PDF Operating Instruction Manual CAT Bucyrus RH 40E Hydraulic Excavator - 1 MB
Master the operation of the powerful CAT Bucyrus RH 40E hydraulic excavator with this official operating instruction manual.
This guide is critical for ensuring operators understand the machine's controls, capabilities, and safety protocols.
It provides clear instructions for daily inspections and routine tasks to maintain peak performance.
Proper operation based on this manual can significantly improve productivity and safety in demanding mining environments.
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--- Page 1 ---
OPERATING INSTRUCTIONS RH 40E
Hydraulic Excavator
RH 40E No.
Bucyrus HEX GmbH
BA RH40E(2 486 214.03)-EN
--- Page 3 ---
Fuel system - Safety instructions ........................................................................................................ 110
Changing the fuel filter ........................................................................................................................ 110
Venting the fuel system ...................................................................................................................... 111
Cleaning the fuel tank .......................................................................................................................... 111
Water trap (option) .............................................................................................................................. 112
Servicing.............................................................................................................................................. 112
Draining off water ................................................................................................................................ 112
ELECTRICAL SYSTEM
Electrical system - Safety instructions ................................................................................................ 113
Alternator - Instructions ...................................................................................................................... 113
Battery main switch / Main fuse .......................................................................................................... 114
Battery ................................................................................................................................................ 114
Checking the battery fluid level............................................................................................................ 114
Checking the battery charge .............................................................................................................. 115
Removing and installing the battery .................................................................................................... 115
HYDRAULIC SYSTEM
Hydraulic system - Safety instructions ................................................................................................ 117
Depressurizing the hydraulic system .................................................................................................. 117
Checking the hydraulic oil level .......................................................................................................... 118
Topping up with hydraulic oil .............................................................................................................. 118
Changing the hydraulic oil return-flow filters........................................................................................ 119
Bypass valves (working circuit) .......................................................................................................... 120
Cleaning the sieve .............................................................................................................................. 120
Replacing the bypass valves and the sealing rings ............................................................................ 120
Bypass valve (cooling circuit) .............................................................................................................. 121
Cleaning the valve .............................................................................................................................. 121
Changing the valve.............................................................................................................................. 121
Breather filter ...................................................................................................................................... 122
Replacing the filter element ................................................................................................................ 122
High-pressure filter for working hydraulics .......................................................................................... 123
Checking/changing the filter elements ................................................................................................ 123
Replacing the filter element ................................................................................................................ 123
High-pressure filter for the servo circuit and the feeding circuit of the slewing pump .......................... 124
Checking the filter element .................................................................................................................. 124
Replacing the filter element ................................................................................................................ 124
Changing the hydraulic oil .................................................................................................................. 125
Draining off the hydraulic oil ................................................................................................................ 125
Cleaning the hydraulic oil reservoir .................................................................................................... 126
Filling in hydraulic oil .......................................................................................................................... 126
Venting the hydraulic system .............................................................................................................. 127
Venting the hydraulic components ...................................................................................................... 127
Cleaning the hydraulic oil cooler.......................................................................................................... 128
Cleaning .............................................................................................................................................. 128
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OPERATING INSTRUCTIONS RH 40-E
Organizational measures 2413495
The operating instructions must always be at Observe all safety instructions and warnings at-
hand at the place of use of the machine, e.g. by tached to the machine.
stowing them in the place provided for such pur-
pose. See to it that safety instructions and warnings
attached to the machine are always complete and
In addition to the operating instructions, observe perfectly legible.
and instruct the user in all other generally ap-
plicable legal and other mandatory regulations In the event of safety-relevant modifications or
relevant to accident prevention and environmental changes in the behaviour of the machine during
protection. operation, stop the machine immediately and re-
port the malfunction to the competent author-
These compulsory regulations may also deal with ity/person.
the handling of hazardous substances, issuing
and/or wearing of personal protective equipment Never make any modifications, additions or con-
or traffic regulations. versions which might affect safety without the
supplier’s approval. This also applies to the in-
The operating instructions must be supplemented stallation and adjustment of safety devices and -
by instructions covering the duties involved in valves as well as to welding work on load-bearing
supervising and notifying special organizational elements.
features, such as job organization, working se-
quences or the personnel entrusted with the Spare parts must comply with the technical re-
work. quirements specified by the manufacturer. Spare
parts from original equipment manufacturers can
Personnel entrusted with work on the machine be relied on to do so.
must have read the operating instructions and in
particular the chapter on safety before beginning Replace hydraulic hoses within stipulated and ap-
work. Reading the instructions after work has be- propriate intervals, even if no safety-relevant de-
gun is too late. This applies especially to persons fects have been detected.
working only occasionally on the machine, e.g.
during setting up or maintenance. Adhere to prescribed intervals or those specified
in the operating instructions for routine checks
Check - at least from time to time - whether the and inspections.
personnel is carrying out the work in compliance
with the operating instructions and paying atten- For the execution of maintenance work, tools and
tion to risks and safety factors. workshop equipment adapted to the task on hand
are absolutely indispensable.
For reasons of security, long hair must be tied
back or otherwise secured, garments must be The personnel must be familiar with the location
close-fitting and no jewellery, such as rings, may and operation of fire extinguishers.
be worn. Injury may result from being caught up
Observe all fire-warning and fire-fighting proce-
in the machinery or from rings catching on mov-
dures.
ing parts.
Use protective equipment wherever required by
the circumstances or by law.
2 486 214.03 en 5
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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 informa-
tion label), when, for example, oil,
grease, fuel or cleaner was spilled.
Such substances may spontane-
ously ignite if they get into the vi-
cinity 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 easi-
ly flammable liquids have spilled
from the excavator onto the
ground.
Flying sparks may cause fire on
the ground that can spread to the
excavator.
2 486 214.03 en 15
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OPERATING INSTRUCTIONS RH 40-E
2 486 214.03 en 25
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OPERATING INSTRUCTIONS RH 40-E
(Fig. 5)
No. Element Function Symbol
53 Switch Stop Engine shut-off
54 Switch Electronic speed regu- Press switch after a fault has been re-
lation (Centry) ported. Warning lamp (2) flashes in a
coded sequence. The coded sequence in-
dicates the cause of the fault.
Contact the O&K Technical Service or
the engine manufacturer
55 Free for optional equipment
56 Free for optional equipment
57 Switch Speed reset To the left: normal operation automatic
speed reduction of diesel en-
gine; active during working
pauses
To the right: automatic speed-reduction func-
tion off
58 Switch Pre-heating system Pre-heating of the fuel system
(optional)
59 Switch Windscreen wiper Permanent operation/intermittent operation
60 Switch Floodlamp Front of superstructure on the right
61 Switch Windscreen washer Wipe/wash operation
62 Switch Floodlamp Counterweight
63 Switch Track parking brake To block the undercarriage.
Actuate switch only when
the excavator is stationary.
The track brake is automati-
cally released when the un-
dercarriage travel function is
switched on
64 Switch Floodlamp Driver’s cab, instrument lighting
2 486 214.03 en 35
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OPERATING INSTRUCTIONS RH 40-E
Shutting off the engine Emergency stop
During interruptions of the work and after the In case of emergency, e.g. if buzzer (50, Fig. 8)
work, stand working equipment on the ground. sounds, the engine can be shut off from full load.
To do so:
Do not shut off engine before the
working equipment rests on the • actuate stop-button (53, Fig. 7) and hold in this
ground. position until the engine has come to a stand-
still;
• Turn speed control knob (71, Fig. 7) counter-
clockwise to the limit stop (idling). • turn key in key-switch (72) to position "0" (elec-
trical system without current).
Fig. 7
Do not shut off the engine out of
Fig. 8
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 com-
bustion heat from the combustion
chamber and from bearings and
shafts.
• Turn key in key-switch (72) to position "0"
(electrical system without current).
2 486 214.03 en 45
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OPERATING INSTRUCTIONS RH 40-E
At low temperatures, bring the en- Parts of the attachment may dam-
gine down to moderate speed, then age the machine if they are moved
activate all hydraulic functions for into extreme positions (see illustra-
about 10 minutes (bring to service tion 1 and 2).
temperature). For further instruc- Work carefully, avoiding extreme
tions, see section "Lubricants". positions of this kind.
If the warning lamps for engine
temperature, engine oil pressure,
coolant level, alternator or hydrau-
lic oil filter control (with hydraulic
oil at service temperature) light up:
Lower the working equipment and
shut off engine.
Fig. 1
Fig. 2
2 486 214.03 en 55
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OPERATING INSTRUCTIONS RH 40-E
Pipe break protection Speed-reduction function
The pipe break protection prevents the working Do not activate the speed-reduction
equipment from lowering if a hydraulic line to the function when the machine is used
boom cylinder breaks. for lifting-gear operation and for
travelling.
The hydraulic connection on the rod side of the The speed-reduction function can
boom cylinder is blocked, so that the hydraulic oil cause the hydraulic output to de-
can flow out only if the "Boom lowering" function crease suddenly.
is initiated.
If a hydraulic line has broken:
The speed-reduction function reduces the drive
• Warn persons in the vicinity of the excavator by engine revolutions to idling if the working equip-
sounding the horn. ment remains inactivated during 10 seconds.
Stop working.
• Secure the working equipment with the at-
tached 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
2 486 214.03 en 65
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OPERATING INSTRUCTIONS RH 40-E
Inspection and servicing plans - Instructions 2413581
Intervals Air-intake system
The inspection and servicing plan lists all jobs The air filter must be serviced only if the vacuum-
which have to be done on the machine at regular meter so indicates.
intervals.
The individual inspection and servicing plans are Oils / Greases
marked with letters providing a link between the
operating hours (OH) recorded by the hours-run For the specification of oils and greases to be
meter of the machine and the inspection and used refer to the "Lubricants" section.
servicing plans. The numerals mentioned in the "Oil / Grease"
column in the inspection and servicing plans have
the following meaning:
Plan Do all jobs ....
V .... once prior to initial commissioning. I Oils for combustion engines and com-
pressors
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 50 OH or weekly1). V Greases for bearings and slewing rings
A .... after every 250 OH. VII Oils for refrigerating compressors
B .... after every 500 OH.
C .... after every 1000 OH. Cleaning jobs
Cleaning jobs, especially on cooling systems,
D .... after every 3000 OH.
must be done at shorter intervals if the machine
E .... after every 6000 OH. 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 perma-
nent 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 .
2 486 214.03 en 75
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OPERATING INSTRUCTIONS RH 40-E
2 486 214.03 en 85
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OPERATING INSTRUCTIONS RH 40-E
III. Oils for gearboxes (selection)
2 486 214.03 en 95
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OPERATING INSTRUCTIONS RH 40-E
Cooling liquid The engine operating instructions describe in de-
tail how to prepare cooling water and how to
check the cooling liquid. Check in case of im-
Read and observe the "Inspection minent frost whether the concentration of the anti-
and servicing - Safety instructions" freeze compound added to the cooling liquid at
chapter. the factory is sufficient for the temperatures to be
Risk of scalding caused by hot expected.
cooling liquid.
The cooler itself may also be hot.
Wear protective gloves and firm
working clothing.
Collect escaping cooling liquid and
discard without polluting the envi-
ronment.
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 - Oth-
er" table.
• Shut off the engine.
• Open hatch II (Fig. 2).
• Unscrew plug (arrow, Fig. 3) and drain off cool-
ing liquid completely.
• Fill in cooling liquid after having re-inserted the
plug with a new sealing ring.
2 486 214.03 en 105
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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
• Unscrew caps of the battery (Fig. 4). and servicing - Safety instructions"
chapter.
• 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 correla-
tion with the battery charge. Shut off the engine before remov-
ing 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 ter-
minal clamping lugs in the pre-
scribed order.
Disconnecting and connecting in
the wrong order may cause short-
circuits.
Fig. 4
Acid density
in kg / dm3 Charge
Normal Tropical
condi- condi-
tions tions
1.28 1.23 fully charged
1.20 1.12 half charged, recharge
1.12 1.08 discharged, recharge imme- Fig. 5
diately
2 486 214.03 en 115
--- Page 17 ---
OPERATING INSTRUCTIONS RH 40-E
Changing the hydraulic oil Draining off the hydraulic oil
• Bring the hydraulic oil to operating temperature
Read and observe the "Inspection (abt. 50˚C).
and servicing - Safety instructions"
chapter. • Position the machine with a slight inclination
Shut off the engine. towards the drain valve (5, Fig. 16).
The drain valve is located at the back of the
Risk of scalding caused by hot hy- hydraulic oil reservoir and accessible from the
draulic oil. bottom.
The hydraulic reservoir itself may
also be hot. • Retract the hydraulic cylinders as far as possi-
ble and stand the working equipment on the
Avoid skin contact. ground.
Contact with hydraulic oil can
cause skin injury. • Shut off the engine.
Wear protective gloves and firm • Place a suitable recipient under the drain valve
working clothing. of the hydraulic oil reservoir (5). Choose the
Collect escaping oil and discard required capacity of the recipient in accordance
without polluting the environment. with the "Refilling quantities - Oil" table.
• Connect hose (15) to drain valve (5) and drain
off used oil completely. Draining is facilitated if
Do not start up the drive engine
the breather filter (6, Fig. 17) is removed during
when the hydraulic oil reservoir is
the process.
empty. The hydraulic pumps may
The use of the oil draining hose is described in
be destroyed if they are allowed to
the "Draining hose for oil changes" section.
run dry.
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 automati-
cally.
Fig. 16
Fig. 17
2 486 214.03 en 125
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OPERATING INSTRUCTIONS RH 40-E
Track pads Technical data
Check fastening screws (5, Fig. 4) regularly for Track tensioning pressure ca. 100 bars
tightness: Pressure limiting valve 250 bars
Gas pressure in diaphragm accumulator
• Tighten screws with a torque wrench to the (nitrogen filling pressure) 80 bars
prescribed tightening torque (cf. table "Tighten-
ing torques"). Function
The tensioning system is under a permanent
pressure of ca. 100 bars which keeps both tracks
permanently tensioned. Pressure losses are com-
pensated 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
Fig. 4 slacken the tracks.
• After the work, screw down the pressure limit-
Track tensioner
ing valves (6) to the limit stop.
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 di-
verted via a corresponding hydraulic switching
device to the track-tensioning circuit. Figs. 5 and
6 show parts of the tracks and the tensioner:
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 maintenance-
Fig. 5 free.
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
2 486 214.03 en 135
--- Page 19 ---
OPERATING INSTRUCTIONS RH 40-E
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMIS-
SIONING 2413688
Putting the excavator out of operation
• Park excavator on firm and level ground. Recommissioning
• Stand working equipment on the ground retrac- • Remove covers.
ting the piston rods of the hydraulic cylinders
as far as possible. • Degrease resp. clean all protected components.
• Set all control levers to position "0". • Remove engine preservative in acc. with the
engine operating instructions.
• Clean the machine.
• Unlock the superstructure.
• Lock the superstructure.
• Check the fuel level in the tank.
• Carry out a visual inspection of the excavator.
• Check tensioning of the tracks (visual inspec-
• Remove gross dirt, snow and ice from the fins tion).
and the fan wheel of the hydraulic oil cooler.
• Check level and condition of the cooling liquid
• Carry out engine preservation. in the cooling system.
• Protect all bright metal parts (e.g. piston rods) • Check grease filling in grease container.
against rust and dirt.
• oil level - drive engine
• Check anti-freeze concentration of the cooling - slewing gearbox
liquid to avoid freezing during the cold season. - pump transfer gearbox
• Fill up the fuel tank. - travel gearboxes
• Remove the batteries. Cf. also Battery sto- • Check oil level in hydraulic oil reservoir.
rage. • Check acid density and battery fluid level.
• Secure the machine against unauthorized start- • Install the batteries and reconnect.
ing by:
- withdrawing the key from the key-switch • Set battery main switch to ON.
- setting the battery main switch to OFF and