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Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651493 – PDF DOWNLOAD
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651493 – PDF DOWNLOAD
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Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651493 – PDF DOWNLOAD
Language : English
Pages : 270
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651493 – 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 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases.............................................................................................................. 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 Gas, dust, steam and smoke............................................................................................................................................. 21 Hydraulic equipment.................................................................................................................................................... 21 Noise.................................................................................................................................................................. 21 Oil, grease and other chemical sub stances............................................................................................................................. 21 Transporting and recommission ing...................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22 NOTES...................................................................................................................................................................... 23 OPERATION...................................................................................................................................................................... 25 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 27 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 29 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 30 Excavator layout....................................................................................................................................................... 31 Undercarriage.......................................................................................................................................................... 32 Superstructure......................................................................................................................................................... 32 Drive.................................................................................................................................................................. 32 Hydraulic system....................................................................................................................................................... 32 Pump Managing System (PMS)............................................................................................................................................. 32 Stored Program Control (SPC)........................................................................................................................................... 32 Electronic Hydraulic Servo-Control (CMS)............................................................................................................................... 32 Demand control / Zero-flow regulation.................................................................................................................................. 33 Automatic engine speed reduction....................................................................................................................................... 33 Board-Control-System (BCS)............................................................................................................................................. 33 Electrical system...................................................................................................................................................... 33 Sign................................................................................................................................................................... 35 Entering and leaving the machine Safety instructions................................................................................................................... 36 Ramp-type ladder (optional)............................................................................................................................................ 37 EMERGENCY STOP pushbuttons............................................................................................................................................. 39 Windscreen washer...................................................................................................................................................... 39 Driver's seat.......................................................................................................................................................... 40 Fire extinguisher...................................................................................................................................................... 41 Automatic fire-extinguishing system (optional)......................................................................................................................... 42 Harness (optional)..................................................................................................................................................... 43 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 46 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 77 Refuelling............................................................................................................................................................. 77 Service station (tanklift)............................................................................................................................................. 77 Switching the electrical system on and off............................................................................................................................. 83 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 84 AIR CONDITIONER (OPTION)................................................................................................................................................... 87 Back-up heating (option)............................................................................................................................................... 89 DRIVING.................................................................................................................................................................... 91 SAFETY INSTRUCTIONS.................................................................................................................................................... 91 Superstructure basic position.......................................................................................................................................... 92 Emergency machine drive................................................................................................................................................ 96 Locking the superstructure............................................................................................................................................. 98 Track parking brake.................................................................................................................................................... 98 TRANSPORTING THE MACHINE................................................................................................................................................... 99 Safety instructions.................................................................................................................................................... 99 WORKING OPERATION..........................................................................................................................................................100 Safety instructions....................................................................................................................................................100 Before starting work...................................................................................................................................................102 Slewing and braking the superstructure.................................................................................................................................102 Braking the superstructure.............................................................................................................................................102 Working................................................................................................................................................................103 After daily operation..................................................................................................................................................104 ASSEMBLING WORKING EQUIPMENT...............................................................................................................................................105 SAFETY INSTRUCTIONS....................................................................................................................................................105 Securing the machine...................................................................................................................................................107 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................108 NOTES......................................................................................................................................................................109 INSPECTION AND SERVICING.......................................................................................................................................................111 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................113 FIRE AND EXPLOSION HAZARD..................................................................................................................................................119 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................121 Intervals..............................................................................................................................................................121 Change of engine oil...................................................................................................................................................121 Air-intake system......................................................................................................................................................121 Oils / Greases.........................................................................................................................................................121 Cleaning jobs..........................................................................................................................................................121 Components.............................................................................................................................................................121 Plan V.................................................................................................................................................................123 Plan N.................................................................................................................................................................125 Plan T.................................................................................................................................................................127 Plan A – E.............................................................................................................................................................129 LUBRICATING CHART – GREASE.................................................................................................................................................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 I. Oils for combustion engines and compressors (selection).............................................................................................................143 II. Oils for hydraulic system (selection)..............................................................................................................................144 III. Oils for gearboxes (selection)....................................................................................................................................145 V. Greases for bearings and slewing rings..............................................................................................................................146 SERVICING WORK.............................................................................................................................................................147 Hose line for oil and cooling liquid changes...........................................................................................................................147 ENGINE.....................................................................................................................................................................148 Engine - Safety instructions...........................................................................................................................................148 Retensioning the alternator/fan belt...................................................................................................................................148 Checking and adjusting the valve clearance.............................................................................................................................148 Checking the engine oil level / Topping up.............................................................................................................................149 Checking the oil level in the engine oil reservoir / topping up (optional).............................................................................................150 Changing the engine oil................................................................................................................................................151 Draining the oil off the engine oil reservoir (optional)...............................................................................................................153 Eliminator filter and centrifuge.......................................................................................................................................155 COOLING SYSTEM.............................................................................................................................................................157 Radiators..............................................................................................................................................................158 Cooling liquid.........................................................................................................................................................160 Water filter...........................................................................................................................................................162 AIR-INTAKE SYSTEM..........................................................................................................................................................163 Main filter elements...................................................................................................................................................163 Safety filter element..................................................................................................................................................165 Air-intake lines.......................................................................................................................................................166 Dust collection........................................................................................................................................................166 FUEL SYSTEM................................................................................................................................................................167 Fuel system - Safety instructions......................................................................................................................................167 Replacing the fuel filter..............................................................................................................................................167 Venting the fuel system................................................................................................................................................168 Cleaning the fuel tanks................................................................................................................................................168 Water trap (option)....................................................................................................................................................170 ELECTRICAL SYSTEM..........................................................................................................................................................172 Electrical system - Safety instructions................................................................................................................................172 Alternator - Instructions..............................................................................................................................................172 Battery................................................................................................................................................................173 Switchgear cabinet.....................................................................................................................................................175 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 slewing pumps...........................................................................................................187 High-pressure filters for slewing circuit..............................................................................................................................188 Changing the hydraulic oil.............................................................................................................................................189 Venting the hydraulic system...........................................................................................................................................192 Cleaning the hydraulic oil cooler......................................................................................................................................193 Electronic excavator control...........................................................................................................................................194 Pressure accumulator - Emergency lowering..............................................................................................................................195 PUMP TRANSFER GEARBOX......................................................................................................................................................196 Checking the gearbox oil level / Topping up with oil...................................................................................................................196 Pre-chamber............................................................................................................................................................197 Changing the gearbox oil...............................................................................................................................................198 Pre-chamber............................................................................................................................................................199 Gearbox venting........................................................................................................................................................200 Pump transfer gearbox lube oil filters.................................................................................................................................201 SLEWING GEARBOX............................................................................................................................................................202 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................202 Changing the gearbox oil...............................................................................................................................................202 Gearbox venting........................................................................................................................................................203 TRAVEL GAERBOX.............................................................................................................................................................204 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................204 Travel gearbox - Changing oil..........................................................................................................................................205 Pre-chamber - Changing the oil.........................................................................................................................................205 Brake chamber - Changing oil...........................................................................................................................................206 Breather filter........................................................................................................................................................206 CRAWLER TRACKS.............................................................................................................................................................207 Track rollers..........................................................................................................................................................208 Track tensioner........................................................................................................................................................209 Pressure-accumulator inspection regulations............................................................................................................................210 Checking the gas charging pressure in the pressure accumulator.........................................................................................................210 SLEWING RING...............................................................................................................................................................211 Slewing ring - Instructions............................................................................................................................................211 Bearing races..........................................................................................................................................................211 CENTRAL LUBRICATING........................................................................................................................................................213 Design.................................................................................................................................................................213 Lube cycle / Pause period..............................................................................................................................................213 Function...............................................................................................................................................................214 Filling up the grease container........................................................................................................................................215 Breather filter........................................................................................................................................................215 Checking the greasing pressure.........................................................................................................................................216 Checking the greasing pressure.........................................................................................................................................217 Unblocking a grease line...............................................................................................................................................218 Unblocking a grease line...............................................................................................................................................218 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................219 Grease filter (Filling the grease container)...........................................................................................................................220 Grease filter (Grease lines)...........................................................................................................................................221 OTHER MAINTENANCE..........................................................................................................................................................222 Engine.................................................................................................................................................................222 Heating and air conditioning...........................................................................................................................................222 Equipment..............................................................................................................................................................223 RAMP-TYPE LADDER (OPTIONAL) (OPTION)......................................................................................................................................224 Guide pulleys and locking bolt.........................................................................................................................................224 Pressure-accumulator inspection regulations............................................................................................................................225 Extract from the German regulations....................................................................................................................................225 Checking the gas charging pressure in the pressure accumulator.........................................................................................................225 ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................226 Monitoring, warning and control elements...............................................................................................................................226 Checking the on-board crane............................................................................................................................................226 Drive unit.............................................................................................................................................................227 On-board crane.........................................................................................................................................................227 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................228 Putting the excavator out of operation.................................................................................................................................228 Battery storage........................................................................................................................................................228 Recommissioning........................................................................................................................................................229 NOTES......................................................................................................................................................................231 REPAIR WORK....................................................................................................................................................................233 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................235 FIRE AND EXPLOSION HAZARD..................................................................................................................................................237 ENGINE.....................................................................................................................................................................238 ELECTRICAL SYSTEM..........................................................................................................................................................239 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................239 Assisted starting (with jumper cables).................................................................................................................................239 Starting the engine with jumper cables (external batteries.............................................................................................................239 HYDRAULIC SYSTEM...........................................................................................................................................................242 Repair.................................................................................................................................................................242 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................243 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................244 NOTES......................................................................................................................................................................245 ANNEX..........................................................................................................................................................................247 TROUBLESHOOTING............................................................................................................................................................249 Instructions on troubleshooting........................................................................................................................................249 Layout of the fault table..............................................................................................................................................249 Possible causes........................................................................................................................................................249 Measures...............................................................................................................................................................249 Section................................................................................................................................................................249 FAULT TABLES...............................................................................................................................................................250 Combustion engine - Fault table........................................................................................................................................250 Working hydraulics – Fault table.......................................................................................................................................251 Track drive – Fault table..............................................................................................................................................252 Slewing mechnism – Fault table.........................................................................................................................................253 Central lubricating system – Fault table...............................................................................................................................254 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................255 ABBREVIATIONS..............................................................................................................................................................258 TECHNICAL DATA.............................................................................................................................................................260 NOTES......................................................................................................................................................................262 INDEX..........................................................................................................................................................................265
DESCRIPTION:
Cat Bucyrus RH200 Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651493 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 120E
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 / ortransport.
- 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.
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