Cat Bucyrus RH 400 Hydraulic Excavator Operating Instructions Manual BI651425 – PDF DOWNLOAD

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Cat Bucyrus RH 400 Hydraulic Excavator Operating Instructions Manual BI651425 – PDF DOWNLOAD

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Cat Bucyrus RH 400 Hydraulic Excavator Operating Instructions Manual BI651425 – PDF DOWNLOAD

Language : English
Pages : 244
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus RH 400 Hydraulic Excavator Operating Instructions Manual BI651425 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH 400
Introduction
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 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 mechanic or by attending an Terex O&K training course for operators or maintenance personnel. The Terex O&K after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. All Terex O&K operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Terex O&K 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 Terex O&K aftersales service.
• The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

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TABLE OF CONTENTS:

Cat Bucyrus RH 400 Hydraulic Excavator Operating Instructions Manual BI651425 – PDF DOWNLOAD

1 INTRODUCTION............................................................................................................................................................... 11
	PREFACE.................................................................................................................................................................. 13
	WARRANTY................................................................................................................................................................. 14
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15
		Warnings and symbols................................................................................................................................................. 15
	DESIGNATED USE........................................................................................................................................................... 16
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 17
		Selection and qualification of personnel; basic responsibilities..................................................................................................... 18
		Safety instructions governing specific operational phases............................................................................................................ 18
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19
		Warning of special dangers........................................................................................................................................... 20
		Gas, dust, steam and smoke........................................................................................................................................... 21
		Hydraulic / pneumatc equipment....................................................................................................................................... 21
		Noise................................................................................................................................................................ 21
		Oil, grease and other chemical substances............................................................................................................................ 21
		Transporting and recommissioning..................................................................................................................................... 21
	ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS ..................................................................................................... 22
	SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR .................................................................................................................. 24
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 25
	NOTES.................................................................................................................................................................... 27
2 OPERATION.................................................................................................................................................................. 29
	OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 31
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 33
	DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 34
		Excavator layout..................................................................................................................................................... 35
		Undercarriage........................................................................................................................................................ 36
		Superstructure....................................................................................................................................................... 36
		Drive................................................................................................................................................................ 36
		Hydraulic system..................................................................................................................................................... 36
		Pump Managing System (PMS)........................................................................................................................................... 36
		Programmable Logic Controller (PLC) ................................................................................................................................. 36
		Control Management System (CMS) ..................................................................................................................................... 36
		Demand control / Zero-flow regulation................................................................................................................................ 37
		Board-Control-System (BCS) .......................................................................................................................................... 37
		Electrical system ................................................................................................................................................... 37
		Signs ............................................................................................................................................................... 41
		Entering and leaving the machine Safety instructions................................................................................................................. 42
		Ramp-type ladder .................................................................................................................................................... 43
		Escape ladder (Optional) ............................................................................................................................................ 44
		EMERGENCY STOP switch ............................................................................................................................................... 46
		Servicing switch .................................................................................................................................................... 47
		Windscreen washer ................................................................................................................................................... 47
		Driver's seat ....................................................................................................................................................... 48
		Fire extinguisher.................................................................................................................................................... 50
		Automatic fire-extinguishing system (optional)....................................................................................................................... 51
		Emergency escape device (optional)................................................................................................................................... 52
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 56
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 75
		Service station (tanklift) .......................................................................................................................................... 75
		Battery main switch, switching on and off ........................................................................................................................... 78
		Electrical system (24V), switching on and off ....................................................................................................................... 78
		Switching the electric motors on and off ............................................................................................................................ 79
		Time-out before restart ............................................................................................................................................. 80
		Electric motors can not be switched on .............................................................................................................................. 81
		In case of failure .................................................................................................................................................. 81
		Circuit breaker, switching on and off ............................................................................................................................... 82
		Motor protection relay, functions ................................................................................................................................... 84
		Air conditioner (option)............................................................................................................................................. 85
	DRIVING SAFETY INSTRUCTIONS ............................................................................................................................................. 86
	TRAVELLING .............................................................................................................................................................. 87
		Superstructure basic position ....................................................................................................................................... 87
		Travelling forwards/backwards ....................................................................................................................................... 87
		Locking the superstructure .......................................................................................................................................... 91
		Track parking brake ................................................................................................................................................. 91
	TRANSPORTING THE MACHINE ................................................................................................................................................ 92
		Transport - Safety instructions ..................................................................................................................................... 92
	WORKING OPERATION - SAFETY INSTRUCTIONS ................................................................................................................................. 93
	WORKING OPERATION ....................................................................................................................................................... 95
		Before starting work ................................................................................................................................................ 95
		Swinging the superstructure ......................................................................................................................................... 95
		Braking the superstructure .......................................................................................................................................... 95
		Working ............................................................................................................................................................. 96
		Emergency lowering of the working equipment ......................................................................................................................... 97
		 After daily operation .............................................................................................................................................. 97
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ...................................................................................................................... 98
		Securing the machine ................................................................................................................................................100
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................101
	NOTES  ..................................................................................................................................................................103
3 INSPECTION AND SERVICING...................................................................................................................................................105
	SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTORS .................................................................................................................107
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................109
	FIRE AND EXPLOSION HAZARD ...............................................................................................................................................115
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................117
		Intervals............................................................................................................................................................117
		Oils / Greases ......................................................................................................................................................117
		Cleaning jobs .......................................................................................................................................................117
		Components ..........................................................................................................................................................117
		Plan V ..............................................................................................................................................................119
		Plan N ..............................................................................................................................................................121
		Plan T and W ........................................................................................................................................................123
		Plan A – E ..........................................................................................................................................................125
	LUBRICATING CHART – GREASE ..............................................................................................................................................132
		Lubricating chart – Grease (legend) .................................................................................................................................133
		Filling quantities - Grease..........................................................................................................................................133
	INSPECTION PLAN - OIL ...................................................................................................................................................134
		Inspection plan – Oil (legend) ......................................................................................................................................135
		Filling quantities - oil ............................................................................................................................................136
		Filling quantities - other...........................................................................................................................................136
	LUBRICANTS ..............................................................................................................................................................137
		Notes on the selection of oils and greases ..........................................................................................................................137
	LUBRICANTS ..............................................................................................................................................................138
		I. Oils for combustion engines (On-Board Crane, option) .............................................................................................................138
		II. Oils for hydraulic system (selection) ...........................................................................................................................139
		III.a Oils for pump gearboxes .......................................................................................................................................140
		III.b Oils for swing gearboxes ......................................................................................................................................141
		III.c Oils for drive gearboxes ......................................................................................................................................142
		V. Greases for bearings and swing rings .............................................................................................................................143
	SERVICING WORK ..........................................................................................................................................................144
		Hose line for oil changes ...........................................................................................................................................144
	ELECTRIC MOTOR ..........................................................................................................................................................145
		Electric motor - Safety instructions ................................................................................................................................145
		Cleaning the electric motors  .......................................................................................................................................145
		Electric motors, greasing ...........................................................................................................................................146
	ELECTRICAL SYSTEM  ......................................................................................................................................................147
		Electrical system - Safety instructions .............................................................................................................................147
		Battery .............................................................................................................................................................148
		Control cabinets ....................................................................................................................................................150
		Slip ring assembly ..................................................................................................................................................152
		Floodlight projector, replacing the lamp ............................................................................................................................153
	HYDRAULIC SYSTEM ........................................................................................................................................................155
		Hydraulic system - Safety instructions ..............................................................................................................................155
		Depressurizing the hydraulic system .................................................................................................................................155
		Checking the hydraulic oil level ....................................................................................................................................156
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................158
		Bypass valves (hydraulic oil reservoir) .............................................................................................................................160
		Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................161
		Bypass valves (filter housing) ......................................................................................................................................162
		Breather filter .....................................................................................................................................................163
		Filter (control circuit).............................................................................................................................................164
		High-pressure filter for working hydraulics .........................................................................................................................165
		High-pressure filters for the servo circuit .........................................................................................................................166
		High-pressure filters for pump-flushing circuit .....................................................................................................................167
		High-pressure filters for slewing circuit ...........................................................................................................................168
		Changing the hydraulic oil ..........................................................................................................................................169
		Venting the hydraulic system.........................................................................................................................................173
		Cleaning the hydraulic oil cooler....................................................................................................................................174
		Electronic excavator control.........................................................................................................................................175
		Pressure accumulator - Emergency lowering............................................................................................................................176
	PUMP TRANSFER GEARBOX ...................................................................................................................................................177
		Checking the gearbox oil level / Topping up with oil ................................................................................................................177
		Gearbox venting .....................................................................................................................................................179
		Pre-chambers, checking oil level ....................................................................................................................................179
		Gear oil filter .....................................................................................................................................................180
	SWING GEARBOX ...........................................................................................................................................................181
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................181
		Changing the gearbox oil ............................................................................................................................................182
		Gearbox venting .....................................................................................................................................................182
	TRAVEL GEARBOX ..........................................................................................................................................................183
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................183
		Travel gearbox - Changing the oil ...................................................................................................................................183
		Preliminary gearbox - Draining off oil ..............................................................................................................................184
	CRAWLER TRACKS ..........................................................................................................................................................185
		Track tensioner .....................................................................................................................................................186
		Pressure-accumulator inspection regulations .........................................................................................................................188
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................188
	SLEWING RING ............................................................................................................................................................189
		Slewing ring - Instructions..........................................................................................................................................189
		Bearing races........................................................................................................................................................189
	CENTRAL LUBRICATING .....................................................................................................................................................191
		Design ..............................................................................................................................................................191
		Function ............................................................................................................................................................192
		Filling up the grease container .....................................................................................................................................193
		Breather filter .....................................................................................................................................................193
		Checking the greasing pressure ......................................................................................................................................194
		Unblocking a grease line ............................................................................................................................................194
		Oilfilter for hydraulic circuit grease pump replace .................................................................................................................195
		Grease filter replace (Filling the grease container) ................................................................................................................196
		Grease filter replace (Grease lines) ................................................................................................................................197
	OTHER MAINTENANCE .......................................................................................................................................................198
		Heating and air conditioning ........................................................................................................................................198
		Equipment ...........................................................................................................................................................198
	LADDER (OPTIONAL) .......................................................................................................................................................199
		Pressure-accumulator inspection regulations .........................................................................................................................200
		Extract from the German regulations..................................................................................................................................200
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................200
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................201
		Monitoring, warning and control elements ............................................................................................................................201
		Checking the on-board crane..........................................................................................................................................201
		Drive unit ..........................................................................................................................................................202
		On-board crane, servicing ...........................................................................................................................................202
		On-Board crane, checking tightness of fastening bolts ...............................................................................................................203
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................204
		Putting the excavator out of operation...............................................................................................................................204
		Battery storage......................................................................................................................................................204
		Recommissioning......................................................................................................................................................204
	NOTES  ..................................................................................................................................................................205
4 REPAIR WORK................................................................................................................................................................209
	SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ..................................................................................................................211
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................213
	FIRE AND EXPLOSION HAZARD ...............................................................................................................................................215
	HYDRAULIC SYSTEM.........................................................................................................................................................216
		Repair ..............................................................................................................................................................216
		Hydraulic hoses – Instructions  .....................................................................................................................................216
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................217
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................218
	NOTES ...................................................................................................................................................................219
5 ANNEX......................................................................................................................................................................221
	TROUBLESHOOTING .........................................................................................................................................................223
		Instructions on troubleshooting .....................................................................................................................................223
		Layout of the fault table ...........................................................................................................................................223
		Possible causes .....................................................................................................................................................223
		Measures ............................................................................................................................................................223
		Section .............................................................................................................................................................223
	FAULT TABLES ............................................................................................................................................................224
		Working hydraulics – Fault table ....................................................................................................................................224
		Track drive – Fault table ...........................................................................................................................................225
		Swing mechnism – Fault table ........................................................................................................................................226
		Central lubricating system – Fault table ............................................................................................................................227
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................228
	ABBREVIATIONS ...........................................................................................................................................................229
	TECHNICAL DATA ..........................................................................................................................................................231
	NOTES  ..................................................................................................................................................................237
6 INDEX......................................................................................................................................................................239

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• 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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