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Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL – PDF DOWNLOAD
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Description
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL – PDF DOWNLOAD
Language : English
Pages : 234
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH200
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
- The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
! 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 user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified GERMANY Germany mechanic or by attending an Terex-Germany training course for operators or maintenance personnel. The Terex-Germany after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
- 1 Complies with VDMA recommendation “Operating instructions” All Terex Germany operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Terex Germany will be pleased to answer.
- The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex Germany after- sales service. The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately.
- The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL – 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 / pneumatc equipment......................................................................................................................................... 21 Noise.................................................................................................................................................................. 21 Oil, grease and other chemical sub stances............................................................................................................................. 21 Transporting and recommission ing...................................................................................................................................... 21 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS........................................................................................................ 22 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR..................................................................................................................... 24 ....................................................................................................................................................................... 24 In the transformer station......................................................................................................................................... 24 On the excavator................................................................................................................................................... 24 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 25 N.......................................................................................................................................................................... 27 NOTES...................................................................................................................................................................... 27 O.......................................................................................................................................................................... 29 OPERATION...................................................................................................................................................................... 29 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 31 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 33 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 34 Excavator layout....................................................................................................................................................... 35 Undercarriage...................................................................................................................................................... 35 Superstructure..................................................................................................................................................... 35 Loading bucket..................................................................................................................................................... 35 Undercarriage.......................................................................................................................................................... 36 Superstructure......................................................................................................................................................... 36 Drive.................................................................................................................................................................. 36 Hydraulic system....................................................................................................................................................... 36 Pump Managing System (PMS)............................................................................................................................................. 36 Stored Program Control (SPC)........................................................................................................................................... 36 Electronic Hydraulic Servo-Control (EHSC).............................................................................................................................. 36 Demand control / Zero-flow regulation.................................................................................................................................. 37 Board-Control-System (BCS)............................................................................................................................................. 37 Electrical system...................................................................................................................................................... 37 Power supply....................................................................................................................................................... 38 Sign................................................................................................................................................................... 41 Warning and instruction signs...................................................................................................................................... 41 Machine number..................................................................................................................................................... 41 Engine number...................................................................................................................................................... 41 Component numbers.................................................................................................................................................. 41 Entering and leaving the machine Safety instructions................................................................................................................... 42 Accsess............................................................................................................................................................ 42 Escape ladder...................................................................................................................................................... 42 Access lighting.................................................................................................................................................... 43 Cab interior lamp.................................................................................................................................................. 44 Servicing lighting................................................................................................................................................. 44 EMERGENCY STOP pushswitch.............................................................................................................................................. 45 Windscreen washer...................................................................................................................................................... 45 Driver's seat.......................................................................................................................................................... 46 Adjusting the backrest............................................................................................................................................. 46 Adjusting the lumbar support....................................................................................................................................... 46 Adjusting the seat cushion......................................................................................................................................... 46 Adjusting the armrests............................................................................................................................................. 46 Fore-and-aft adjustment............................................................................................................................................ 46 Adjusting the seat suspension...................................................................................................................................... 46 Fore-and-aft adjustment of the seat plate.......................................................................................................................... 46 Fire extinguisher...................................................................................................................................................... 47 Extinguishing agent................................................................................................................................................ 47 Handling........................................................................................................................................................... 47 Inspection......................................................................................................................................................... 47 Automatic fire-extinguishing system (optional)......................................................................................................................... 48 Inspection......................................................................................................................................................... 48 Manual activation.................................................................................................................................................. 48 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 50 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 67 Service station (tanklift)............................................................................................................................................. 67 Lowering the service station....................................................................................................................................... 67 Raising the service station........................................................................................................................................ 67 Refilling and draining............................................................................................................................................. 67 Switching the electrical system on and off............................................................................................................................. 70 Battery main switch................................................................................................................................................ 70 Switching the electric motor on and off................................................................................................................................ 71 Before switching on the electric motor............................................................................................................................. 71 Switching on the circuit breaker................................................................................................................................... 73 Switching off the circuit breaker.................................................................................................................................. 73 Switching on the electric motor.................................................................................................................................... 74 Switching off the electric motor................................................................................................................................... 75 Fault of the electric motor........................................................................................................................................ 75 Emergency - stop................................................................................................................................................... 76 Motor protective relay............................................................................................................................................. 77 AIR CONDITIONER (OPTION)................................................................................................................................................... 78 ....................................................................................................................................................................... 78 Ventilation / Heating.............................................................................................................................................. 78 Control panel (Greentop)........................................................................................................................................... 79 Control panel (Sigma).............................................................................................................................................. 79 Back-up heating (option)............................................................................................................................................... 80 Control panel (Eberpächer)......................................................................................................................................... 80 Control panel...................................................................................................................................................... 81 DRIVING SAFETY INSTRUCTIONS................................................................................................................................................ 82 TRAVELLING................................................................................................................................................................. 83 Superstructure basic position.......................................................................................................................................... 83 Travelling forwards/backwards.......................................................................................................................................... 83 Regulating the travelling speed.................................................................................................................................... 84 Travelling uphill and downhill..................................................................................................................................... 84 Cornering.......................................................................................................................................................... 85 Turning............................................................................................................................................................ 85 Note............................................................................................................................................................... 85 Travelling over long distances..................................................................................................................................... 86 Emergency machine drive................................................................................................................................................ 87 Moving the excavator after failure of the hydraulics............................................................................................................... 87 Required equipment................................................................................................................................................. 87 Positioning of the machines........................................................................................................................................ 88 Emergency travel................................................................................................................................................... 88 Emergency travelling............................................................................................................................................... 89 Locking the superstructure............................................................................................................................................. 90 Track parking brake.................................................................................................................................................... 90 TRANSPORTING THE MACHINE................................................................................................................................................... 91 Transport - Safety instructions........................................................................................................................................ 91 Transport.......................................................................................................................................................... 91 WORKING OPERATION - SAFETY INSTRUCTIONS.................................................................................................................................... 92 WORKING OPERATION.......................................................................................................................................................... 94 Before starting work................................................................................................................................................... 94 Switching on the electronic excavator control...................................................................................................................... 94 Slewing and braking the superstructure................................................................................................................................. 94 Braking the superstructure............................................................................................................................................. 94 Working................................................................................................................................................................ 95 Raising and lowering the boom...................................................................................................................................... 95 Extending and retracting the bucket stick.......................................................................................................................... 95 Filling and emptying the bucket.................................................................................................................................... 95 Opening and closing the bottom-dump bucket......................................................................................................................... 95 After daily operation.................................................................................................................................................. 96 Parking the machine................................................................................................................................................ 96 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 97 ....................................................................................................................................................................... 98 Protective roof against falling objects............................................................................................................................ 98 Securing the machine................................................................................................................................................... 99 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................100 .......................................................................................................................................................................100 Part nos. for Voler A.C............................................................................................................................................100 Application of Voler A.C...........................................................................................................................................100 NOTES......................................................................................................................................................................101 INSPECTION AND SERVICING.......................................................................................................................................................103 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR.....................................................................................................................105 .......................................................................................................................................................................105 In the transformer station.........................................................................................................................................105 On the excavator...................................................................................................................................................105 On the hydraulic excavator.........................................................................................................................................106 In the transformer station.........................................................................................................................................106 On the hydraulic excavator.........................................................................................................................................106 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................107 FIRE AND EXPLOSION HAZARD..................................................................................................................................................113 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................115 Intervals..............................................................................................................................................................115 Change of engine oil l.................................................................................................................................................115 Oils / Greases.........................................................................................................................................................115 Cleaning jobs..........................................................................................................................................................115 Components.............................................................................................................................................................115 Plan V.................................................................................................................................................................117 Plan N.................................................................................................................................................................119 Plan T.................................................................................................................................................................121 Plan A – E.............................................................................................................................................................123 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................130 Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................131 Filling quantities - Grease............................................................................................................................................131 INSPECTION PLAN - OIL......................................................................................................................................................132 Inspection plan – Oil (legend) ).......................................................................................................................................133 Filling quantities - oil...............................................................................................................................................134 Filling quantities - other.............................................................................................................................................134 LUBRICANTS.................................................................................................................................................................135 I. Oils for combustion engines and compressors (selection).............................................................................................................135 II. Oils for hydraulic system (selection)..............................................................................................................................136 III. Oils for gearboxes (selection)....................................................................................................................................137 V. Greases for bearings and slewing rings..............................................................................................................................138 SERVICING WORK.............................................................................................................................................................139 Hose line for oil and cooling liquid changes...........................................................................................................................139 ELECTRIC MOTOR.............................................................................................................................................................140 Electric motor - Safety instructions...................................................................................................................................140 Electric motor.........................................................................................................................................................140 Cleaning the electric motor........................................................................................................................................140 Greasing the electric motor........................................................................................................................................141 Other servicing works..............................................................................................................................................141 ELECTRICAL SYSTEM..........................................................................................................................................................142 Electrical system - Safety instructions................................................................................................................................142 Battery main switch....................................................................................................................................................142 Battery................................................................................................................................................................143 Checking the battery fluid level...................................................................................................................................143 Removing and installing the battery................................................................................................................................143 Removing and installing the battery................................................................................................................................144 Charging the batteries.............................................................................................................................................145 Switchgear cabinet.....................................................................................................................................................145 Breather filter....................................................................................................................................................145 Emptying dust trap.................................................................................................................................................146 Emptying the dust collector........................................................................................................................................146 Filter element.....................................................................................................................................................146 Checking and cleaning the filter element...........................................................................................................................147 Replacing filter mats..............................................................................................................................................148 Draining water from the switchgear cabinet.........................................................................................................................148 Slip ring..............................................................................................................................................................148 HYDRAULIC SYSTEM...........................................................................................................................................................149 Hydraulic system - Safety instructions.................................................................................................................................149 Depressurizing the hydraulic system....................................................................................................................................149 Checking the hydraulic oil level.......................................................................................................................................150 Changing the hydraulic oil return-flow filter (hydraulic oil reservoir)................................................................................................152 Bypass valves (hydraulic oil reservoir)................................................................................................................................154 Cleaning the filter screens........................................................................................................................................154 Replacing the bypass valves and sealing rings......................................................................................................................154 Breather filter........................................................................................................................................................155 Replacing the filter elements......................................................................................................................................155 Filter (control circuit)...............................................................................................................................................156 Replacing the filter elements......................................................................................................................................156 High-pressure filter for working hydraulics............................................................................................................................157 Checking/cleaning the filter elements..............................................................................................................................157 Replacing the filter elements......................................................................................................................................157 High-pressure filters for the servo circuit............................................................................................................................158 Checking/cleaning the filter elements..............................................................................................................................158 Replacing the filter elements......................................................................................................................................158 High-pressure filters for swing circuit................................................................................................................................159 Checking/cleaning the filter element...............................................................................................................................159 Replacing the filter elements......................................................................................................................................159 High-pressure filters for cooling oil circuit..........................................................................................................................160 Checking/cleaning the filter element...............................................................................................................................160 Replacing the filter elements......................................................................................................................................160 Changing the hydraulic oil.............................................................................................................................................161 Drawing off hydaulic oil...........................................................................................................................................161 Cleaning the hydraulic oil reservoir...............................................................................................................................162 Filling in hydraulic oil...........................................................................................................................................163 Venting the hydraulic system...........................................................................................................................................165 Venting the hydraulic components...................................................................................................................................165 Cleaning the hydraulic oil cooler......................................................................................................................................166 Cleaning...........................................................................................................................................................166 Electronic excavator control...........................................................................................................................................167 Joystick...........................................................................................................................................................167 Pedal..............................................................................................................................................................167 Pressure accumulator - Emergency lowering..............................................................................................................................168 Pressure-accumulator inspection regulations........................................................................................................................168 Extract from the German regulations................................................................................................................................168 Extract from the German acceptance regulations.....................................................................................................................168 PUMP TRANSFER GEARBOX......................................................................................................................................................169 Checking the gearbox oil level / Topping up with oil...................................................................................................................169 Drawing off oil (optional).........................................................................................................................................170 Drawing off oil (optional).........................................................................................................................................170 Filling in oil.....................................................................................................................................................171 Filling in oil.....................................................................................................................................................171 Gearbox venting........................................................................................................................................................171 Pre-chambers working pumps, check oil level, filling in oil, draining oil, changing oil................................................................................172 Pre-chambers slewing pumps, check oil level, filling in oil, draining oil, changing oil................................................................................172 Gear oil filter........................................................................................................................................................173 Check the gear oil filter..........................................................................................................................................173 Changing filter element............................................................................................................................................173 SLEWING GEARBOX............................................................................................................................................................174 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................174 Changing the gearbox oil...............................................................................................................................................174 Draining off oil...................................................................................................................................................174 Filling in new oil / Topping up....................................................................................................................................175 Gearbox venting........................................................................................................................................................175 Slewing gear neck......................................................................................................................................................175 TRAVEL GAERBOX.............................................................................................................................................................176 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................176 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................176 Pre-chamber - Check the oil level / Top up with oil....................................................................................................................177 Travel gearbox - Changing the oil......................................................................................................................................177 Draining off oil...................................................................................................................................................177 Filling in oil.....................................................................................................................................................177 Breather filter........................................................................................................................................................178 CRAWLER TRACKS.............................................................................................................................................................179 .......................................................................................................................................................................179 Cleaning...........................................................................................................................................................179 Track rollers..........................................................................................................................................................180 Track roller fastening.............................................................................................................................................180 Support roller fastening...........................................................................................................................................180 Track tensioner........................................................................................................................................................181 Design.............................................................................................................................................................181 Techncal data......................................................................................................................................................181 Function...........................................................................................................................................................181 Pressure-accumulator inspection regulations............................................................................................................................182 Extract from the German regulations................................................................................................................................182 Extract from the German acceptance regulations.....................................................................................................................182 Checking the gas charging pressure in the pressure accumulator.........................................................................................................182 Idlers.................................................................................................................................................................183 Checking the oil level.............................................................................................................................................183 Filling in oil.....................................................................................................................................................183 SLEWING RING...............................................................................................................................................................184 Slewing ring - Instructions............................................................................................................................................184 Bearing races..........................................................................................................................................................184 Internal gearing...................................................................................................................................................184 Slewing ring - Checking the grease filling.........................................................................................................................185 Slewing ring - Filling in grease...................................................................................................................................185 Slewing ring - Checking the screws for tightness...................................................................................................................185 CENTRAL LUBRICATING........................................................................................................................................................186 Design and function....................................................................................................................................................186 Lube cycle / Pause period..............................................................................................................................................186 Lube cycle manual lubricating (optional)...............................................................................................................................186 Filling up the grease container........................................................................................................................................187 Breather filter........................................................................................................................................................188 Checking the greasing pressure.........................................................................................................................................188 Unblocking a grease line...............................................................................................................................................189 Cleaning...........................................................................................................................................................189 Manual greasing (option)...............................................................................................................................................189 Heating and air conditioning...........................................................................................................................................190 ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................191 Monitoring, warning and control elements...............................................................................................................................191 Checking the on-board crane............................................................................................................................................191 Extract from the inspection and testing regulations................................................................................................................191 Drive unit.............................................................................................................................................................192 Crane engine.......................................................................................................................................................192 Air-intake system..................................................................................................................................................192 Hydraulic system...................................................................................................................................................192 On-board crane.........................................................................................................................................................192 Servicing..........................................................................................................................................................192 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................193 Putting the excavator out of operation.................................................................................................................................193 Battery storage........................................................................................................................................................193 Recommissioning........................................................................................................................................................194 NOTES......................................................................................................................................................................196 REPAIR WORK....................................................................................................................................................................201 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR.....................................................................................................................203 .......................................................................................................................................................................203 In the transformer station.........................................................................................................................................203 On the excavator...................................................................................................................................................203 On the hydraulic excavator.........................................................................................................................................204 In the transformer station.........................................................................................................................................204 On the hydraulic excavator.........................................................................................................................................204 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................205 FIRE AND EXPLOSION HAZARD..................................................................................................................................................207 HYDRAULIC SYSTEM...........................................................................................................................................................208 Repair.................................................................................................................................................................208 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................209 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................210 NOTES......................................................................................................................................................................211 ANNEX..........................................................................................................................................................................213 TROUBLESHOOTING............................................................................................................................................................215 Instructions on troubleshooting........................................................................................................................................215 Layout of the fault table..............................................................................................................................................215 Fault..............................................................................................................................................................215 Possible causes........................................................................................................................................................215 Measures...............................................................................................................................................................215 Section................................................................................................................................................................215 FAULT TABLES...............................................................................................................................................................216 Working hydraulics – Fault table.......................................................................................................................................216 Track drive – Fault table..............................................................................................................................................217 Slewing mechnism – Fault table.........................................................................................................................................218 Central lubricating system – Fault table...............................................................................................................................219 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................220 .......................................................................................................................................................................220 Legend (loading bucket)............................................................................................................................................220 TIGHTENING TORQUES AND ANGLES – TABLE......................................................................................................................................222 ABBREVIATIONS..............................................................................................................................................................224 TECHNICAL DATA.............................................................................................................................................................226 INDEX..........................................................................................................................................................................230
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