PDF Operating Instructions Manual Cat Bucyrus RH200 Electric Hydraulic Excavator - 1 MB
Master the operation of the Cat Bucyrus RH200 Electric Hydraulic Excavator with this official operating instructions manual.
This document is the primary resource for machine operators, covering all controls, systems, and safety procedures.
Proper understanding and application of the information within this guide are crucial for maximizing productivity and ensuring a safe work environment in demanding mining operations.
It provides the foundation for efficient and correct machine handling.
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OPERATING INSTRUCTIONS RH200 Electric
Hydraulic Excavator
RH200 Electric No.
Bucyrus HEX GmbH
BA RH200(3 725 049.00)-EN
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OPERATING INSTRUCTIONS RH200 Electric
Introduction
1 INTRODUCTION
Operating instructions Target group
Part 1 INTRODUCTION Operating personnel
+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.
Part 3 INSPECTION AND Inspection and servicing personnel
The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.
Part 4 REPAIR WORK Repair personnel
The repair personnel must have know-how
and experience relevant to the repair of this
or comparable machines.
Part 5 ANNEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
Part 6 INDEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
BA RH200(3 725 049.00)-EN 1-1
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OPERATING INSTRUCTIONS RH200 Electric
Introduction
machine on enclosed premises, make sure that Noise
there is sufficient ventilation.
During operation, all sound baffles of the machine
Observe the regulations in force at the respective must be closed.
site.
Always wear the prescribed ear protectors.
Carry out welding, flame-cutting and grinding work
on the machine only if this has been expressly au-
thorized, as there may be a risk of explosion and Oil, grease and other chemical sub-
fire. stances
Before carrying out welding, flame-cutting and When handling oil, grease or other chemical sub-
grinding operations, clean the machine and its sur- stances, observe the product-related safety regula-
roundings from dust and other inflammable sub- tions (see safety specifications).
stances and make sure that the premises are ade-
quately ventilated (risk of explosion). Be careful when handling hot consumables (risk of
burning or scalding).
Hydraulic / pneumatc equipment
Transporting and recommissioning
Check all lines, hoses and screwed connections
regularly for leaks and obvious damage. Repair The machine must be loaded and transported only
damage immediately. Splashed oil may cause injury in accordance with the operating instructions.
and fire. Use only appropriate means of transport and lifting
Depressurize all system sections and pressure gear of adequate capacity.
pipes (hydraulic / pneumatic system) to be removed The recommisioning procedure must be strictly in
in accordance with the specific instructions for the accordance with the operating instructions.
unit concerned before carrying out any repair work.
Hydraulic- and pneumatic lines must be laid and
fitted properly. Ensure that no connections are in-
terchanged. The fittings, lengths and quality of the
hoses must comply with the technical requirements.
BA RH200(3 725 049.00)-EN 1-11
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
FIRE AND EXPLOSION HAZARD
Safety instructions
Avoid smoking and open fire on, next
to and below the machine.
Combustible and easily flammable substances or
liquids increase the fire and explosion hazard.
Do not store such substances on the excavator.
Clean the excavator thoroughly, if possible, with a
steam jet (rubber parts and electric components
with compressed air - refer to information label),
when, for example, oil, grease, fuel or cleaner was
spilled.
Such substances may spontaneously ignite if they
get into the vicinity of hot units.
Even battery gases can ignite in open flames or
fire.
Avoid parking the excavator in places where
– combustible substances such as coal dust or tar
are present,
– open or smouldering fire may occur.
Remove the excavator from such an area where
combustible or easily flammable liquids have
spilled from the excavator onto the ground.
Flying sparks may cause fire on the ground that can
spread to the excavator.
BA RH200(3 725 049.00)-EN 2-5
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
Fig. 2-9:
BA RH200(3 725 049.00)-EN 2-15
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
Machine number
The identification plate (Fig. 2-20:) with the machine
number is attached to the front side of the A-frame
(arrow, Fig. 2-19:).
Fig. 2-20:
Fig. 2-19: Motor number
The serial number plates (Fig. 2-21:) for the electric
motor are located on the electric motor.
Fig. 2-21:
Component numbers
Other larger units also have identification plates
indicating, among other things, their serial number.
On steel components, the Bucyrus HEX part num-
ber or the serial number may be stamped into the
metal at a clearly visible place.
BA RH200(3 725 049.00)-EN 2-25
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
Fig. 2-47:
BA RH200(3 725 049.00)-EN 2-35
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
(Fig. 2-63)
No. Element Function Symbol
30 Lamp Illuminates the front side of the control col-
umn.
31 Pushswitch Emergency OFF The entire electrical system is interrupted in
all poles by the on-board circuit breaker.
Even after actuation of the
EMERGENCY STOP switch, me-
dium voltage (6.6 KV) is present
(primarily) from the transformer
station via drag cable and slip
ring assembly to the circuit brea-
ker.
32 Key-switch Switches the low voltage system on and off.
33 Buzzer Gives an acoustic warning signal if a fault
is reported:
Electric motor
– winding temperature too high
– bearing temperature too high
bord transformer temperature too high
Hydraulic oil level too low
Distributor gearbox temperature too high
Swing pump temperature (1 and / or 2;
too high
Swing gearbox temperature (1 and / or
2) too high
Fault in lubricating system
Lower the equipment to the
ground and switch off electric
motor immediately if the buzzer
(33) sounds and the BCS indi-
cates a fault. The buzzer (33) con-
tinues to sound until the fault has
been retified.
BA RH200(3 725 049.00)-EN 2-45
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
(Fig. 2-68:)
No. Element Function Symbol
91 Switch Emergency Operati- Actuate and hold if boom and stick must be
on Boom/Stick lowered in an emergency.
92 Button Dumper count RESET
93 Switch Activates boom cylinder limit switch (op-
tional)
94 Button When switched it is possible to swing the
uppercarriage and to drive the excavator
even when the hydraulic ladder or the
service station is in the lower position.
Risk of damaging the ladder or
the service station!
Be careful and swing the upper-
carriage and drive the excavator
very slowly and only a short
way.
95 Switch Lighting Switches on the lighting for servicing work.
96 Switch Lighting Switches the cab lighting on and off.
97 Switch Windscreen wiper Activates permanent wiping.
rear window (op-
tional)
98 Switch Beacon (optional) Switches the beacon on and off.
BA RH200(3 725 049.00)-EN 2-55
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
Assemblies resp. Measuring device Remarks
reservoirs
Pump transfer Dipstick (1, Fig. 2-74:) Stop filling when the oil reaches the "max" mark on the
gearbox dipstick (see Part 3, chapter "Pump transfer gearbox -
Checking the gearbox oil level / Filling in oil").
Hydraulic oil tank BCS monitor (Fig. 2-77:), Checking the oil level:
Inspection glass (1, Fig. Extend the piston rods of stick and bucket cylinders
2-75:), signs (2, Fig. 2-75: halfway (see sign).
and Fig. 2-76:)
Stand working equipment on the ground.
Check oil level at an oil temperature of ca. 50 °C
(122°F), with the electric motor shut off.
Fill in oil when the oil level in the inspection glass has-
dropped below the "min" mark. Stop filling if the oil rea-
ches the "max" mark on the inspection glass or the
acoustic warning signal "Travel alarm" sounds (see
chapter "Hydraulic system - Checking the hydraulic oil
level / Refilling hydraulic oil").
Fig. 2-74:
Fig. 2-76:
Fig. 2-75:
BA RH200(3 725 049.00)-EN 2-65
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
Warm-up procedure for electric
excavators
Operator procedure during start up in
extreme cold weather
After starting the electric motor check for any
faults on the BCS display.
Make sure the “SERVO” switch (74, Fig. 2-93:)
is in the OFF position.
Use the “Boom up” (116, Fig. 2-94: back-
wards) or “Stick out” function (115, Fig. 2-94:
forwards) to engage the hydraulic pumps.
This will engage the pumps without moving the
attachment.
Do so until:
- the hydraulic oil temperature reaches 10°C
on the gauge and
- the PTO temperature has reached 5°C.
You can now turn ON the “SERVO” switch (74, Fig. 2-93:
Fig. 2-93:) and move the attachment in a slow
function one at a time.
Do not extend the cylinders fully.
Swing circuit warm-up before you start
digging
Make sure the attachment or bucket is on the
ground.
Turn “Swing brake” switch OFF (82, Fig.
2-93:).
Turn “SERVO” switch ON (74).
Use “Swing left” or “Swing right” function (115,
Fig. 2-94:) slowly. This will heat the swing hy-
draulic circuit quickly. Fig. 2-94:
Once the swing temperature is warm you can
lift the attachment and swing the excavator in a
slow 360° left then right.
Fig. 2-95:
BA RH200(3 725 049.00)-EN 2-75
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OPERATING INSTRUCTIONS RH200 Electric
OPeration
Avoid extreme positions of the attach-
ment
Parts of the attachment may damage
the machine if they are moved into
extreme positions (see illustrations
Fig. 2-112: - Fig. 2-116:).
Work carefully, avoiding extreme posi-
tions of this kind.
Fig. 2-114:
Fig. 2-112:
Fig. 2-115:
Fig. 2-113:
Fig. 2-116:
BA RH200(3 725 049.00)-EN 2-85
--- Page 14 ---
OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
3 INSPECTION AND SERVICING
Operating instructions Target group
Part 1 INTRODUCTION Operating personnel
+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.
Part 3 INSPECTION AND Inspection and servicing personnel
The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.
Part 4 REPAIR WORK Repair personnel
The repair personnel must have know-how
and experience relevant to the repair of this
or comparable machines.
Part 5 ANNEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
Part 6 INDEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
BA RH200(3 725 049.00)-EN 3-1
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OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
FIRE AND EXPLOSION HAZARD
Safety Instructions
Avoid smoking and open fire on, next to and below
the machine.
Combustible and easily flammable substances or
liquids increase the fire and explosion hazard.
Do not store such substances on the excavator.
Clean the excavator thoroughly, if possible, with a
steam jet (rubber parts and electric components
with compressed air - refer to information label),
when, for example, oil, grease, fuel or cleaner was
spilled.
Such substances may spontaneously ignite if they
get into the vicinity of hot units.
Even battery gases can ignite in open flames or
fire.
Avoid parking the excavator in places where
combustible substances such as coal dust or
tar are present.
open or smouldering fire may occur.
Remove the excavator from such an area where
combustible or easily flammable liquids have spil-
led from the excavator onto the ground.
Flying sparks may cause fire on the ground that
can spread to the excavator.
BA RH200(3 725 049.00)-EN 3-11
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OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
Plan A – E
Plan A - after every 250 OH Plan B - after every 500 OH
(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH
(at 10000, 20000, 30000, ... OH)
Page 1 of 6
Location Servicing work Menge / Plan Plan Plan Plan Plan
No. A B C D E
Servicing in acc.
with W or T
Monitoring, warning and
control elements
- Joysticks
- Control spool, Grease lightly 2x45
plate, cardan joint
- Pedals
- Control spool Grease lightly 3x25
(machine with loading
shovel)
Electric motor Grease bearings 2
Check for vibration
Visual inspect interior of ma-
chine for degree of dirt depos-
its
Rotor (inside and outside of Visual inspect all accessible
machine) places for rust
Terminals Check tightness
Check for degree of dirt de-
posits
Coupling Check for alignment and re-
cord measurements
Screw connections Check condition and tightness
See Electric motor manufac-
turer´s servicing instructions
for further details.
5
apply a thin layer of low temperature grease
BA RH200(3 725 049.00)-EN 3-21
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OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
Inspection plan – Oil (legend)
No. Location Number Lubricant Check oil level Change oil
properties 14 every ... OH every ... OH
1 Hydraulic system 1 10 10000 15
II
2 Pump transfer gearbox 1 60 1000
2 -Pre-chambers, expansion res- 10 1000
ervoir
III.a
3 Swing gearbox 4 10 1000
III.b
4 Travel gearbox 2 500 5000
- Pre-chamber / spur gear sec- 2x1 500 5000
tion (PN 2763214 only)
III.c
- Brake-chambers 2x2 500 5000
5 On-board crane (optional)
- Crane drive engine 1 10 250 16
I
- Hydraulic oil reservoir 1 10 1000 17
II
14
see "LUBRICANTS" section
15
Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every
3 years.
16
Change oil at least once a year.
17
Change hydraulic oil at least once a year.
BA RH200(3 725 049.00)-EN 3-31
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OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
ELECTRIC MOTOR
Electric motor - Safety instruc-
tions
Read and observe: "Inspection and
Servicing – Safety Instructions" and
the electric motor operating instruc-
tions.
Secure the machine as described in the "Securing
the machine" section.
Wear protective gloves and firm working clothing.
Switch off electric motor, to do so actuate
switch (52, Fig. 3-17:).
Set servicing switch (4, Fig. 3-18:) to locked
position and secure in this position with a pad-
lock.
Fig. 3-17:
Cleaning the electric motor
Clean the electric motor, the cooling fins, bearing
shields and ventilators from dust with compressed
air, brushes and clothes only.
Remove the fan guard before cleaning the ventila-
tor fan. Install it after cleaning.
Don't damage the protective coating while cleaning
the electric-motor.
For more information see the manufacturers man-
ual for the electric motor.
It is not permissible to clean the elec-
tric motor or any live excavator com-
ponents with a steam cleaner and
steam jet.
After finishing work on the electric motor re-
move the padlock from servicing switch (4, Fig.
3-18:) and unlock.
Fig. 3-18:
BA RH200(3 725 049.00)-EN 3-41
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OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
Replacing a defective Xenon-lamp
Read and observe the:
„Floodlight projector, replacing the
lamp, Safety instructions“.
Switch off the projector, shut off the electric
motor and cut out the battery main switch.
Wait until the housing of the floodlight projector
has cooled down.
Withdraw the power supply connector from the
projector.
Remove four screws (1, Fig. 3-31) and with-
Fig. 3-31 draw the reflector (2) from the projector hous-
ing.
Withdraw connector (Fig. 3-32) from Xenon
lamp socket.
Unscrew Xenon lamp holding clamp (Fig.
3-33).
Remove the defective Xenon lamp and replace
by a new one. Do not touch the glass bulb of
the lamp.
Reinstall the new lamp. Screw lamp holding
clamp back in place.
Plug the power supply connector onto the
lamp.
Re-assemble the housing.
Fig. 3-32
Fig. 3-33
BA RH200(3 725 049.00)-EN 3-51
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OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
High-pressure filters for swing Checking/cleaning the filter element
Detach flange (4, Fig. 3-55:).
circuit
The excavator has three high-pressure filters (Fig. Remove filter housings and pour out used oil.
3-54:) for the feeding circuits of the swing pumps.
Withdraw filter element (6) from filter housing
The filters are located in front of the hydraulic oil (5).
reservoir.
Read and observe: "Inspection and Clean filter housings and sealing faces at filter
servicing - Safety instructions". head with white spirit or paraffin oil.
Insert new filter element into filter housing (5)
and refit to filter head with a new, lightly oiled
sealing ring (8).
Check the high-pressure filter for leaks after
putting it into operation.
Fig. 3-54:
Switch off the electric motor.
Risk of scalding from hot hydraulic oil.
The filter housings may also be hot.
Avoid skin contact.
Skin contact with hydraulic oil may cause skin in-
jury.
Wear protective gloves and firm protective cloth-
ing.
Collect escaping hydraulic oil and discard without Fig. 3-55:
polluting the environment.
Replacing the filter elements
Detach the filter elements as described under
"Checking the filter elements".
Install new filter element (6, Fig. 3-55:) and re-
assemble with a new, lightly oiled sealing ring
(7).
Check the high-pressure filter for leaks after
putting it into operation.
BA RH200(3 725 049.00)-EN 3-61
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OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
Pump gearbox, pre-chambers Pump gearbox, venting
Checking oil level, topping up with oil The gearbox is vented through the breather valve
(arrow, Fig. 3-72).
The oil level in the pre-chambers is visually at the
inspection glas (3, Fig. 3-71) in expansion reser- Clean breather valve in accordance with servicing
voir (1). plan.
The oil level should reach up at least to the middle Unscrew breather filter, clean with white spirit
of the inspection glas (3). Top up with gearbox oil, or paraffin oil and blow dry with compressed
if required. air.
Screw breather filter back in place.
Fig. 3-71 Fig. 3-72
BA RH200(3 725 049.00)-EN 3-71
--- Page 23 ---
OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
Brake chambers - Changing oil Breather filters
Draining off oil Unscrew breather filters (1 and 5, Fig. 3-91:)
and clean in white spirit or parafin.
Place a collecting recipient for used oil under
the brake-chambers.
Choose the required capacity in accordance
with the "Refilling quantities - Oil" table.
Unscrew drain plugs (7, Fig. 3-91:) and drain
off the oil completely.
Slackening breather filter (5) allows the oil to
run out more readily.
Clean screw plugs (7).
Screw screw plugs (7) back in place.
Filling in oil
Details for selecting the correct gearoil refer to
Fig. 3-92:
chapter “LUBRICANTS”.
Unscrew screw plugs (6).
Fill in oil through opening of breather filter (5)
until it flows out of opening in plugs (6).
Screw plugs (6) and breather filters (5) back in
place.
Fig. 3-91:
BA RH200(3 725 049.00)-EN 3-81
--- Page 24 ---
OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
Checking the greasing pressure The necessary greasing pressure of 320 bar /
4641psi for the superstructure is generated by
Check every week, whether the oil pressure indi- means of a pressure translator.
cated by pressure gauge (4, Fig. 3-111:) is 60 bars
/ 870psi (the pressure is dependind on tempera- The greasing pressure is indicated by pressure
ture and viscosity of the oil and may vary). gauge (9).
In the event of deviating pressure values, switch
off the electric motor and check the central greas-
ing system.
Lower oil pressure means that not all of the greas-
ing points are supplied with grease.
Higher oil pressure may cause
bursting of a greasing line.
Always refill the grease container in time to avoid
air from penetrating into the greasing system. Air in
the greasing may cause malfunctions.
Fig. 3-111:
This oil pressure is reduced so that the pressure
indicated by pressure gauge (2) is 47 – 50 bars
(681-725psi).
BA RH200(3 725 049.00)-EN 3-91
--- Page 25 ---
OPERATING INSTRUCTIONS RH200 Electric
Inspection and servicing
Drive unit Air-intake system
The drive unit comprises: Never start up the engine when the air filter is re-
moved.
crane engine
Hydraulic system
hydraulic system
See crane operating instructions.
Crane engine Prior to each deployment, check the hydraulic
See operating instructions for the crane engine. oil level at the inspection glass (12, Fig.
Fill up fuel tank through filler (5, Fig. 3-129:) 3-129:); top up if necessary.
after each deployment.