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CAT Bucyrus RH200 Hydraulic Excavator Operating Instruction Manual 3725014 – PDF DOWNLOAD
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CAT Bucyrus RH200 Hydraulic Excavator Operating Instruction Manual 3725014 – PDF DOWNLOAD
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Description
CAT Bucyrus RH200 Hydraulic Excavator Operating Instruction Manual 3725014 – PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus RH200 Hydraulic Excavator Operating Instruction Manual 3725014 – PDF DOWNLOAD
Language : English
Pages : 283
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT Bucyrus RH200 Hydraulic Excavator Operating Instruction Manual 3725014 – PDF DOWNLOAD
PREFACE:
- These operating instructions are designed to famil- iarize the operator with the machine and its
desig- nated 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, 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 Bu- cyrus HEX mechanic or by attending an Bucyrus HEX training course for
operators or maintenance personnel. - The Bucyrus HEX after-sales service will be pleased to deal with any queries you
may have after reading through the operating instructions. - All Bucyrus HEX operating manuals are issued in German and then translated. Even a good transla-
tion may give rise to questions which Bucyrus HEX 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 Bucyrus HEX 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
instruc- tions 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:
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TABLE OF CONTENTS:
CAT Bucyrus RH200 Hydraulic Excavator Operating Instruction Manual 3725014 – PDF DOWNLOAD
TITLEPAGE.................................................................................................................................................................... 1 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 .......................................................................................................................................... 20 Hydraulic equipment ................................................................................................................................................. 20 FIRE AND EXPLOSION HAZARD ............................................................................................................................................... 22 NOTES ................................................................................................................................................................... 23 2 OPERATION.................................................................................................................................................................. 25 OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 27 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 28 OPERATION, 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 Central Management System (CMS) ..................................................................................................................................... 32 Demand control / Zero-flow regulation................................................................................................................................ 33 Automatic engine speed reduction .................................................................................................................................... 33 Board-Control-System (BCS) .......................................................................................................................................... 33 Electrical system ................................................................................................................................................... 33 Signs ............................................................................................................................................................... 35 Entering and leaving the machine, Safety instructions................................................................................................................ 36 Access lighting ..................................................................................................................................................... 36 Folding ladder (optional) ........................................................................................................................................... 37 Swinging ladder (optional) .......................................................................................................................................... 38 Cab interior lamp ................................................................................................................................................... 39 Servicing lighting .................................................................................................................................................. 40 Illuminating the control column ..................................................................................................................................... 40 EMERGENCY STOP switch ............................................................................................................................................... 41 Escape ladder ....................................................................................................................................................... 42 Trainer's / instructor's seat ....................................................................................................................................... 43 Windscreen washer ................................................................................................................................................... 43 Driver's seat ....................................................................................................................................................... 44 Fire extinguisher ................................................................................................................................................... 46 Automatic fire-extinguishing system (optional) ...................................................................................................................... 47 Harness (optional) .................................................................................................................................................. 48 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 52 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 82 Refuelling .......................................................................................................................................................... 82 Service station (tanklift) .......................................................................................................................................... 82 Switching the electrical system on and off .......................................................................................................................... 88 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 89 Starting the engines ................................................................................................................................................ 89 Starting the engines at low temperatures ............................................................................................................................ 90 Shutting off the engines ............................................................................................................................................ 91 Emergency - stop .................................................................................................................................................... 91 AIR CONDITIONER (OPTION) ................................................................................................................................................ 92 Back-up heating (option) ............................................................................................................................................ 93 TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 95 Superstructure basic position ....................................................................................................................................... 96 Travel forwards/backwards ........................................................................................................................................... 96 Emergency machine drive .............................................................................................................................................100 Superstructure holding brakes .......................................................................................................................................102 Track parking brake .................................................................................................................................................102 TRANSPORTING THE MACHINE ................................................................................................................................................103 Transport - Safety instructions .....................................................................................................................................103 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................104 WORKING OPERATION .......................................................................................................................................................106 Before starting work ................................................................................................................................................106 Swing the superstructure ............................................................................................................................................106 Braking the superstructure ..........................................................................................................................................106 Working movements ...................................................................................................................................................107 After daily operation ...............................................................................................................................................108 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................109 Securing the machine ................................................................................................................................................111 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................112 NOTES ...................................................................................................................................................................113 3 INSPECTION AND SERVICING...................................................................................................................................................115 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................117 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................123 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................125 Intervals............................................................................................................................................................125 Change of engine oil ................................................................................................................................................125 Air-intake system ...................................................................................................................................................125 Oils / Greases ......................................................................................................................................................125 Cleaning jobs .......................................................................................................................................................125 Components ..........................................................................................................................................................125 Plan V ..............................................................................................................................................................127 Plan N ..............................................................................................................................................................129 Plan T and W ........................................................................................................................................................131 Plan A – E ..........................................................................................................................................................133 LUBRICATING CHART – GREASE ..............................................................................................................................................142 Lubricating chart – Grease (legend) .................................................................................................................................143 Filling quantities – Grease .........................................................................................................................................143 INSPECTION PLAN - OIL ...................................................................................................................................................144 Inspection plan – Oil (legend) ......................................................................................................................................145 Filling quantities - oil ............................................................................................................................................146 Filling quantities – other ..........................................................................................................................................146 LUBRICANTS ..............................................................................................................................................................147 Notes on the selection of oils and greases ..........................................................................................................................147 Avoid mixing of different hydraulic fluids ..........................................................................................................................147 I. Oils for combustion engines ......................................................................................................................................148 II. Oils for hydraulic system .......................................................................................................................................149 III.a Oils for pump gearboxes .......................................................................................................................................150 III.b Oils for swing gearboxes ......................................................................................................................................151 III.c Oils for travel gearboxes .....................................................................................................................................152 V. Greases for bearings and swing rings .............................................................................................................................153 Fluid grease for idlers, track rollers and support rollers ..........................................................................................................154 SERVICING WORK ..........................................................................................................................................................155 Hose line for oil and cooling liquid changes ........................................................................................................................155 ENGINE ..................................................................................................................................................................156 Engine - Safety instructions ........................................................................................................................................156 Engine oil, checking the level / topping up .........................................................................................................................157 Engine oil reservoir, checking the oil level / topping up ...........................................................................................................158 Engine oil, change ..................................................................................................................................................159 Engine oil reservoir (optional), draining the oil off ...............................................................................................................161 Eliminator filter and centrifuge (optional) .........................................................................................................................163 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................165 COOLING SYSTEM ..........................................................................................................................................................166 Temperature .........................................................................................................................................................166 Radiators ...........................................................................................................................................................167 Cooling liquid, change ..............................................................................................................................................169 Water filter, change ................................................................................................................................................171 AIR-INTAKE SYSTEM .......................................................................................................................................................172 Main filter elements, removal and installation ......................................................................................................................173 Main filter elements, checking and cleaning .........................................................................................................................174 Safety filter element, replace ......................................................................................................................................175 Air-intake lines ....................................................................................................................................................176 Dust collection .....................................................................................................................................................176 FUEL SYSTEM .............................................................................................................................................................177 Fuel system, Safety instructions ....................................................................................................................................177 Fuel filter, replace ................................................................................................................................................177 Fuel system, venting ................................................................................................................................................178 Cleaning the fuel tanks .............................................................................................................................................178 Water trap (option) .................................................................................................................................................180 ELECTRICAL SYSTEM ......................................................................................................................................................182 Electrical system - Safety instructions .............................................................................................................................182 Alternator - Instructions ...........................................................................................................................................182 Battery .............................................................................................................................................................183 Switchgear cabinet ..................................................................................................................................................185 Floodlight projector, replacing the lamp ............................................................................................................................187 HYDRAULIC SYSTEM ........................................................................................................................................................189 Hydraulic system - Safety instructions ..............................................................................................................................189 Depressurizing the hydraulic system .................................................................................................................................189 Checking the hydraulic oil level ....................................................................................................................................190 Changing the hydraulic oil return-flow filters (hydraulic oil reservoir) ............................................................................................192 Bypass valves (hydraulic oil reservoir) .............................................................................................................................194 Replacing the bypass valves and sealing rings .......................................................................................................................194 Breather filter .....................................................................................................................................................195 Filter (control circuit).............................................................................................................................................196 High-pressure filter for working hydraulics .........................................................................................................................197 High-pressure filters for the servo circuit .........................................................................................................................198 High-pressure filters for feeding circuits and slewing pumps ........................................................................................................199 High-pressure filters for slewing circuit ...........................................................................................................................200 Changing the hydraulic oil ..........................................................................................................................................201 Venting the hydraulic system.........................................................................................................................................204 Cleaning the hydraulic oil cooler....................................................................................................................................205 Electronic excavator control.........................................................................................................................................206 Pressure accumulator - Emergency lowering............................................................................................................................207 PUMP TRANSFER GEARBOX ...................................................................................................................................................208 Checking the gearbox oil level / Topping up with oil ................................................................................................................208 Changing the gearbox oil ............................................................................................................................................209 Gearbox venting .....................................................................................................................................................210 Pump transfer gearbox lube oil filters ..............................................................................................................................211 SWING GEARBOX ...........................................................................................................................................................212 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................212 Changing the gearbox oil ............................................................................................................................................212 Gearbox venting .....................................................................................................................................................213 TRAVEL GEARBOX ..........................................................................................................................................................214 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................214 Travel gearbox - Changing oil .......................................................................................................................................215 Pre-chamber - Changing the oil .....................................................................................................................................215 Brake chambers - Changing oil .......................................................................................................................................216 Breather filters ....................................................................................................................................................216 CRAWLER TRACKS ..........................................................................................................................................................217 Track roller, Support roller ........................................................................................................................................218 Track tensioner .....................................................................................................................................................219 Pressure-accumulator inspection regulations .........................................................................................................................220 Checking the gas charging pressure in the pressure accumulator.......................................................................................................220 SWING RING ..............................................................................................................................................................221 Swing ring - Instructions............................................................................................................................................221 Bearing races........................................................................................................................................................221 CENTRAL LUBRICATING .....................................................................................................................................................223 Design ..............................................................................................................................................................223 Function ............................................................................................................................................................224 Filling up the grease container .....................................................................................................................................225 Breather filter .....................................................................................................................................................225 Checking the greasing pressure ......................................................................................................................................226 Unblocking a grease line.............................................................................................................................................227 Oilfilter (hydraulic circuit grease pump) ...........................................................................................................................228 Grease filter (Filling the grease container) ........................................................................................................................229 Grease filter (Grease lines) ........................................................................................................................................230 OTHER MAINTENANCE .......................................................................................................................................................231 Engine ..............................................................................................................................................................231 Equipment, checking .................................................................................................................................................232 Hydraulic ladder (optional) .........................................................................................................................................232 Pressure-accumulator inspection regulations .........................................................................................................................233 Extract from the German regulations..................................................................................................................................233 Checking the gas charging pressure in the pressure accumulator.......................................................................................................233 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................234 Monitoring, warning and control elements ............................................................................................................................234 Checking the on-board crane..........................................................................................................................................234 Drive unit ..........................................................................................................................................................235 On-board crane ......................................................................................................................................................235 On-Board crane, checking tightness of fastening bolts ...............................................................................................................236 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................237 Putting the excavator out of operation...............................................................................................................................237 Battery storage......................................................................................................................................................237 Recommissioning......................................................................................................................................................237 NOTES ..................................................................................................................................................................239 4 REPAIR WORK................................................................................................................................................................241 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................243 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................245 REPAIR WORK, ENGINE......................................................................................................................................................246 ELECTRICAL SYSTEM .......................................................................................................................................................247 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................247 Assisted starting (with jumper cables)...............................................................................................................................247 Starting the engine with jumper cables (external batteries ..........................................................................................................247 HYDRAULIC SYSTEM.........................................................................................................................................................249 Repair instructions .................................................................................................................................................249 Hydraulic hoses – Instructions ......................................................................................................................................249 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................250 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................251 NOTES ...................................................................................................................................................................253 5 ANNEX......................................................................................................................................................................255 TROUBLESHOOTING .........................................................................................................................................................257 Instructions on troubleshooting .....................................................................................................................................257 Layout of the fault table ...........................................................................................................................................257 Possible causes .....................................................................................................................................................257 Measures ............................................................................................................................................................257 Section .............................................................................................................................................................257 FAULT TABLES ............................................................................................................................................................258 Combustion engine - Fault table .....................................................................................................................................258 Working hydraulics – Fault table ....................................................................................................................................259 Track drive – Fault table ...........................................................................................................................................260 Swing mechnism – Fault table ........................................................................................................................................261 Central lubricating system – Fault table ............................................................................................................................262 Engine electronic unit, displaying stored fault codes ...............................................................................................................263 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................264 ABBREVIATIONS ...........................................................................................................................................................265 ABBREVIATIONS........................................................................................................................................................266 TECHNICAL DATA ..........................................................................................................................................................267 NOTES ...................................................................................................................................................................277 6 INDEX......................................................................................................................................................................279
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