Cat Bucyrus RH340B Hydraulic Excavator Operating Instructions Manual BI651409 – PDF DOWNLOAD

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Cat Bucyrus RH340B Hydraulic Excavator Operating Instructions Manual BI651409 – PDF DOWNLOAD

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Cat Bucyrus RH340B Hydraulic Excavator Operating Instructions Manual BI651409 – PDF DOWNLOAD

Language : English
Pages : 298
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus RH340B Hydraulic Excavator Operating Instructions Manual BI651409 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH340B
PREFACE
About this Operating Instructions

PREFACE
About this Operation and Maintenance Manual

• These Operation and Maintenance Manual are designed to familiarize the operator with the machine and its designated use.
• The Operation and Maintenance Manual 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 Operation and Maintenance Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The Operation and Maintenance Manual must always be available in the driver’s cab of the machine.
• The Operation and Maintenance Manual 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 Operation and Maintenance Manual 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 Operation and Maintenance Manual are directed to the mining-machine specialist. They cannot provide basic know-how.
• This can be acquired, for example, in several days’ instruction by a qualified CGM HMS GmbH (Caterpillar Global Mining Hydraulic Mining Shovels GmbH) mechanic or by attending an CGM HMS GmbH training course for operators or maintenance personnel.
• The CGM HMS GmbH after-sales service will be pleased to deal with any queries you may have after reading through the Operation and Maintenance Manual.
• All CGM HMS GmbH Operation and Maintenance Manuals are issued in German and then translated. Even a good translation may give rise to questions which CGM HMS GmbH will be pleased to answer
• The Operation and Maintenance Manual are not work instructions for carrying out major repairs. Such work is willingly done for you by the CGM HMS GmbH after-sales service

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Cat Bucyrus RH340B Hydraulic Excavator Operating Instructions Manual BI651409 – PDF DOWNLOAD

1 INTRODUCTION................................................................................................................................................................ 13
	PREFACE .................................................................................................................................................................. 15
		About this Operating Instructions .................................................................................................................................... 15
		Further machine documentation ........................................................................................................................................ 15
	WARRANTY ................................................................................................................................................................. 16
	FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................................................................................... 17
		Warnings and symbols ................................................................................................................................................. 17
	DESIGNATED USE ........................................................................................................................................................... 18
	ORGANIZATIONAL MEASURES .................................................................................................................................................. 19
		Selection and qualification of personnel; basic responsibilities ..................................................................................................... 20
		Safety instructions governing specific operational phases ............................................................................................................ 20
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 21
		Warning of special dangers ........................................................................................................................................... 22
		Gas, dust, steam and smoke ........................................................................................................................................... 22
		Hydraulic equipment .................................................................................................................................................. 23
	FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 24
	NOTES .................................................................................................................................................................... 25
2 OPERATION................................................................................................................................................................... 27
	OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 29
		Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 30
	FIRE AND EXPLOSION HAZARD................................................................................................................................................. 31
	DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................. 32
		Excavator layout ..................................................................................................................................................... 33
		Undercarriage ........................................................................................................................................................ 34
		Superstructure ....................................................................................................................................................... 34
		Drive ................................................................................................................................................................ 34
		Hydraulic system ..................................................................................................................................................... 34
		Control and Monitoring Platform (CAMP) ............................................................................................................................... 34
		Board-Control-System (BCS) ........................................................................................................................................... 35
		Demand control / Zero-flow regulation................................................................................................................................. 35
		Automatic reset to idling............................................................................................................................................. 35
		Electrical system .................................................................................................................................................... 35
		Signs ................................................................................................................................................................ 37
		Entering and leaving the machine, Safety instructions ................................................................................................................ 38
		Access ladder lighting ............................................................................................................................................... 38
		Swinging ladder ...................................................................................................................................................... 39
		Folding ladder (optional) ............................................................................................................................................ 40
		Escape ladder (optional) ............................................................................................................................................. 41
		Switching the cab interior lighting on and off ....................................................................................................................... 42
		Switching the maintenance lights on and off .......................................................................................................................... 43
		Emergency shut-off function .......................................................................................................................................... 44
		Shutting off the supply voltage (battery main switch) ................................................................................................................ 45
		Driver’s seat  ....................................................................................................................................................... 46
		Reducing operators exposure to vibrations ............................................................................................................................ 48
		Trainer's / instructor's seat ........................................................................................................................................ 48
		Windscreen washer .................................................................................................................................................... 48
		Fire extinguisher..................................................................................................................................................... 49
		Automatic fire-extinguishing system (optional) ....................................................................................................................... 50
		Harness (optional) ................................................................................................................................................... 51
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 54
		Engine 1 (LH), control and monitoring ................................................................................................................................ 61
		Engine 2 (RH), control and monitoring ................................................................................................................................ 63
	PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 80
		Reducing the operator's exposure to noise ............................................................................................................................ 80
		Refuelling ........................................................................................................................................................... 80
		Back-up heating (option), filling in fuel ............................................................................................................................ 81
		Service station (tanklift) ........................................................................................................................................... 81
		Switching the electrical system on and off ........................................................................................................................... 87
		Engines, emergency shut-off .......................................................................................................................................... 87
		Preheating system for engine and hydraulic oil (optional) ............................................................................................................ 88
		Fuel preheating system (optional) .................................................................................................................................... 89
	STARTING AND STOPPING THE ENGINES ........................................................................................................................................ 90
		Starting the engines ................................................................................................................................................. 90
		Starting the left-hand engine......................................................................................................................................... 90
		Starting the right-hand engine........................................................................................................................................ 90
		Engines – adjusting the speed ........................................................................................................................................ 91
		Starting the engines at low temperatures ............................................................................................................................. 91
		Shutting off the engines ............................................................................................................................................. 92
		Shutting off the left-hand engine..................................................................................................................................... 92
		Shutting off the right-hand engine.................................................................................................................................... 92
	AIR CONDITIONER (OPTIONAL) ............................................................................................................................................... 93
		Back-up heating driver’s cab (optional) .............................................................................................................................. 93
		Back-up heating (optional) ........................................................................................................................................... 94
	TRAVELLING, SAFETY INSTRUCTIONS .......................................................................................................................................... 95
	TRAVELLING ............................................................................................................................................................... 96
		Superstructure basic position ........................................................................................................................................ 96
		Travelling forwards/backwards ........................................................................................................................................ 96
		Superstructure holding brake .........................................................................................................................................100
		Track parking brake ..................................................................................................................................................100
	TRANSPORTING THE MACHINE .................................................................................................................................................101
		Transport - Safety instructions ......................................................................................................................................101
	WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................102
	WORKING OPERATION ........................................................................................................................................................104
		Before starting work .................................................................................................................................................104
		Activating the electronic excavator control ..........................................................................................................................104
		Swinging the superstructure ..........................................................................................................................................105
		Braking the superstructure ...........................................................................................................................................105
		Working ..............................................................................................................................................................106
		After daily operation ................................................................................................................................................107
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................108
		Securing the machine .................................................................................................................................................109
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................110
	NOTES ....................................................................................................................................................................111
3 INSPECTION AND SERVICING....................................................................................................................................................113
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................115
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................121
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................123
		Intervals ............................................................................................................................................................123
		Change of engine oil .................................................................................................................................................123
		Air-intake system ....................................................................................................................................................123
		Oils / Greases .......................................................................................................................................................123
		Cleaning jobs ........................................................................................................................................................123
		Components ...........................................................................................................................................................123
		Plan V ...............................................................................................................................................................125
		Plan N ...............................................................................................................................................................127
		Plan T ...............................................................................................................................................................129
		Plan A – E ...........................................................................................................................................................131
	LUBRICATING CHART ........................................................................................................................................................138
		Lubricating chart – Grease (legend) ..................................................................................................................................139
		Filling quantities - Grease...........................................................................................................................................139
	INSPECTION PLAN - OIL ....................................................................................................................................................140
		Inspection plan – Oil (legend) .......................................................................................................................................141
		Filling quantities - oil .............................................................................................................................................142
		Filling quantities - other............................................................................................................................................142
	LUBRICANTS ...............................................................................................................................................................143
		Notes on the selection of oils and greases ...........................................................................................................................143
		Avoid mixing of different hydraulic fluids ...........................................................................................................................143
		I. Oils for combustion engines and compressors .......................................................................................................................144
		II. Oils for hydraulic system (selection) ............................................................................................................................145
		III.a Oils for pump distribution gearboxes ...........................................................................................................................146
		III.b Oils for swing gearboxes .......................................................................................................................................147
		III.c Oils for travel gearboxes ......................................................................................................................................148
		V. Greases for bearings and swing rings ..............................................................................................................................149
	SERVICING WORK ...........................................................................................................................................................150
		Hose line for oil and cooling liquid changes .........................................................................................................................150
	ENGINE ...................................................................................................................................................................151
		Engine - Safety instructions .........................................................................................................................................151
		Checking the engine oil level / Topping up  ..........................................................................................................................152
		Changing the engine oil ..............................................................................................................................................153
		Replacing the oil filter .............................................................................................................................................155
		Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................156
	COOLING SYSTEM ...........................................................................................................................................................157
		Radiators ............................................................................................................................................................158
		Cooling liquid, change ...............................................................................................................................................160
	AIR-INTAKE SYSTEM ........................................................................................................................................................161
		Dust trap, cleaning  .................................................................................................................................................161
		Main filter elements .................................................................................................................................................162
		Safety filter element ................................................................................................................................................164
		Air-intake lines .....................................................................................................................................................164
	FUEL SYSTEM ..............................................................................................................................................................165
		Fuel system - Safety instructions ....................................................................................................................................165
		Replacing the fuel filter ............................................................................................................................................165
		Venting the fuel system ..............................................................................................................................................166
		Cleaning the fuel tanks ..............................................................................................................................................166
		Water trap (option) ..................................................................................................................................................168
	ELECTRICAL SYSTEM  .......................................................................................................................................................170
		Electrical system - Safety instructions ..............................................................................................................................170
		Alternator - Instructions ............................................................................................................................................170
		Battery ..............................................................................................................................................................171
		Switchgear cabinet ...................................................................................................................................................173
		Floodlight projector, replacing the lamp .............................................................................................................................175
	HYDRAULIC SYSTEM .........................................................................................................................................................177
		Hydraulic system - Safety instructions ...............................................................................................................................177
		Depressurizing the hydraulic system ..................................................................................................................................177
		Checking the hydraulic oil level .....................................................................................................................................178
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................180
		Bypass valves (hydraulic oil reservoir) ..............................................................................................................................182
		Breather filter ......................................................................................................................................................183
		Filter (control circuit)..............................................................................................................................................184
		High-pressure filter for working hydraulics ..........................................................................................................................185
		High-pressure filters for the servo circuit ..........................................................................................................................186
		High-pressure filters for feeding circuits and swing pumps ...........................................................................................................187
		High-pressure filters for swing circuit ..............................................................................................................................188
		Bearing flushing for main pumps, replace filter ......................................................................................................................189
		Changing the hydraulic oil ...........................................................................................................................................190
		Venting the hydraulic system..........................................................................................................................................193
		Cleaning the hydraulic oil cooler.....................................................................................................................................194
		Electronic excavator controls.........................................................................................................................................195
		Pressure accumulator - Emergency lowering.............................................................................................................................196
	PUMP TRANSFER GEARBOX ....................................................................................................................................................197
		Checking the gearbox oil level / Topping up with oil .................................................................................................................197
		Pre-chambers, checking oil level, topping up with oil ................................................................................................................197
		Changing the gearbox oil .............................................................................................................................................198
		Pre-chambers, changing the gearbox oil ...............................................................................................................................199
		Gearbox venting ......................................................................................................................................................199
		Pre-chamber venting ..................................................................................................................................................200
		Pump transfer gearbox lube oil filters ...............................................................................................................................201
	SWING GEARBOX ............................................................................................................................................................202
		Swing Gearbox - Checking the oil level / Topping up with oil .........................................................................................................202
		Changing the gearbox oil .............................................................................................................................................203
		Swing Gearbox venting ................................................................................................................................................203
	TRAVEL GEARBOX (GEARBOX P/N 3683483)  ....................................................................................................................................204
		Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................204
		Travel gearbox - Changing oil ........................................................................................................................................205
		Travel gearbox - Breather filter .....................................................................................................................................206
	TRAVEL GEARBOX(GEARBOX P/N 3683496)  .....................................................................................................................................207
		Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................207
		Travel gearbox - Changing oil ........................................................................................................................................209
		Travel gearbox -Breather filter ......................................................................................................................................210
	CRAWLER TRACKS ...........................................................................................................................................................211
		Track rollers ........................................................................................................................................................212
		Track tensioner ......................................................................................................................................................213
		Pressure-accumulator inspection regulations ..........................................................................................................................214
		Checking the gas charging pressure in the pressure accumulator........................................................................................................214
	SWING RING ...............................................................................................................................................................215
		Swing ring - Instructions.............................................................................................................................................215
		Bearing races.........................................................................................................................................................215
	CENTRAL LUBRICATING ......................................................................................................................................................217
		Design ...............................................................................................................................................................217
		Function .............................................................................................................................................................218
		Filling up the grease container ......................................................................................................................................219
		Breather filter ......................................................................................................................................................219
		Checking the greasing pressure .......................................................................................................................................220
		Unblocking a grease line..............................................................................................................................................221
		Oilfilter (hydraulic circuit grease pump) ............................................................................................................................222
		Grease filter (Filling the grease container) .........................................................................................................................223
		Grease filter (Grease lines) .........................................................................................................................................224
	OTHER MAINTENANCE ........................................................................................................................................................225
		Engine ...............................................................................................................................................................225
		Heating and air conditioning .........................................................................................................................................225
		Hydraulic ladder, pressure accumulator ...............................................................................................................................226
		Pressure-accumulator inspection regulations ..........................................................................................................................227
		Extract from the German regulations...................................................................................................................................227
		Checking the gas charging pressure in the pressure accumulator........................................................................................................227
	ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................228
		Monitoring, warning and control elements .............................................................................................................................228
		Checking the on-board crane...........................................................................................................................................228
		Drive unit ...........................................................................................................................................................229
		On-board crane........................................................................................................................................................229
		On-Board crane, checking tightness of fastening bolts ................................................................................................................230
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................231
		Putting the excavator out of operation ...............................................................................................................................231
		Battery storage ......................................................................................................................................................231
		Recommissioning ......................................................................................................................................................231
	NOTES  ...................................................................................................................................................................233
4 REPAIR WORK.................................................................................................................................................................235
	REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................237
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................238
	REPAIR WORK, ENGINE ......................................................................................................................................................239
	ELECTRICAL SYSTEM ........................................................................................................................................................240
		Assisted starting (with jumper cables) – Safety instructions .........................................................................................................240
		Assisted starting (with jumper cables)................................................................................................................................240
		Starting the engine with jumper cables (external batteries ...........................................................................................................240
	HYDRAULIC SYSTEM .........................................................................................................................................................242
		Repair instructions ..................................................................................................................................................242
		Hydraulic hoses – Instructions  ......................................................................................................................................242
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................243
	WELDING OPERATIONS - SAFETY INSTRUCTIONS .................................................................................................................................244
	NOTES ....................................................................................................................................................................245
5 ANNEX.......................................................................................................................................................................247
	BOARD-CONTROL-SYSTEM .....................................................................................................................................................249
		BCS III, what’s that? ................................................................................................................................................249
		The keys on the front side ...........................................................................................................................................250
		Other elements on the front side .....................................................................................................................................250
		BCSIII, the start screen .............................................................................................................................................251
		Information given on the start screen, top section ...................................................................................................................252
		Information given on the start screen, central section ...............................................................................................................253
		Information given on the start screen, lower section .................................................................................................................254
		Information given on the “Service” screen ............................................................................................................................255
		Engine data screen ...................................................................................................................................................256
		Hydraulic data screen ................................................................................................................................................257
		Lubrication data screen ..............................................................................................................................................258
		Controls adjustment data screen ......................................................................................................................................259
		View documents screen ................................................................................................................................................260
		Signal table screen ..................................................................................................................................................261
		Signal table screen, location ........................................................................................................................................262
		Signal table screen, diagram .........................................................................................................................................263
		Signal table screen, diagram configuration ...........................................................................................................................264
		Code table screen ....................................................................................................................................................265
		BCS III, interfaces ..................................................................................................................................................266
		USB interface, data storage ..........................................................................................................................................266
		Saving data to a USB stick ...........................................................................................................................................267
		Saving data to a USB stick, continued ................................................................................................................................268
		Saving data to a USB stick, continued ................................................................................................................................269
		BCSIII, cleaning .....................................................................................................................................................270
		BCSIII, disposal .....................................................................................................................................................270
	TROUBLESHOOTING ..........................................................................................................................................................271
		Instructions on troubleshooting ......................................................................................................................................271
		Layout of the fault table ............................................................................................................................................271
		Possible causes ......................................................................................................................................................271
		Measures .............................................................................................................................................................271
		Section ..............................................................................................................................................................271
	FAULT TABLES .............................................................................................................................................................272
		Combustion engine - Fault table ......................................................................................................................................272
		Working hydraulics – Fault table .....................................................................................................................................273
		Track drive – Fault table ............................................................................................................................................274
		Swing mechnism – Fault table .........................................................................................................................................275
		Central lubricating system – Fault table .............................................................................................................................276
	HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................277
		Vibration data .......................................................................................................................................................277
	ABBREVIATIONS ............................................................................................................................................................278
		ABBREVIATIONS.........................................................................................................................................................279
	TECHNICAL DATA ...........................................................................................................................................................281
		Product Specification Sheet...........................................................................................................................................  0
			page 1............................................................................................................................................................283
			page 2............................................................................................................................................................284
			page 3............................................................................................................................................................285
			page 4............................................................................................................................................................286
			page 5............................................................................................................................................................287
			page 6............................................................................................................................................................288
			page 7............................................................................................................................................................289
			page 8............................................................................................................................................................290
	NOTES ....................................................................................................................................................................291
6 INDEX.......................................................................................................................................................................293

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