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Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651465 – PDF DOWNLOAD
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Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651465 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651465 – PDF DOWNLOAD
Language : English
Pages : 266
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651465 – 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 driverโs 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
- In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the userโs 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 daysโ 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 โOperating instructionsโ 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus RH 200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651465 – 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 ....................................................................................................................................................................... 17 Personal protective equipment and the working clothing............................................................................................................. 17 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases.............................................................................................................. 18 Standard operation................................................................................................................................................. 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 Electric energy.................................................................................................................................................... 20 High-voltage system................................................................................................................................................ 20 Battery............................................................................................................................................................ 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...................................................................................................................................................... 31 Superstructure..................................................................................................................................................... 31 Loading bucket..................................................................................................................................................... 31 Backhoe bucket..................................................................................................................................................... 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 Warning and instruction signs...................................................................................................................................... 35 Machine number..................................................................................................................................................... 35 Engine number...................................................................................................................................................... 35 Component numbers.................................................................................................................................................. 35 Entering and leaving the machine Safety instructions................................................................................................................... 36 Ramp lighting...................................................................................................................................................... 36 Ramp-type ladder (optional)............................................................................................................................................ 37 Escape ladder...................................................................................................................................................... 37 Cab interior lamp.................................................................................................................................................. 38 Servicing lighting................................................................................................................................................. 38 EMERGENCY STOP pushbuttons............................................................................................................................................. 39 Windscreen washer...................................................................................................................................................... 39 Driver's seat.......................................................................................................................................................... 40 Adjusting the backrest............................................................................................................................................. 40 Adjusting the lumbar support....................................................................................................................................... 40 Adjusting the seat cushion......................................................................................................................................... 40 Adjusting the armrests............................................................................................................................................. 40 Fore-and-aft adjustment............................................................................................................................................ 40 Adjusting the seat suspension...................................................................................................................................... 40 Fore-and-aft adjustment of the seat plate.......................................................................................................................... 40 Fire extinguisher...................................................................................................................................................... 41 Extinguishing agent................................................................................................................................................ 41 Handling........................................................................................................................................................... 41 Inspection......................................................................................................................................................... 41 Automatic fire-extinguishing system (optional)......................................................................................................................... 42 Inspection......................................................................................................................................................... 42 Manual activation.................................................................................................................................................. 42 Harness (optional)..................................................................................................................................................... 43 Elements of the harness............................................................................................................................................ 43 Important hints.................................................................................................................................................... 43 Taking on harness.................................................................................................................................................. 44 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 46 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 77 Refuelling............................................................................................................................................................. 77 Refuelling - Safety instructions................................................................................................................................... 77 Service station (tanklift)............................................................................................................................................. 77 Lowering the service station....................................................................................................................................... 78 Raising the service station........................................................................................................................................ 78 Refilling and draining............................................................................................................................................. 78 Switching the electrical system on and off............................................................................................................................. 82 Battery main switch................................................................................................................................................ 82 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 83 ....................................................................................................................................................................... 83 Starting the engines............................................................................................................................................... 83 Shutting off the engines........................................................................................................................................... 84 Emergency - stop................................................................................................................................................... 85 AIR CONDITIONER (OPTION)................................................................................................................................................... 86 ....................................................................................................................................................................... 86 Ventilation / Heating.............................................................................................................................................. 86 Control panel (Greentop)........................................................................................................................................... 87 Control panel (Sigma).............................................................................................................................................. 87 Back-up heating (option)............................................................................................................................................... 88 Control panel (Eberpรคcher)......................................................................................................................................... 88 Control panel...................................................................................................................................................... 89 DRIVING.................................................................................................................................................................... 90 SAFETY INSTRUCTIONS.................................................................................................................................................... 90 Superstructure basic position.......................................................................................................................................... 91 Regulating the travelling speed.................................................................................................................................... 92 Travelling uphill and downhill..................................................................................................................................... 92 Cornering.......................................................................................................................................................... 93 Turning............................................................................................................................................................ 93 Note............................................................................................................................................................... 93 Travelling over long distances..................................................................................................................................... 94 Emergency machine drive................................................................................................................................................ 95 Moving the excavator after failure of the hydraulics............................................................................................................... 95 Required equipment................................................................................................................................................. 95 Positioning of the machines........................................................................................................................................ 96 Emergency travel................................................................................................................................................... 96 Locking the superstructure............................................................................................................................................. 97 Track parking brake.................................................................................................................................................... 97 TRANSPORTING THE MACHINE................................................................................................................................................... 98 Safety instructions.................................................................................................................................................... 98 Transport.......................................................................................................................................................... 98 WORKING OPERATION.......................................................................................................................................................... 99 Safety instructions.................................................................................................................................................... 99 Before starting work...................................................................................................................................................101 Switching on the electronic excavator control......................................................................................................................101 Slewing and braking the superstructure.................................................................................................................................101 Braking the superstructure.............................................................................................................................................101 Working................................................................................................................................................................102 Raising and lowering the boom......................................................................................................................................102 Extending and retracting the bucket or backhoe bucket stick........................................................................................................102 Filling and emptying the bucket or the backhoe.....................................................................................................................102 Opening and closing the bottom-dump bucket.........................................................................................................................102 After daily operation..................................................................................................................................................103 Parking the machine................................................................................................................................................103 ASSEMBLING WORKING EQUIPMENT...............................................................................................................................................104 SAFETY INSTRUCTIONS....................................................................................................................................................104 Protective roof against falling objects............................................................................................................................105 Securing the machine...................................................................................................................................................106 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................107 .......................................................................................................................................................................107 Part nos. for Voler A.C............................................................................................................................................107 Application of Voler A.C...........................................................................................................................................107 NOTES......................................................................................................................................................................109 INSPECTION AND SERVICING.......................................................................................................................................................111 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................113 FIRE AND EXPLOSION HAZARD..................................................................................................................................................119 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................121 Intervals..............................................................................................................................................................121 Change of engine oil...................................................................................................................................................121 Air-intake system......................................................................................................................................................121 Oils / Greases.........................................................................................................................................................121 Cleaning jobs..........................................................................................................................................................121 Components.............................................................................................................................................................121 Plan V.................................................................................................................................................................123 Plan N.................................................................................................................................................................125 Plan T.................................................................................................................................................................127 Plan A โ E.............................................................................................................................................................129 LUBRICATING CHART โ GREASE.................................................................................................................................................138 Lubricating chart โ Grease (legend)....................................................................................................................................139 Filling quantities - Grease............................................................................................................................................139 INSPECTION PLAN - OIL......................................................................................................................................................140 Inspection plan โ Oil (legend) ).......................................................................................................................................141 Filling quantities - oil...............................................................................................................................................142 Filling quantities - other.............................................................................................................................................142 LUBRICANTS.................................................................................................................................................................143 I. Oils for combustion engines.........................................................................................................................................143 II. Oils for hydraulic system..........................................................................................................................................144 III.a Oils for pump gearboxes..........................................................................................................................................145 III.b Oils for slewing gearboxes.......................................................................................................................................146 III.c Oils for travel gearboxes........................................................................................................................................147 V. Greases for bearings and slewing rings..............................................................................................................................148 SERVICING WORK.............................................................................................................................................................149 Hose line for oil and cooling liquid changes...........................................................................................................................149 ENGINE.....................................................................................................................................................................150 Engine - Safety instructions...........................................................................................................................................150 Retensioning the alternator/fan belt...................................................................................................................................150 Checking and adjusting the valve clearance.............................................................................................................................150 Checking the engine oil level / Topping up.............................................................................................................................151 Checking the oil level in the engine oil reservoir / topping up (optional).............................................................................................152 Changing the engine oil................................................................................................................................................153 Drawing off engine oil with the service station....................................................................................................................153 Filling in engine oil..............................................................................................................................................154 Filling in engine oil through the service station..................................................................................................................154 Draining the oil off the engine oil reservoir (optional)...............................................................................................................155 Draining off the oil...............................................................................................................................................155 Filling in engine oil..............................................................................................................................................156 Eliminator filter and centrifuge.......................................................................................................................................157 Centrifuge.........................................................................................................................................................157 Dismantling the centrifuge.........................................................................................................................................157 Cleaning the centrifuge............................................................................................................................................158 Assembling the centrifuge..........................................................................................................................................158 COOLING SYSTEM.............................................................................................................................................................159 .......................................................................................................................................................................159 Temperature........................................................................................................................................................159 Radiators..............................................................................................................................................................160 Cooling-liquid level...............................................................................................................................................160 Topping up cooling liquid..........................................................................................................................................161 Checking the DAC concentration.....................................................................................................................................161 Topping up cooling liquid..........................................................................................................................................162 Cooling liquid.........................................................................................................................................................162 Drawing off cooling liquid.........................................................................................................................................163 Filling in cooling liquid..........................................................................................................................................163 Testing the cooling liquid composition.............................................................................................................................163 Water filter...........................................................................................................................................................164 AIR-INTAKE SYSTEM..........................................................................................................................................................165 Main filter elements...................................................................................................................................................165 Removal and installation...........................................................................................................................................165 Checking and cleaning the main filter element......................................................................................................................166 Safety filter element..................................................................................................................................................167 Replacement........................................................................................................................................................167 Air-intake lines.......................................................................................................................................................168 Dust collection........................................................................................................................................................168 FUEL SYSTEM................................................................................................................................................................169 Fuel system - Safety instructions......................................................................................................................................169 Replacing the fuel filter..............................................................................................................................................169 Venting the fuel system................................................................................................................................................170 Cleaning the fuel tanks................................................................................................................................................170 Water trap (option)....................................................................................................................................................172 Servicing..........................................................................................................................................................172 ELECTRICAL SYSTEM..........................................................................................................................................................174 Electrical system - Safety instructions................................................................................................................................174 Alternator - Instructions..............................................................................................................................................174 Battery................................................................................................................................................................175 Checking the battery fluid level...................................................................................................................................175 Removing and installing the battery................................................................................................................................175 Removing and installing the battery................................................................................................................................176 Switchgear cabinet.....................................................................................................................................................177 Breather filter....................................................................................................................................................177 Emptying dust trap.................................................................................................................................................177 Emptying the dust collector........................................................................................................................................177 Filter element.....................................................................................................................................................177 Checking and cleaning the filter element...........................................................................................................................178 HYDRAULIC SYSTEM...........................................................................................................................................................179 Hydraulic system - Safety instructions.................................................................................................................................179 Depressurizing the hydraulic system....................................................................................................................................179 Checking the hydraulic oil level.......................................................................................................................................180 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................182 Bypass valves (hydraulic oil reservoir)................................................................................................................................184 Cleaning the filter screens........................................................................................................................................184 Replacing the bypass valves and sealing rings......................................................................................................................184 Breather filter........................................................................................................................................................185 Replacing the filter elements......................................................................................................................................185 Filter (control circuit)...............................................................................................................................................186 Replacing the filter element.......................................................................................................................................186 High-pressure filter for working hydraulics............................................................................................................................187 Checking/cleaning the filter elements..............................................................................................................................187 Replacing the filter elements......................................................................................................................................187 High-pressure filters for the servo circuit............................................................................................................................188 Checking/cleaning the filter elements..............................................................................................................................188 Replacing the filter elements......................................................................................................................................188 High-pressure filters for feeding circuits and slewing pumps...........................................................................................................189 Checking/cleaning the filter element...............................................................................................................................189 Replacing the filter elements......................................................................................................................................189 High-pressure filters for slewing circuit..............................................................................................................................190 Checking/cleaning the filter elements..............................................................................................................................190 Replacing the filter elements......................................................................................................................................190 Changing the hydraulic oil.............................................................................................................................................191 Drawing off hydaulic oil...........................................................................................................................................191 Drawing off hydaulic oil...........................................................................................................................................192 Cleaning the hydraulic oil reservoir...............................................................................................................................192 Filling in hydraulic oil...........................................................................................................................................193 Venting the hydraulic system...........................................................................................................................................194 Venting the hydraulic components...................................................................................................................................194 Cleaning the hydraulic oil cooler......................................................................................................................................195 Cleaning...........................................................................................................................................................195 Electronic excavator control...........................................................................................................................................196 Joystick...........................................................................................................................................................196 Pedal..............................................................................................................................................................196 Pressure accumulator - Emergency lowering..............................................................................................................................197 Pressure-accumulator inspection regulations........................................................................................................................197 Extract from the German regulations................................................................................................................................197 Extract from the German acceptance regulations.....................................................................................................................197 PUMP TRANSFER GEARBOX......................................................................................................................................................198 Checking the gearbox oil level / Topping up with oil...................................................................................................................198 Pre-chamber............................................................................................................................................................199 Check oil level....................................................................................................................................................199 Pre-chamber........................................................................................................................................................199 Changing the gearbox oil...............................................................................................................................................200 Draining off oil...................................................................................................................................................200 Filling in oil.....................................................................................................................................................200 Pre-chamber............................................................................................................................................................201 Draining off oil...................................................................................................................................................201 Filling in oil.....................................................................................................................................................201 Gearbox venting........................................................................................................................................................202 Pre-chamber........................................................................................................................................................202 Pre-chamber........................................................................................................................................................202 Pump transfer gearbox lube oil filters.................................................................................................................................203 SLEWING GEARBOX............................................................................................................................................................204 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................204 Changing the gearbox oil...............................................................................................................................................204 Draining off oil...................................................................................................................................................204 Filling in new oil / Topping up....................................................................................................................................205 Gearbox venting........................................................................................................................................................205 TRAVEL GAERBOX.............................................................................................................................................................206 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................206 Pre-chamber - Check the oil level / Top up with oil................................................................................................................206 Brake chamber - Checking the oil level / Topping up with oil.......................................................................................................206 Travel gearbox - Changing oil..........................................................................................................................................207 Draining off oil...................................................................................................................................................207 Pre-chamber - Changing the oil.........................................................................................................................................207 Draining off oil...................................................................................................................................................207 Filling in oil.....................................................................................................................................................207 Brake chamber - Changing oil...........................................................................................................................................208 Draining off oil...................................................................................................................................................208 Filling in oil.....................................................................................................................................................208 Breather filter........................................................................................................................................................208 CRAWLER TRACKS.............................................................................................................................................................209 .......................................................................................................................................................................209 Cleaning...........................................................................................................................................................209 Track roller fastening.............................................................................................................................................210 Support roller fastening...........................................................................................................................................210 Track tensioner........................................................................................................................................................211 Design.............................................................................................................................................................211 Techncal data......................................................................................................................................................211 Function...........................................................................................................................................................211 Pressure-accumulator inspection regulations............................................................................................................................212 Extract from the German regulations................................................................................................................................212 Extract from the German acceptance regulations.....................................................................................................................212 Checking the gas charging pressure in the pressure accumulator.........................................................................................................212 SLEWING RING...............................................................................................................................................................213 Slewing ring - Instructions............................................................................................................................................213 Bearing races..........................................................................................................................................................213 Internal gearing...................................................................................................................................................213 Slewing ring - Checking the grease filling.........................................................................................................................214 Slewing ring - Filling in grease...................................................................................................................................214 Slewing ring - Checking the screws for tightness...................................................................................................................214 CENTRAL LUBRICATING........................................................................................................................................................215 Design.................................................................................................................................................................215 Lube cycle / Pause period..............................................................................................................................................215 Function...............................................................................................................................................................216 Replacing the grease drum..............................................................................................................................................216 Checking the greasing pressure.........................................................................................................................................217 Unblocking a grease line...............................................................................................................................................218 Cleaning...........................................................................................................................................................218 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................219 Replacing the filter element.......................................................................................................................................219 Grease filter (Grease lines)...........................................................................................................................................220 Checking the filter element........................................................................................................................................220 Replacing the filter element.......................................................................................................................................220 OTHER MAINTENANCE..........................................................................................................................................................221 Engine.................................................................................................................................................................221 Cleaning...........................................................................................................................................................221 Means of fastening.................................................................................................................................................221 Cooling system.....................................................................................................................................................221 Exhaust system.....................................................................................................................................................221 Heating and air conditioning...........................................................................................................................................221 Equipment..............................................................................................................................................................222 RAMP-TYPE LADDER (OPTIONAL) (OPTION)......................................................................................................................................223 Pressure-accumulator inspection regulations............................................................................................................................224 Extract from the German regulations....................................................................................................................................224 Extract from the German acceptance regulations.....................................................................................................................224 Checking the gas charging pressure in the pressure accumulator.........................................................................................................224 ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................225 Monitoring, warning and control elements...............................................................................................................................225 Checking the on-board crane............................................................................................................................................225 Extract from the inspection and testing regulations................................................................................................................225 Drive unit.............................................................................................................................................................226 Crane engine.......................................................................................................................................................226 Air-intake system..................................................................................................................................................226 Hydraulic system...................................................................................................................................................226 On-board crane.........................................................................................................................................................226 Servicing..........................................................................................................................................................226 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................227 Putting the excavator out of operation.................................................................................................................................227 Battery storage........................................................................................................................................................227 Recommissioning........................................................................................................................................................228 Notes..................................................................................................................................................................229 REPAIR WORK....................................................................................................................................................................231 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................233 FIRE AND EXPLOSION HAZARD..................................................................................................................................................235 ENGINE.....................................................................................................................................................................236 ELECTRICAL SYSTEM..........................................................................................................................................................237 Assisted starting (with jumper cables) โ Safety instructions...........................................................................................................237 Assisted starting (with jumper cables).................................................................................................................................237 Prior to assisted starting.........................................................................................................................................237 Starting the engine with jumper cables (external batteries.............................................................................................................237 Assisted starting without batteries installed (only for engine trial run)..........................................................................................238 Connecting the jumper cables.......................................................................................................................................239 Starting up the engines............................................................................................................................................239 Disconnecting the jumper cables....................................................................................................................................239 HYDRAULIC SYSTEM...........................................................................................................................................................240 Repair.................................................................................................................................................................240 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................241 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................242 NOTES......................................................................................................................................................................243 ANNEX..........................................................................................................................................................................245 TROUBLESHOOTING............................................................................................................................................................247 Instructions on troubleshooting........................................................................................................................................247 Layout of the fault table..............................................................................................................................................247 Fault..............................................................................................................................................................247 Possible causes........................................................................................................................................................247 Measures...............................................................................................................................................................247 Section................................................................................................................................................................247 FAULT TABLES...............................................................................................................................................................248 Combustion engine - Fault table........................................................................................................................................248 Working hydraulics โ Fault table.......................................................................................................................................249 Track drive โ Fault table..............................................................................................................................................250 Slewing mechnism โ Fault table.........................................................................................................................................251 Central lubricating system โ Fault table...............................................................................................................................252 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................253 ABBREVIATIONS..............................................................................................................................................................254 TECHNICAL DATA.............................................................................................................................................................257 NOTES......................................................................................................................................................................259 INDEX..........................................................................................................................................................................261
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