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Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651477 – PDF DOWNLOAD
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Description
Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651477 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651477 – PDF DOWNLOAD
Language : English
Pages : 270
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651477 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 200 E
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
- The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
-operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
-maintenance (inspection, servicing, repair) and / or
-transport.
- In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified mechanic or by attending an Terex|O&K training course for operators or maintenance personnel. The Terex|O&K after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. All Terex|O&K operating manuals are issued in German and then translated.
- Even a good translation may give rise to questions which Terex|O&K will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex|O&K aftersales service.
- The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine.
- On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651477 – 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 Harness (optional)..................................................................................................................................................... 43 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 46 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 77 Refuelling............................................................................................................................................................. 77 Service station (tanklift)............................................................................................................................................. 78 Switching the electrical system on and off............................................................................................................................. 84 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 85 Starting the engines................................................................................................................................................... 85 AIR CONDITIONER (OPTION)................................................................................................................................................... 88 Back-up heating (option)............................................................................................................................................... 90 DRIVING SAFETY INSTRUCTIONS................................................................................................................................................ 92 TRAVELLING................................................................................................................................................................. 93 Superstructure basic position.......................................................................................................................................... 93 Travelling forwards/backwards.......................................................................................................................................... 93 Emergency machine drive................................................................................................................................................ 97 Locking the superstructure............................................................................................................................................. 99 Track parking brake.................................................................................................................................................... 99 TRANSPORTING THE MACHINE...................................................................................................................................................100 Transport - Safety instructions........................................................................................................................................100 WORKING OPERATION - SAFETY INSTRUCTIONS....................................................................................................................................101 WORKING OPERATION..........................................................................................................................................................103 Before starting work...................................................................................................................................................103 Slewing and braking the superstructure.................................................................................................................................103 Braking the superstructure.............................................................................................................................................103 Working................................................................................................................................................................104 After daily operation..................................................................................................................................................105 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS.........................................................................................................................106 Securing the machine...................................................................................................................................................108 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................110 NOTES......................................................................................................................................................................112 INSPECTION AND SERVICING.......................................................................................................................................................115 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................117 FIRE AND EXPLOSION HAZARD..................................................................................................................................................123 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................125 Intervals..............................................................................................................................................................125 Change of engine oil l.................................................................................................................................................125 Air-intake system......................................................................................................................................................125 Oils / Greases.........................................................................................................................................................125 Cleaning jobs..........................................................................................................................................................125 Components.............................................................................................................................................................125 Plan V.................................................................................................................................................................127 Plan N.................................................................................................................................................................129 Plan T.................................................................................................................................................................131 Plan A – E.............................................................................................................................................................133 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................142 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................143 Filling quantities - Grease............................................................................................................................................143 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................145 Filling quantities - Grease............................................................................................................................................145 INSPECTION PLAN - OIL......................................................................................................................................................146 Inspection plan – Oil (legend) ).......................................................................................................................................147 Filling quantities - oil...............................................................................................................................................148 Filling quantities - other.............................................................................................................................................148 LUBRICANTS.................................................................................................................................................................149 I. Oils for combustion engines and compressors (selection).............................................................................................................149 II. Oils for hydraulic system (selection)..............................................................................................................................150 III. Oils for gearboxes (selection)....................................................................................................................................151 V. Greases for bearings and slewing rings..............................................................................................................................152 SERVICING WORK.............................................................................................................................................................153 Hose line for oil and cooling liquid changes...........................................................................................................................153 ENGINE.....................................................................................................................................................................154 Engine - Safety instructions...........................................................................................................................................154 Retensioning the alternator/fan belt...................................................................................................................................154 Checking and adjusting the valve clearance.............................................................................................................................154 Checking the engine oil level / Topping up.............................................................................................................................154 Checking the oil level in the engine oil reservoir / topping up (optional).............................................................................................155 Changing the engine oil................................................................................................................................................156 Draining the oil off the engine oil reservoir (optional)...............................................................................................................158 Replacing the oil filter...............................................................................................................................................160 Replacing the oil filter (oil interval prolonging).....................................................................................................................160 Centrifuge (optional)..................................................................................................................................................161 COOLING SYSTEM.............................................................................................................................................................162 Radiators..............................................................................................................................................................162 Cooling liquid.........................................................................................................................................................164 Water filter...........................................................................................................................................................165 AIR-INTAKE SYSTEM..........................................................................................................................................................166 Main filter elements...................................................................................................................................................166 Safety filter element..................................................................................................................................................168 Air-intake lines.......................................................................................................................................................169 Dust collection........................................................................................................................................................169 FUEL SYSTEM................................................................................................................................................................170 Fuel system - Safety instructions......................................................................................................................................170 Replacing the fuel filter..............................................................................................................................................170 Venting the fuel system................................................................................................................................................171 Cleaning the fuel tanks................................................................................................................................................171 Water trap (option)....................................................................................................................................................173 ELECTRICAL SYSTEM..........................................................................................................................................................175 Electrical system - Safety instructions................................................................................................................................175 Alternator - Instructions..............................................................................................................................................175 Battery................................................................................................................................................................176 Switchgear cabinet.....................................................................................................................................................178 Equipotential bonding..................................................................................................................................................180 HYDRAULIC SYSTEM...........................................................................................................................................................182 Hydraulic system - Safety instructions.................................................................................................................................182 Depressurizing the hydraulic system....................................................................................................................................182 Checking the hydraulic oil level.......................................................................................................................................183 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................185 Bypass valves (hydraulic oil reservoir)................................................................................................................................187 Replacing the hydraulic oil return-flow filters (filter housing).......................................................................................................188 Bypass valves (filter housing - cooling system)........................................................................................................................189 Breather filter........................................................................................................................................................190 Filter (control circuit and auxiliary control circuit).................................................................................................................191 High-pressure filter for working hydraulics............................................................................................................................192 High-pressure filters for slewing circuit..............................................................................................................................193 Changing the hydraulic oil.............................................................................................................................................194 Venting the hydraulic system...........................................................................................................................................197 Cleaning the hydraulic oil cooler......................................................................................................................................198 Electronic excavator control...........................................................................................................................................199 Pressure accumulator - Emergency lowering..............................................................................................................................200 PUMP TRANSFER GEARBOX......................................................................................................................................................201 Checking the gearbox oil level / Topping up with oil...................................................................................................................201 Gearbox venting........................................................................................................................................................203 Pump transfer gearbox lube oil filters.................................................................................................................................204 SLEWING GEARBOX............................................................................................................................................................205 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................205 Changing the gearbox oil...............................................................................................................................................205 Gearbox venting........................................................................................................................................................206 TRAVEL GAERBOX.............................................................................................................................................................207 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................207 Travel gearbox - Changing oil..........................................................................................................................................208 Pre-chamber - Changing the oil.........................................................................................................................................208 Brake chamber - Changing oil...........................................................................................................................................209 Breather filter........................................................................................................................................................209 CRAWLER TRACKS.............................................................................................................................................................210 Track roller, Support roller...........................................................................................................................................211 Track tensioner........................................................................................................................................................212 Pressure-accumulator inspection regulations............................................................................................................................213 Checking the gas charging pressure in the pressure accumulator.........................................................................................................213 SLEWING RING...............................................................................................................................................................214 Slewing ring - Instructions............................................................................................................................................214 Bearing races..........................................................................................................................................................214 CENTRAL LUBRICATING........................................................................................................................................................216 Design.................................................................................................................................................................216 Lube cycle / Pause period..............................................................................................................................................216 Function...............................................................................................................................................................217 Fig. 3 130.............................................................................................................................................................217 Replacing the grease drum..............................................................................................................................................218 Checking the greasing pressure.........................................................................................................................................219 Unblocking a grease line...............................................................................................................................................219 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................220 Grease filter (Grease lines)...........................................................................................................................................221 OTHER MAINTENANCE..........................................................................................................................................................222 Engine.................................................................................................................................................................222 Heating and air conditioning...........................................................................................................................................222 RAMP-TYPE LADDER (OPTIONAL) (OPTION)......................................................................................................................................223 Guide pulleys and locking bolt.........................................................................................................................................223 Pressure-accumulator inspection regulations............................................................................................................................224 Extract from the German regulations....................................................................................................................................224 Checking the gas charging pressure in the pressure accumulator.........................................................................................................224 ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................225 Monitoring, warning and control elements...............................................................................................................................225 Checking the on-board crane............................................................................................................................................225 Drive unit.............................................................................................................................................................226 On-board crane.........................................................................................................................................................226 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................227 Putting the excavator out of operation.................................................................................................................................227 Battery storage........................................................................................................................................................227 Recommissioning........................................................................................................................................................228 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...................................................................................................................................242 NOTES......................................................................................................................................................................244 ANNEX..........................................................................................................................................................................247 TROUBLESHOOTING............................................................................................................................................................249 Instructions on troubleshooting........................................................................................................................................249 Layout of the fault table..............................................................................................................................................249 Possible causes........................................................................................................................................................249 Measures...............................................................................................................................................................249 Section................................................................................................................................................................249 FAULT TABLES...............................................................................................................................................................250 Combustion engine - Fault table........................................................................................................................................250 Working hydraulics – Fault table.......................................................................................................................................251 Track drive – Fault table..............................................................................................................................................252 Slewing mechnism – Fault table.........................................................................................................................................253 Central lubricating system – Fault table...............................................................................................................................254 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................256 ABBREVIATIONS..............................................................................................................................................................259 TECHNICAL DATA.............................................................................................................................................................261 NOTES......................................................................................................................................................................263 INDEX..........................................................................................................................................................................265
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