Cat Bucyrus 120E Hydraulic Excavator Operating Instructions Manual BI651472 – PDF DOWNLOAD

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Cat Bucyrus 120E Hydraulic Excavator Operating Instructions Manual BI651472 – PDF DOWNLOAD

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Cat Bucyrus 120E Hydraulic Excavator Operating Instructions Manual BI651472 – PDF DOWNLOAD

Language : English
Pages : 257
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus 120E Hydraulic Excavator Operating Instructions Manual BI651472 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH200
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

• 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 Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel. The Bucyrus HEX 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 Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX 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 Bucyrus HEX 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.

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TABLE OF CONTENTS:

Cat Bucyrus 120E Hydraulic Excavator Operating Instructions Manual BI651472 – PDF DOWNLOAD

TABLE OF CONTENTS..............................................................................................................................................................  5
INTRODUCTION................................................................................................................................................................... 11
	PREFACE.................................................................................................................................................................... 13
	WARRANTY................................................................................................................................................................... 14
	FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 15
		Warnings and symbols................................................................................................................................................... 15
	DESIGNATED USE............................................................................................................................................................. 16
	ORGANIZATIONAL MEASURES.................................................................................................................................................... 17
		Selection and qualification of 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
		Noise.................................................................................................................................................................. 21
		Oil, grease and other chemical substances............................................................................................................................. 21
		Transporting and recommissioning...................................................................................................................................... 21
	FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22
	NOTES...................................................................................................................................................................... 23
OPERATION...................................................................................................................................................................... 25
	OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 27
	FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 29
	DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 30
		Excavator layout....................................................................................................................................................... 31
		Undercarriage.......................................................................................................................................................... 32
		Superstructure......................................................................................................................................................... 32
		Drive.................................................................................................................................................................. 32
		Hydraulic system....................................................................................................................................................... 32
		Pump Managing System (PMS)............................................................................................................................................. 32
		Stored Program Control (SPC)........................................................................................................................................... 32
		Electronic Hydraulic Servo-Control (EHSC).............................................................................................................................. 32
		Demand control / Zero-flow regulation.................................................................................................................................. 33
		Automatic engine speed reduction....................................................................................................................................... 33
		Board-Control-System (BCS)............................................................................................................................................. 33
		Electrical system...................................................................................................................................................... 33
		Sign................................................................................................................................................................... 35
		Entering and leaving the machine Safety instructions................................................................................................................... 36
		Ramp-type ladder (optional)............................................................................................................................................ 37
		Ramp-type ladder (optional)............................................................................................................................................ 38
		EMERGENCY STOP pushbuttons............................................................................................................................................. 40
		Windscreen washer...................................................................................................................................................... 40
		Driver's seat.......................................................................................................................................................... 41
		Adjusting the control consoles......................................................................................................................................... 42
		Fire extinguisher...................................................................................................................................................... 43
		Fire extinguisher (option)............................................................................................................................................. 43
		Automatic fire-extinguishing system (optional)......................................................................................................................... 44
		Harness (optional)..................................................................................................................................................... 45
	MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 48
	PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 73
		Refuelling............................................................................................................................................................. 73
		Service station (tanklift)............................................................................................................................................. 74
		Switching the electrical system on and off............................................................................................................................. 80
	STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 81
		Starting the engines................................................................................................................................................... 81
	AIR CONDITIONER (OPTION)................................................................................................................................................... 84
		Back-up heating (option)............................................................................................................................................... 86
	DRIVING, SAFETY INSTRUCTIONS............................................................................................................................................... 88
	TRAVELLING................................................................................................................................................................. 89
		Superstructure basic position.......................................................................................................................................... 89
		Travelling forwards/backwards.......................................................................................................................................... 89
		Emergency machine drive................................................................................................................................................ 93
		Locking the superstructure............................................................................................................................................. 95
		Track parking brake.................................................................................................................................................... 95
	TRANSPORTING THE MACHINE................................................................................................................................................... 96
		Transport - Safety instructions........................................................................................................................................ 96
	WORKING OPERATION - SAFETY INSTRUCTIONS.................................................................................................................................... 97
	WORKING OPERATION.......................................................................................................................................................... 99
		Before starting work................................................................................................................................................... 99
		Slewing and braking the superstructure................................................................................................................................. 99
		Braking the superstructure............................................................................................................................................. 99
		Working................................................................................................................................................................100
		After daily operation..................................................................................................................................................101
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS.........................................................................................................................102
		Securing the machine...................................................................................................................................................104
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................105
	NOTES......................................................................................................................................................................107
INSPECTION AND SERVICING.......................................................................................................................................................109
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................111
	FIRE AND EXPLOSION HAZARD..................................................................................................................................................117
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................119
		Intervals..............................................................................................................................................................119
		Change of engine oil l.................................................................................................................................................119
		Air-intake system......................................................................................................................................................119
		Oils / Greases.........................................................................................................................................................119
		Cleaning jobs..........................................................................................................................................................119
		Components.............................................................................................................................................................119
		Plan V.................................................................................................................................................................121
		Plan N.................................................................................................................................................................123
		Plan T.................................................................................................................................................................125
		Plan A – E.............................................................................................................................................................127
	LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................134
		Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................135
		Filling quantities - Grease............................................................................................................................................135
	LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND).......................................................................................................................136
		Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................137
		Filling quantities - Grease............................................................................................................................................137
	INSPECTION PLAN - OIL......................................................................................................................................................138
		Inspection plan – Oil (legend).........................................................................................................................................139
		Filling quantities - oil...............................................................................................................................................140
		Filling quantities - other.............................................................................................................................................140
	LUBRICANTS.................................................................................................................................................................141
		I.	Oils for combustion engines and compressors (selection).............................................................................................................141
		II.	Oils for hydraulic system (selection)..............................................................................................................................142
		III.	Oils for gearboxes (selection)....................................................................................................................................143
		V.	Greases for bearings and slewing rings..............................................................................................................................144
	SERVICING WORK.............................................................................................................................................................145
		Hose line for oil and cooling liquid changes...........................................................................................................................145
	ENGINE.....................................................................................................................................................................146
		Engine - Safety instructions...........................................................................................................................................146
		Retensioning the alternator/fan belt...................................................................................................................................146
		Checking and adjusting the valve clearance.............................................................................................................................146
		Checking the engine oil level / Topping up.............................................................................................................................146
		Changing the engine oil................................................................................................................................................148
		Replacing the oil filters..............................................................................................................................................150
	COOLING SYSTEM.............................................................................................................................................................151
		Radiators..............................................................................................................................................................151
		Cooling liquid.........................................................................................................................................................153
	AIR-INTAKE SYSTEM..........................................................................................................................................................154
		Main filter elements...................................................................................................................................................154
		Safety filter element..................................................................................................................................................156
		Air-intake lines.......................................................................................................................................................157
		Dust collection........................................................................................................................................................157
	FUEL SYSTEM................................................................................................................................................................158
		Fuel system - Safety instructions......................................................................................................................................158
		Replacing the fuel filter..............................................................................................................................................158
		Venting the fuel system................................................................................................................................................159
		Cleaning the fuel tanks................................................................................................................................................159
		Water trap (option)....................................................................................................................................................161
	ELECTRICAL SYSTEM..........................................................................................................................................................163
		Electrical system - Safety instructions................................................................................................................................163
		Alternator - Instructions..............................................................................................................................................163
		Battery................................................................................................................................................................164
		Switchgear cabinet.....................................................................................................................................................166
		Equipotential bonding..................................................................................................................................................168
	HYDRAULIC SYSTEM...........................................................................................................................................................170
		Hydraulic system - Safety instructions.................................................................................................................................170
		Depressurizing the hydraulic system....................................................................................................................................170
		Checking the hydraulic oil level.......................................................................................................................................171
		Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................173
		Bypass valves (hydraulic oil reservoir)................................................................................................................................175
		Replacing the hydraulic oil return-flow filters (filter housing).......................................................................................................176
		Bypass valves (filter housing - cooling system)........................................................................................................................177
		Breather filter........................................................................................................................................................178
		Filter (control circuit and auxiliary control circuit).................................................................................................................179
		High-pressure filter for working hydraulics............................................................................................................................180
		High-pressure filters for slewing circuit..............................................................................................................................181
		Changing the hydraulic oil.............................................................................................................................................182
		Venting the hydraulic system...........................................................................................................................................185
		Cleaning the hydraulic oil cooler......................................................................................................................................186
		Electronic excavator control...........................................................................................................................................187
		Pressure accumulator - Emergency lowering..............................................................................................................................188
	PUMP TRANSFER GEARBOX......................................................................................................................................................189
		Checking the gearbox oil level / Topping up with oil...................................................................................................................189
		Gearbox venting........................................................................................................................................................191
		Pump transfer gearbox lube oil filters.................................................................................................................................192
	SLEWING GEARBOX............................................................................................................................................................193
		Gearbox - Checking the oil level / Topping up with oil.................................................................................................................193
		Changing the gearbox oil...............................................................................................................................................193
		Gearbox venting........................................................................................................................................................194
	TRAVEL GEARBOX.............................................................................................................................................................195
		Gearbox - Checking the oil level / Topping up with oil.................................................................................................................195
		Travel gearbox - Changing oil..........................................................................................................................................196
		Pre-chamber - Changing the oil.........................................................................................................................................196
		Brake chamber - Changing oil...........................................................................................................................................197
		Breather filter........................................................................................................................................................197
	CRAWLER TRACKS.............................................................................................................................................................198
		Track roller, Support roller...........................................................................................................................................199
		Track tensioner........................................................................................................................................................200
		Pressure-accumulator inspection regulations............................................................................................................................201
		Checking the gas charging pressure in the pressure accumulator.........................................................................................................201
	SLEWING RING...............................................................................................................................................................202
		Slewing ring - Instructions............................................................................................................................................202
		Bearing races..........................................................................................................................................................202
	CENTRAL LUBRICATING........................................................................................................................................................204
		Design.................................................................................................................................................................204
		Lube cycle / Pause period..............................................................................................................................................204
		Lube cycle manual lubricating (optional)...............................................................................................................................204
		Function...............................................................................................................................................................205
		Filling up the grease container........................................................................................................................................206
		Breather filter........................................................................................................................................................206
		Checking the greasing pressure.........................................................................................................................................207
		Unblocking a grease line...............................................................................................................................................208
		Oilfilter (hydraulic circuit grease pump) )............................................................................................................................209
		Grease filter (Filling the grease container)...........................................................................................................................210
		Grease filter (Grease lines)...........................................................................................................................................211
	OTHER MAINTENANCE..........................................................................................................................................................212
		Engine.................................................................................................................................................................212
		Heating and air conditioning...........................................................................................................................................212
	RAMP-TYPE LADDER (OPTIONAL)  (OPTION)......................................................................................................................................213
		Guide pulleys and locking bolt.........................................................................................................................................213
		Pressure-accumulator inspection regulations............................................................................................................................214
		Extract from the German regulations....................................................................................................................................214
		Checking the gas charging pressure in the pressure accumulator.........................................................................................................214
	ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................215
		Monitoring, warning and control elements...............................................................................................................................215
		Checking the on-board crane............................................................................................................................................215
		Drive unit.............................................................................................................................................................216
		On-board crane.........................................................................................................................................................216
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................217
		Putting the excavator out of operation.................................................................................................................................217
		Battery storage........................................................................................................................................................217
		Recommissioning........................................................................................................................................................218
	NOTIZEN....................................................................................................................................................................219
REPAIR WORK....................................................................................................................................................................221
	REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................223
	FIRE AND EXPLOSION HAZARD..................................................................................................................................................225
	ENGINE.....................................................................................................................................................................226
	ELECTRICAL SYSTEM..........................................................................................................................................................227
		Assisted starting (with jumper cables) – Safety instructions...........................................................................................................227
		Assisted starting (with jumper cables).................................................................................................................................227
		Starting the engine with jumper cables (external batteries.............................................................................................................227
	HYDRAULIC SYSTEM...........................................................................................................................................................229
		Repair.................................................................................................................................................................229
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................230
	WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................231
	NOTES......................................................................................................................................................................233
ANNEX..........................................................................................................................................................................235
	TROUBLESHOOTING............................................................................................................................................................237
		Instructions on troubleshooting........................................................................................................................................237
		Layout of the fault table..............................................................................................................................................237
		Possible causes........................................................................................................................................................237
		Measures...............................................................................................................................................................237
		Section................................................................................................................................................................237
	FAULT TABLES...............................................................................................................................................................238
		Combustion engine - Fault table........................................................................................................................................238
		Working hydraulics – Fault table.......................................................................................................................................239
		Track drive – Fault table..............................................................................................................................................240
		Slewing mechnism – Fault table.........................................................................................................................................241
		Central lubricating system – Fault table...............................................................................................................................242
	HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................244
	ABBREVIATIONS..............................................................................................................................................................246
	ABBREVIATIONS..............................................................................................................................................................247
	TECHNICAL DATA.............................................................................................................................................................249
	NOTES......................................................................................................................................................................251
INDEX..........................................................................................................................................................................253

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