Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI015326 – PDF DOWNLOAD

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Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI015326 – PDF DOWNLOAD

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Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI015326 – PDF DOWNLOAD

Language : English
Pages : 283
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Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI015326 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH200
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 Bucyrus 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.
• 1 Complies with VDMA recommendation “Operating instructions” All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX 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 Bucyrus HEX 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 RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI015326 – 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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