Cat Bucyrus RH170 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651421 – PDF DOWNLOAD

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Cat Bucyrus RH170 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651421 – PDF DOWNLOAD

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Cat Bucyrus RH170 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651421 – PDF DOWNLOAD

Language : English
Pages : 278
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Cat Bucyrus RH170 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651421 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH170B
Introduction
PREFACE

• These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
• The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as

• In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
• This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel. The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
• 1 Complies with VDMA recommendation “Operating instructions” All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service.
• The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

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TABLE OF CONTENTS:

Cat Bucyrus RH170 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651421 – PDF DOWNLOAD

1 INTRODUCTION............................................................................................................................................................... 11
	PREFACE ................................................................................................................................................................. 13
	WARRANTY ................................................................................................................................................................ 14
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15
		Warnings and symbols................................................................................................................................................. 15
	DESIGNATED USE........................................................................................................................................................... 16
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 17
		Personal protective equipment and the working clothing .............................................................................................................. 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
	FIRE AND EXPLOSION HAZARD ............................................................................................................................................... 22
	NOTES ................................................................................................................................................................... 23
2 OPERATION.................................................................................................................................................................. 25
	OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 27
		Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 28
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 29
	DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................ 30
		Excavator layout .................................................................................................................................................... 31
		Undercarriage ....................................................................................................................................................... 32
		Superstructure ...................................................................................................................................................... 32
		Drive................................................................................................................................................................ 32
		Hydraulic system .................................................................................................................................................... 32
		Pump Managing System (PMS) .......................................................................................................................................... 32
		Stored Program Control (SPC) ........................................................................................................................................ 32
		Central Management System (CMS) ..................................................................................................................................... 32
		Demand control / Zero-flow regulation................................................................................................................................ 33
		Automatic engine speed reduction .................................................................................................................................... 33
		Board-Control-System (BCS) .......................................................................................................................................... 33
		Electrical system ................................................................................................................................................... 33
		Signs and labels .................................................................................................................................................... 35
		Entering and leaving the machine, Safety instructions................................................................................................................ 36
		Access lighting, switching on and off ............................................................................................................................... 36
		Folding ladder (optional) ........................................................................................................................................... 37
		Swinging ladder (optional) .......................................................................................................................................... 38
		Cab interior lamp, switching on /off ................................................................................................................................ 39
		Servicing lighting, switching on /off ............................................................................................................................... 40
		Illuminating the control column ..................................................................................................................................... 40
		EMERGENCY STOP switch ............................................................................................................................................... 41
		Windscreen washer ................................................................................................................................................... 42
		Trainer's / instructor's seat ....................................................................................................................................... 42
		Driver's seat ....................................................................................................................................................... 43
		Fire extinguisher ................................................................................................................................................... 45
		Automatic fire-extinguishing system (optional) ...................................................................................................................... 46
		Harness (optional) .................................................................................................................................................. 47
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 50
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 82
		Refuelling .......................................................................................................................................................... 82
		Service station (tanklift) .......................................................................................................................................... 82
		Switching the electrical system on and off .......................................................................................................................... 88
		Battery main switch ................................................................................................................................................. 88
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 89
		Starting the engines ................................................................................................................................................ 89
		Starting the engines at low temperatures ............................................................................................................................ 90
		Shutting off the engines ............................................................................................................................................ 91
		Engines, emergency - stop ........................................................................................................................................... 91
	AIR CONDITIONER (OPTION)................................................................................................................................................. 92
		Control panel (Sigma) ............................................................................................................................................... 92
		Back-up heating (option) ............................................................................................................................................ 93
	DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................ 95
	TRAVELLING .............................................................................................................................................................. 96
		Superstructure basic position ....................................................................................................................................... 96
		Travelling forwards / backwards ..................................................................................................................................... 96
		Emergency machine drive .............................................................................................................................................100
		Superstructure holding brakes .......................................................................................................................................102
		Track parking brake .................................................................................................................................................102
	TRANSPORTING THE MACHINE ................................................................................................................................................103
		Transport - Safety instructions .....................................................................................................................................103
	WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................104
		Running-in instructions for hydraulic cylinders .....................................................................................................................104
		Warming-up phase for the hydraulic system ...........................................................................................................................104
		Avoid extreme positions of the working equipment ....................................................................................................................105
	WORKING OPERATION .......................................................................................................................................................106
		Before starting work ................................................................................................................................................106
		Switching on the electronic excavator control .......................................................................................................................106
		Swinging the superstructure .........................................................................................................................................106
		Braking the superstructure ..........................................................................................................................................106
		Working movements ...................................................................................................................................................107
		After daily operation ...............................................................................................................................................108
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................109
		Securing the machine ................................................................................................................................................111
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................112
	NOTES ...................................................................................................................................................................113
3 INSPECTION AND SERVICING...................................................................................................................................................115
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................117
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................123
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................125
		Intervals............................................................................................................................................................125
		Change of engine oil ................................................................................................................................................125
		Air-intake system ...................................................................................................................................................125
		Oils / Greases ......................................................................................................................................................125
		Cleaning jobs .......................................................................................................................................................125
		Components ..........................................................................................................................................................125
		Plan V ..............................................................................................................................................................127
		Plan N ..............................................................................................................................................................129
		Plan T and W ........................................................................................................................................................131
		Plan A – E ..........................................................................................................................................................133
	LUBRICATING CHART – GREASE ..............................................................................................................................................140
		Lubricating chart – Grease (legend) .................................................................................................................................141
		Filling quantities - Grease..........................................................................................................................................141
	INSPECTION PLAN - OIL ...................................................................................................................................................142
		Inspection plan – Oil (legend) ......................................................................................................................................143
		Filling quantities - oil ............................................................................................................................................144
		Filling quantities - other...........................................................................................................................................144
	LUBRICANTS ..............................................................................................................................................................145
		Notes on the selection of oils and greases ..........................................................................................................................145
		I. Oils for combustion engines ......................................................................................................................................146
		II. Oils for hydraulic system .......................................................................................................................................147
		III.a Oils for pump gearboxes .......................................................................................................................................148
		III.b Oils for swing gearboxes ......................................................................................................................................149
		III.c Oils for travel gearboxes .....................................................................................................................................150
		V. Greases for bearings and swing rings .............................................................................................................................151
	SERVICING WORK ..........................................................................................................................................................152
		Hose line for oil and cooling liquid changes ........................................................................................................................152
	ENGINE ..................................................................................................................................................................153
		Engine - Safety instructions ........................................................................................................................................153
		Checking the engine oil level / Topping up  .........................................................................................................................154
		Changing the engine oil .............................................................................................................................................155
		Replacing the oil filters ...........................................................................................................................................157
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................158
	COOLING SYSTEM ..........................................................................................................................................................159
		Cooling liquid, change ..............................................................................................................................................161
	AIR-INTAKE SYSTEM .......................................................................................................................................................162
		Dust trap, cleaning  ................................................................................................................................................162
		Main filter elements ................................................................................................................................................163
		Safety filter element ...............................................................................................................................................165
		Air-intake lines ....................................................................................................................................................165
	FUEL SYSTEM .............................................................................................................................................................166
		Fuel system - Safety instructions ...................................................................................................................................166
		Replacing the fuel filter ...........................................................................................................................................166
		Primary fuel filter, drain water ....................................................................................................................................167
		Replacing the primary fuel filter ...................................................................................................................................167
		Venting the fuel system .............................................................................................................................................168
		Cleaning the fuel tanks .............................................................................................................................................168
		Water trap (option)..................................................................................................................................................170
	ELECTRICAL SYSTEM  ......................................................................................................................................................172
		Electrical system - Safety instructions .............................................................................................................................172
		Alternator - Instructions ...........................................................................................................................................172
		Battery .............................................................................................................................................................173
		Switchgear cabinet ..................................................................................................................................................175
		 Floodlight projector, replacing the lamp ...........................................................................................................................177
	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
		Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................185
		Bypass valves (filter housing - cooling system) .....................................................................................................................186
		Breather filter .....................................................................................................................................................187
		Filter (control circuit and auxiliary control circuit)...............................................................................................................188
		High-pressure filter for working hydraulics .........................................................................................................................189
		High-pressure filters for the servo circuit .........................................................................................................................190
		High-pressure filters for feeding circuits and slewing pumps ........................................................................................................191
		Changing the hydraulic oil ..........................................................................................................................................192
		Venting the hydraulic system.........................................................................................................................................195
		Cleaning the hydraulic oil cooler....................................................................................................................................196
		Electronic excavator control ........................................................................................................................................197
		Pressure accumulator - Emergency lowering............................................................................................................................198
	PUMP TRANSFER GEARBOX ...................................................................................................................................................199
		Checking the gearbox oil level / Topping up with oil ................................................................................................................199
		Changing the gearbox oil ............................................................................................................................................200
		Gearbox venting .....................................................................................................................................................202
		Pump transfer gearbox lube oil filters ..............................................................................................................................203
	SWING GEARBOX ...........................................................................................................................................................204
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................204
		Changing the gearbox oil ............................................................................................................................................204
		Gearbox venting .....................................................................................................................................................205
	SWING GEARBOX ...........................................................................................................................................................206
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................206
		Changing the gearbox oil ............................................................................................................................................207
		Gearbox venting .....................................................................................................................................................208
	TRAVEL GEARBOX ..........................................................................................................................................................209
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................209
		Pre-chamber / spur wheel section, Check the oil level / Top up with oil .............................................................................................209
		Hydraulic motor chamber - Check the oil level / Top up with oil .....................................................................................................209
		Travel gearbox, Changing oil ........................................................................................................................................210
		Pre-chamber / spur wheel section, Changing oil ......................................................................................................................210
		Hydraulic motor chamber, Changing oil ...............................................................................................................................211
		Breather filter, Clean / Replace ....................................................................................................................................211
	CRAWLER TRACKS ..........................................................................................................................................................212
		Track roller ........................................................................................................................................................213
		Track roller, Support roller ........................................................................................................................................213
		Track tensioner .....................................................................................................................................................214
		Pressure-accumulator inspection regulations .........................................................................................................................215
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................215
	SWING RING ..............................................................................................................................................................216
		Swing ring - Instructions............................................................................................................................................216
		Bearing races........................................................................................................................................................216
	CENTRAL LUBRICATING .....................................................................................................................................................218
		Design ..............................................................................................................................................................218
		Function ............................................................................................................................................................219
		Filling up the grease container .....................................................................................................................................220
		Breather filter .....................................................................................................................................................220
		Checking the greasing pressure ......................................................................................................................................221
		Unblocking a grease line.............................................................................................................................................222
		Oilfilter (hydraulic circuit grease pump) ...........................................................................................................................223
		Grease filter (Filling the grease container) ........................................................................................................................224
		Grease filter (Grease lines) ........................................................................................................................................225
	OTHER MAINTENANCE .......................................................................................................................................................226
		Engine ..............................................................................................................................................................226
		Heating and air conditioning ........................................................................................................................................226
	RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................227
		Pressure-accumulator inspection regulations .........................................................................................................................228
		Extract from the German regulations..................................................................................................................................228
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................228
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................229
		Monitoring, warning and control elements ............................................................................................................................229
		Checking the on-board crane..........................................................................................................................................229
		Drive unit ..........................................................................................................................................................230
		On-board crane ......................................................................................................................................................230
		On-Board crane, checking tightness of fastening bolts ...............................................................................................................231
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................232
		Putting the excavator out of operation ..............................................................................................................................232
		Battery storage .....................................................................................................................................................232
		Recommissioning .....................................................................................................................................................232
	NOTES  ..................................................................................................................................................................233
4 REPAIR WORK................................................................................................................................................................235
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................237
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................239
	REPAIR WORK, ENGINE .....................................................................................................................................................240
	ELECTRICAL SYSTEM .......................................................................................................................................................241
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................241
		Assisted starting (with jumper cables)...............................................................................................................................241
		Starting the engine with jumper cables (external batteries ..........................................................................................................241
	HYDRAULIC SYSTEM.........................................................................................................................................................243
		Repair instructions .................................................................................................................................................243
		Hydraulic hoses – Instructions  .....................................................................................................................................243
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................244
		Welding operations - Safety instructions ............................................................................................................................245
	NOTES ...................................................................................................................................................................247
5 ANNEX......................................................................................................................................................................249
	TROUBLESHOOTING .........................................................................................................................................................251
		Instructions on troubleshooting .....................................................................................................................................251
		Layout of the fault table ...........................................................................................................................................251
		Possible causes .....................................................................................................................................................251
		Measures ............................................................................................................................................................251
		Section .............................................................................................................................................................251
	FAULT TABLES ............................................................................................................................................................252
		Combustion engine - Fault table .....................................................................................................................................252
		Working hydraulics – Fault table ....................................................................................................................................253
		Track drive – Fault table ...........................................................................................................................................254
		Swing mechnism – Fault table ........................................................................................................................................255
		Central lubricating system – Fault table ............................................................................................................................256
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................257
	ABBREVIATIONS ...........................................................................................................................................................259
		ABBREVIATIONS........................................................................................................................................................260
	TECHNICAL DATA ..........................................................................................................................................................261
	NOTES ...................................................................................................................................................................271
6 INDEX......................................................................................................................................................................273

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