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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD
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Description
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD
Language : English
Pages : 267
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 120 E
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
- The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
! operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair) and / or
transport.
- In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified GERMANY Germany mechanic or by attending an Terex-Germany training course for operators or maintenance personnel. The Terex-Germany 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 Germany operating manuals are issued in German and then translated.
- Even a good translation may give rise to questions which Terex Germany 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 Germany after- sales 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 – 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 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 EMERGENCY STOP pushbuttons............................................................................................................................................. 39 Windscreen washer...................................................................................................................................................... 39 Driver's seat.......................................................................................................................................................... 40 Fire extinguisher...................................................................................................................................................... 41 Fire extinguisher (option)............................................................................................................................................. 41 Automatic fire-extinguishing system (optional)......................................................................................................................... 42 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 44 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 75 Refuelling............................................................................................................................................................. 75 Service station (tanklift)............................................................................................................................................. 76 Switching the electrical system on and off............................................................................................................................. 82 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 83 Starting the engines................................................................................................................................................... 83 AIR CONDITIONER (OPTION)................................................................................................................................................... 86 Back-up heating (option)............................................................................................................................................... 88 DRIVING SAFETY INSTRUCTIONS................................................................................................................................................ 90 TRAVELLING................................................................................................................................................................. 91 Superstructure basic position.......................................................................................................................................... 91 Travelling forwards/backwards.......................................................................................................................................... 91 Emergency machine drive................................................................................................................................................ 95 Locking the superstructure............................................................................................................................................. 97 Track parking brake.................................................................................................................................................... 97 TRANSPORTING THE MACHINE................................................................................................................................................... 98 Transport - Safety instructions........................................................................................................................................ 98 WORKING OPERATION - SAFETY INSTRUCTIONS.................................................................................................................................... 99 WORKING OPERATION..........................................................................................................................................................101 Before starting work...................................................................................................................................................101 Slewing and braking the superstructure.................................................................................................................................101 Braking the superstructure.............................................................................................................................................101 Working................................................................................................................................................................102 After daily operation..................................................................................................................................................103 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS.........................................................................................................................104 Securing the machine...................................................................................................................................................106 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................107 NOTES......................................................................................................................................................................109 INSPECTION AND SERVICING.......................................................................................................................................................111 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................113 FIRE AND EXPLOSION HAZARD..................................................................................................................................................119 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................121 Intervals..............................................................................................................................................................121 Change of engine oil l.................................................................................................................................................121 Air-intake system......................................................................................................................................................121 Oils / Greases.........................................................................................................................................................121 Cleaning jobs..........................................................................................................................................................121 Components.............................................................................................................................................................121 Plan V.................................................................................................................................................................123 Plan N.................................................................................................................................................................125 Plan T.................................................................................................................................................................127 Plan A – E.............................................................................................................................................................129 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................138 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................139 Filling quantities - Grease............................................................................................................................................139 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................141 Filling quantities - Grease............................................................................................................................................141 INSPECTION PLAN - OIL......................................................................................................................................................142 Inspection plan – Oil (legend) ).......................................................................................................................................143 Filling quantities - oil...............................................................................................................................................144 Filling quantities - other.............................................................................................................................................144 LUBRICANTS.................................................................................................................................................................145 I. Oils for combustion engines and compressors (selection).............................................................................................................145 II. Oils for hydraulic system (selection)..............................................................................................................................146 III. Oils for gearboxes (selection)....................................................................................................................................147 V. Greases for bearings and slewing rings..............................................................................................................................148 SERVICING WORK.............................................................................................................................................................149 Hose line for oil and cooling liquid changes...........................................................................................................................149 ENGINE.....................................................................................................................................................................150 Engine - Safety instructions...........................................................................................................................................150 Retensioning the alternator/fan belt...................................................................................................................................150 Checking and adjusting the valve clearance.............................................................................................................................150 Checking the engine oil level / Topping up.............................................................................................................................150 Checking the oil level in the engine oil reservoir / topping up (optional).............................................................................................151 Changing the engine oil................................................................................................................................................152 Draining the oil off the engine oil reservoir (optional)...............................................................................................................154 Replacing the oil filter...............................................................................................................................................156 Centrifuge (optional)..................................................................................................................................................157 COOLING SYSTEM.............................................................................................................................................................158 Radiators..............................................................................................................................................................158 Cooling liquid.........................................................................................................................................................160 Water filter...........................................................................................................................................................161 AIR-INTAKE SYSTEM..........................................................................................................................................................162 Main filter elements...................................................................................................................................................162 Safety filter element..................................................................................................................................................164 Air-intake lines.......................................................................................................................................................165 Dust collection........................................................................................................................................................165 FUEL SYSTEM................................................................................................................................................................166 Fuel system - Safety instructions......................................................................................................................................166 Replacing the fuel filter..............................................................................................................................................166 Venting the fuel system................................................................................................................................................167 Cleaning the fuel tanks................................................................................................................................................167 Water trap (option)....................................................................................................................................................169 ELECTRICAL SYSTEM..........................................................................................................................................................171 Electrical system - Safety instructions................................................................................................................................171 Alternator - Instructions..............................................................................................................................................171 Battery................................................................................................................................................................172 Switchgear cabinet.....................................................................................................................................................174 Equipotential bonding..................................................................................................................................................176 HYDRAULIC SYSTEM...........................................................................................................................................................178 Hydraulic system - Safety instructions.................................................................................................................................178 Depressurizing the hydraulic system....................................................................................................................................178 Checking the hydraulic oil level.......................................................................................................................................179 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................181 Bypass valves (hydraulic oil reservoir)................................................................................................................................183 Replacing the hydraulic oil return-flow filters (filter housing).......................................................................................................184 Bypass valves (filter housing - cooling system)........................................................................................................................185 Breather filter........................................................................................................................................................186 Filter (control circuit and auxiliary control circuit).................................................................................................................187 High-pressure filter for working hydraulics............................................................................................................................188 High-pressure filters for slewing circuit..............................................................................................................................189 Changing the hydraulic oil.............................................................................................................................................190 Venting the hydraulic system...........................................................................................................................................193 Cleaning the hydraulic oil cooler......................................................................................................................................194 Electronic excavator control...........................................................................................................................................195 Pressure accumulator - Emergency lowering..............................................................................................................................196 PUMP TRANSFER GEARBOX......................................................................................................................................................197 Checking the gearbox oil level / Topping up with oil...................................................................................................................197 Gearbox venting........................................................................................................................................................199 Pump transfer gearbox lube oil filters.................................................................................................................................200 SLEWING GEARBOX............................................................................................................................................................201 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................201 Brake chamber - Checking the oil level / Topping up with oil...........................................................................................................201 Changing the gearbox oil...............................................................................................................................................202 Brake chamber - changing the oil.......................................................................................................................................203 Gearbox venting........................................................................................................................................................203 Brake chamber..........................................................................................................................................................203 TRAVEL GAERBOX.............................................................................................................................................................204 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................204 Travel gearbox - Changing oil..........................................................................................................................................205 Pre-chamber - Changing the oil.........................................................................................................................................205 Brake chamber - Changing oil...........................................................................................................................................206 Breather filter........................................................................................................................................................206 CRAWLER TRACKS.............................................................................................................................................................207 Track roller, Support roller...........................................................................................................................................208 Track tensioner........................................................................................................................................................209 Pressure-accumulator inspection regulations............................................................................................................................210 Checking the gas charging pressure in the pressure accumulator.........................................................................................................210 SLEWING RING...............................................................................................................................................................211 Slewing ring - Instructions............................................................................................................................................211 Bearing races..........................................................................................................................................................211 CENTRAL LUBRICATING........................................................................................................................................................213 Design.................................................................................................................................................................213 Lube cycle / Pause period..............................................................................................................................................213 Lube cycle manual lubricating (optional)...............................................................................................................................213 Function...............................................................................................................................................................214 Filling up the grease container........................................................................................................................................215 Breather filter........................................................................................................................................................215 Checking the greasing pressure.........................................................................................................................................216 Unblocking a grease line...............................................................................................................................................217 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................218 Grease filter (Filling the grease container)...........................................................................................................................219 Grease filter (Grease lines)...........................................................................................................................................220 OTHER MAINTENANCE..........................................................................................................................................................221 Engine.................................................................................................................................................................221 Heating and air conditioning...........................................................................................................................................221 RAMP-TYPE LADDER (OPTIONAL) (OPTION)......................................................................................................................................222 Guide pulleys and locking bolt.........................................................................................................................................222 Pressure-accumulator inspection regulations............................................................................................................................223 Extract from the German regulations....................................................................................................................................223 Checking the gas charging pressure in the pressure accumulator.........................................................................................................223 ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................224 Monitoring, warning and control elements...............................................................................................................................224 Checking the on-board crane............................................................................................................................................224 Drive unit.............................................................................................................................................................225 On-board crane.........................................................................................................................................................225 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................226 Putting the excavator out of operation.................................................................................................................................226 Battery storage........................................................................................................................................................226 Recommissioning........................................................................................................................................................227 NOTIZEN....................................................................................................................................................................229 REPAIR WORK....................................................................................................................................................................231 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................233 FIRE AND EXPLOSION HAZARD..................................................................................................................................................235 ENGINE.....................................................................................................................................................................236 ELECTRICAL SYSTEM..........................................................................................................................................................237 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................237 Assisted starting (with jumper cables).................................................................................................................................237 Starting the engine with jumper cables (external batteries.............................................................................................................237 HYDRAULIC SYSTEM...........................................................................................................................................................239 Repair.................................................................................................................................................................239 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................240 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................241 NOTES......................................................................................................................................................................243 ANNEX..........................................................................................................................................................................245 TROUBLESHOOTING............................................................................................................................................................247 Instructions on troubleshooting........................................................................................................................................247 Layout of the fault table..............................................................................................................................................247 Possible causes........................................................................................................................................................247 Measures...............................................................................................................................................................247 Section................................................................................................................................................................247 FAULT TABLES...............................................................................................................................................................248 Combustion engine - Fault table........................................................................................................................................248 Working hydraulics – Fault table.......................................................................................................................................249 Track drive – Fault table..............................................................................................................................................250 Slewing mechnism – Fault table.........................................................................................................................................251 Central lubricating system – Fault table...............................................................................................................................252 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................254 ABBREVIATIONS..............................................................................................................................................................257 TECHNICAL DATA.............................................................................................................................................................259 NOTES......................................................................................................................................................................261 INDEX..........................................................................................................................................................................263
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