Shut off the engine.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

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

• Place a suitable recipient under the drain valve of the hydraulic oil reservoir (5). Choose the required capacity of the recipient in accordance with the "Refilling quantities - Oil" table.

• Connect hose (15) to drain valve (5) and drain off used oil completely. Draining is facilitated if the breather filter (6, Fig. 17) is removed during the process.

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

When the machine is in operation, the hose (15, Fig. 16) must be stowed away in the tool box.

• Remove hose. The drain valve closes automatically.

Fig. 16

Fig. 17

138

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Cleaning the hydraulic oil reservoir

Explosion hazard.

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

Shut off the engine.

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

Filling in hydraulic oil 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.

Use diesel fuel or a special flushing oil.

Avoid skin contact.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.

• Drain off the hydraulic oil as described under "Draining off the hydraulic oil".

• Remove cover (7, Fig. 18).

Fig. 18

• 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.

• Refit cover (7).

2 804 411.00 en

139

OPERATING INSTRUCTIONS RH 40 E Venting the hydraulic system Hydraulic pumps, motors, cylinders, travel brake valves, suction lines of hydraulic pumps, hydraulic oil cooler manifolds and the servo control system must be vented • after the assembly on site and prior to initial commissioning • before each recommissioning of the excavator, e.g. after extensive repair work on the hydraulic system or after prolonged downtimes • after each hydraulic oil change • after replacement of hoses or lines.

Fig. 20

Venting the hydraulic components

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

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

•

the piston-side port (3) when the piston rod (1, Fig. 19) is retracted and

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

•

the rod-side port (4) when the piston rod (1, Fig. 20) is extended.

Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump resp. the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air existing 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 its two end positions. This means that the piston rod (1, Figs. 19 and 20) must be completely extended or retracted.

If, for assembly reasons, the piston rod is in the center 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. Extend or retract the piston rod therefore as slowly as possible.

The screw / nozzle of the following components must be open until oil emerges bubble-free from the opening.

Always vent only that section of the system that has been opened.

Vent - the travel brake valve at the venting screw - the oil cooler manifold at the mini-measuring ports - the servo system at the venting screws of the control blocks (under the servo caps) - the intake line at the venting screw (with the drive engine stationary).

Fig. 19

140

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Cleaning the hydraulic oil cooler Risk of injury caused by rotating cooler fan blades.

Shut off the engine.

Do not start cleaning before the cooler fan blades have stopped turning.

Cleaning • Remove the grid (7, Fig. 21) above the cooler.

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

Loose dirt drops through the cooler down to the ground.

The hydraulic oil cooler is at the same temperature as the hydraulic oil. Risk of burning.

Allow the machine to cool down.

Wear protective gloves and firm working clothing.

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

Fig. 21

The speed of the fan motor is controlled by a thermostat. The fan motor runs at maximum speed when the hydraulic oil temperature reaches ca. 60˚C.

2 804 411.00 en

141

OPERATING INSTRUCTIONS RH 40 E Pressure accumulator

Excerpt from the German regulations

To permit lowering of the working equipment in case of emergency, the machine is equipped with a pressure accumulator (1, Fig. 22).

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

The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Works on systems containing accumulators (repairs, connection of pressure gauges or similar work) may only be carried out after the fluid pressure has been released.

Excerpt from the acceptance regulations Hydraulic accumulators are pressure vessels and therefore subject to the "Druckbehälterverordnung (DruckbehV.)" [Pressure Vessel Regulations].

Their installation, equipment and operation is 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 contents l in liters and the product of pressure and contents p˙l. Depending on the class to which the accumulator belongs the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator Fig. 22

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

142

After commissioning (new installation resp. repair), the gas charging pressure in the diaphragm accumulator must be checked at least once in the first week. If no pressure losses are detected, the second pressure test must be performed after ca.

3 months. If no pressure losses are detected in this test , the testing interval can be fixed at one pressure test every year.

For measuring the charge pressure in the diaphragm accumulator, observe the instructions set out in the booklet "Filling and testing device for diaphragm accumulators" annexed to this documentation.

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

Group

Inspections prior to commissioning at the factory

II p> _ l bar und p˙l < _ 200

Pressure testing Manufacturer s certificate of satisfactory manufacturer and pressure testing

2 804 411.00 en

Regular

at the place of use

inspections

Inspection certificate (check of correctness and correct installation) issued by authorities

Test programme to be drawn up by end user based upon experience with the type of operation and fluid.

143

OPERATING INSTRUCTIONS RH 40 E PUMP TRANSFER GEARBOX 2804429 Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engine.

The gearbox housing itself may also be hot.

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

Avoid skin contact with gearbox oil.

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

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

• Unscrew plug (3, Fig. 2) and drain off oil.

Screwing out breather filter (2, Fig. 1) facilitates draining off the used oil. Plug (3, Fig. 2) is accessible from the bottom.

• Screw plug (3) back in place.

Contact with gearbox oil can cause skin injury.

Wear protective gloves and firm working clothing.

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

• Screw out dipstick (1, Fig. 1), wipe clean and screw back in place.

Fig. 2

• Screw out dipstick (1) again.

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

• Screw dipstick (14) back in place.

Filling oil • Unscrew breather filter (2, Fig. 1).

• Fill in new oil through opening of breather filter (2). After oil changes, plug (3, Fig. 2) must be tightened beforehand.

• Check oil level with dipstick (1, Fig. 2).

Gearbox venting The gearbox is vented through breather filter (2, Fig. 1).

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.

Fig. 1

144

• Screw breather filter back in place.

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

SLEWING GEARBOX

2413594

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

Shut off the engine.

The gearbox housing itself may also be hot.

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

Avoid skin contact with gearbox oil.

Contact with gearbox oil can cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 2

Draining off oil • Attach hose (8, Fig. 2) to drain valve (7) and drain off oil completely. Unscrewing cover (8, Fig. 1) facilitates draining off the used oil.

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

The drain valve (7, Fig. 2) is accessible from the undercarriage.

Fig. 1

• Remove hose. The oil drain valve closes automatically.

Gearbox - Checking the oil level / Topping up with oil

Filling in new oil / Topping up

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

• Unscrew cover (8, Fig. 1) and fill in new oil through expansion tank (6). The expansion tank (6) must be filled with gearbox oil up to ca. 1/3.

• Check the oil level visually at expansion tank (6, Fig. 1). The expansion tank must be filled with gearbox oil up to abt. 1/3.

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

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

Gearbox venting The gearbox is vented through cap (8, Fig. 1).

Venting bore Check venting bore in cover (8) for contamination and clean, if required.

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

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

2 804 411.00 en

145

OPERATING INSTRUCTIONS RH 40 E TRAVEL GEARBOXES Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engine.

Risk of scalding caused by hot gearbox oil.

The gearbox housings may also be hot.

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

Avoid skin contact.

Contact with gearbox oil can cause skin injury.

Wear protective gloves and firm working clothing.

Gearbox - Checking the oil level / Topping up with oil

2413595

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

• Move the excavator until one of the two drain plugs (6, Fig. 1) is at the bottom and screw out the upper plug.

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

The gearbox is vented through breather filter (2, Fig. 2).

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

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

• Screw breather filter back in place.

Fig. 1 Fig. 2

146

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E CRAWLER TRACKS

2413697

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

Cleaning is especially important in winter to prevent

Track roller fastening Check fastening screws (3, Fig. 2) regularly for tightness: • Tighten screws with a torque wrench to the prescribed tightening torque (cf. table "Tightening torques").

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

Fig. 2

Support roller fastening

Fig. 1

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) regularly for tightness: • Tighten screws with a torque wrench to the prescribed tightening torque (cf. table "Tightening torques").

• clean the side member supporting the track; • clean track and support rollers (1 and 2 , Fig. 1) 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. 2) and the support rollers (2, Fig. 3) have a permanent oil filling.

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

2 804 411.00 en

Fig. 3

147

OPERATING INSTRUCTIONS RH 40 E Track pads Check fastening screws (5, Fig. 4) regularly for tightness: • Tighten screws with a torque wrench to the prescribed tightening torque (cf. table "Tightening torques").

Fig. 5

Function

Fig. 4

Track tensioner System configuration The tracks are tensioned automatically when a travel movement is initiated. Inthis case, oil and a required pressure from the servo pump are diverted via a corresponding hydraulic switching device to the track-tensioning circuit. Figs. 5 and 6 show parts of the tracks and the tensioner: 4 Diaphragm accumulator 5 Pressure cylinder 6 Pressure-limiting valve 9 Mini-measuring port 10 Idler 11 Sprocket 12 Track roller 13 Track 14 Support roller

The tensioning system is under a permanent pressure of ca. 100 bars which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the track drives are switched on. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so: • stop the engine • open both pressure limiting valves (6, Fig. 5) to slacken the tracks.

• After the work, screw down the pressure limiting valves (6) to the limit stop.

Technical data Track tensioning pressure ca. 100 bars Pressure limiting valve 250 bars Gas pressure in diaphragm accumulator (nitrogen filling pressure) 80 bars

Fig. 6

The pressure-limiting valves (6) are preset to a pressure of 250 bars and sealed in this position.

The lead seal must not be removed and the pressure setting of 250 bars must not be changed.

The track tensioners are otherwise maintenancefree.

148

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Pressure-accumulator inspection regulations

Checking the gas charging pressure in the diaphragm accumulator

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

After commissioning (new installation resp. repair), the gas charging pressure in the diaphragm accumulator must be checked at least once in the first week. If no pressure losses are detected, the second pressure test must be performed after ca.

3 months. If no pressure losses are detected in this test , the testing interval can be fixed at one pressure test every year.

Excerpt from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Works on systems containing accumulators (repairs, connection of pressure gauges or similar work) may only be carried out after the fluid pressure has been released.

Excerpt from the acceptance regulations Hydraulic accumulators are pressure vessels and therefore subject to the "Druckbehälterverordnung (DruckbehV.)" [Pressure Vessel Regulations].

Their installation, equipment and operation is 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 contents l in liters and the product of pressure and contents p˙l. Depending on the class to which the accumulator belongs the following inspections are mandatory:

Group III p> _ l bar p˙l > _ 200 and p˙l_ < 1000

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner.

They are no substitute or the inspections required by the "Pressure Vessel Regulations".

Before checking the gas charging pressure (nitrogen filling pressure) in the diaphragm accumulator, the track must first be slackened, i.e. the hydraulic part of the tensioning system must be depressurized. Cf. under "Function".

For measuring the charge pressure in the diaphragm accumulator, observe the instructions set out in the booklet "Filling and testing device for diaphragm accumulators" annexed to this documentation.

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

Regular inspections

Preliminary inspection by an Acceptance inspection by an ex- The inspection intervals expert pert have to be stipulated by Prototype and pressure test the user based the on excertified by the manufacturer perience made with op(type approval) or by an expert erating conditions and operating fluid

2 804 411.00 en

149

OPERATING INSTRUCTIONS RH 40 E Idlers The idlers have a permanent oil filling.

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

Checking the oil level The checking plug (arrow, Fig. 7) is located either on the inside or outside of the idler.

To check the oil level, the checking plug must be approximately 30o above the horizontal axis (2 o’clock position) (Fig. 7). Unscrew checking plug.

The oil level must reach up to the lower edge of the opening.

If the oil level is below the opening, move the excavator until the plug hole is in the horizontal plane (3 o’clock position). If no oil emerges from the opening in this position, checking of the idler seals is absolutely necessary.

It is possible to continue working with the excavator if the oil level is topped up and checked in short intervals.

Filling in oil The checking plug hole must be in the same position as for oil-level checking (2 o’clock position). Fill in oil up to the lower edge of the plug hole.

Fig. 7

150

2 804 411.00 en

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

Shut off the engine.

Wear protective gloves and firm working clothing.

2413596

Internal gearing The internal gearing and the pinion are enclosed in a housing (5, Fig. 2). The housing forms a grease-filled trough in which the pinion of the slewing mechanism moves.

Slewing ring - Instructions The grease filling must be renewed: - if 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 grease losses are detected, locate cause immediately to avoid damage to the slewing ring.

Greases and greasy cleaning rags must not be allowed to pollute the environment. Dispose of greases and cleaning rags without polluting the environment and separately from other waste.

Fig. 2

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 1). The central lubricating system adds the amount of grease used up during operation.

The housings have a check opening which is closed with a cover (6, Fig. 3). For checking, the cover must be removed.

Bearing races The central lubricating system supplies continuously grease to the two roller bearing races and the internal gearing .

The grease is pumped to the greasing points of the bearing races by the distributor (Fig. 1).

Fig. 3

Fig. 1

2 804 411.00 en

151

OPERATING INSTRUCTIONS RH 40 E Slewing ring - Checking the grease filling Read and observe the "Inspection and servicing - Safety instructions" chapter.

Slewing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Shut off the engine.

Add grease when

Wear protective gloves and firm working clothing.

• the housing has been replaced • old grease has been removed in the course of other work.

At regular intervals • check internal gearing and teeth of the slewing mechanism pinion for condition • check that the grease filling is sufficient.

The housing must always contain enough grease, so that the internal gearing - measured from its lower edge - runs in at least 20 mm of grease over the whole circumference (Fig. 4).

In case 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.

Always fill in fresh grease by hand.

Risk of accident. Never slew the superstructure when refilling grease.

Slewing ring - Checking the screws for tightness Tighten the fastening screws of the slewing ring at superstructure and undercarriage with checking torque (see table: "Tightening torques)".

The screws are tight when the checking torque is reached.

Slack screws before tightening them with a torque wrench to the prescribed tightening torque (cf. table "Tightening torques").

Fig. 4

152

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E CENTRAL LUBRICATING SYSTEM 2486213

Design and function The excavator is equipped with an automatic central lubricating system ensuring regular the regular supply of grease to all greasing points except those mentioned in the "Lubricating chart Grease" for the backhoe bucket.

A grease pump (5, Fig. 3) with attached grease container (6) pumps the grease through lines (7) to the main distributors (17 and 18, Fig. 3 and Fig. 4).

There is no main distributor (18) if the excavator is equipped with a backhoe bucket.

Fig. 1

When the electrical system is switched on with the key- switch, the indicator lamp (23, Fig. 1) lights up and the lubricating system is activated.

The indicator lamp (23) is visible after removing cover (20, Fig. 2).

All lubricating points connected to the system are greased at regular intervals. During the greasing cycle, indicator lamp (24, Fig. 1) is lit up.

Fig. 3

Fig. 4

Fig. 2

2 804 411.00 en

153

OPERATING INSTRUCTIONS RH 40 E In the case of trouble-free operation, two control pins in the main distributors must always move up and down when the pertaining pistons in the main distributors are being switched over. Control pin movement is monitored by means of sensors. Indicator lamp (24, Fig. 1) flashes on and off in the event of a fault.

See fault indication table.

In the event of trouble, shut off engine and rectify.

Check during every working shift - that no grease escapes from the pressure-relief valves (9, Fig. 5) and - that the grease container contains a sufficient amount of grease.

Fig. 6

Always refill the grease container in time to avoid malfunctions caused by air penetrating into the lubricating system.

The grease container (6) can also be filled by hand.

Switch off the electrical system and withdraw key from the key-switch.

Unscrew cover (8)of the grease container and fill in grease manually.

Screw cover (8) back in place.

Fig. 5

The level of grease in the container is visible from outside.

If grease escapes from the pressure valves (9), the line system is clogged. In this case, rectifiy the fault as described under "Unblocking a grease line".

If the amount of grease left in the container is insufficient, refill container through greasing nipple (10, Fig. 6) with a manual grease gun or with a mobile service station. The filling pressure must be ca. 5 - 8 bars.

154

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Greasing cycle

Indicators

The greasing cycle is initiated by a electronic unit. The duration of a single cycle is controlled by the check-back signal from the sensors in the greasing circuit.

Diode (23, Fig. 7) lights up when the power supply in on.

Presetting the pause duration The pause duration is preset with jumper (21, Fig. 7) and rotary switch (22).

- Jumper (21) placed over contact pins on the left and in the middle: presetting of minutes Do not change the setting

Diode (24) lights up in the event of malfunctions (code flashing sequence see table in Fig. 8).

The control panel indicator "Lubrication" in the driver›s cab flashes in the same sequence.

A = Drive motor defective B = Malfunction of lubricating circuit 1 C = Malfunction of lubricating circuit 2 D = Malfunction of lubricating circuits 1 and 2 E = Container empty F = Pump running indicator extinguished during greasing pauses

Rotary switch (22) is used to preset 15 time ranges 1 thru and A thru F.

Fig. 7

Rotary switch (22) is set to range "1". The corresponding pause duration is the 4 minutes.

If rotorary switch (22) is set to range "2", the pause duration will 8 minutes. In range "3", the duration is 12 minutes.

Increasing the range by one step of the switch prolongs the pause duration by another 4 minutes.

Set the pause duration at first to 4 minutes.

If required, the pause can be prolonged later on.

The optimal adjustment of the pause duration is attained when an increasing ring of grease forms at the greasing (friction) points.

If one of the greasing points shows a different behaviour, it is not being supplied with sufficient grease. In this case, the pause duration must be adapted accordingly.

2 804 411.00 en

Fig. 8

Malfunctions - greasing point(s) blocked up - distributor (s) blocked up - main line to distributor with piston movement sensor interrupted - air in greasing system - container empty Reset button (25, Fig. 7) Depressing reset button (25) for more than 2 seconds initiates an additional greasing cycle.

After having rectified a malfunction, reset button (25) must be depressed shortly (1 second) to cancel the fault message.

155

OPERATING INSTRUCTIONS RH 40 E The malfunctions mentioned above prevent the pistons in the monitored distributor from moving up and down. Lamp (24) will then indicate the corresponding fault by flashing on and off in the following intervals: Malfunction of lubricating circuit 1 B = 0,5 seconds - "ON" - 1 second "OFF" Malfunction of lubricating circuit 2 C = 1 second - "ON" - 0,5 seconds "OFF" Malfunction of lubricating circuit 1 and 2 D = 2 seconds - "ON" - 2 seconds "OFF"

Fig. 9

Container empty (option)

Venting the grease lines

Indicator lamp (24) flashes in the following intervals E = 0,5 seconds - "ON" - 0,5 seconds " OFF"

If air has penetrated into the line system - e.g. when lines are being replaced - the lubricating system must be vented.

The "container empty" signal starts flashing only after 6 revolutions of the motor.

In the event of malfunction, the piston sensor (initiator) can no longer detect piston movements and therefore not switch off the motor.

• Disconnect lines (7, Fig. 9) from the distributors.

• Start up grease pump (5) until grease emerges from lines (7).

• Switch off grease pump (5) and reconnect lines (7) to the distributors.

The monitoring timer of the control unit operating in parallel switches off the pump after the monitoring time has elapsed.

• Disconnect all other lines one after the other from the distributors, start up grease pump (5) and wait until grease emerges from the respective connection.

The system indicates a fault.

• Repeat these procedures at all other distributors.

Indicator lamp (24) flashes on and off.

The pump does not restart automatically.

Venting the grease pump • Refill grease container (6, Fig. 9).

• Unscrew lines (7) from connections (12).

• Start up grease pump (5) until grease emerges from connections (12).

Unblocking a grease line • Proceed as described under "Venting the line system".

Put the excavator back into operation only after the lubricating system works properly and after activating the unloaded working equipment for abt. 5 minutes. This is required to supply sufficient grease to the cylinder bearings.

• Switch off grease pump and reconnect lines (7).

156

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Cleaning the grease sieves

Lubricating the grease distributor of the working equipment

Check the grease sieves (13, Fig. 9) for contamination and clean, if required. The grease sieves must also be cleaned after a blockage in one of the grease lines has been removed (13).

• Withdraw protective cap from greasing nipple.

• Clean greasing nipple.

Cleaning

• Press nozzle of the grease gun onto the greasing nipple.

• Loosen nut (12) by holding union (16) in place with a wrench.

• Inject grease until the fresh grease squeezes the used grease out of the bearing joints.

• Unscrew disk (14).

• Remove sieve (13) and clean with white spirit or paraffin oil.

• Refit (13) and fasten with disk (14).

• Screw nut (12) onto the union.

Make sure that used grease emerges from all greasing points connected to the distributor.

Only then have all greasing points connected to the grease distributor been properly greased.

• Wipe off used grease with cleaning rags.

• After greasing, place protective cap back on the greasing nipple.

Dispose of cleaning rags without polluting the environment.

2 804 411.00 en

157

OPERATING INSTRUCTIONS RH 40 E PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMIS2413688 SIONING Putting the excavator out of operation • Park excavator on firm and level ground.

Recommissioning

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

• Remove covers.

• Set all control levers to position "0".

• Remove engine preservative in acc. with the engine operating instructions.

• Clean the machine.

• Lock the superstructure.

• Carry out a visual inspection of the excavator.

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

• Degrease resp. clean all protected components.

• Unlock the superstructure.

• Check the fuel level in the tank.

• Check tensioning of the tracks (visual inspection).

• Carry out engine preservation.

• Check level and condition of the cooling liquid in the cooling system.

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

• Check grease filling in grease container.

• Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.

• Fill up the fuel tank.

• oil level

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

• Remove the batteries. Cf. also Battery storage.

• Check oil level in hydraulic oil reservoir.

• Secure the machine against unauthorized starting by: - withdrawing the key from the key-switch - setting the battery main switch to OFF and withdrawing the key handle - locking the cab door - securing all lockable hatches.

• Install the batteries and reconnect.

• Cover up openings.

Battery storage During prolonged downtimes of the machine, remove the batteries and store in a dry room at ca.

20oC ambient temperature. Observe the following maintenance points:

• Check acid density and battery fluid level.

• Set battery main switch to ON. • Control and monitoring elements: carry out a function check of all monitoring and warning lamps and the buzzer by turning the key-switch to the respective position.

• Function checks:

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

• Check the vacuummeter.

• Vent the hydraulic system.

• Clean the batteries.

• Check acid density and battery fluid level once a fortnight.

• Recharge the batteries at the latest when the acid density has fallen to 1.23 kg/dm3.

• Keep the outside of batteries clean and dry.

158

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E NOTES

2 804 411.00 en

2804180

159

OPERATING INSTRUCTIONS RH 40 E

160

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E PART 4 - REPAIR WORK

Operating manual

Part 1 INTRODUCTION

2804054

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

2 804 411.00 en

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

Operating personnel + Inspection and servicing personnel + Repair personnel

Operating personnel + Inspection and servicing personnel + Repair personnel

161

OPERATING INSTRUCTIONS RH 40 E

162

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Repair work - Safety instructions

2804243

Operating instructions

Prestressed units

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

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

Pay special attention to:

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

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

The operating manual contains no information on this point.

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

Dismantling components

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

Repair personnel Repair personnel must have knowhow 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 O&K-Mining.

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.

2 804 411.00 en

Never do dismantling while the machine is at operating temperature.

Oils, greases, brake fluid 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.

163

OPERATING INSTRUCTIONS RH 40 E

Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of O&K-Mining.

Never remove lead seals from pressure relief valves and accumulators.

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

On completing the work, re-assemble all protective devices, covers and sound- and vibration-insulation material.

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

Check the repaired components and all machine functions with a trial run.

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

164

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Fire and Explosion Hazard

2796687

Safety Instructions Prior to commencing work, inform - on the national and corporate rules for prevention of accidents. Pay particular attention to hazards caused by combustible and easily flammable substances.

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

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

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

If necessary, also cover the ground with fire-protective blankets.

Ensure sufficient ventilation.

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

Clean the excavator before starting a job.

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

Do not store or handle any flammable substances during operation.

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

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

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

Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where - combustible substances such as coal dust or tar are present.

- open or smouldering fire may occur.

Do not extinguish flammable liquids with water. Use: - dry-powder, - carbon-dioxide or - foam extinguishing compounds.

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

Call the fire brigade.

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

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

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

2 804 411.00 en

165

OPERATING INSTRUCTIONS RH 40 E ENGINE

2413690

Read and observe the "Repair Safety instructions" chapter and the engine operating instructions before working on the engine.

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

Shut off the engine and allow to cool down.

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

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

ELECTRICAL SYSTEM

2413691

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

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

Risk of injury from acid splashes and battery gases.

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

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

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

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

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

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

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

Assisted starting (with jumpercables) Prior to assisted starting Read and observe the section: "Assisted starting, safety instructions".

Starting the engine with jumper cables (external batteries)

166

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Before connecting the jumper cables (external batteries) check the own batteries for proper operation. Checking is done by switching on the excavator’s electrical system in which case the engine monitoring lamps ("Alternator" and "Engine oil pressure") must light up.

Do not switch on electrical consumers (e.g. floodlamps) when checking the batteries. In case of doubt, remove the batteries and have them tested.

- Assisted starting with batteries installed - Connect first the positive terminal of the jumper cable to the batteries and then to the supplying unit. Connect the negative terminals in the same order. After starting, disconnect the jumper cable in reverse order, i.e. first the negative terminal and then the positive terminal.

- Assisted starting without batteries installed (only for engine trial run) Do not disconnect the starting aid when the engine is running.

After disconnecting, the alternator runs without batteries.

- Connect the jumper cable in the above-described order and disconnect after starting.

After disconnecting the supplying unit, the engine monitoring lamps are without current. Disconnect the jumper cables, therefore, only after the engine monitoring lamps have gone out.

• Switch off all consumers at the receiving machine and turn the key-operated switch to 0 .

• Switch off all consumers at the supplying machine (charged batteries) and shut off the engine.

Connecting the jumper cables

• Connect the red jumper cable to the positive pole of the empty battery (1, Fig. 1), then to the positive pole of the charged battery (2).

• Connect the black jumper cable first to the negative terminal of the booster battery (3) and then to a bare-metalpart of the machine (4).

Expolsion 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 discharged batteries as possiblee.

Starting up the engines • Start up the engines of the supplying machine and run at high speed.

• Start up the engine of the receiving machine. If the engine fails to start up after 15 seconds, wait for one minute and then start again.

• When the engine has started up, continue running both machines in no-load operation for about two or three minutes with the jumper cables still connected.

Disconnecting the jumper cables • Negative pole at the receiving machine (4) • 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. 1

2 804 411.00 en

167

OPERATING INSTRUCTIONS RH 40 E HYDRAULIC SYSTEM

2804218

Accumulators, safety instructions 2411963

Repair Before disconnecting hydraulic hoses: depressurize the hydraulic system.

Replace damaged or leaking hydraulic hoses by new ones.

Use original O&K-Mining spare parts. These parts are specially suitable for the respective function.

Do not re-use used hoses.

Dispose of spilt oil and oily wastes without polluting the environment.

These wastes must not be allowed to penetrate into the soil.

Hydraulic hoses should be replaced after a service life of 6 years.

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

Accumulators are installed in the hydraulic system. These accumulators contain nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen remains in the accumulator.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So: - Never handle accumulator mechanically, never weld or solder it.

- 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.

168

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E WELDING OPERATIONS Welding operations - Safety instructions Never perform welding operations unless you are qualified to do so.

Observe the accident prevention regulations.

Any work on receptacles that contain or have contained substances which are - combustible or which encourage combustion, which - are susceptible to explosion, or which - may develop health-hazardous gases, vapours, mist or dust during welding operations must be carried out only under expert supervision and only by experienced persons authorized to do such work.

Detailed information on the correct execution of welding operations is given in the technical manual "Welding for maintenance and repair".

Should you have any problems or queries, apply to the O&K-Mining after-sales service department.

2804217

Prior to any welding operations on the machine: - Set battery main switch to OFF Disconnect the battery, first at the negative pole and then at the positive pole.

Protect the disconnected terminals and plugs from short-circuiting and soiling by covering them with foil or adhesive tape.

Attach the welding pincers close to the welding zone (max. 2 - 3 m) The welding current must not flow via the ball rsp. the roller bearing slewing ring, via pin couplings, articulated joints or hydraulic cylinders.

An electric current flowing over an air gap (in an articulated joint, for instance) generates sparks that damage metallic furfaces.

On completion of the welding operation, restore all electrical connections.

- Set battery main switch to ON

If parts of the machine have to be dimantled, read and take note of the following sections: "Assembling attachments, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

2 804 411.00 en

169

OPERATING INSTRUCTIONS RH 40 E

170

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E NOTES

2 804 411.00 en

2804180

171

OPERATING INSTRUCTIONS RH 40 E

172

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E PART 5 - ANNEX

Operating manual

Part 1 INTRODUCTION

2804055

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

2 804 411.00 en

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

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

173

OPERATING INSTRUCTIONS RH 40 E

174

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E TROUBLESHOOTING Instructions on troubleshooting Faults are often due to the machine not being correctly operated or serviced.

For this reason, it is vital to read through the relevant section of the operating manual once again before rectifying any faults.

2804216

Layout of the fault table Fault The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

If you are unable to detect the cause of the fault or rectify it, apply to the O&K-Mining 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 O&K-Mining after-sales service. Exact data allow for fast troubleshooting.

- Which warning signals preceded the fault?

Never do any jobs for which you are not qualified.

- Is it one or several simultaneously occurring faults?

This fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

Ask yourself the following questions:

- What repair and servicing work was carried out previously?

- Has this defect already occurred?

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.

Measure This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the operating manual. If there is no entry, the O&K-Mining after-sales service should be consulted.

2 804 411.00 en

175

OPERATING INSTRUCTIONS RH 40 E FAULT TABLES

2804257

Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts, but runs unevenly or intermittently

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

Engine gets too hot, temperature warning activated Engine not working at full power Engine not working on full cylinder capacity Engine without oil pressure or oil pressure too low

1) Contact the O&K-Mining Service

Engine oil consumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly

•

•

• •

•

• •

• • • • •

• •

•

•

•

•

•

• •

•

•

Cause

Chapter ref.

Temperature below start limit temperature

Engine start

P

Oil level too low

Engine oil level

Oil level too high

Engine oil level

Engine inclination too big

Engine OI

Engine oil of wrong SAE class

Lubricants

A S P W W P

Fuel quality not corresponding to specification

Engine OI

Air filter contaminated/turbo-charger defective

Air-intake system

Fuel filter contaminated

Fuel filter

•

•

LDA defective (LDA=Charge-pressure-dependent full-load limiter)

• •

•

Charge-air line leaking

•

Oil cooler/cooling fins contaminated

•

Cooling fan defective or loose

•

Cooling-air gets too hot/heat build-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

176

•

• •

P Cooler cleaning R Engine OI P/W P Battery P P P 1) Engine OI E P Engine OI P/W

Combustion engine blocked on output side

1)

•

PMS malfunction

1)

•

Coding lamp flashing/lit (engine monitoring)

1)

•

•

P/W 1)

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Working hydraulics - Fault table Fault Working and slewing functions not operational No boom function No bucket function No backhoe function

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

No stick function Working movements too slow Power loss in working hydraulics

1) Contact the O&K-Mining Service

Uncontrolled working movements Cause

Chapter ref.

•

Servo control not activated / defective

Working

P

•

Hydraulic oil level too low

Hydraulic oil

P/A

• • • • •

•

Malfunction of pressure-relief servo valve (valve stacking)

1)

•

•

Servo system pump defective

1)

Malfunction of primary / secondary pressure-relief valves

1)

•

Engine speed too low

P

•

ECO power switch in 80% position

P

•

Fuel filter contaminated

Fuel filter

•

Insufficient engine power

Engine malfunc- 1) tion

•

Hydraulic oil temperature too high (warning lamp lit, PMS fault indicator lamp lit) oil cooler contamined

Hydraulic oil cooler cleaning

•

Engine coolant temperature too high, warning lamp lit and PMS fault indicator lamp flashing

1)

•

Malfunction of servo valve

1)

•

Malfunction of control spool

1)

• • • • •

• •

2 804 411.00 en

•

P/W

P/R

Engine coupling defective

177

OPERATING INSTRUCTIONS RH 40 E Track drive - Fault table Fault No forward travel and no reversing possible Maximum travel speed cannot be reached Insufficient traction power

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the O&K-Mining Service

•

Cause

Chapter ref.

Hydraulic oil level too low

Hydraulic oil

•

•

•

Malfunction of pressure-relief servo valve (valve stacking)

•

•

•

Servo system pump defective

•

•

•

Malfunction of travel valve (pedal)

• •

178

Engine nominal speed too low •

Malfunction of control spool

P/A 1) 1) 1) 1) 1) P

•

ECO power switch in 80% position

Travelling

•

Insufficient engine power

Engine malfunction

1)

•

Hydraulic oil temperature too high (warning lamp lit, PMS fault indicator lamp lit) Oil cooler contaminated

Hydraulic oil cooler cleaning

P/R

•

Coolant temperature too high, warning lamp lit and PMS fault indicator lamp flashing

1)

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Slewing mechanism - Fault table Fault No slewing possible No righthand and lefthand slewing Slewing performance insufficient Uncontrolled slewing movement

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the O&K-Mining Service Cause

Chapter ref.

•

Servo control not activated / defective

Working

P

•

Hydraulic oil level too low

Hydraulic oil level

P/A

•

Superstructure locking mechanism engaged

Transport

P

•

Pressure-relief servo valves (valve stacking) adjusted at too low level / defective

1)

Servo system pump defective

1)

•

Malfunction in feed-pressure circuit of slewing pump

1)

•

Malfunction in high-pressure circuit of slewing system

1)

•

Malfunction of moment regulating valve

1)

Malfunction in slewing pump displacement cylinder

1)

Excessive leakage in slewing motor

1)

•

• •

• •

• •

2 804 411.00 en

179

OPERATING INSTRUCTIONS RH 40 E Central lubricating system - Fault table Fault Grease pump not working, pilot lamp not lit Automatic circuit breaker on Grease pump not working, pilot lamp lit Grease escapes from over-pressure valve Grease pump working, no grease delivered

Cause •

Chapter ref.

P/W

Lines between timer and electric motor defective

P/W

Electric motor defective

P/W

Grease pump defective

P/W

•

Grease sieve clogged

P/R

•

Distributor defective

P/W

•

Grease container

P/A

•

Grease pump

P/L

•

Lines

P/L

•

Non-return valve defective

P/W

• •

180

Check P Adjust E Replace W Top up A Reduce S Clean R Vent L 1) Contact the O&K-Mining Service

Timer defective

•

•

Remedial action

•

•

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

2 804 411.00 en

181

OPERATING INSTRUCTIONS RH 40 E Hydraulic plan

2413694

Legend (loading bucket) Designation

Item

1 1

Diesel engine Pump transfer gearbox

2 1 1 1 1 1 1 1 2 1 1 2 1 1 3

Variable displacement pump Coupling Coupling Slewing pump Cooling oil pump Servo pump Variable displacement pump Filter Pressure limiting valve (55 bars) Pressure regulating valve (35 bars) Filter Non-return valve Proportional valve, complete Moment pressure regulating valve Measuring port

1 3 2 2 1 1

Hydraulic oil reservoir, complete Return-flow filter Bypass valve Tank-line precharging valve Intermediate shut-off cock Filter

2 2 2

High-pressure filter with pressure relief Line filter Pressure limiting valve (330 bars)

1 1 1

Fan motor Fan wheel Cooler for hydraulic oil

1 1 1

Thermostat valve Thermostat valve Non-return valve

1 1 1

Slewing gearbox, complete Slewing motor Superstructure holding brake

62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122

Item

No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

1 1 1 1 1 1 4 4

Travel block, complete Rotor Valve (travelling right) Valve (travelling left) Valve (travel brake right) Valve (travel brake left) Anti-cavitation valve Cover plate

2 2 2 2 2 2 2

Track tensioner Diaphragm accumulator Track tensioning cylinder Pressure limiting valve (250 bars) Travel gearbox, complete Travel motor Track brake

No.

Designation

1 6 1 2 1

Triple control block (working equipment) Pressure/anti-cavitation valve Single control block (bottom dump) Pressure/anti-cavitation valve Valve (quick-action boom)

2 1 2 2

Boom cylinder Stick cylinder Bucket tipping cylinder Bottom-dump cylinder

2 3 1

Servo valve, left Pedal valve (travelling, bottom dump) Pedal valve (dump/lift limiter)

1 1 1 1 1 1

One-way restrictor valve Distributor strip (servo cvontroö) Pressure accumulator Non-return valve Valve block Control block

9 5

Shuttle valve Shuttle valve

1 2 2 3 3

Pressure pick-up Pressure switch (3,5 bars) Pressure switch (3,5 bars) Protective cap Connecting piece

3 3 1 1 1

Solenoid valve Port plate Measuring port Microprocessor Magnetic pick-up

1 2

Strip Cover plate

4

Flange (travel block/quick-action valve)

1 1 1 1 2 1 1

Housing (cooling oil pump) Block (control spool) Block (control spool) Coupling (dump spool) Distributor (bucket tipping) T-flange (control spool/dump spool) Disk (control spool)

1

Distributor (bottom dump)

(Drawing no. 2 273 065)

182

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E

2 804 411.00 en

183

OPERATING INSTRUCTIONS RH 40 E Hydraulic plan

2413694

Legend (backhoe configuration) Designation

Item

1 1

Diesel engine Pump transfer gearbox

2 1 1 1 1 1 1 1 2 1 1 2 1 1 2

Variable displacement pump Coupling Coupling Slewing pump Cooling oil pump Servo pump Variable displacement pump Filter Pressure limiting valve (55 bars) Pressure regulating valve (35 bars) Filter Non-return valve Proportional valve, complete Moment pressure regulating valve Measuring port

1 3 2 2 1 1

Hydraulic oil reservoir, complete Return-flow filter Bypass valve Tank-line precharging valve Intermediate shut-off cock Filter

2 2 2

High-pressure filter with pressure relief Line filter Pressure limiting valve (330 bars)

1 1 1

Fan motor Fan wheel Cooler for hydraulic oil

1 1 1

Thermostat valve Thermostat valve Non-return valve

1 1 1

Slewing gearbox, complete Slewing motor Superstructure holding brake

62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123

Item

No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

1 1 1 1 1 1 4 4

Travel block, complete Rotor Valve (travelling right) Valve (travelling left) Valve (travel brake right) Valve (travel brake left) Anti-cavitation valve Cover plate

2 2 2 2 2 2 2

Track tensioner Diaphragm accumulator Track tensioning cylinder Pressure limiting valve (250 bars) Travel gearbox, complete Travel motor Track brake

No.

Designation

1 6

Triple control block (working equipment) Pressure/anti-cavitation valve

2 2 1

Boom cylinder Stick cylinder Backhoe cylinder

2 2

Servo valve, left Pedal valve (travelling, bottom dump)

1 1 1 1 1

Distributor strip (servo control) Pressure accumulator Non-return valve Valve block Valve block

9 5

Shuttle valve Shuttle valve

1 2 1 3 3

Pressure pick-up Pressure switch (3,5 bars) Pressure switch (3,5 bars) Protective cap Connecting piece

2 2 1 1 1

Solenoid valve Port plate Measuring port Microprocessor Magnetic pick-up

3 1 3

One.way restrictor valve Strip Cover plate

1 4

Distributor Flange (travel block/travel spool)

1

Block (control spool)

1 1 1

Distributor (stick) T-flange (control spool) Disk (control spool)

1

Distributor (boom)

1

Block (control spool/hydraulic oil reservoir)

(Drawing no. 2 455 702)

184

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E Tightening torques and -angles Table Bolt Slewing ring Slewing ring/superstructure - tightening torque (prestress 325 KN) Slewing ring/undercarriage - tightening torque (prestress 325 KN)

Bolt size

2413696

MA Nm

Tightening angle˚

Checking torque

550

60 + _ 2,5

1100

680

60 + _ 2,5

1100

M 27 x 200 / 10.9 / SW 41

M 27 x 260 / 10.9 / SW 41

Slewing gearbox

M 24 x 300 / 10.9 / SW 36

960

Counter weight

M 36 x 440 / 10.9 / SW 55

3000

Track pads

1" 14NS x 81 / 12.9 / SW 38

1560

Track rollers

M 24 x 160 / SW 36

1100

Support rollers

M 24 x 160 / SW 36

1100

2 804 411.00 en

185

OPERATING INSTRUCTIONS RH 40 E

186

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E ABBREVIATIONS A A abt. acc.

Ad. 1 Ah

Ampere (SI base unit of electric current) Four-wheel drive about according to with reference to 1 Ampere hours (SI base unit of quantity of electricity) API American Petroleum Institute approx. approximately BA bar Bh

= OI = Operating instructions unit of pressure measurement (1 bar = 14.5 psi) = OH = Operating hour

CE

Communaute Européenne = European Community CECE Committee for European Construction Equipment (Defines a measure for bucket, grab, or scoop filling) CEN European Standardization Committee cf. refer to cm centimeter (= 1/100 m) cm3/rev Cubic centimeters per revolution dB(A) dia.

DIN

Decibel (Sound intensity according to measuring method A) Diameter German Standardisation Organization

EDCV EDS eff. e.g. etc.

Electronic drive control (Grader) Electronic diagnostic system effective for example etcetera

fig.

FOPS GLR

Figure, serial number of illustration Falling objects protective structures Full-load controller (electronic module for PMS)

HD HDS hp Hydr.

Heavy duty Heavy duty small Horsepower /1 hp = 0.7457 kW) Hydraulic, Hydraulics

2 804 411.00 en

2804493

i i.e.

IFN incl.

ISO kg kg/dm3 km/h kNm kW l Lb/in2 LC LDA LED l/min LpA LPS LS LS LwA

m MA mA max. min. min-1 mm

Transmission ratio id est = that is ISO service rating, blocked including, inclusive of International Standardisation Organisation Kilogram (unit of weight) Kilograms per cubic decimeter ( = unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp) Liter Pounds per square inch (= psi) Long crawler Charge pressure-dependent full-load limiter Light-emitting diode Liters per minute Sound pressure at workplace Load-sensing Power System Limited slip Load sensing Sound power level of the machine in stationary operation Meters Tightening torque Milliampere (= 1/1000 A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (= 1/1000 m)

N N, kN NLGI

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) NLGI- Consistency - lubricant classification Klasse acc. to DIN 51 818 Nm Newtonmeter (unit of torque) No./Nos. number/numbers

187

OPERATING INSTRUCTIONS RH 40 E ABBREVIATIONS OH Operating hour op. inst. Operating Instructions OW Superstructure PLA PMS P/No. PS

Bulldozer blade Pump Managing System Part number Metric horsepower (1 PS = 0.74 kW)

Qty.

Quantity

R, r resp.

RH ROPS rpm

Radius Respectively Crawler hydraulics (excavator) Roll-over protective structures Revolutions per minute (= min-1)

SAE sec.

SN SW

Society of Automotive Engineers (USA) Second Item number Width across flats

t THB TL tm typ.

Metric ton (= 1000 kg) Technical Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of slewing torque) Typical

U/min

Revolutions per minute

V VDMA

Volt (unit of electric voltage) Association of Germany Machinery and Systems Manufacturers

W

Watt (unit of electric power)

˚C ˚kW

Degrees Celsius (temperature) Degrees crank angle

> <

greater than less than

188

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E TECHNICAL DATA

2 804 411.00 en

2461197

189

OPERATING INSTRUCTIONS RH 40 E

190

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E NOTES

2 804 411.00 en

2804180

191

OPERATING INSTRUCTIONS RH 40 E

192

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E PART 6 - INDEX

Operating manual

Part 1 INTRODUCTION

2804056

Target group Operating personnel + Inspection and servicing personnel

FUNDAMENTAL + SAFETY INSTRUCTIONS Repair personnel Operating personnel

Part 2 OPERATION

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Inspection and servicing personnel

Part 3 INSPECTION AND SERVICING

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

Repair personnel

Part 4 REPAIR WORK

Part 5 ANNEX

Part 6 INDEX

2 804 411.00 en

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

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

193

OPERATING INSTRUCTIONS RH 40 E

194

2 804 411.00 en

OPERATING INSTRUCTIONS RH 40 E INDEX

2 804 411.00 en

2486289

195

OPERATING INSTRUCTIONS RH 40 E

196

2 804 411.00 en

C A

Cab interior lighting ............................................ 27

ABBREVIATIONS .................................... 187, 188

CENTRAL LUBRICATING SYSTEM ................ 153

Accumulators, safety instructions .................... 168

Central lubricating system - Fault table ............ 180

Activating and de-activating the pump servo control ................................................................ 63

Centrifuge (optional) ........................................ 115

Adjusting the armrests ........................................ 26 Adjusting the backrest ........................................ 26 Adjusting the heating performance .................... 52 Adjusting the lumbar support .............................. 26 Adjusting the seat cushion .................................. 26 Adjusting the seat suspension ............................ 26 After daily operation............................................ 65 Air-intake line .................................................... 121 Air-intake system ................................................ 87 AIR-INTAKE SYSTEM...................................... 119 Alternator - Instructions .................................... 126 Application of Voler A.C. .................................... 69 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ...................................... 66

Change of engine oil .......................................... 87 Changing the engine oil .................................... 113 Changing the engine oil filter ............................ 114 Changing the fuel filter ...................................... 123 Changing the gearbox oil .......................... 144, 145 Changing the hydraulic oil ................................ 138 Changing the hydraulic oil return-flow filters .... 132 Changing the valve .......................................... 134 Checking and adjusting the valve clearance .... 112 Checking and cleaning the main filter element 120 Checking the battery charge ............................ 128 Checking the battery fluid level ........................ 127 Checking the cooling liquid .............................. 117 Checking the engine oil level / Topping up with oil ...................................................................... 112

Assisted starting (with jumper cables) - Safety instructions ...................................................... 166

Checking the filter element .............................. 137

Assisted starting (with jumpercables) .............. 166

Checking the gas charging pressure in the diaphragm accumulator .................................... 149

Automatic engine speed reduction .................... 20

B

Checking the gas charging pressure in the pressure accumulator ...................................... 142

Backhoe bucket .................................................. 19

Checking the gearbox oil level / Topping up with oil .............................................................. 144

Battery .............................................................. 127

Checking the hydraulic oil level ........................ 131

Battery main switch ............................................ 49

Checking the oil level........................................ 150

Battery main switch / Main fuse ........................ 127

Checking the overload warning system .............. 71

Battery storage ................................................ 158

Checking the V-belt tension .............................. 112

Bearing races .................................................. 151

Checking/changing the filter elements .............. 136

Before starting work ............................................ 63

Cleaning .......................................... 141, 147, 157

Breather filter .................................................... 135

Cleaning jobs ...................................................... 87

Bypass valve (cooling circuit) .......................... 134

Cleaning the fuel tank ...................................... 124

Bypass valves (working circuit) ........................ 133

Cleaning the grease sieves .............................. 157 Cleaning the hydraulic oil cooler ...................... 141

Cleaning the hydraulic oil reservoir .................. 139

Engine number .................................................. 23

Cleaning the sieve ............................................ 133

Entering and leaving the machine - Safety instructions ........................................................ 25

Cleaning the valve ............................................ 134 Combustion engine - Fault table ...................... 176

Environment-friendly lubricants and gearbox oils ...................................................................... 86

Component numbers .......................................... 23

Environmentally compatible hydraulic fluid ........ 84

Connecting the jumper cables .......................... 167

Environmentally compatible hydraulic fluid operating instructions ........................................ 84

Cooling liquid .................................................... 117 COOLING SYSTEM ........................................ 116 Cornering ............................................................ 55 Corrosion protection for pins and bearings (bushings and hubs) .......................................... 69 CRAWLER TRACKS ........................................ 147

D Depressurizing the hydraulic system ................ 130 DESCRIPTION OF THE EXCAVATOR .............. 18

Environmentally compatible hydraulic fluid Sampling ............................................................ 85 Environmentally compatible hydraulic fluid, conversion .......................................................... 84 Excavator layout ................................................ 19 Excerpt from the acceptance regulations 142, 149 Excerpt from the German regulations ...... 142, 149 Extending and retracting the bucket or backhoe bucket stick .................................................. 64 Extinguishing agent ............................................ 24

Design and function .......................................... 153 DESIGNATED USE .............................................. 4

F

Disconnecting the jumper cables ...................... 167

Fault.................................................................. 175

Draining hose for oil changes .......................... 111

FAULT TABLES .............................................. 176

Draining off oil .......................................... 144, 145

Filling and emptying bucket ot backhoe bucket .. 64

Draining off the hydraulic oil ............................ 138

Filling in fuel........................................................ 46

Draining off water ............................................ 125

Filling in hydraulic oil ........................................ 139

Drive unit ............................................................ 19

Filling in new oil / Topping up .................. 145, 146

DRIVER’S CAB .................................................. 25

Filling in oil ........................................................ 150

Driver’s seat........................................................ 26

Filling oil............................................................ 144

Driving - Safety instructions ................................ 53

Fire and Explosion Hazard ............ 10, 17, 83, 165

Dust collection .................................................. 121

Fire extinguishing system (optional) .................. 24 Fire-extinguisher ................................................ 24

E Electric energy ...................................................... 8 Electrical system ................................................ 20 ELECTRICAL SYSTEM............................ 126, 166 Electrical system - Safety instructions .............. 126 Emergency stop.................................................. 51 ENGINE .................................................... 112, 166 Engine - Safety instructions .............................. 112

Fore-and-aft position .......................................... 26 FUEL SYSTEM ................................................ 122 Fuel system - Safety instructions ...................... 122 Function ............................................................ 148 FUNDAMENTAL SAFETY INSTRUCTIONS ........ 4

G

L

Gas, dust, steam and smoke ................................ 8

Layout of the fault table .................................... 175

Gearbox - Checking the oil level / Topping up with oil ...................................................... 145, 146

Legend (backhoe configuration) ...................... 184

Gearbox oils ...................................................... 86 Gearbox venting .............................. 144, 145, 146 Greases for bearings and slewing rings .......... 110 Greasing cycle .................................................. 155

H Handling ............................................................ 24 High-pressure filter for the servo circuit and the feeding circuit of the slewing pump ............ 137

Legend (loading bucket) .................................. 182 Lifting capacity of the excavator ........................ 71 Lifting capacity of the load-hook ........................ 71 LIFTING-GEAR OPERATION ............................ 71 Lifting-gear operation - Safety instructions ........ 70 Load-hooks on backhoe buckets ........................ 71 Load-Sensing control / Zero-flow regulation ...... 20 Loading bucket .................................................. 19 LUBRICANTS .................................................. 107

High-pressure filter for working hydraulics........ 136

Lubricants for bearings ...................................... 86

Hydraulic equipment ............................................ 9

LUBRICATING CHART - GREASE (Backhoe Bucket) ............................................................ 102

Hydraulic hammer .............................................. 73 Hydraulic plan .......................................... 182, 184 Hydraulic system ................................................ 20 HYDRAULIC SYSTEM ............................ 130, 168 Hydraulic system - Safety instructions .............. 130

LUBRICATING CHART - GREASE (Loading Bucket) ............................................................ 100 Lubricating chart - Grease / Backhoe Bucket .. 103 Lubricating chart - Grease / Loading Bucket .... 101 Lubricating the grease distributor of the working equipment ................................................ 157

I Idlers ................................................................ 150

M

INDEX .............................................................. 195

Machine number ................................................ 23

Indicators .......................................................... 155

Main filter element ............................................ 119

Inspection .......................................................... 24

Measure............................................................ 175

Inspection and servicing - Safety instructions .... 79

MONITORING, WARNING AND CONTROL ELEMENTS ........................................................ 28

Inspection and servicing plans - Instructions ...... 87 INSPECTION PLAN - OIL ................................ 104

N

Inspection plan - Oil .......................................... 105

Noise .................................................................... 9

Instructions on troubleshooting ........................ 175

Note .................................................................... 56

Internal gearing ................................................ 151

NOTES ................................ 11, 75, 159, 171, 191

Intervals .............................................................. 87

O Oil, grease and other chemical substances .......... 9 Oils / Greases .................................................... 87 Oils for combustion engines and compressors (selection) ........................................................ 107

Oils for gearboxes (selection) .......................... 109 Oils for hydraulic systems (selection) .............. 108 Opening and closing the bottom-dump bucket .. 64 Operation - Safety instructions .......................... 15

PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING................ 158 PUTTING THE MACHINE INTO OPERATION .. 46 Putting the overload warning system out of operation ............................................................ 71

Organizational measures...................................... 5 Overload warning system .................................. 71

R Radiator ............................................................ 116

P

Raising and lowering the boom .......................... 64

Parking the machine .......................................... 65

Recommissioning ............................................ 158

PART 1 - INTRODUCTION .................................. 1

Refilling and draining .......................................... 48

PART 2 - OPERATION ...................................... 13

Refilling quantities - Grease...................... 101, 103

PART 3 - INSPECTION AND SERVICING ........ 77

Refilling quantities - Oil .................................... 105

PART 4 - REPAIR WORK ................................ 161

Refilling quantities - Other ................................ 106

PART 5 - ANNEX ............................................ 173

Refuelling............................................................ 46

PART 6 - INDEX .............................................. 193

Refuelling - Safety instructions .......................... 46

Part nos. for Voler A.C. ...................................... 69

Refuelling station (optional) .............................. 124

Pipe break protection.......................................... 72 Plan A .............................................. 95, 96, 97, 98

Refuelling with the refuelling system (optional equipment).......................................................... 46

Plan B .............................................. 95, 96, 97, 98

Regulating the travel speed ................................ 55

Plan C .............................................. 95, 96, 97, 98

Removal and installation .................................. 119

Plan D .............................................. 95, 96, 97, 98

Removing and installing the battery.................. 128

Plan E .............................................. 95, 96, 97, 98

Repair .............................................................. 168

Plan N .......................................................... 91, 92

Repair work - Safety instructions ...................... 163

Plan T .......................................................... 93, 94

Replacement .................................................... 121

Plan V ................................................................ 89

Replacing the bypass valves and the sealing rings .................................................................. 133

Plan W .......................................................... 93, 94 Possible causes................................................ 175 Preface ................................................................ 3

Replacing the filter element .............. 135, 136, 137 Retensioning the alternator/fan belt .................. 112 Retensioning the fan belt .................................. 112

Presetting the pause duration .......................... 155 Pressure accumulator ...................................... 142

S

Pressure-accumulator inspection regulations 142, 149

Safety filter element .......................................... 121

Prior to assisted starting .................................. 166

Safety instructions governing specific operational phases ............................................................ 6

PUMP TRANSFER GEARBOX ........................ 144 Pump-Managing-System .................................... 20 Putting the excavator out of operation .............. 158

Screen-washer .................................................. 27 Section.............................................................. 175 Securing the machine ........................................ 68

Selection and qualification of personnel - basic responsibilities ...................................................... 6

T Technical data .................................................. 148

Service station (optional equipment) .................. 48 TECHNICAL DATA .......................................... 189 Servicing .......................................................... 125 Temperature .................................................... 116 SERVICING WORK.......................................... 111 Tightening torques and -angles ........................ 185 Shutting off the engine ........................................ 51 Topping up with hydraulic oil ............................ 131 Signs .................................................................. 23 Track drive - Fault table .................................... 178 Slewing and braking the superstructure ............ 63 Track pads ........................................................ 148 SLEWING GEARBOX ...................................... 145 Track parking brake ............................................ 58 Slewing mechanism - Fault table ...................... 179 Track roller fastening ........................................ 147 SLEWING RING .............................................. 151 Track rollers, support rollers, track pads .......... 147 Slewing ring - Checking the grease filling ........ 152 Track tensioner ................................................ 148 Slewing ring - Checking the screws for tightness .................................................................. 152

Transport ............................................................ 59

Slewing ring - Filling in grease .......................... 152

Transport - Safety instructions ............................ 59

Slewing ring - Instructions ................................ 151

Transporting and recommissioning ...................... 9

Special work in conjunction with utilization of the machine - maintenance and repairs during operation - disposal of parts and consumables .... 7

Transporting the machine .................................. 59

Speed-reduction function.................................... 72 Standard operation .............................................. 6 Starting and stopping the engine ........................ 50 Starting the engine ............................................ 50 Starting the engine with jumper cables (external batteries) .................................................... 166 Starting up the engines .................................... 167

Travel gearbox - Changing the oil .................... 146 TRAVEL GEARBOXES .................................... 146 TRAVELLING .................................................... 54 Travelling downhill .............................................. 55 Travelling forwards/backwards .......................... 54 Travelling over long distances ............................ 57 TROUBLESHOOTING .................................... 175 Turning .............................................................. 55

Superstructure .................................................... 19 Superstructure basic position ............................ 54

U

Superstructure lock ............................................ 58

Unblocking a grease line .................................. 156

Support roller fastening .................................... 147

Undercarriage .................................................... 19

Switching on the pump servo system ................ 63

Using the cold-starting aid for starting ................ 50

Switching the electrical system on and off .......... 48

Using the refuelling system ................................ 47

System configuration ........................................ 148

V Ventilation .......................................................... 52 Ventilation and heating ...................................... 52 Venting bore .................................................... 145 Venting the fuel system .................................... 123 Venting the grease lines .................................. 156 Venting the grease pump ................................ 156 Venting the hydraulic components .................. 140 Venting the hydraulic system ............................ 140

W Warning and instructions signs .......................... 23 Warning of special dangers .................................. 8 Warnings and symbols ........................................ 4 Warranty .............................................................. 3 Water filter ........................................................ 118 Water trap (option) ............................................ 125 WELDING OPERATIONS ................................ 169 Welding operations - Safety instructions .......... 169 Working .............................................................. 64 Working hydraulics - Fault table ...................... 177 WORKING OPERATION .................................... 63 Working operation - Safety instructions .............. 61 Working with the hydraulic hammer - Safety instructions ........................................................ 73