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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651487 – PDF DOWNLOAD
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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651487 – PDF DOWNLOAD
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Description
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651487 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651487 – PDF DOWNLOAD
Language : English
Pages : 285
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651487 – PDF DOWNLOAD
OPERATING INSTRUCTIONS 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.
- 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 BI651487 – 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 per sonnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases.............................................................................................................. 18 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.... 19 Warning of special dangers............................................................................................................................................. 20 Gas, dust, steam and smoke............................................................................................................................................. 21 Hydraulic equipment.................................................................................................................................................... 21 Noise.................................................................................................................................................................. 21 Oil, grease and other chemical sub stances............................................................................................................................. 21 Transporting and recommission ing...................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22 OPERATION...................................................................................................................................................................... 23 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 25 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 27 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 28 Excavator layout....................................................................................................................................................... 29 Undercarriage.......................................................................................................................................................... 30 Superstructure......................................................................................................................................................... 30 Drive.................................................................................................................................................................. 30 Hydraulic system....................................................................................................................................................... 30 Pump Managing System (PMS)............................................................................................................................................. 30 Demand control / Zero-flow regulation.................................................................................................................................. 30 Automatic engine speed reduction....................................................................................................................................... 30 Electrical system...................................................................................................................................................... 30 Sign................................................................................................................................................................... 33 Fire-extinguisher...................................................................................................................................................... 34 DRIVER'S CAB............................................................................................................................................................... 35 Entering and leaving the machine - Safety instructions................................................................................................................. 35 Driver's seat.......................................................................................................................................................... 36 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 38 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 57 Refuelling............................................................................................................................................................. 57 Service Station (optional equipment)................................................................................................................................... 58 Switching the electrical system on and off............................................................................................................................. 59 Battery main switch.................................................................................................................................................... 60 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 61 VENTILATION AND HEATING.................................................................................................................................................... 63 DRIVING.................................................................................................................................................................... 64 SAFETY INSTRUCTIONS.................................................................................................................................................... 64 TRAVELLING............................................................................................................................................................. 66 Locking the superstructure............................................................................................................................................. 70 Track parking brake.................................................................................................................................................... 70 TRANSPORTING THE MACHINE................................................................................................................................................... 71 Transport - Safety instructions........................................................................................................................................ 71 WORKING OPERATION.......................................................................................................................................................... 73 SAFETY INSTRUCTIONS.................................................................................................................................................... 73 Before starting work................................................................................................................................................... 75 Slewing and braking the superstructure................................................................................................................................. 75 Working................................................................................................................................................................ 76 After daily operation.................................................................................................................................................. 77 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 78 Securing the machine................................................................................................................................................... 80 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)............................................................................................................. 81 LIFTING OPERATIONS......................................................................................................................................................... 82 Safety instructions.................................................................................................................................................... 82 Load-hooks on backhoe buckets.......................................................................................................................................... 83 NOTES...................................................................................................................................................................... 87 INSPECTION AND SERVICING....................................................................................................................................................... 89 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS............................................................................................................................. 91 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 97 ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID................................................................................................................................. 98 Environmentally compatible hydraulic fluid - operating instructions.................................................................................................... 98 Environmentally compatible hydraulic fluid, conversion................................................................................................................. 98 Environmentally compatible hydraulic fluid - Sampling.................................................................................................................. 99 ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS...........................................................................................................................100 Lubricants for bearings................................................................................................................................................100 Gearbox oils...........................................................................................................................................................100 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................101 Intervals..............................................................................................................................................................101 Change of engine oil l.................................................................................................................................................101 Oils / Greases.........................................................................................................................................................101 Cleaning jobs..........................................................................................................................................................101 Components.............................................................................................................................................................101 Plan V.................................................................................................................................................................103 Plan N.................................................................................................................................................................105 Plan T.................................................................................................................................................................107 Plan A – E.............................................................................................................................................................109 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................114 Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................115 Filling quantities - Grease............................................................................................................................................115 LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND).......................................................................................................................116 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................117 Filling quantities - Grease............................................................................................................................................117 INSPECTION PLAN - OIL......................................................................................................................................................118 Inspection plan – Oil (legend) ).......................................................................................................................................119 Filling quantities - oil...............................................................................................................................................119 Filling quantities - other.............................................................................................................................................120 LUBRICANTS.................................................................................................................................................................121 I. Oils for combustion engines and compressors (selection).............................................................................................................121 II. Oils for hydraulic system (selection)..............................................................................................................................122 III. Oils for gearboxes (selection)....................................................................................................................................123 V. Greases for bearings and slewing rings..............................................................................................................................124 SERVICING WORK.............................................................................................................................................................125 Hose line for oil and cooling liquid changes...........................................................................................................................125 ENGINE.....................................................................................................................................................................126 Engine - Safety instructions...........................................................................................................................................126 Checking the V-belt tension............................................................................................................................................126 Retensioning the alternator/fan belt...................................................................................................................................126 Checking and adjusting the valve clearance.............................................................................................................................126 Checking the engine oil level / Topping up.............................................................................................................................126 Changing the engine oil................................................................................................................................................127 Replacing the oil filter...............................................................................................................................................128 Centrifuge (optional)..................................................................................................................................................129 COOLING SYSTEM.............................................................................................................................................................130 Radiators..............................................................................................................................................................130 Cooling liquid.........................................................................................................................................................131 Water filter...........................................................................................................................................................132 AIR-INTAKE SYSTEM..........................................................................................................................................................133 Main filter elements...................................................................................................................................................133 Safety filter element..................................................................................................................................................135 Air-intake lines.......................................................................................................................................................135 Dust collection........................................................................................................................................................135 FUEL SYSTEM................................................................................................................................................................136 Fuel system - Safety instructions......................................................................................................................................136 Replacing the fuel filter..............................................................................................................................................137 Venting the fuel system................................................................................................................................................137 Cleaning the fuel tanks................................................................................................................................................138 Refuelling station (optional)..........................................................................................................................................138 Water trap (option)....................................................................................................................................................139 ELECTRICAL SYSTEM..........................................................................................................................................................141 Electrical system - Safety instructions................................................................................................................................141 Alternator - Instructions..............................................................................................................................................141 Battery main switch / Main fuse........................................................................................................................................142 Battery................................................................................................................................................................142 HYDRAULIC SYSTEM...........................................................................................................................................................145 Hydraulic system - Safety instructions.................................................................................................................................145 Depressurizing the hydraulic system....................................................................................................................................145 Checking the hydraulic oil level.......................................................................................................................................146 Topping up with hydraulic oil..........................................................................................................................................146 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................147 Bypass valves (working circuit)........................................................................................................................................148 Bypass valves (cooling circuit)........................................................................................................................................149 Breather filter........................................................................................................................................................150 High-pressure filter for working hydraulics............................................................................................................................151 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump................................................................................152 Changing the hydraulic oil.............................................................................................................................................153 Venting the hydraulic system...........................................................................................................................................155 Cleaning the hydraulic oil cooler......................................................................................................................................156 Pressure accumulator...................................................................................................................................................157 PUMP TRANSFER GEARBOX......................................................................................................................................................158 Checking the gearbox oil level / Topping up with oil...................................................................................................................158 Changing the gearbox oil...............................................................................................................................................158 SLEWING GEARBOX............................................................................................................................................................160 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................160 Changing the gearbox oil...............................................................................................................................................160 Gearbox venting........................................................................................................................................................161 Output pinion..........................................................................................................................................................161 TRAVEL GAERBOX.............................................................................................................................................................162 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................162 Travel gearbox - Changing the oil......................................................................................................................................162 Gearbox venting........................................................................................................................................................162 CRAWLER TRACKS.............................................................................................................................................................163 Track rollers, support rollers, track pads.............................................................................................................................163 Track tensioner........................................................................................................................................................165 Pressure-accumulator inspection regulations............................................................................................................................166 Checking the gas charging pressure in the pressure accumulator.........................................................................................................166 Idlers.................................................................................................................................................................167 SLEWING RING...............................................................................................................................................................168 Slewing ring - Instructions............................................................................................................................................168 Bearing races..........................................................................................................................................................168 CENTRAL LUBRICATING........................................................................................................................................................170 Design and function....................................................................................................................................................170 Greasing cycle.........................................................................................................................................................172 Venting the grease pump................................................................................................................................................174 Venting the grease lines...............................................................................................................................................174 Unblocking a grease line...............................................................................................................................................174 Cleaning the grease sieves.............................................................................................................................................175 Lubricating the grease distributor of the working equipment............................................................................................................175 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................176 Putting the excavator out of operation.................................................................................................................................176 Battery storage........................................................................................................................................................176 Recommissioning........................................................................................................................................................177 NOTES......................................................................................................................................................................178 REPAIR WORK....................................................................................................................................................................181 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................183 FIRE AND EXPLOSION HAZARD..................................................................................................................................................185 ENGINE.....................................................................................................................................................................186 ELECTRICAL SYSTEM..........................................................................................................................................................187 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................187 Assisted starting (with jumper cables).................................................................................................................................187 Starting the engine with jumper cables (external batteries.............................................................................................................187 HYDRAULIC SYSTEM...........................................................................................................................................................189 Repair.................................................................................................................................................................189 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................190 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................191 NOTES......................................................................................................................................................................193 ANNEX..........................................................................................................................................................................195 TROUBLESHOOTING............................................................................................................................................................197 Instructions on troubleshooting........................................................................................................................................197 Layout of the fault table..............................................................................................................................................197 Possible causes........................................................................................................................................................197 Measures...............................................................................................................................................................197 Section................................................................................................................................................................197 FAULT TABLES...............................................................................................................................................................198 Combustion engine - Fault table........................................................................................................................................198 Working hydraulics – Fault table.......................................................................................................................................199 Track drive – Fault table..............................................................................................................................................200 Slewing mechnism – Fault table.........................................................................................................................................201 Central lubricating system – Fault table...............................................................................................................................202 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................204 ABBREVIATIONS..............................................................................................................................................................207 TECHNICAL DATA.............................................................................................................................................................209 INDEX..........................................................................................................................................................................213
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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
