Cat Bucyrus RH 200 Hydraulic Shovel OPERATING INSTRUCTIONS MANUAL BI651520 – PDF DOWNLOAD

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Cat Bucyrus RH 200 Hydraulic Shovel OPERATING INSTRUCTIONS MANUAL BI651520 – PDF DOWNLOAD

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Cat Bucyrus RH 200 Hydraulic Shovel OPERATING INSTRUCTIONS MANUAL BI651520 – PDF DOWNLOAD

Language : English
Pages : 286
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus RH 200 Hydraulic Shovel OPERATING INSTRUCTIONS MANUAL BI651520 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH 200
Preface

• These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
• The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. 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

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]

• [1] Complies with VDMA recommendation “Operating instructions” 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 work instructions for carrying out major repairs.
• Such work is willingly done for you by the O&K Mining after-sales service. The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Cat Bucyrus RH 200 Hydraulic Shovel OPERATING INSTRUCTIONS MANUAL BI651520 – PDF DOWNLOAD

PART 1 – INTRODUCTION __ 1
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 6
Standard operation 6
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 7
WARNING OF SPECIAL DANGERS _ 8
Electric energy___ 8
High-voltage system ____ 8
Battery __ 8
Gas, dust, steam and smoke ___ 9
Hydraulic and pneumatic 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 13
OPERATION – SAFETY INSTRUCTIONS ___ 15
FIRE AND EXPLOSION HAZARD 17
DESCRIPTION OF THE EXCAVATOR 18
Excavator layout 19
Undercarriage __ 20
Superstructure__ 20
Drive __ 20
Hydraulic system 20
Pump Managing System (PMS) 20
Stored Program Control (SPC) _ 20
Demand control / Zero-flow regulation ____ 21
Automatic engine speed reduction 21
Board-Control-System (BCS) __ 21
Electrical system 21
Signs __ 23
Entering and leaving the machine Safety instructions __ 24
Ramp-type ladder (optional) ___ 26
EMERGENCY STOP pushbuttons 28
Windscreen washer____ 28
Driver’s seat____ 29
Fire extinguisher 30
Automatic fire-extinguishing system (optional) 31
MONITORING, WARNING AND CONTROL ELEMENTS __ 32
PUTTING THE MACHINE INTO OPERATION _ 63
REFUELLING ____ 63
Refuelling – Safety instructions _ 63
SERVICE STATION (TANKLIFT) _ 63
Switching the electrical system on and off _ 69
Starting and stopping the engines_ 70
Air conditioner (option) _ 73
Control panel (Greentop) 74
OPERATING INSTRUCTIONS RH 200

Control panel (Sigma) __ 74
Back-up heating (option) 75
Control panel (Eberpächer) ____ 75
Control panel ___ 76
DRIVING SAFETY INSTRUCTIONS 77
TRAVELLING 78
Superstructure basic position __ 78
Travelling forwards/backwards _ 78
Emergency machine drive_____ 82
Locking the superstructure ____ 84
Track parking brake ___ 84
TRANSPORTING THE MACHINE __ 85
Transport – Safety instructions _ 85
WORKING OPERATION – SAFETY INSTRUCTIONS _____ 87
WORKING OPERATION ___ 89
Before starting work ___ 89
Slewing and braking the superstructure ___ 89
Braking the superstructure ____ 89
Working 90
After daily operation____ 91
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS __ 93
Securing the machine __ 95
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___ 96
NOTES ____ 97
PART 3 INSPECTION AND SERVICING 99
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS __ 101
FIRE AND EXPLOSION HAZARD _ 107
INSPECTION AND SERVICING PLANS – INSTRUCTIONS ___ 109
Intervals 109
Change of engine oil l _ 109
Air-intake system 109
Oils / Greases _ 109
Cleaning jobs__ 109
Plan V – Once prior to initial commissioning _ 111
Plan V – Once prior to initial commissioning _ 112
Plan N – After initial commissioning and during the running-in period ____ 113
Plan T – Every 10 OH or every working shift ______ 115
Plan W – Every 60 OH or every working shift ______ 115
Plan T – Every 10 OH or every working shift ______ 116
Plan W – Every 60 OH or every working shift ______ 116
Plan A – after every 250 OH 117
Plan B – after every 500 OH 117
Plan C – after every 1000 OH _ 117
Plan D – after every 5000 Bh 117
Plan E – after every 10000 OH 117
Plan A – after every 250 OH 118
Plan B – after every 500 OH 118
Plan C – after every 1000 OH _ 118
Plan D – after every 5000 Bh 118
Plan E – after every 10000 OH 118
Plan A – after every 250 OH 120
Plan B – after every 500 OH 120
Plan C – after every 1000 OH _ 120
Plan D – after every 5000 Bh 120
OPERATING INSTRUCTIONS RH 200

Plan E – after every 10000 OH 120
Plan A – after every 250 OH 121
Plan B – after every 500 OH 121
Plan C – after every 1000 OH _ 121
Plan D – after every 5000 Bh 121
Plan E – after every 10000 OH 121
Plan A – after every 250 OH 122
Plan B – after every 500 OH 122
Plan C – after every 1000 OH _ 122
Plan D – after every 5000 Bh 122
Plan E – after every 10000 OH 122
Plan A – after every 250 OH 123
Plan B – after every 500 OH 123
Plan C – after every 1000 OH _ 123
Plan D – after every 5000 Bh 123
Plan E – after every 10000 OH 123
Plan A – after every 250 OH 124
(at 250, 750, 1250 … OH) ____ 124
Plan B – after every 500 OH 124
Plan C – after every 1000 OH _ 124
Plan D – after every 5000 Bh 124
Plan E – after every 10000 OH 124
Plan A – after every 250 OH 125
(at 250, 750, 1250 … OH) ____ 125
Plan B – after every 500 OH 125
Plan C – after every 1000 OH _ 125
Plan D – after every 5000 Bh 125
Plan E – after every 10000 OH 125
LUBRICATING CHART – GREASE (LOADING BUCKET) 127
Lubricating chart – Grease / Loading bucket (legend) 128
Filling quantities – Grease ____ 128
LUBRICATING CHART – GREASE (BACKHOE BUCKET) _____ 129
Lubricating chart – Grease / Backhoe bucket (legend) 130
Filling quantities – Grease ____ 130
INSPECTION PLAN – OIL _ 131
Inspection plan – Oil (legend) ) 132
Filling quantities – oil __ 133
Filling quantities – other 133
LUBRICANTS_____ 133
I. OILS FOR COMBUSTION ENGINES AND COMPRESSORS (SELECTION) 133
II. OILS FOR HYDRAULIC SYSTEM (SELECTION) _ 134
III. OILS FOR GEARBOXES (SELECTION) _ 135
V. GREASES FOR BEARINGS AND SLEWING RINGS ____ 136
SERVICING WORK 137
Hose line for oil and cooling liquid changes _ 137
ENGINE ___ 138
Engine – Safety instructions___ 138
Checking the V-belt tension __ 138
Retensioning the alternator/fan belt 138
Checking and adjusting the valve clearance _ 138
Checking the engine oil level / Topping up 138
Checking the oil level in the engine oil reservoir /topping up (optional)____ 139
Changing the engine oil 140
Draining off engine oil _ 140
Draining the oil off the engine oil reservoir (optional) _ 142
Replacing the oil filter _ 143
OPERATING INSTRUCTIONS RH 200

Replacing the oil filter for engine oil reservoir (optional) _____ 144
Eliminator filter and centrifuge_ 146
Centrifuge ____ 146
COOLING SYSTEM 148
Temperature __ 148
Radiators _____ 148
Cooling liquid __ 150
Water filter____ 153
AIR-INTAKE SYSTEM ____ 154
Main filter elements ___ 154
Checking and cleaning the main filter element ______ 155
Safety filter element___ 156
Air-intake lines_ 157
Dust collection _ 157
FUEL SYSTEM ____ 158
Fuel system – Safety instructions_ 158
Replacing the fuel filter 158
Venting the fuel system 159
Cleaning the fuel tanks 159
Water trap (option) ___ 161
Servicing _____ 161
ELECTRICAL SYSTEM ___ 162
Electrical system – Safety instructions ____ 162
Alternator – Instructions 162
Switchgear cabinet ___ 165
Emptying the dust trap_ 165
HYDRAULIC SYSTEM ____ 167
Hydraulic system – Safety instructions ____ 167
Depressurizing the hydraulic system _____ 167
Checking the hydraulic oil level / Topping up with oil _ 168
Changing the hydraulic oil return-flow (hydraulic oil reservoir) 170
Bypass valves _ 172
Breather filter__ 173
High-pressure filter for working hydraulics 174
High-pressure filter for servo circuit 175
High-pressure filter for feeding circuits and slewing pumps __ 176
High-pressure filters for slewing circuit ___ 177
Changing the hydraulic oil ____ 178
Venting the hydraulic system__ 181
Cleaning the hydraulic oil cooler _ 182
Pressure accumulator – Emergency lowering 183
Pressure-accumulator inspection regulations 183
Checking the gas charging pressure in the pressure accumulator _ 183
PUMP TRANSFER GEARBOX ___ 185
Checking the gearbox oil level / Topping up with oil __ 185
Changing the gearbox oil_____ 185
Gearbox venting 187
Pre-chamber __ 187
Pump transfer gearbox lube oil filters ____ 188
SLEWING GEARBOX 189
Gearbox – Checking the oil level / Topping up with oil _ 189
Changing the gearbox oil_____ 189
Gearbox venting 190
Slewing gear neck ____ 190
OPERATING INSTRUCTIONS RH 200

TRAVEL GEARBOXES ___ 191
Gearbox – Checking the oil level / Topping up with oil _ 191
Travel gearbox – Changing oil _ 193
CRAWLER TRACKS 196
Cleaning _____ 196
Track rollers___ 196
Track rollers___ 197
Track and support rollers fastening 197
Track tensioner 198
Pressure-accumulator inspection regulations 199
Checking the gas charging pressure in the pressure accumulator _ 199
Idlers _ 200
SLEWING RING ___ 201
Slewing ring – Instructions ____ 201
Bearing races _ 201
Slewing ring – Checking the grease filling _ 202
Slewing ring – Filling in grease_ 202
Slewing ring – Checking the screws for tightness ____ 202
CENTRAL LUBRICATING _ 203
Design and function___ 203
Unblocking a grease line. ____ 206
Manual greasing (option)_____ 206
OTHER MAINTENANCE __ 208
Engine 208
RAMP-TYPE LADDER (OPTIONAL) (OPTION) _ 209
Guide pulleys and locking bolt_ 209
Pressure-accumulator inspection regulations 210
Checking the gas charging pressure in the pressure accumulator _ 210
ON-BOARD CRANE (OPTIONAL)_ 211
Monitoring, warning and control elements _ 211
Checking the on-board crane _ 211
Drive unit _____ 212
On-board crane 212
ALTERNATOR (OPTIONAL) _____ 213
Drive unit _____ 213
PUTTING OUT OF OPERATION AND RECOMMISSIONING ___ 214
Putting the excavator out of operation ____ 214
Battery storage 214
Recommissioning ____ 214
NOTES ___ 215
PART 4 – REPAIR WORK__ 217
REPAIR WORK – SAFETY INSTRUCTIONS 219
FIRE AND EXPLOSION HAZARD _ 221
ENGINE ___ 223
ELECTRICAL SYSTEM ___ 223
Assisted starting (with jumper cables) – Safety instructions __ 223
Assisted starting (with jumper cables) ____ 224
HYDRAULIC SYSTEM ____ 225
OPERATING INSTRUCTIONS RH 200

PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS ____ 225
WELDING OPERATIONS__ 226
WELDING OPERATIONS – SAFETY INSTRUCTIONS _ 226
PART 5 – ANNEX __ 229
TROUBLESHOOTING ____ 231
INSTRUCTIONS ON TROUBLESHOOTING 231
LAYOUT OF THE FAULT TABLE 231
Fault __ 231
Possible causes 231
Measures_____ 231
Section 231
FAULT TABLES ___ 232
Combustion engine – Fault table _ 232
Working hydraulics – Fault table _ 233
Track drive – Fault table _____ 234
Slewing mechnism – Fault table _ 235
Central lubricating system – Fault table __ 236
HYDRAULIC CIRCUIT DIAGRAM _ 238
Legend (loading bucket) _____ 238
HYDRAULIC CIRCUIT DIAGRAM _ 240
Legend (backhoe bucket) ____ 240
TIGHTENING TORQUES AND ANGLES – TABLE ______ 241
ABBREVIATIONS__ 243
ABBREVIATIONS__ 244
TECHNICAL DATA_ 245
PART 6 – INDEX___ 249
INDEX ____ 251

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