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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651439 – PDF DOWNLOAD
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Description
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651439 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651439 – PDF DOWNLOAD
Language : English
Pages : 277
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651439 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 200 E
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
- The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
-operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
-maintenance (inspection, servicing, repair) and / or
-transport.
- In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified mechanic or by attending an Terex|O&K training course for operators or maintenance personnel. The Terex|O&K after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. All Terex|O&K operating manuals are issued in German and then translated.
- Even a good translation may give rise to questions which Terex|O&K 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|O&K aftersales service.
- The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine.
- On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651439 – PDF DOWNLOAD
1 INTRODUCTION............................................................................................................................................................... 11 PREFACE ................................................................................................................................................................. 13 WARRANTY................................................................................................................................................................. 14 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15 Warnings and symbols................................................................................................................................................. 15 DESIGNATED USE........................................................................................................................................................... 16 ORGANIZATIONAL MEASURES.................................................................................................................................................. 17 Selection and qualification of personnel; basic responsibilities..................................................................................................... 18 Safety instructions governing specific operational phases............................................................................................................ 18 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19 Warning of special dangers........................................................................................................................................... 20 Gas, dust, steam and smoke........................................................................................................................................... 21 Hydraulic equipment.................................................................................................................................................. 21 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 22 NOTES ................................................................................................................................................................... 23 2 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 Central Management System (CMS) ..................................................................................................................................... 32 Demand control / Zero-flow regulation................................................................................................................................ 33 Automatic engine speed reduction .................................................................................................................................... 33 Board-Control-System (BCS) .......................................................................................................................................... 33 Electrical system ................................................................................................................................................... 33 Signs and labels .................................................................................................................................................... 35 Entering and leaving the machine, Safety instructions................................................................................................................ 36 Folding ladder (optional) ........................................................................................................................................... 37 Swinging ladder (optional) .......................................................................................................................................... 38 EMERGENCY STOP switch ............................................................................................................................................... 40 Windscreen washer ................................................................................................................................................... 40 Driver's seat ....................................................................................................................................................... 41 Fire extinguisher ................................................................................................................................................... 42 Fire extinguisher (option) .......................................................................................................................................... 42 Automatic fire-extinguishing system (optional)....................................................................................................................... 43 Harness (optional) .................................................................................................................................................. 44 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 48 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 80 Refuelling .......................................................................................................................................................... 80 Service station (tanklift) .......................................................................................................................................... 80 Switching the electrical system on and off .......................................................................................................................... 86 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 87 Starting the engines ................................................................................................................................................ 87 Starting the engines at low temperatures ............................................................................................................................ 88 AIR CONDITIONER (OPTION)................................................................................................................................................. 90 Back-up heating (option) ............................................................................................................................................ 91 DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................ 93 TRAVELLING .............................................................................................................................................................. 94 Superstructure basic position ....................................................................................................................................... 94 Travelling forwards/backwards ....................................................................................................................................... 94 Emergency machine drive ............................................................................................................................................. 98 Locking the superstructure ..........................................................................................................................................100 Track parking brake .................................................................................................................................................100 TRANSPORTING THE MACHINE ................................................................................................................................................101 Transport - Safety instructions .....................................................................................................................................101 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................102 Running-in instructions for hydraulic cylinders .....................................................................................................................102 Warming-up phase for the hydraulic system ...........................................................................................................................102 Avoid extreme positions of the working equipment ....................................................................................................................103 WORKING OPERATION .......................................................................................................................................................104 Before starting work ................................................................................................................................................104 Switching on the electronic excavator control .......................................................................................................................104 Swinging the superstructure .........................................................................................................................................104 Braking the superstructure ..........................................................................................................................................104 Working movements ...................................................................................................................................................105 After daily operation ...............................................................................................................................................106 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................107 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 l...............................................................................................................................................123 Air-intake system ...................................................................................................................................................123 Oils / Greases ......................................................................................................................................................123 Cleaning jobs .......................................................................................................................................................123 Components ..........................................................................................................................................................123 Plan V ..............................................................................................................................................................125 Plan N ..............................................................................................................................................................127 Plan T and W.........................................................................................................................................................129 Plan A – E ..........................................................................................................................................................131 LUBRICATING CHART – GREASE (LOADING BUCKET) .............................................................................................................................138 Lubricating chart – Grease / Loading bucket (legend) ................................................................................................................139 Filling quantities - Grease..........................................................................................................................................139 LUBRICATING CHART – GREASE / BACKHOE BUCKET .............................................................................................................................140 Lubricating chart – Grease / Backhoe bucket (legend) ................................................................................................................141 Filling quantities - Grease..........................................................................................................................................141 INSPECTION PLAN - OIL ...................................................................................................................................................142 Inspection plan – Oil (legend) ......................................................................................................................................143 Filling quantities - oil ............................................................................................................................................144 Filling quantities - other...........................................................................................................................................144 LUBRICANTS ..............................................................................................................................................................145 Notes on the selection of oils and greases ..........................................................................................................................145 I. Oils for combustion engines ......................................................................................................................................146 II. Oils for hydraulic system .......................................................................................................................................147 III.a Oils for pump gearboxes .......................................................................................................................................148 III.b Oils for swing gearboxes ......................................................................................................................................149 III.c Oils for travel gearboxes .....................................................................................................................................150 V. Greases for bearings and swing rings .............................................................................................................................151 SERVICING WORK ..........................................................................................................................................................152 Hose line for oil and cooling liquid changes ........................................................................................................................152 ENGINE ..................................................................................................................................................................153 Engine - Safety instructions ........................................................................................................................................153 Checking the engine oil level / Topping up .........................................................................................................................154 Changing the engine oil .............................................................................................................................................155 Replacing the oil filters ...........................................................................................................................................157 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................158 COOLING SYSTEM ..........................................................................................................................................................159 Radiators ...........................................................................................................................................................159 Cooling liquid ......................................................................................................................................................161 AIR-INTAKE SYSTEM .......................................................................................................................................................162 Dust trap, cleaning ................................................................................................................................................162 Main filter elements ................................................................................................................................................163 Safety filter element ...............................................................................................................................................165 Air-intake lines ....................................................................................................................................................165 FUEL SYSTEM .............................................................................................................................................................166 Fuel system - Safety instructions ...................................................................................................................................166 Replacing the fuel filter ...........................................................................................................................................166 Primary fuel filter, drain water ....................................................................................................................................167 Replacing the primary 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 Equipotential bonding ...............................................................................................................................................177 Floodlight projector, replacing the lamp ............................................................................................................................179 HYDRAULIC SYSTEM ........................................................................................................................................................181 Hydraulic system - Safety instructions ..............................................................................................................................181 Depressurizing the hydraulic system .................................................................................................................................181 Checking the hydraulic oil level ....................................................................................................................................182 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................184 Bypass valves (hydraulic oil reservoir) .............................................................................................................................186 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................187 Bypass valves (filter housing - cooling system) .....................................................................................................................188 Breather filter .....................................................................................................................................................189 Filter (control circuit and auxiliary control circuit)...............................................................................................................190 High-pressure filter for working hydraulics .........................................................................................................................191 High-pressure filters for swing circuit .............................................................................................................................192 Changing the hydraulic oil ..........................................................................................................................................193 Venting the hydraulic system.........................................................................................................................................196 Cleaning the hydraulic oil cooler....................................................................................................................................197 Electronic excavator control.........................................................................................................................................198 Pressure accumulator - Emergency lowering............................................................................................................................199 PUMP TRANSFER GEARBOX ...................................................................................................................................................200 Checking the gearbox oil level / Topping up with oil ................................................................................................................200 Gearbox venting .....................................................................................................................................................202 Pump transfer gearbox lube oil filters ..............................................................................................................................203 SWING GEARBOX ...........................................................................................................................................................204 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................204 Changing the gearbox oil ............................................................................................................................................204 Gearbox venting .....................................................................................................................................................205 SWING GEARBOX ...........................................................................................................................................................206 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................206 Changing the gearbox oil ............................................................................................................................................207 Gearbox venting .....................................................................................................................................................208 TRAVEL GEARBOX ..........................................................................................................................................................209 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................209 Travel gearbox - Changing oil .......................................................................................................................................210 Pre-chamber - Changing the oil ......................................................................................................................................210 Brake chamber - Changing oil ........................................................................................................................................211 Breather filter .....................................................................................................................................................211 CRAWLER TRACKS ..........................................................................................................................................................212 Track roller, Support roller ........................................................................................................................................213 Track tensioner .....................................................................................................................................................214 Pressure-accumulator inspection regulations .........................................................................................................................215 Checking the gas charging pressure in the pressure accumulator.......................................................................................................215 SWING RING ..............................................................................................................................................................216 Swing ring - Instructions............................................................................................................................................216 Bearing races........................................................................................................................................................216 CENTRAL LUBRICATING .....................................................................................................................................................218 Design ..............................................................................................................................................................218 Function ............................................................................................................................................................219 Filling up the grease container .....................................................................................................................................220 Breather filter .....................................................................................................................................................220 Checking the greasing pressure ......................................................................................................................................221 Unblocking a grease line.............................................................................................................................................222 Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................223 Grease filter (Filling the grease container) ........................................................................................................................224 Grease filter (Grease lines) ........................................................................................................................................225 OTHER MAINTENANCE .......................................................................................................................................................226 Engine ..............................................................................................................................................................226 Heating and air conditioning ........................................................................................................................................226 RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................227 Pressure-accumulator inspection regulations .........................................................................................................................228 Extract from the German regulations..................................................................................................................................228 Checking the gas charging pressure in the pressure accumulator.......................................................................................................228 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................229 Monitoring, warning and control elements ............................................................................................................................229 Checking the on-board crane..........................................................................................................................................229 Drive unit ..........................................................................................................................................................230 On-board crane.......................................................................................................................................................230 On-Board crane, checking tightness of fastening bolts ...............................................................................................................231 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................232 Putting the excavator out of operation...............................................................................................................................232 Battery storage......................................................................................................................................................232 Recommissioning......................................................................................................................................................232 NOTES ..................................................................................................................................................................233 4 REPAIR WORK................................................................................................................................................................235 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................237 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................239 REPAIR WORK, ENGINE......................................................................................................................................................240 ELECTRICAL SYSTEM .......................................................................................................................................................241 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................241 Assisted starting (with jumper cables)...............................................................................................................................241 Starting the engine with jumper cables (external batteries ..........................................................................................................241 HYDRAULIC SYSTEM.........................................................................................................................................................243 Repair instructions .................................................................................................................................................243 Hydraulic hoses – Instructions .....................................................................................................................................243 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................244 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................245 NOTES ...................................................................................................................................................................247 5 ANNEX......................................................................................................................................................................249 TROUBLESHOOTING .........................................................................................................................................................251 Instructions on troubleshooting .....................................................................................................................................251 Layout of the fault table ...........................................................................................................................................251 Possible causes .....................................................................................................................................................251 Measures ............................................................................................................................................................251 Section .............................................................................................................................................................251 FAULT TABLES ............................................................................................................................................................252 Combustion engine - Fault table .....................................................................................................................................252 Working hydraulics – Fault table ....................................................................................................................................253 Track drive – Fault table ...........................................................................................................................................254 Swing mechnism – Fault table ........................................................................................................................................255 Central lubricating system – Fault table ............................................................................................................................256 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................257 ABBREVIATIONS ...........................................................................................................................................................259 ABBREVIATIONS........................................................................................................................................................260 TECHNICAL DATA ..........................................................................................................................................................261 NOTES ...................................................................................................................................................................271 6 INDEX......................................................................................................................................................................273
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