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Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651509 – PDF DOWNLOAD
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Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651509 – PDF DOWNLOAD
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Description
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651509 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651509 – PDF DOWNLOAD
Language : English
Pages : 270
Downloadable : Yes
File Type : PDF
DESCRIPTION
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651509 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 200
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
! operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair) and / or
transport.
- 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 GERMANY Germany mechanic or by attending an Terex-Germany training course for operators or maintenance personnel. The Terex-Germany 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 Terex Germany operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Terex Germany 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 Germany after- sales service. The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
TABLE OF CONTENTS:
Cat Bucyrus RH90C Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651523 – PDF DOWNLOAD
TABLE OF CONTENTS.............................................................................................................................................................. 5 INTRODUCTION................................................................................................................................................................... 11 PREFACE.................................................................................................................................................................... 13 WARRANTY................................................................................................................................................................... 14 FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 15 Warnings and symbols................................................................................................................................................... 15 DESIGNATED USE............................................................................................................................................................. 16 ORGANIZATIONAL MEASURES.................................................................................................................................................... 17 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases.............................................................................................................. 18 Special work in conjunction with utilization of the machine and mainten ance and repairs as well as trouble shooting during work; disposal of parts and consumables.... 19 Warning of special dangers............................................................................................................................................. 20 Gas, dust, steam and smoke............................................................................................................................................. 21 Hydraulic equipment.................................................................................................................................................... 21 Noise.................................................................................................................................................................. 21 Oil, grease and other chemical sub stances............................................................................................................................. 21 Transporting and recommission ing...................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22 NOTES...................................................................................................................................................................... 23 OPERATION...................................................................................................................................................................... 25 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 27 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 Electronic Hydraulic Servo-Control (CMS)............................................................................................................................... 32 Demand control / Zero-flow regulation.................................................................................................................................. 33 Automatic engine speed reduction....................................................................................................................................... 33 Board-Control-System (BCS)............................................................................................................................................. 33 Electrical system...................................................................................................................................................... 33 Sign................................................................................................................................................................... 35 Entering and leaving the machine Safety instructions................................................................................................................... 36 Ramp-type ladder (optional)............................................................................................................................................ 37 EMERGENCY STOP pushbuttons............................................................................................................................................. 39 Windscreen washer...................................................................................................................................................... 39 Driver's seat.......................................................................................................................................................... 40 Fire extinguisher...................................................................................................................................................... 41 Automatic fire-extinguishing system (optional)......................................................................................................................... 42 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 44 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 75 Refuelling............................................................................................................................................................. 75 Service station (tanklift)............................................................................................................................................. 75 Switching the electrical system on and off............................................................................................................................. 81 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 82 AIR CONDITIONER (OPTION)................................................................................................................................................... 85 Back-up heating (option)............................................................................................................................................... 87 DRIVING.................................................................................................................................................................... 89 SAFETY INSTRUCTIONS.................................................................................................................................................... 89 Superstructure basic position.......................................................................................................................................... 90 Emergency machine drive................................................................................................................................................ 94 Locking the superstructure............................................................................................................................................. 96 Track parking brake.................................................................................................................................................... 96 TRANSPORTING THE MACHINE................................................................................................................................................... 97 Safety instructions.................................................................................................................................................... 97 WORKING OPERATION.......................................................................................................................................................... 98 Safety instructions.................................................................................................................................................... 98 Before starting work...................................................................................................................................................100 Slewing and braking the superstructure.................................................................................................................................100 Braking the superstructure.............................................................................................................................................100 Working................................................................................................................................................................101 After daily operation..................................................................................................................................................102 ASSEMBLING WORKING EQUIPMENT...............................................................................................................................................103 SAFETY INSTRUCTIONS....................................................................................................................................................103 Securing the machine...................................................................................................................................................105 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................106 NOTES......................................................................................................................................................................107 INSPECTION AND SERVICING.......................................................................................................................................................109 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................111 FIRE AND EXPLOSION HAZARD..................................................................................................................................................117 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................119 Intervals..............................................................................................................................................................119 Change of engine oil...................................................................................................................................................119 Air-intake system......................................................................................................................................................119 Oils / Greases.........................................................................................................................................................119 Cleaning jobs..........................................................................................................................................................119 Components.............................................................................................................................................................119 Plan V.................................................................................................................................................................121 Plan N.................................................................................................................................................................123 Plan T.................................................................................................................................................................125 Plan A – E.............................................................................................................................................................127 LUBRICATING CHART – GREASE.................................................................................................................................................136 Lubricating chart – Grease (legend)....................................................................................................................................137 Filling quantities - Grease............................................................................................................................................137 INSPECTION PLAN - OIL......................................................................................................................................................138 Inspection plan – Oil (legend) ).......................................................................................................................................139 Filling quantities - oil...............................................................................................................................................140 Filling quantities - other.............................................................................................................................................140 LUBRICANTS.................................................................................................................................................................141 I. Oils for combustion engines and compressors (selection).............................................................................................................141 II. Oils for hydraulic system (selection)..............................................................................................................................142 III. Oils for gearboxes (selection)....................................................................................................................................143 V. Greases for bearings and slewing rings..............................................................................................................................144 SERVICING WORK.............................................................................................................................................................145 Hose line for oil and cooling liquid changes...........................................................................................................................145 ENGINE.....................................................................................................................................................................146 Engine - Safety instructions...........................................................................................................................................146 Retensioning the alternator/fan belt...................................................................................................................................146 Checking and adjusting the valve clearance.............................................................................................................................146 Checking the engine oil level / Topping up.............................................................................................................................147 Checking the oil level in the engine oil reservoir / topping up (optional).............................................................................................148 Changing the engine oil................................................................................................................................................149 Draining the oil off the engine oil reservoir (optional)...............................................................................................................151 Eliminator filter and centrifuge.......................................................................................................................................153 COOLING SYSTEM.............................................................................................................................................................155 Radiators..............................................................................................................................................................156 Cooling liquid.........................................................................................................................................................158 Water filter...........................................................................................................................................................160 AIR-INTAKE SYSTEM..........................................................................................................................................................161 Main filter elements...................................................................................................................................................161 Safety filter element..................................................................................................................................................163 Air-intake lines.......................................................................................................................................................164 Dust collection........................................................................................................................................................164 FUEL SYSTEM................................................................................................................................................................165 Fuel system - Safety instructions......................................................................................................................................165 Replacing the fuel filter..............................................................................................................................................165 Venting the fuel system................................................................................................................................................166 Cleaning the fuel tanks................................................................................................................................................166 Water trap (option)....................................................................................................................................................168 ELECTRICAL SYSTEM..........................................................................................................................................................170 Electrical system - Safety instructions................................................................................................................................170 Alternator - Instructions..............................................................................................................................................170 Battery................................................................................................................................................................171 Switchgear cabinet.....................................................................................................................................................173 HYDRAULIC SYSTEM...........................................................................................................................................................175 Hydraulic system - Safety instructions.................................................................................................................................175 Depressurizing the hydraulic system....................................................................................................................................175 Checking the hydraulic oil level.......................................................................................................................................176 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................178 Bypass valves (hydraulic oil reservoir)................................................................................................................................180 Breather filter........................................................................................................................................................181 Filter (control circuit)...............................................................................................................................................182 High-pressure filter for working hydraulics............................................................................................................................183 High-pressure filters for the servo circuit............................................................................................................................184 High-pressure filters for feeding circuits and slewing pumps...........................................................................................................185 High-pressure filters for slewing circuit..............................................................................................................................186 Changing the hydraulic oil.............................................................................................................................................187 Venting the hydraulic system...........................................................................................................................................190 Cleaning the hydraulic oil cooler......................................................................................................................................191 Electronic excavator control...........................................................................................................................................192 Pressure accumulator - Emergency lowering..............................................................................................................................193 PUMP TRANSFER GEARBOX......................................................................................................................................................194 Checking the gearbox oil level / Topping up with oil...................................................................................................................194 Pre-chamber............................................................................................................................................................195 Changing the gearbox oil...............................................................................................................................................196 Pre-chamber............................................................................................................................................................197 Gearbox venting........................................................................................................................................................198 Pump transfer gearbox lube oil filters.................................................................................................................................199 SLEWING GEARBOX............................................................................................................................................................200 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................200 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................201 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................201 Changing the gearbox oil...............................................................................................................................................202 Gearbox venting........................................................................................................................................................203 TRAVEL GAERBOX.............................................................................................................................................................204 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................204 Pre-chamber - Check the oil level / Top up with oil....................................................................................................................205 Travel gearbox - Changing the oil......................................................................................................................................205 Pre-chamber - Changing the oil.........................................................................................................................................206 Breather filter........................................................................................................................................................206 CRAWLER TRACKS.............................................................................................................................................................207 Track rollers..........................................................................................................................................................208 Track tensioner........................................................................................................................................................209 Pressure-accumulator inspection regulations............................................................................................................................210 Checking the gas charging pressure in the pressure accumulator.........................................................................................................210 SLEWING RING...............................................................................................................................................................211 Slewing ring - Instructions............................................................................................................................................211 Bearing races..........................................................................................................................................................211 CENTRAL LUBRICATING........................................................................................................................................................213 Design.................................................................................................................................................................213 Lube cycle / Pause period..............................................................................................................................................213 Function...............................................................................................................................................................214 Filling up the grease container........................................................................................................................................215 Breather filter........................................................................................................................................................215 Checking the greasing pressure.........................................................................................................................................216 Checking the greasing pressure.........................................................................................................................................217 Unblocking a grease line...............................................................................................................................................218 Unblocking a grease line...............................................................................................................................................218 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................219 Grease filter (Filling the grease container)...........................................................................................................................220 Grease filter (Grease lines)...........................................................................................................................................221 OTHER MAINTENANCE..........................................................................................................................................................222 Engine.................................................................................................................................................................222 Heating and air conditioning...........................................................................................................................................222 Equipment..............................................................................................................................................................223 RAMP-TYPE LADDER (OPTIONAL) (OPTION)......................................................................................................................................224 Guide pulleys and locking bolt.........................................................................................................................................224 Pressure-accumulator inspection regulations............................................................................................................................225 Extract from the German regulations....................................................................................................................................225 Checking the gas charging pressure in the pressure accumulator.........................................................................................................225 ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................226 Monitoring, warning and control elements...............................................................................................................................226 Checking the on-board crane............................................................................................................................................226 Drive unit.............................................................................................................................................................227 On-board crane.........................................................................................................................................................227 ALTERNATOR (OPTIONAL)......................................................................................................................................................228 Drive unit.............................................................................................................................................................228 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................229 Putting the excavator out of operation.................................................................................................................................229 Battery storage........................................................................................................................................................229 Recommissioning........................................................................................................................................................230 NOTES......................................................................................................................................................................231 REPAIR WORK....................................................................................................................................................................233 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................235 FIRE AND EXPLOSION HAZARD..................................................................................................................................................237 ENGINE.....................................................................................................................................................................238 ELECTRICAL SYSTEM..........................................................................................................................................................239 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................239 Assisted starting (with jumper cables).................................................................................................................................239 Starting the engine with jumper cables (external batteries.............................................................................................................239 HYDRAULIC SYSTEM...........................................................................................................................................................242 Repair.................................................................................................................................................................242 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................243 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................244 NOTES......................................................................................................................................................................245 ANNEX..........................................................................................................................................................................247 TROUBLESHOOTING............................................................................................................................................................249 Instructions on troubleshooting........................................................................................................................................249 Layout of the fault table..............................................................................................................................................249 Possible causes........................................................................................................................................................249 Measures...............................................................................................................................................................249 Section................................................................................................................................................................249 FAULT TABLES...............................................................................................................................................................250 Combustion engine - Fault table........................................................................................................................................250 Working hydraulics – Fault table.......................................................................................................................................251 Track drive – Fault table..............................................................................................................................................252 Slewing mechnism – Fault table.........................................................................................................................................253 Central lubricating system – Fault table...............................................................................................................................254 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................255 ABBREVIATIONS..............................................................................................................................................................258 TECHNICAL DATA.............................................................................................................................................................260 NOTES......................................................................................................................................................................262 INDEX..........................................................................................................................................................................265
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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