Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651449 – PDF DOWNLOAD

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Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651449 – PDF DOWNLOAD

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Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651449 – PDF DOWNLOAD

Language : English
Pages : 282
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Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651449 – 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

• 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 Terex|O&K mechanic or by attending an Terex|O&K training course for operators or maintenance personnel. The Terex|O&K after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. 1 Complies with VDMA recommendation “Operating instructions” All Terex|O&K operating manuals are issued in German and then translated.
• Even a good translation may give rise to questions which Terex|O&K will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex|O&K aftersales service. The documentation relating to the machine is listed according to scope
• , quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

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TABLE OF CONTENTS:

Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651449 – PDF DOWNLOAD

1 INTRODUCTION............................................................................................................................................................... 11
	PREFACE.................................................................................................................................................................. 13
	WARRANTY................................................................................................................................................................. 14
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15
		Warnings and symbols................................................................................................................................................. 15
	DESIGNATED USE........................................................................................................................................................... 16
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 17
		Selection and qualification of personnel; basic responsibilities..................................................................................................... 18
		Safety instructions governing specific operational phases............................................................................................................ 18
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19
		Warning of special dangers........................................................................................................................................... 20
		Gas, dust, steam and smoke........................................................................................................................................... 21
		Hydraulic equipment.................................................................................................................................................. 21
		Noise................................................................................................................................................................ 21
		Oil, grease and other chemical substances............................................................................................................................ 21
		Transporting and recommissioning..................................................................................................................................... 21
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 22
	NOTES ................................................................................................................................................................... 23
2 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
		Programmable Logic Controller (PLC) ................................................................................................................................. 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
		Sign ................................................................................................................................................................ 35
		Entering and leaving the machine Safety instructions................................................................................................................. 36
		Ramp-type ladder (optional) ......................................................................................................................................... 37
		Ramp-type ladder (optional) ......................................................................................................................................... 38
		EMERGENCY STOP pushbuttons .......................................................................................................................................... 41
		Windscreen washer ................................................................................................................................................... 41
		Driver's seat ....................................................................................................................................................... 42
		Adjusting the control consoles ...................................................................................................................................... 43
		Fire extinguisher.................................................................................................................................................... 44
		Automatic fire-extinguishing system (optional)....................................................................................................................... 45
		Harness (optional)................................................................................................................................................... 46
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 50
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 81
		Refuelling .......................................................................................................................................................... 81
		Service station (tanklift) .......................................................................................................................................... 81
		Switching the electrical system on and off .......................................................................................................................... 87
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 88
	AIR CONDITIONER (OPTION)................................................................................................................................................. 91
		Back-up heating (option) ............................................................................................................................................ 93
	DRIVING ................................................................................................................................................................. 95
		SAFETY INSTRUCTIONS ................................................................................................................................................. 95
		Superstructure basic position ....................................................................................................................................... 96
		Emergency machine drive .............................................................................................................................................100
		Locking the superstructure ..........................................................................................................................................102
		Track parking brake .................................................................................................................................................102
	TRANSPORTING THE MACHINE ................................................................................................................................................103
		Safety instructions .................................................................................................................................................103
	WORKING OPERATION .......................................................................................................................................................104
		Safety instructions .................................................................................................................................................104
		Before starting work ................................................................................................................................................106
		Slewing and braking the superstructure ..............................................................................................................................106
		Braking the superstructure ..........................................................................................................................................106
		Working .............................................................................................................................................................107
		After daily operation ...............................................................................................................................................108
	ASSEMBLING WORKING EQUIPMENT ............................................................................................................................................109
		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
	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 ..............................................................................................................................................................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
		I. Oils for combustion engines ......................................................................................................................................147
		II. Oil for hydraulic system ........................................................................................................................................148
		III.a Oils for pump gearboxes .......................................................................................................................................149
		III.b Oils for swing gearboxes ......................................................................................................................................150
		III.c Oils for travel gearboxes .....................................................................................................................................151
		V. Greases for bearings and slewing rings ...........................................................................................................................152
	SERVICING WORK ..........................................................................................................................................................153
		Hose line for oil and cooling liquid changes ........................................................................................................................153
	ENGINE ..................................................................................................................................................................154
		Engine - Safety instructions ........................................................................................................................................154
		Retensioning the alternator/fan belt ................................................................................................................................154
		Checking and adjusting the valve clearance ..........................................................................................................................154
		Checking the engine oil level / Topping up  .........................................................................................................................155
		Checking the oil level in the engine oil reservoir / topping up (optional) ..........................................................................................156
		Changing the engine oil .............................................................................................................................................157
		Draining the oil off the engine oil reservoir (optional) ............................................................................................................159
		Eliminator filter and centrifuge ....................................................................................................................................161
	COOLING SYSTEM ..........................................................................................................................................................163
		Radiators ...........................................................................................................................................................164
		Cooling liquid ......................................................................................................................................................166
		Water filter ........................................................................................................................................................168
	AIR-INTAKE SYSTEM .......................................................................................................................................................169
		Main filter elements ................................................................................................................................................169
		Safety filter element ...............................................................................................................................................171
		Air-intake lines ....................................................................................................................................................172
		Dust collection .....................................................................................................................................................172
	FUEL SYSTEM .............................................................................................................................................................173
		Fuel system - Safety instructions ...................................................................................................................................173
		Replacing the fuel filter ...........................................................................................................................................173
		Venting the fuel system .............................................................................................................................................174
		Cleaning the fuel tanks .............................................................................................................................................174
		Water trap (option)..................................................................................................................................................176
	ELECTRICAL SYSTEM  ......................................................................................................................................................178
		Electrical system - Safety instructions .............................................................................................................................178
		Alternator - Instructions ...........................................................................................................................................178
		Battery .............................................................................................................................................................179
		Switchgear cabinet ..................................................................................................................................................181
	HYDRAULIC SYSTEM ........................................................................................................................................................183
		Hydraulic system - Safety instructions ..............................................................................................................................183
		Depressurizing the hydraulic system .................................................................................................................................183
		Checking the hydraulic oil level ....................................................................................................................................184
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................186
		Bypass valves (hydraulic oil reservoir) .............................................................................................................................188
		Breather filter .....................................................................................................................................................189
		Filter (control circuit).............................................................................................................................................190
		High-pressure filter for working hydraulics .........................................................................................................................191
		High-pressure filters for the servo circuit .........................................................................................................................192
		High-pressure filters for feeding circuits and slewing pumps ........................................................................................................193
		High-pressure filters for slewing circuit ...........................................................................................................................194
		Changing the hydraulic oil ..........................................................................................................................................195
		Venting the hydraulic system.........................................................................................................................................198
		Cleaning the hydraulic oil cooler....................................................................................................................................199
		Electronic excavator control.........................................................................................................................................200
		Pressure accumulator - Emergency lowering............................................................................................................................201
	PUMP TRANSFER GEARBOX ...................................................................................................................................................202
		Checking the gearbox oil level / Topping up with oil ................................................................................................................202
		Pre-chamber .........................................................................................................................................................203
		Changing the gearbox oil ............................................................................................................................................204
		Pre-chamber .........................................................................................................................................................205
		Gearbox venting .....................................................................................................................................................206
		Pump transfer gearbox lube oil filters ..............................................................................................................................207
	SLEWING GEARBOX .........................................................................................................................................................208
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................208
		Changing the gearbox oil ............................................................................................................................................208
		Gearbox venting .....................................................................................................................................................209
	TRAVEL GAERBOX ..........................................................................................................................................................210
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................210
		Travel gearbox - Changing oil .......................................................................................................................................211
		Pre-chamber - Changing the oil ......................................................................................................................................211
		Brake chamber - Changing oil ........................................................................................................................................212
		Breather filter .....................................................................................................................................................212
	CRAWLER TRACKS ..........................................................................................................................................................213
		Track rollers........................................................................................................................................................214
		Track tensioner .....................................................................................................................................................215
		Pressure-accumulator inspection regulations .........................................................................................................................216
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................216
	SLEWING RING ............................................................................................................................................................217
		Slewing ring - Instructions..........................................................................................................................................217
		Bearing races........................................................................................................................................................217
	CENTRAL LUBRICATING .....................................................................................................................................................219
		Design ..............................................................................................................................................................219
		Function ............................................................................................................................................................220
		Filling up the grease container .....................................................................................................................................221
		Breather filter .....................................................................................................................................................221
		Checking the greasing pressure ......................................................................................................................................222
		Checking the greasing pressure ......................................................................................................................................223
		Unblocking a grease line.............................................................................................................................................224
		Unblocking a grease line.............................................................................................................................................224
		Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................225
		Grease filter (Filling the grease container) ........................................................................................................................226
		Grease filter (Grease lines) ........................................................................................................................................227
	 OTHER MAINTENANCE ......................................................................................................................................................228
		Engine ..............................................................................................................................................................228
		Heating and air conditioning ........................................................................................................................................228
		Equipment ...........................................................................................................................................................229
	RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................230
		Pressure-accumulator inspection regulations .........................................................................................................................231
		Extract from the German regulations..................................................................................................................................231
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................231
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................232
		Monitoring, warning and control elements ............................................................................................................................232
		Checking the on-board crane..........................................................................................................................................232
		Drive unit...........................................................................................................................................................233
		On-board crane.......................................................................................................................................................233
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................234
		Putting the excavator out of operation...............................................................................................................................234
		Battery storage......................................................................................................................................................234
		Recommissioning......................................................................................................................................................235
		Notes ...............................................................................................................................................................237
4 REPAIR WORK................................................................................................................................................................239
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................241
	FIRE AND EXPLOSION HAZARD ...............................................................................................................................................243
	ENGINE...................................................................................................................................................................244
	ELECTRICAL SYSTEM .......................................................................................................................................................245
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................245
		Assisted starting (with jumper cables)...............................................................................................................................245
		Starting the engine with jumper cables (external batteries ..........................................................................................................245
	HYDRAULIC SYSTEM.........................................................................................................................................................248
		Repair ..............................................................................................................................................................248
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................249
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................250
	NOTES ...................................................................................................................................................................251
5 ANNEX......................................................................................................................................................................253
	TROUBLESHOOTING .........................................................................................................................................................255
		Instructions on troubleshooting .....................................................................................................................................255
		Layout of the fault table ...........................................................................................................................................255
		Possible causes .....................................................................................................................................................255
		Measures ............................................................................................................................................................255
		Section .............................................................................................................................................................255
	FAULT TABLES ............................................................................................................................................................256
		Combustion engine - Fault table .....................................................................................................................................256
		Working hydraulics – Fault table ....................................................................................................................................257
		Track drive – Fault table ...........................................................................................................................................258
		Slewing mechnism – Fault table ......................................................................................................................................259
		Central lubricating system – Fault table ............................................................................................................................260
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................261
	ABBREVIATIONS ...........................................................................................................................................................262
	TECHNICAL DATA ..........................................................................................................................................................265
	NOTES ...................................................................................................................................................................275
6 INDEX......................................................................................................................................................................277

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