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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651471 – PDF DOWNLOAD
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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651471 – PDF DOWNLOAD
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Description
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651471 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651471 – PDF DOWNLOAD
Language : English
Pages : 222
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651471 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 120E
Introduction
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The instruction manual contains 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 instruction manual 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 operator’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 Terex|O&K 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. 1 Complies with VDMA
- recommendation “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 OPERATING INSTRUCTIONS MANUAL BI651471 – PDF DOWNLOAD
TABLE OF CONTENTS.............................................................................................................................................................. 5 INTRODUCTION................................................................................................................................................................... 9 PREFACE.................................................................................................................................................................... 11 WARRANTY................................................................................................................................................................... 12 FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 13 Warnings and symbols................................................................................................................................................... 13 DESIGNATED USE............................................................................................................................................................. 14 ORGANIZATIONAL MEASURES.................................................................................................................................................... 15 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 16 Safety instructions governing specific operational phases.............................................................................................................. 16 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.... 17 Warning of special dangers............................................................................................................................................. 18 Transporting and recommission ing...................................................................................................................................... 19 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS........................................................................................................ 20 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR..................................................................................................................... 22 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 23 NOTES...................................................................................................................................................................... 25 OPERATION...................................................................................................................................................................... 27 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 29 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 31 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 32 Excavator layout....................................................................................................................................................... 33 Undercarriage.......................................................................................................................................................... 34 Superstructure......................................................................................................................................................... 34 Drive.................................................................................................................................................................. 34 Hydraulic system....................................................................................................................................................... 34 Pump Managing System (PMS)............................................................................................................................................. 34 Storage Programmable Control (SPC)..................................................................................................................................... 34 Electronic Hydraulic Servo-Control (EHSC).............................................................................................................................. 34 Demand control / Zero-flow regulation.................................................................................................................................. 35 Board-Control-System (BCS)............................................................................................................................................. 35 Electrical system...................................................................................................................................................... 35 Sign................................................................................................................................................................... 39 Entering and leaving the machine Safety instructions................................................................................................................... 40 Windscreen washer...................................................................................................................................................... 43 EMERGENCY STOP pushswitch.............................................................................................................................................. 44 Driver's seat.......................................................................................................................................................... 45 Adjusting the control consoles......................................................................................................................................... 46 Fire extinguisher...................................................................................................................................................... 47 Automatic fire-extinguishing system (optional)......................................................................................................................... 48 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 50 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 67 Service station (tanklift)............................................................................................................................................. 67 Switching the electrical system on and off............................................................................................................................. 69 Switching the electric motor on and off................................................................................................................................ 70 AIR CONDITIONER (OPTION)................................................................................................................................................... 77 TRAVELLING................................................................................................................................................................. 78 DRIVING SAFETY INSTRUCTIONS............................................................................................................................................ 78 TRAVELLING............................................................................................................................................................. 79 Emergency machine drive................................................................................................................................................ 83 Locking the superstructure............................................................................................................................................. 85 Track parking brake.................................................................................................................................................... 85 TRANSPORTING THE MACHINE................................................................................................................................................... 86 Transport - Safety instructions........................................................................................................................................ 86 WORKING OPERATION.......................................................................................................................................................... 87 Safety instructions.................................................................................................................................................... 87 WORKING OPERATION...................................................................................................................................................... 89 Working................................................................................................................................................................ 90 After daily operation.................................................................................................................................................. 91 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 92 Securing the machine................................................................................................................................................... 94 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)............................................................................................................. 96 NOTES...................................................................................................................................................................... 98 INSPECTION AND SERVICING.......................................................................................................................................................101 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR.....................................................................................................................103 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................105 FIRE AND EXPLOSION HAZARD..................................................................................................................................................111 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................113 Intervals..............................................................................................................................................................113 Oils / Greases.........................................................................................................................................................113 Cleaning jobs..........................................................................................................................................................113 Components.............................................................................................................................................................113 Plan V.................................................................................................................................................................115 Plan N.................................................................................................................................................................117 Plan T and W...........................................................................................................................................................119 Plan A – E.............................................................................................................................................................121 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................126 Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................127 Filling quantities - Grease............................................................................................................................................127 INSPECTION PLAN - OIL......................................................................................................................................................128 Inspection plan – Oil (legend) ).......................................................................................................................................129 Filling quantities - oil...............................................................................................................................................130 Filling quantities - other.............................................................................................................................................130 LUBRICANTS.................................................................................................................................................................131 II. Oils for hydraulic system (selection)..............................................................................................................................131 III. Oils for gearboxes (selection)....................................................................................................................................132 V. Greases for bearings and slewing rings..............................................................................................................................133 SERVICING WORK.............................................................................................................................................................134 Hose line for oil and cooling liquid changes...........................................................................................................................134 ELECTRIC MOTOR.............................................................................................................................................................135 Electric motor - Safety instructions...................................................................................................................................135 Electric motor.........................................................................................................................................................135 ELECTRICAL SYSTEM..........................................................................................................................................................137 Electrical system - Safety instructions................................................................................................................................137 Battery main switch....................................................................................................................................................137 Battery................................................................................................................................................................138 Switchgear cabinet.....................................................................................................................................................140 Slip ring..............................................................................................................................................................143 HYDRAULIC SYSTEM...........................................................................................................................................................144 Hydraulic system - Safety instructions.................................................................................................................................144 Depressurizing the hydraulic system....................................................................................................................................144 Checking the hydraulic oil level.......................................................................................................................................145 Changing the hydraulic oil return-flow filter (hydraulic oil reservoir)................................................................................................147 Bypass valves (hydraulic oil reservoir)................................................................................................................................149 Replacing the hydraulic oil return-flow filters (filter housing).......................................................................................................150 Bypass valves (filter housing - cooling system)........................................................................................................................151 Breather filter........................................................................................................................................................152 Filter (control circuit and auxiliary control circuit).................................................................................................................153 High-pressure filter for working hydraulics............................................................................................................................154 High-pressure filters for slewing circuit..............................................................................................................................155 High-pressure filters for feeding circuits and slewing pumps...........................................................................................................156 Changing the hydraulic oil.............................................................................................................................................157 Venting the hydraulic system...........................................................................................................................................160 Cleaning the hydraulic oil cooler......................................................................................................................................161 Electronic excavator control...........................................................................................................................................162 Pressure accumulator - Emergency lowering..............................................................................................................................163 Pressure accumulator – Servo control- and feeding circuit..............................................................................................................163 PUMP TRANSFER GEARBOX......................................................................................................................................................165 Checking the gearbox oil level / Topping up with oil...................................................................................................................165 Gearbox venting........................................................................................................................................................167 Pump transfer gearbox lube oil filters.................................................................................................................................168 SLEWING GEARBOX............................................................................................................................................................169 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................169 Changing the gearbox oil...............................................................................................................................................169 Gearbox venting........................................................................................................................................................170 TRAVEL GAERBOX.............................................................................................................................................................171 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................171 Travel gearbox - Changing oil..........................................................................................................................................172 Pre-chamber - Changing the oil.........................................................................................................................................172 Brake chamber - Changing oil...........................................................................................................................................173 Breather filter........................................................................................................................................................173 CRAWLER TRACKS.............................................................................................................................................................174 Track roller, Support roller...........................................................................................................................................175 Track tensioner........................................................................................................................................................176 Pressure-accumulator inspection regulations............................................................................................................................177 Checking the gas charging pressure in the pressure accumulator.........................................................................................................177 SLEWING RING...............................................................................................................................................................178 Slewing ring - Instructions............................................................................................................................................178 Bearing races..........................................................................................................................................................178 CENTRAL LUBRICATING........................................................................................................................................................180 Design.................................................................................................................................................................180 Lube cycle / Pause period..............................................................................................................................................180 Function...............................................................................................................................................................181 Fig. 3 100.............................................................................................................................................................181 Replacing the grease drum..............................................................................................................................................182 Checking the greasing pressure.........................................................................................................................................183 Unblocking a grease line...............................................................................................................................................183 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................184 Grease filter (Grease lines)...........................................................................................................................................185 OTHER MAINTENANCE..........................................................................................................................................................186 Heating and air conditioning...........................................................................................................................................186 Intake filter..........................................................................................................................................................186 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................187 Putting the excavator out of operation.................................................................................................................................187 Battery storage........................................................................................................................................................187 Recommissioning........................................................................................................................................................188 NOTES......................................................................................................................................................................191 REPAIR WORK....................................................................................................................................................................193 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR.....................................................................................................................195 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................197 FIRE AND EXPLOSION HAZARD..................................................................................................................................................199 HYDRAULIC SYSTEM...........................................................................................................................................................200 Repair.................................................................................................................................................................200 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................201 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................202 NOTES......................................................................................................................................................................203 ANNEX..........................................................................................................................................................................205 TROUBLESHOOTING............................................................................................................................................................207 Instructions on troubleshooting........................................................................................................................................207 Layout of the fault table..............................................................................................................................................207 Possible causes........................................................................................................................................................207 Measures...............................................................................................................................................................207 Section................................................................................................................................................................207 FAULT TABLES...............................................................................................................................................................208 Working hydraulics – Fault table.......................................................................................................................................208 Track drive – Fault table..............................................................................................................................................209 Slewing mechnism – Fault table.........................................................................................................................................210 Central lubricating system – Fault table...............................................................................................................................211 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................212 ABBREVIATIONS..............................................................................................................................................................213 TECHNICAL DATA.............................................................................................................................................................215 INDEX..........................................................................................................................................................................219
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M
