PDF Operating Manual CAT Bucyrus RH 170 Hydraulic Excavator - 1 MB
Gain a thorough understanding of the CAT Bucyrus RH 170 Hydraulic Excavator with this complete operating instruction manual.
This guide is designed to help operators learn the machine's controls, systems, and safety features.
Following the factory-approved procedures ensures maximum productivity and a safe working environment.
It is the definitive resource for anyone operating this massive piece of mining equipment.
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OPERATING INSTRUCTIONS RH 170
Hydraulic Excavator
RH 170 No.
Bucyrus HEX GmbH
BA RH170(3 725 031.00)-EN
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OPERATING INSTRUCTIONS RH170
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 RH170(3 725 031.00)-EN 1-1
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OPERATING INSTRUCTIONS RH170
Introduction
Warning of special dangers Observe the regulations in force at the respective
site.
Electric energy Carry out welding, flame-cutting and grinding work
Use only original fuses with the specified current on the machine only if this has been expressly
rating. Switch off the machine immediately if trou- authorized, as there may be a risk of explosion and
ble occurs in the electrical system. fire.
When working with the machine, maintain a safe Before carrying out welding, flame-cutting and
distance from overhead electric lines. If work is to grinding operations, clean the machine and its
be carried out close to overhead lines, the working surroundings from dust and other inflammable
equipment must be kept well away from them. substances and make sure that the premises are
Caution, danger! Check out the prescribed safety adequately ventilated (risk of explosion).
distances.
CALIFORNIA Proposition 65 Warning
If your machine comes into contact with a live wire Diesel fuel and Diesel engine exhaust and some of
ο do not leave the machine its constituents are known to the State of California
to cause cancer, birth defects, and other reproduc-
ο drive the machine out of the hazard zone; tive harm.
warn others against approaching and touching
the machine
ο have the live wire de-energized Hydraulic equipment
Check all lines, hoses and screwed connections
ο do not leave the machine until the damaged or regularly for leaks and obvious damage. Repair
contacted line has been safely de-energized. damage immediately. Splashed oil may cause
injury and fire.
The electrical equipment of machines is to be in-
spected and checked at regular intervals. Defects Depressurize all system sections and pressure
such as loose connections or scorched cables pipes (hydraulic system) to be removed in accor-
must be rectified immediately. dance with the specific instructions for the unit
concerned before carrying out any repair work.
High-voltage system Hydraulic lines must be laid and fitted properly.
Floodlamps equipped with gaz discharge lamps Ensure that no connections are interchanged. The
require a high-voltage supply (ca. 25 kV). fittings, lengths and quality of the hoses must com-
ply with the technical requirements.
The high voltage is generated by a ballast unit.
Switch off the electrical system of the excavator
before touching the lamp or the ballast unit.
Battery
Warning! Battery Posts, terminals and related ac-
cessories contain lead and lead compounds,
chemicals known to cause cancer and reproduc-
tive harm. Wash hands after handling
Gas, dust, steam and smoke
Always start and operate the engine in a well-
vented area;
If in an enclosed area, vent the exhaust to the out-
side;
Do not modify or tamper with the exhaust system
Diesel engine exhaust and some of its constituents
are known to cause cancer, birth defects, and
other reproductive harm
Operate fuel-operated heating systems only on
adequately ventilated premises. Before starting the
machine on enclosed premises, make sure that
there is sufficient ventilation.
BA RH170(3 725 031.00)-EN 1-11
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OPERATING INSTRUCTIONS RH170
Operation
OPERATION, FIRE AND EXPLO-
SION HAZARD Remove the excavator from such an area where
combustible or easily flammable liquids have
Safety instructions spilled from the excavator onto the ground.
Prior to commencing work, obtain Flying sparks (caused by welding, flame cutting,
informationon the national and corpo- grinding, electrical short-circuit) may cause fire on
rate rules for the prevention of acci- the ground that can spread to the excavator.
dents and avoiding fires. Clean the excavator before starting work.
Pay particular attention to hazards Place suitable fire guardings (fire barriers) if open
caused by combustible and easily fire or flying sparks cannot be avoided during re-
flammable substances. pair work.
Obtain information on the safe han- If necessary, also cover the ground with fire-
dling of the fire extinguishers to be protective blankets.
used. Apply special protection to cables, cable ducts as
well as to hose and pipe lines.
Avoid smoking and open fire on, next to and below The engine compartment can be equipped with
the excavator. pressure vessels containing cold-starting fluid
Combustible and easily or highly inflammable sub- (ether). Ether is toxic and highly flammable; the
stances or liquids increase the risk of fire and ex- vessels are under pressure. These pressure ves-
plosion sels can explode if exposed to high temperatures
Do not store or transport flammable substances on (above 49Β°C / 120Β°F) or in the event of damage.
the excavator during the work. This is also valid for Protect the pressure vessels against damage be-
pressure vessels containing flammable substances fore beginning to work in or close to the engine
as, for instance, spray oil or cold-starting fluid compartment.
(ether). They are heat-sensitive and can explode Ensure sufficient ventilation.
even if exposed only to intensive sunlight. Do not keep any fire extinguishers that are not
Clean the excavator carefully, if oil, grease, fuel, suitable or have not been tested.
detergents or cold-starting fluid have been spilt Do not extinguish flammable liquids with water.
over the machine. If possible, use a steam-jet Use:
cleaner for cleaning.
ο§ dry-powder, carbon-dioxide or foam extin-
These substance can also ignite themselves if they guishing compounds.
come close to hot units or objects as, for instance,
a turbocharger. When getting into contact with burning substances,
the fire-fighting water would abruptly evaporate
Clean rubber or electrical with compressed air
and distribute the substance such as oil over a
only.
wide area. Water causes short-circuits in the elec-
Ensure sufficient ventilation. trical system thus possibly entailing new hazards.
Even battery gases can ignite in open flames or Call the fire brigade.
fire.
Have all your welding, flame cutting and grinding
Avoid parking the excavator in places where work approved before starting work.
ο§ combustible substances such as coal dust or
tar are present.
ο§ open or smouldering fire may occur.
BA RH170(3 725 031.00)-EN 2-5
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OPERATING INSTRUCTIONS RH170
Operation
Cab interior lamp
The interior lamp is switched on and off with switch
(Fig. 2-17:).
Switch position 0 - lamp off,
1 - lamp on.
The interior lamp is also switched on and off with
switches (arrow, Fig. 2-18:) and / or (96, Fig.
2-19:).
The interior lamp can be used even if the electrical
system is switched off.
Therefore, switch off the interior lamp when leaving
the machine. The batteries may be discharged if
the interior lamp is left on for prolonged periods.
Fig. 2-17:
Fig. 2-18:
Fig. 2-19:
BA RH170(3 725 031.00)-EN 2-15
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OPERATING INSTRUCTIONS RH170
Operation
ο Hang up loop (4, Fig. Fig. 2-42:) into snap If you have the harness put on in such a way in
hook (16). case of danger you can escape from the excavator
(Fig. 2-44:).
Fig. 2-42:
Fig. 2-44:
ο Release hooking safety device (17, Fig. 2-43:).
Fig. 2-43:
BA RH170(3 725 031.00)-EN 2-25
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OPERATING INSTRUCTIONS RH170
Operation
Fig. 2-49:
No. Element Function Symbol
51 Switch Starting Starts the engine:
(left engine 1) Hold switch approx. 5 β 7 sec.
This is necessary to start and pressurize the
engines prelube system.
After then the engine starts automatically.
52 Switch Stopping Shuts off the engine.
(left engine 1)
53 Switch Idling Shuts off the engine with 5 minutes after run.
(left engine 1)
54 Switch Not connected.
55 Momentary switch Diagnostic ON / OFF With the engine at standstill push momentary
switch to the left and hold:
Stored faults in the left engines electronic
unit can be displayed. Faults are displayed
by warning lamp no. 43 as flashing se-
quences (see: "Engine electronic unit, dis-
playing stored fault codes").
56 Speed adjustment Potentiometer Changes engine speed:
(left engine 1)
ο§ turn CCW to limit stop -
idling speed
ο§ turn CW to limit stop -
full-load speed
57 Momentary switch Diagnostic incre- Not connected.
ment / decrement
BA RH170(3 725 031.00)-EN 2-35
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OPERATING INSTRUCTIONS RH170
Operation
Fig. 2-54:
No. Element Function Symbol
101 Button Counting dumpers Reset with switch (92).
102 Button Stick floating posi- If actuated:
tion Stick cylinders are pressurized when re-
(only for loading tracted.
shovel equipment)
Actuate button (102) only when
control lever (115) is in β0β posi-
tion.
103 Button Boom floating posi- If actuated:
tion Boom cylinders are pressurized when re-
tracted.
Actuate button (103) only when
control lever (116) is in β0β posi-
tion.
104 Button Warning signal Activates the horn.
105 Button Electronic excavator Switches the electronic excavator control on
control and off.
111 Pedal Bottom-dump Opens / closes the bottom-dump bucket.
bucket
(only for loading
shovel equipment)
112 Pedal Travelling, left track Forwards / reverse
113 Pedal Travelling, right Forwards / reverse
track
115 Control lever Lifts and lowers the bucket / backhoe bucket
stick;
Swings and brakes the superstructure.
116 Control lever Raises and lowers the boom;
Tipping and rearward tilting of bucket resp.
backhoe bucket.
117 Button Bottom-dump To the left β opens the bottom-dump bucket.
bucket (only for To the right β closes the bottom-dump
loading shovel bucket.
equipment
118 Button By-pass for the To the left β automatically stopped stick-
automatically and/or backhoe cylinders can be driven
switch off for stick- slowly to the limit stopps.
and /or backhoe To the right β Not connected.
cylinders (Option)
BA RH170(3 725 031.00)-EN 2-45
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OPERATING INSTRUCTIONS RH170
Operation
(Fig. 2-59:)
(Options. Depending on the options ordered with the machine, the described elements can be found on dif-
ferent positions on the control column).
Pos. Benennung Funktion Symbol
211 Warning lamp Oil interval prolong- Lamp is lit up, when one oil pump is
ing (left engine 1) running
flashes or pulsates, when both oil pump
are running
212 Warning lamp Oil burning left en- Lamp lits up green, when the oil burning
gine 1) system is ready to operate.
Additional a fault code is indicated.
213 Warning lamp Oil burning left en- Lamp lits up red, when a fault occurs in the
gine 1) oil burning system.
Additional a fault code is indicated.
214 Warning lamp Oil interval prolong- lamp is lit up, when one oil pump is
ing (right engine 2) running
flashes or pulsates, when both oil pump
are running
215 Warning lamp Oil burning right Lamp lits up green, when the oil burning
engine 2) system is ready to operate.
Additional a fault code is indicated.
216 Warning lamp Oil burning right Lamp lits up red, when a fault occurs in the
engine 2) oil burning system.
Additional a fault code is indicated.
BA RH170(3 725 031.00)-EN 2-55
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OPERATING INSTRUCTIONS RH170
Operation
Shutting off the engines Emergency - stop
During interruptions of the work and after the work, In case of emergency, e.g. if buzzer (33, Fig.
stand working equipment on the ground. 2-81:) sounds, the engine can be shut off from full
load.
Do not shut off the engines before the
working equipment rests on the To do so:
ground. ο Depress stop-switch (31) (the whole electrical
system is switched off).
The engines are shut off.
ο Turn speed control knob (56 and 66, Fig.
2-80:) counter-clockwise to the limit stop (idling ο Turn key in key-switch (32) counter-clockwise
speed). and withdraw.
Fig. 2-81:
Fig. 2-80:
Do not shut off the engine out of full
load.
The engine should be run at no more
than one-half of the rated rpm for an-
other 5 minutes to allow the lubricat-
ing oil and the cooling liquid to dissi-
pate the combustion heat from the
combustion chamber and from bear-
ings and shafts.
ο Depress key (52) for the lefthand engine.
ο Depress key (62) for the righthand engine.
ο Turn key in key-switch (32) counter-clockwise
and withdraw (electrical system without cur-
rent).
BA RH170(3 725 031.00)-EN 2-65
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OPERATING INSTRUCTIONS RH170
Operation
Positioning of the machines Emergency travel
The auxiliary machine is driven close to the ο Start up the engine of the auxiliary machine.
RH170B from behind (Fig. 2-100:). The brakes of the RH170B are released by
travel pressure.
Loosen the high-pressure lines (1, 2, 3 and 4, Fig.
2-101) and close the open ends of the hoses. ο Initiate the travelling movements carefully with
ο Connect the hoses from the auxiliary machine the control levers. Adjust the direction and
to the ports of the "travel hydraulics" of the ex- travelling speed of both tracks accordingly.
cavator.
ο Shift the control lever to the final position.
ο High-pressure hoses (1 and 2) - circuit 1 on Make sure the auxiliary machine is able to "fol-
auxiliary machine low"
ο High-pressure hoses (3 and 4) - circuit 2 on The RH170B can be steered as usual by releasing
auxiliary machine the one or the other control lever briefly.
Do not allow pressure in control line Drive the excavator out of the hazard
to rise above 30 bars / 435psi as this zone only.
will shift the track gears into their
βfastβ ranges.
Fig. 2-101
:
BA RH170(3 725 031.00)-EN 2-75
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OPERATING INSTRUCTIONS RH170
Operation
Secure the machine as described below:
Securing the machine
ο§ before carrying out any fitting and modification
Risk of injury work on the working equipment,
The machine must not be started by unauthorized ο§ before carrying out any servicing and repair
persons. work on the machine.
Therefore, secure the machine. ο Park the machine on level and stable ground.
Observe the accident prevention regulations.
ο Stand the working equipment on the ground.
Depressurize pipeline systems, on which work is to
be carried out, by appropriate measures. ο Shut off the engines.
Protective shrouds of moving machine parts may
only be opened or removed when the drive unit is ο Depressurize the hydraulic system.
stationary and protected against inadvertent start-
ing. ο Withdraw the key from the key-switch.
Before carrying out fitting works, the machine and
the equipment must be protected against inadver-
tent starting by placing chocks under the tracks
and by standing the working equipment on the
ground.
Hydraulic and lubricating systems
Close all open bores, pipe and hose connections
with pressure-resistant plugs.
Refill collected hydraulic oil back into the hydraulic
system only through the return-flow filters. Dispose
of non re-usable oils without polluting the environ-
ment.
All components of Bucyrus HEX machines have
been carefully purpose-coordinated. Trouble-free
operation and a long service life can only be
achieved with original Bucyrus HEX spare parts.
Respect the sequence of working operations when
fitting or replacing the attachments. The sequence
has been determined and tested by qualified ex-
perts.
BA RH170(3 725 031.00)-EN 2-85
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OPERATING INSTRUCTIONS RH170
Inspection and servicing
Handling batteries Handling of cold-starting fluid (ether)
Battery Posts, terminals and related accessories The engine compartment can be equipped with
contain lead and lead compounds, chemicals pressure vessels containing cold-starting fluid
known to cause cancer and reproductive harm. (ether).
Wash hands after handling. Ether is toxic and highly flammable; the vessels
Batteries give off explosive gases. are under pressure. These pressure vessels can
explode if exposed to high temperatures (above
Never handle batteries close to naked flames and
49Β°C / 120Β°F) or in the event of damage.
unshielded light sources, never smoke.
Protect the pressure vessels against damage be-
Battery acid is toxic and corrosive.
fore beginning to work in or close to the engine
Avoid any contact with the skin, mouth, eyes and compartment.
clothing. Avoid spilling battery acid or inhaling the
Read and observe the instructions on the pressure
vapours.
vessels.
Wear gloves, firm protective clothing and goggles
For further details please refer to the instructions
when handling batteries.
and safety data-sheets of the manufacturer / sup-
If the skin is splashed with acid, rinse thoroughly plier of pressure vessels with cold starting fluid
with running water and consult a doctor. (ether).
If the eyes are splashed with acid, rinse thoroughly Provide for sufficient ventilation.
with running water and consult a doctor immedi-
Do not eat, drink or smoke when replacing an
ately.
empty vessel.
Never set tools down on the battery. They may
Do not inhale the vapours of escaping cold-starting
induce a short circuit, causing irreparable damage
fluid.
to the battery and injuring persons.
In contact with the skin, ether can cause frostbites
Never wear metal necklaces, bracelets or watch-
and irritations. Avoid skin contact.
straps when working on the battery. The metal
parts may induce a short-circuit resulting in burns. Wear suitable protective gloves and goggles.
Dispose of used batteries separately from other Even apparently empty pressure vessels can still
waste in the interests of environmental protection. contain rests of ether and therefore explode if they
are damaged or heated up above 49Β°C. They must
Before working on the electrical sys- therefore be handled in the same way as full pres-
tem sure vessels.
ο§ Do not keep them on the machine.
Before performing work on the electrical system
where tools, spare parts, etc. can come into con- ο§ Do not damage or open the vessels.
tact with electrical conductors or contacts, the bat-
ο§ Do not expose the vessels to great heat or
tery must be disconnected.
direct sunlight.
Disconnect first the negative and then the positive
terminal. ο§ Do not dispose of in fire.
After the work: ο§ Keep the vessels in a place inaccessible to
Reconnect first the positive and then the negative unauthorized persons.
terminal. ο§ Dispose of the vessels properly.
BA RH170(3 725 031.00)-EN 3-7
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OPERATING INSTRUCTIONS RH170
Inspection and servicing
Plan T and W
Plan T Every 10 OH or every working shift
(whichever comes first)
Plan W Every 60 OH or every working shift
(whichever comes first)
Page 1 of 2
Location Servicing work Quantity/ Plan Plan
No. T W
Engine Check oil level 2 ο¬ ο¬
Engine oil tank Check oil level 2 ο¬ ο¬
Cooling system
Cooling fluid level Check 2 ο¬ ο¬
Radiator Check / clean 2 ο¬ ο¬
Fuel system
Fuel filter Drain off water 2x2 ο¬ ο¬
Water trap (optional) Drain off water 2x1 ο¬ ο¬
Fuel tanks Drain off water and dirt 2 ο¬ ο¬
Air-intake system Check BCS β indication 1 ο¬
Intake and clean-air lines Check for tightness and leaks ο¬
Electrical system
Lighting Check operation ο¬ ο¬
Switchgear cabinet
- Breather filter
- Dust trap Remove dust 1 ο¬
- EMERGENCY OFF button Check function 2 ο¬
Monitoring, warning and control Check function of monitoring, warning ο¬ ο¬
elements and control elements
BCS Check function ο¬ ο¬
Hydraulic system Check function of working and travel- ο¬ ο¬
ling movement
Inspect visually for leaks ο¬
Hydraulic oil reservoir Check oil level 1 ο¬ ο¬
Oil cooler Check / clean 2 ο¬
Fan wheel Check condition 2 ο¬ ο¬
Pump transfer gearbox Check oil level 2 ο¬
- pre-chambers expansion reservoir Check oil level 2 ο¬ ο¬
Oil filter (tell-tale) Check 2x1 ο¬
Swing gearbox Check oil level 3 ο¬ ο¬
Travel gearbox Check for leaks 2 ο¬ ο¬
BA RH170(3 725 031.00)-EN 3-17
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OPERATING INSTRUCTIONS RH170
Inspection and servicing
BA RH170(3 725 031.00)-EN 3-27
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OPERATING INSTRUCTIONS RH170
Inspection and servicing
III.b Oils for swing gearboxes
Fig. 3-6:
BA RH170(3 725 031.00)-EN 3-37
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OPERATING INSTRUCTIONS RH170
Inspection and servicing
Filling in engine oil
The engine oil is filled in with the service station
(Fig. 3-23:) through
ο§ express coupling (6) for the lefthand engine oil
reservoir,
ο§ express coupling (7) for the righthand engine
oil reservoir,
until the the inspection glas (1, Fig. 3-24:) is com-
plete filled with oil.
ο Unscrew cap of express coupling and connect
hose line of the service vehicle.
The hose line and its use are described in the
"Hose line for oil and cooling liquid changes" sec-
Fig. 3-23:
tion.
ο Start the engines and allow to run at idling for
abt. 2 minutes.
ο Check oil level and top up with engine oil until
the oil level has reached the mark on dipstick
(3, Fig. 3-24:).
ο Remove the hose line.
The express coupling closes automatically.
ο Screw on protective cap.
Fig. 3-24:
BA RH170(3 725 031.00)-EN 3-47
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OPERATING INSTRUCTIONS RH170
Inspection and servicing
Topping up cooling liquid Cooling liquid, change
The cooling liquid can also be filled in with the
service station (Fig. 3-39:) through Risk of scalding from hot cooling liq-
uid.
ο§ express coupling (2) for the lefthand engine,
Read and observe: Inspection and
ο§ express coupling (3) for the righthand engine.
servicing β Safety instructions.
The radiators may also be hot. Wear protective
gloves and firm working clothing.
Collect escaping cooling liquid and discard without
polluting the environment.