CAT Bucyrus RH 400 Hydraulic Excavator Operating Instruction Manual 2731030 – PDF DOWNLOAD

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CAT Bucyrus RH 400 Hydraulic Excavator Operating Instruction Manual 2731030 – PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus RH 400 Hydraulic Excavator Operating Instruction Manual 2731030 – PDF DOWNLOAD

Language : English
Pages : 258
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus RH 400 Hydraulic Excavator Operating Instruction Manual 2731030 – PDF DOWNLOAD

Preface:

• These operating instructions are designed to fa- miliarize the operator with the machine
  and its designated use.
• The instruction manual contains important infor- mation 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 avail- able 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 pro- duction waste and disposal of fuels and con- sumables.
– 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 O&K mechanic or by attending an O&K training course for operators or
  maintenance personnel.
• The O&K after-sales service will be pleased to deal with any queries you may have after
  reading through the operating instructions.
• All O&K operating manuals are issued in German and then translated. Even a good translation may
  give rise to questions which O&K 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 O&K after-sales service.
• The documentation relating to the machine is list- ed according to scope, quantity and
  language in the shipping note of the machine or in the cover- ing 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 400 Hydraulic Excavator Operating Instruction Manual 2731030 – PDF DOWNLOAD

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 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
Operation – Safety instructions 15
Fire and Explosion Hazard 17
DESCRIPTION OF THE EXCAVATOR
Excavator layout 19
Undercarriage 19
Superstructure 19
Loading bucket 19
Undercarriage 20
Superstructure 20
Drive 20
Hydraulic system 20
Pump Managing System (PMS) 20
Stored Program Control (SPC) 20
Electronic Hydraulic Servo-Control (EHSC) 20
Demand control / Zero-flow regulation 21
Automatic engine speed reduction 21
Board Control System (BCS) 21
Electrical system 21
Signs 23
Warning and instruction signs 23
Machine number 23
Engine number 23
Component numbers 23
Entering and leaving the machine – Safety instructions 24
Ramp-type ladder 24
Access 25
Escape ladder 25
Ramp lighting 25
Cab interior lamp 26
Servicing lighting 27
110 V socket 27
EMERGENCY STOP pushbuttons 28
Windscreen washer 28
Driver’s seat 29
Adjusting the backrest 29
Adjusting the lumbar support 29
Adjusting the seat cushion 29
Adjusting the armrests 29
Fore-and-aft adjustment 29
Adjusting the seat suspension 29
Fore-and-aft adjustment of the seat plate 29
Passenger seat 30
Adjusting the backrest 30
Adjusting the seat cushion 30
Adjusting the armrests 30
Fore-and-aft adjustment 30
Adjusting the seat suspension 30
Automatic fire-extinguishing system 31
Manual activation 31
Inspection 32
MONITORING, WARNING AND CONTROL ELEMENTS 34
PUTTING THE MACHINE INTO OPERATION 68
Refuelling
Refuelling – Safety instructions 68
Service station (tank lift) 68
Lowering the service station 69
Lifting the service station 69
Refilling and/or draining 69
Measuring devices for fluids 70
Switching the electrical system on and off 74
Battery main switches 74
Starting and stopping the engines 75
Starting the engines 75
Starting the engines with the cold-starting aid 76
Shutting off the engines 77
Emergency stop 77
Driving 78
TRAVELLING
Superstructure basic position 79
Travelling forwards/in reverse 79
Regulating the travelling speed 80
Travelling uphill and downhill 80
Cornering 80
Turning 80
Note 81
Travelling over longer distances 82
Locking the superstructure 83
Track parking brake 83
Transporting the machine
Transport – Safety instructions 84
Transport 84
WORKING OPERATION, SAFETY INSTRUCTIONS 85
WORKING OPERATION
Before starting work 87
Switching on the electronic excavator control 87
Slewing and braking the superstructure 87
Braking the superstructure 87
Working 88
Raising and lowering the boom 88
Extending and retracting the bucket or backhoe bucket stick 88
Filling and emptying the bucket 88
Opening and closing the bucket 88
Lowering the equipment in an emergency 88
After daily operation 89
Parking the machine 89
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS
Securing the machine 92
Corrosion protection for pins and bearings (bushings and hubs)
Part nos for Voler A C 93
Application of Voler A C 93
NOTES 95
PART 3 – INSPECTION AND SERVICING
Inspection and servicing – Safety instructions 99
Fire and Explosion Hazard 103
Inspection and servicing plans – Instructions
Intervals 105
Change of engine oil 105
Air-intake system 105
Oils / Greases 105
Cleaning jobs 105
Plan V 107
Plan N 109
Plan T 111
Plan W 111
Plan T 112
Plan W 112
Plan A 113
Plan B 113
Plan C 113
Plan D 113
Plan E 113
Plan A 114
Plan B 114
Plan C 114
Plan D 114
Plan E 114
Plan A 115
Plan B 115
Plan C 115
Plan D 115
Plan E 115
Plan A 116
Plan B 116
Plan C 116
Plan D 116
Plan E 116
Plan A 117
Plan B 117
Plan C 117
Plan D 117
Plan E 117
LUBRICATING CHART – GREASE (Loading bucket)
Lubricating chart – Grease / Loading bucket 119
Filling quantities – Grease 119
INSPECTION PLAN – OIL
Inspection plan – Oil 121
Filling quantities – Oil 122
Filling quantities – other 122
LUBRICANTS 123
Oils for combustion engines and compressors (selection) 123
Oils for hydraulic systems (selection) 124
Oils for gearboxes (selection) 125
Greases for bearings and slewing rings 126
SERVICING WORK
Hose line for oil and coolant changes 127
ENGINE
Engine – Safety instructions 128
Checking/adjusting the V-belt tension 128
Checking/adjusting the valve clearance 128
Checking the engine oil level / Topping up 128
Checking the oil level in the engine oil reservoir / Topping up 129
Changing the engine oil 130
Drawing off engine oil with the service station 130
Filling in engine oil through the service station 131
Changing the oil of the engine oil reservoir 132
Drawing off engine oil 132
Drain off engine oil 132
Filling in engine oil 133
Eliminator filter and centrifuge 134
Centrifuge 134
Dismantling the centrifuge 134
Cleaning the centrifuge 135
Assembling the centrifuge 135
COOLING SYSTEM
Temperature 136
Radiators 136
Coolant level 136
Topping up coolant 137
Coolant 138
Drawing off coolant 138
Filling in coolant 139
Testing the coolant composition 139
Water filter 140
AIR-INTAKE SYSTEM
Main filter elements 141
Removal and installation 141
Checking and cleaning the main filter element 142
Safety filter element 143
Replacement 143
Air-intake lines 144
Dust collection 144
FUEL SYSTEM
Fuel system – Safety instructions 145
Replacing the fuel filter 145
Venting the fuel system 146
Cleaning the fuel tanks 146
ELECTRICAL SYSTEM
Electrical system – Safety instructions 148
Alternator – Instructions 148
Battery main switches§/§Main fuse 149
Batteries 149
Removing and installing the batteries 149
Battery box 150
Removing and installing the battery box 150
HYDRAULIC SYSTEM
Hydraulic system – Safety instructions 151
Depressurizing the hydraulic system 151
Checking the hydraulic oil level / Topping up 152
Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) 154
Bypass valves (hydraulic oil reservoir) 156
Cleaning the filter screens 156
Replacing the hydraulic oil return-flow filters (filter housing – cooling system) 157
Bypass valves (filter housing – cooling system) 158
Cleaning the filter screens 158
Breather filters 159
Replacing the filter elements 159
High-pressure filter for working hydraulics 159
Checking/cleaning the filter elements 160
Replacing the filter elements 160
High-pressure filter for the servo circuits 161
Checking/cleaning the filter elements 161
Replacing the filter elements 161
High-pressure filters for pump-flushing circuit 162
Checking/cleaning the filter elements 162
Replacing the filter elements 162
High-pressure filters for feeding circuits/slewing gear pumps 163
Checking/cleaning the filter elements 163
Replacing the filter elements 163
High-pressure filters for slewing circuit 164
Changing the hydraulic oil 165
Drawing off the hydraulic oil 165
Cleaning the hydraulic oil reservoir 166
Filling in hydraulic oil 167
Venting the hydraulic system 168
Venting the hydraulic components 168
Cleaning the hydraulic oil cooler 169
Cleaning 169
Pressure accumulator – Emergency lowering
Pressure-accumulator inspection regulations 170
Extract from the German regulations 170
Extract from the German acceptance regulations 170
Checking the gas charging pressure in the pressure accumulator 170
PUMP TRANSFER GEARBOX
Checking the gearbox oil level / Topping up 171
Drawing off oil 171
Filling in oil 172
Gearbox venting 173
Pre-chamber 173
Checking the oil level 173
SLEWING GEARBOX
Gearbox – Checking the oil level / Topping up 174
Changing the gearbox oil 174
Draining off oil 174
Filling in new oil / Topping up 175
Gearbox venting 175
Venting bore 175
Slewing gear neck 175
TRAVEL GEARBOXES
Travel gearbox – Checking the oil level / Topping up 176
Travel gearbox – Changing the oil 176
Main gearbox – Draining off oil 176
Preliminary gearbox – Draining off oil 176
Main and preliminary gearbox – Filling in oil 177
Pre-chamber – Draining off oil 177
Pre-chamber – Filling in oil 177
CRAWLER TRACKS
Cleaning 178
Track rollers 178
Track roller fastening 179
Support rollers 179
Support roller fastening 179
Track tensioner 179
Design 179
Technical data 180
Function 180
Pressure-accumulator inspection regulations 180
Extract from the German regulations 180
Extract from the German acceptance regulations 181
Checking the gas charging pressure in the pressure accumulator 181
Idlers 182
Checking the oil level 182
Filling in oil 182
Greasing the idler guides 182
SLEWING RING
Slewing ring – Instructions 183
Bearing races 183
Internal gearing 183
Slewing ring – Checking the grease filling 184
Slewing ring – Filling in grease 184
Slewing ring – Checking the screws for tightness 184
CENTRAL LUBRICATING SYSTEM
Design and function 185
Filling the grease container 186
Breather filter 186
Checking the grease pressure 187
Unblocking a grease line 187
Cleaning the grease sieve 187
Cleaning 187
OTHER MAINTENANCE WORK
Engine 188
Cleaning 188
Fastenings 188
Cooling system 188
Exhaust system 188
RAMP-TYPE LADDER
Guide pulleys and locking bolt 189
Pressure-accumulator inspection regulations 190
Extract from the German regulations 190
Extract from the German acceptance regulations 190
Checking the gas charging pressure in the pressure accumulator 190
ON-BOARD CRANE
Monitoring, warning and control elements 191
Checking the on-board crane 191
Extract from the inspection and testing regulations 191
Drive unit 192
Crane engine 192
Air-intake system 192
Hydraulic system 192
On-board crane 192
Servicing 192
ALTERNATOR
Monitoring, warning and control elements 193
Drive motor 193
Air-intake system 193
Servicing 194
Cleaning the prefractionator 194
Emptying the dust trap 195
Main filter element 195
Checking and cleaning the main filter element 196
Safety filter element 197
Replacement 197
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING
Putting the excavator out of operation 198
Battery storage 198
Recommissioning 198
NOTES 199
PART 4 – REPAIR WORK
Repair work – Safety instructions 203
Fire and Explosion Hazard 205
ENGINE 206
ELECTRICAL SYSTEM
Assisted starting (with jumper cables) – Safety instructions 206
Assisted starting (with jumper cables) 207
Prior to assisted starting 207
Starting the engine with jumper cables (external batteries) 207
Connecting the jumper cables 207
Starting up the engines 207
Disconnecting the jumper cables 207
HYDRAULIC SYSTEM
Repair 208
Accumulators, safety instructions 208
WELDING OPERATIONS 209
Welding operations – Safety instructions 209
NOTES 211
PART 5 – ANNEX
TROUBLESHOOTING 215
Instructions on troubleshooting 215
Layout of the fault table
Fault 215
Causes 215
Remedial action 215
Section 215
FAULT TABLES
Combustion engine – Fault table 216
Working hydraulics – Fault table 217
Fahrantrieb – Fault table 218
Slewing mechanism, Fault table 219
Central lubricating system – Fault table 220
Hydraulic circuit diagram
Legend (loading bucket) 222
Tightening torques and angles – Table 223
ABBREVIATIONS 225
TECHNICAL DATA 227
NOTES 229
PART 6 – INDEX
INDEX 233

Questions? Email us: [email protected]

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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