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CAT Bucyrus RH 200 Hydraulic Excavator Operating Instruction Manual 3666410 – PDF DOWNLOAD
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CAT Bucyrus RH 200 Hydraulic Excavator Operating Instruction Manual 3666410 – PDF DOWNLOAD
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Description
CAT Bucyrus RH 200 Hydraulic Excavator Operating Instruction Manual 3666410 – PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus RH 200 Hydraulic Excavator Operating Instruction Manual 3666410 – PDF DOWNLOAD
Language : English
Pages : 272
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT Bucyrus RH 200 Hydraulic Excavator Operating Instruction Manual 3666410 – PDF DOWNLOAD
PREFACE:
- These operating instructions are designed to fa- miliarize the operator with the machine
and its designated use. - The operating instructions contain important in- formation on how to operate the machine
safely, properly and with maximum efficiency. Observing these instructions helps to
prevent hazardous situations, to reduce repair costs and downtimes and to increase the
reliability and service life of the machine. - The operating instructions must be supplemented by the respective national rules and regulations
for accident prevention and environmental protection. - The operating instructions must always be avail- able in the driver’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, troubleshoot- ing 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 pre- vention 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 - The operating instructions are directed to the con- struction-machine specialist. They cannot
provide basic know-how. This can be acquired, for exam- ple, in several days’ instruction by
a qualified GERMANY Germany mechanic or by attending an Terex-Germany training course for
operators or maintenance personnel. - The Terex-Germany after-sales service will be pleased to deal with any queries you may
have after reading through the operating instructions. - All Terex Germany operating manuals are issued in German and then translated. Even a good
translation may give rise to questions which Terex Germany will be pleased to answer. - The operating instructions are not work instruc- tions for carrying out major repairs. Such
work is willingly done for you by the Terex Germany af- ter-sales service. - The documentation relating to the machine is listed according to scope, quantity and language in
the shipping note of the machine or in the covering letter if supplied separately. The operating
instruc- tions and spare-parts list are marked with the se- rial number of the machine. - On taking receipt of the consignment, please check that the documentation is
complete and in the language requested by you.
TABLE OF CONTENTS:
CAT Bucyrus RH 200 Hydraulic Excavator Operating Instruction Manual 3666410 – PDF DOWNLOAD
TABLE OF CONTENTS.............................................................................................................................................................. 5 INTRODUCTION................................................................................................................................................................... 11 PREFACE.................................................................................................................................................................... 13 WARRANTY................................................................................................................................................................... 14 FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 15 Warnings and symbols................................................................................................................................................... 15 DESIGNATED USE............................................................................................................................................................. 16 ORGANIZATIONAL MEASURES.................................................................................................................................................... 17 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases.............................................................................................................. 18 Special work in conjunction with utilization of the machine and mainten ance and repairs as well as trouble shooting during work; disposal of parts and consumables.... 19 Warning of special dangers............................................................................................................................................. 20 Gas, dust, steam and smoke............................................................................................................................................. 21 Hydraulic equipment.................................................................................................................................................... 21 Noise.................................................................................................................................................................. 21 Oil, grease and other chemical sub stances............................................................................................................................. 21 Transporting and recommission ing...................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22 NOTES...................................................................................................................................................................... 23 OPERATION...................................................................................................................................................................... 25 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 27 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 29 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 30 Excavator layout....................................................................................................................................................... 31 Undercarriage.......................................................................................................................................................... 32 Superstructure......................................................................................................................................................... 32 Drive.................................................................................................................................................................. 32 Hydraulic system....................................................................................................................................................... 32 Pump Managing System (PMS)............................................................................................................................................. 32 Stored Program Control (SPC)........................................................................................................................................... 32 Electronic Hydraulic Servo-Control (CMS)............................................................................................................................... 32 Demand control / Zero-flow regulation.................................................................................................................................. 33 Automatic engine speed reduction....................................................................................................................................... 33 Board-Control-System (BCS)............................................................................................................................................. 33 Electrical system...................................................................................................................................................... 33 Sign................................................................................................................................................................... 35 Entering and leaving the machine Safety instructions................................................................................................................... 36 Ramp-type ladder (optional)............................................................................................................................................ 37 EMERGENCY STOP pushbuttons............................................................................................................................................. 39 Windscreen washer...................................................................................................................................................... 39 Driver's seat.......................................................................................................................................................... 40 Fire extinguisher...................................................................................................................................................... 41 Automatic fire-extinguishing system (optional)......................................................................................................................... 42 Harness (optional)..................................................................................................................................................... 43 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 46 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 77 Refuelling............................................................................................................................................................. 77 Service station (tanklift)............................................................................................................................................. 77 Switching the electrical system on and off............................................................................................................................. 83 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 84 AIR CONDITIONER (OPTION)................................................................................................................................................... 87 Back-up heating (option)............................................................................................................................................... 89 DRIVING.................................................................................................................................................................... 91 SAFETY INSTRUCTIONS.................................................................................................................................................... 91 Superstructure basic position.......................................................................................................................................... 92 Emergency machine drive................................................................................................................................................ 96 Locking the superstructure............................................................................................................................................. 98 Track parking brake.................................................................................................................................................... 98 TRANSPORTING THE MACHINE................................................................................................................................................... 99 Safety instructions.................................................................................................................................................... 99 WORKING OPERATION..........................................................................................................................................................100 Safety instructions....................................................................................................................................................100 Before starting work...................................................................................................................................................102 Slewing and braking the superstructure.................................................................................................................................102 Braking the superstructure.............................................................................................................................................102 Working................................................................................................................................................................103 After daily operation..................................................................................................................................................104 ASSEMBLING WORKING EQUIPMENT...............................................................................................................................................105 SAFETY INSTRUCTIONS....................................................................................................................................................105 Securing the machine...................................................................................................................................................107 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................108 NOTES......................................................................................................................................................................109 INSPECTION AND SERVICING.......................................................................................................................................................111 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................113 FIRE AND EXPLOSION HAZARD..................................................................................................................................................119 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................121 Intervals..............................................................................................................................................................121 Change of engine oil...................................................................................................................................................121 Air-intake system......................................................................................................................................................121 Oils / Greases.........................................................................................................................................................121 Cleaning jobs..........................................................................................................................................................121 Components.............................................................................................................................................................121 Plan V.................................................................................................................................................................123 Plan N.................................................................................................................................................................125 Plan T.................................................................................................................................................................127 Plan A – E.............................................................................................................................................................129 LUBRICATING CHART – GREASE.................................................................................................................................................138 Lubricating chart – Grease (legend)....................................................................................................................................139 Filling quantities - Grease............................................................................................................................................139 INSPECTION PLAN - OIL......................................................................................................................................................140 Inspection plan – Oil (legend) ).......................................................................................................................................141 Filling quantities - oil...............................................................................................................................................142 Filling quantities - other.............................................................................................................................................142 LUBRICANTS.................................................................................................................................................................143 I. Oils for combustion engines and compressors (selection).............................................................................................................143 II. Oils for hydraulic system (selection)..............................................................................................................................144 III. Oils for gearboxes (selection)....................................................................................................................................145 V. Greases for bearings and slewing rings..............................................................................................................................146 SERVICING WORK.............................................................................................................................................................147 Hose line for oil and cooling liquid changes...........................................................................................................................147 ENGINE.....................................................................................................................................................................148 Engine - Safety instructions...........................................................................................................................................148 Retensioning the alternator/fan belt...................................................................................................................................148 Checking and adjusting the valve clearance.............................................................................................................................148 Checking the engine oil level / Topping up.............................................................................................................................149 Checking the oil level in the engine oil reservoir / topping up (optional).............................................................................................150 Changing the engine oil................................................................................................................................................151 Draining the oil off the engine oil reservoir (optional)...............................................................................................................153 Eliminator filter and centrifuge.......................................................................................................................................155 COOLING SYSTEM.............................................................................................................................................................157 Radiators..............................................................................................................................................................158 Cooling liquid.........................................................................................................................................................160 Water filter...........................................................................................................................................................162 AIR-INTAKE SYSTEM..........................................................................................................................................................163 Main filter elements...................................................................................................................................................163 Safety filter element..................................................................................................................................................165 Air-intake lines.......................................................................................................................................................166 Dust collection........................................................................................................................................................166 FUEL SYSTEM................................................................................................................................................................167 Fuel system - Safety instructions......................................................................................................................................167 Replacing the fuel filter..............................................................................................................................................167 Venting the fuel system................................................................................................................................................168 Cleaning the fuel tanks................................................................................................................................................168 Water trap (option)....................................................................................................................................................170 ELECTRICAL SYSTEM..........................................................................................................................................................172 Electrical system - Safety instructions................................................................................................................................172 Alternator - Instructions..............................................................................................................................................172 Battery................................................................................................................................................................173 Switchgear cabinet.....................................................................................................................................................175 HYDRAULIC SYSTEM...........................................................................................................................................................177 Hydraulic system - Safety instructions.................................................................................................................................177 Depressurizing the hydraulic system....................................................................................................................................177 Checking the hydraulic oil level.......................................................................................................................................178 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................180 Bypass valves (hydraulic oil reservoir)................................................................................................................................182 Breather filter........................................................................................................................................................183 Filter (control circuit)...............................................................................................................................................184 High-pressure filter for working hydraulics............................................................................................................................185 High-pressure filters for the servo circuit............................................................................................................................186 High-pressure filters for feeding circuits and slewing pumps...........................................................................................................187 High-pressure filters for slewing circuit..............................................................................................................................188 Changing the hydraulic oil.............................................................................................................................................189 Venting the hydraulic system...........................................................................................................................................192 Cleaning the hydraulic oil cooler......................................................................................................................................193 Electronic excavator control...........................................................................................................................................194 Pressure accumulator - Emergency lowering..............................................................................................................................195 PUMP TRANSFER GEARBOX......................................................................................................................................................196 Checking the gearbox oil level / Topping up with oil...................................................................................................................196 Pre-chamber............................................................................................................................................................197 Changing the gearbox oil...............................................................................................................................................198 Pre-chamber............................................................................................................................................................199 Gearbox venting........................................................................................................................................................200 Pump transfer gearbox lube oil filters.................................................................................................................................201 SLEWING GEARBOX............................................................................................................................................................202 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................202 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................203 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................203 Changing the gearbox oil...............................................................................................................................................204 Gearbox venting........................................................................................................................................................205 TRAVEL GAERBOX.............................................................................................................................................................206 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................206 Travel gearbox - Changing oil..........................................................................................................................................207 Pre-chamber - Changing the oil.........................................................................................................................................207 Brake chamber - Changing oil...........................................................................................................................................208 Breather filter........................................................................................................................................................208 CRAWLER TRACKS.............................................................................................................................................................209 Track rollers..........................................................................................................................................................210 Track tensioner........................................................................................................................................................211 Pressure-accumulator inspection regulations............................................................................................................................212 Checking the gas charging pressure in the pressure accumulator.........................................................................................................212 SLEWING RING...............................................................................................................................................................213 Slewing ring - Instructions............................................................................................................................................213 Bearing races..........................................................................................................................................................213 CENTRAL LUBRICATING........................................................................................................................................................215 Design.................................................................................................................................................................215 Lube cycle / Pause period..............................................................................................................................................215 Function...............................................................................................................................................................216 Filling up the grease container........................................................................................................................................217 Breather filter........................................................................................................................................................217 Checking the greasing pressure.........................................................................................................................................218 Checking the greasing pressure.........................................................................................................................................219 Unblocking a grease line...............................................................................................................................................220 Unblocking a grease line...............................................................................................................................................220 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................221 Grease filter (Filling the grease container)...........................................................................................................................222 Grease filter (Grease lines)...........................................................................................................................................223 OTHER MAINTENANCE..........................................................................................................................................................224 Engine.................................................................................................................................................................224 Heating and air conditioning...........................................................................................................................................224 Equipment..............................................................................................................................................................225 RAMP-TYPE LADDER (OPTIONAL) (OPTION)......................................................................................................................................226 Guide pulleys and locking bolt.........................................................................................................................................226 Pressure-accumulator inspection regulations............................................................................................................................227 Extract from the German regulations....................................................................................................................................227 Checking the gas charging pressure in the pressure accumulator.........................................................................................................227 ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................228 Monitoring, warning and control elements...............................................................................................................................228 Checking the on-board crane............................................................................................................................................228 Drive unit.............................................................................................................................................................229 On-board crane.........................................................................................................................................................229 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................230 Putting the excavator out of operation.................................................................................................................................230 Battery storage........................................................................................................................................................230 Recommissioning........................................................................................................................................................231 NOTES......................................................................................................................................................................233 REPAIR WORK....................................................................................................................................................................235 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................237 FIRE AND EXPLOSION HAZARD..................................................................................................................................................239 ENGINE.....................................................................................................................................................................240 ELECTRICAL SYSTEM..........................................................................................................................................................241 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................241 Assisted starting (with jumper cables).................................................................................................................................241 Starting the engine with jumper cables (external batteries.............................................................................................................241 HYDRAULIC SYSTEM...........................................................................................................................................................244 Repair.................................................................................................................................................................244 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................245 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................246 NOTES......................................................................................................................................................................247 ANNEX..........................................................................................................................................................................249 TROUBLESHOOTING............................................................................................................................................................251 Instructions on troubleshooting........................................................................................................................................251 Layout of the fault table..............................................................................................................................................251 Possible causes........................................................................................................................................................251 Measures...............................................................................................................................................................251 Section................................................................................................................................................................251 FAULT TABLES...............................................................................................................................................................252 Combustion engine - Fault table........................................................................................................................................252 Working hydraulics – Fault table.......................................................................................................................................253 Track drive – Fault table..............................................................................................................................................254 Slewing mechnism – Fault table.........................................................................................................................................255 Central lubricating system – Fault table...............................................................................................................................256 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................258 ABBREVIATIONS..............................................................................................................................................................261 TECHNICAL DATA.............................................................................................................................................................263 NOTES......................................................................................................................................................................265 INDEX..........................................................................................................................................................................267
IMAGES PREVIEW OF THE MANUAL:
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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