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Cat Bucyrus Hydraulic Excavator RH120E Operating Instructions Manual BI651415 – PDF DOWNLOAD
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Description
Cat Bucyrus Hydraulic Excavator RH120E Operating Instructions Manual BI651415 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus Hydraulic Excavator RH120E Operating Instructions Manual BI651415 – PDF DOWNLOAD
Language : English
Pages : 312
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus Hydraulic Excavator RH120E Operating Instructions Manual BI651415 – PDF DOWNLOAD
PREFACE
About this Operating Instructions
- 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
ο§ operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
ο§ maintenance (inspection, servicing, repair) and / or
ο§ 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 mining- machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel
- The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
- All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer.
- The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus Hydraulic Excavator RH120E Operating Instructions Manual BI651415 – PDF DOWNLOAD
1 INTRODUCTION............................................................................................................................................................... 13 PREFACE ................................................................................................................................................................. 15 About this Operating Instructions ................................................................................................................................... 15 Further machine documentation ....................................................................................................................................... 15 WARRANTY ................................................................................................................................................................ 16 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................ 17 Contents of the Declaration of Conformity ........................................................................................................................... 17 DESIGNATED USE........................................................................................................................................................... 18 Noise emissions ..................................................................................................................................................... 19 Vibration data ...................................................................................................................................................... 19 ORGANIZATIONAL MEASURES.................................................................................................................................................. 20 Selection and qualification of personnel; basic responsibilities..................................................................................................... 21 Safety instructions governing specific operational phases............................................................................................................ 21 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 22 Warning of special dangers........................................................................................................................................... 23 Gas, dust, steam and smoke .......................................................................................................................................... 23 Hydraulic equipment ................................................................................................................................................. 24 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 25 NOTES ................................................................................................................................................................... 27 2 OPERATION.................................................................................................................................................................. 29 OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 31 Operating Instructions, where to store it in the driverβs cab ....................................................................................................... 32 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 33 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 34 Excavator layout..................................................................................................................................................... 35 Undercarriage ....................................................................................................................................................... 36 Superstructure ...................................................................................................................................................... 36 Drive ............................................................................................................................................................... 36 Hydraulic system .................................................................................................................................................... 36 Control and Monitoring Platform (CAMP) .............................................................................................................................. 36 Board-Control-System (BCS) .......................................................................................................................................... 37 Demand control / Zero-flow regulation................................................................................................................................ 37 Automatic reset to idling............................................................................................................................................ 37 Electrical system ................................................................................................................................................... 37 Signs ............................................................................................................................................................... 39 Entering and leaving the machine Safety instructions................................................................................................................. 40 Access ladder lighting .............................................................................................................................................. 40 Swinging ladder ..................................................................................................................................................... 41 Folding ladder (optional) ........................................................................................................................................... 42 Escape ladder (optional) ............................................................................................................................................ 43 Switching the cab interior lighting on and off ...................................................................................................................... 44 Switching the maintenance lights on and off ......................................................................................................................... 45 Emergency shut-off function ......................................................................................................................................... 46 Shutting off the supply voltage (battery main switch) ............................................................................................................... 47 Driverβs seat ...................................................................................................................................................... 48 Reducing the operators exposure to vibrations ....................................................................................................................... 50 Trainer's / instructor's seat ....................................................................................................................................... 50 Fire extinguisher.................................................................................................................................................... 51 Fire extinguisher (option) .......................................................................................................................................... 51 Automatic fire-extinguishing system (optional) ...................................................................................................................... 52 Windscreen washer ................................................................................................................................................... 52 Harness (optional) .................................................................................................................................................. 53 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 56 Engine 1 (LH), control and monitoring ............................................................................................................................... 63 Engine 2 (RH), control and monitoring ............................................................................................................................... 65 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 82 Reducing the operator's exposure to noise ........................................................................................................................... 82 Refuelling .......................................................................................................................................................... 82 Back-up heating (option), filling in fuel ........................................................................................................................... 83 Service station (tanklift) .......................................................................................................................................... 83 Switching the electrical system on and off .......................................................................................................................... 89 Engines, emergency shut-off ......................................................................................................................................... 89 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 90 Fuel preheating system (optional) ................................................................................................................................... 91 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 92 Starting the engines ................................................................................................................................................ 92 Starting the left-hand engine........................................................................................................................................ 92 Starting the right-hand engine....................................................................................................................................... 92 Engines β adjusting the speed ....................................................................................................................................... 93 Starting the engines at low temperatures ............................................................................................................................ 93 Shutting off the engines ............................................................................................................................................ 94 Shutting off the left-hand engine.................................................................................................................................... 94 Shutting off the right-hand engine................................................................................................................................... 94 AIR CONDITIONER (OPTION) ................................................................................................................................................ 95 Back-up heating driverβs cab (option) ............................................................................................................................... 95 Back-up heating (option) ............................................................................................................................................ 96 TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 97 TRAVELLING .............................................................................................................................................................. 98 Superstructure basic position ....................................................................................................................................... 98 Travelling forwards/backwards ....................................................................................................................................... 98 Superstructure holding brake ........................................................................................................................................102 Track parking brake .................................................................................................................................................102 TRANSPORTING THE MACHINE ................................................................................................................................................103 Transport - Safety instructions .....................................................................................................................................103 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................104 WORKING OPERATION .......................................................................................................................................................106 Before starting work ................................................................................................................................................106 Activating the electronic excavator control .........................................................................................................................106 Swinging the superstructure .........................................................................................................................................107 Braking the superstructure ..........................................................................................................................................107 Working .............................................................................................................................................................108 After daily operation ...............................................................................................................................................109 OPTIONAL EQUIPMENT ......................................................................................................................................................110 Water spraying system ...............................................................................................................................................110 Additional silencers ................................................................................................................................................110 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................111 Securing the machine ................................................................................................................................................112 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................113 NOTES ...................................................................................................................................................................115 3 INSPECTION AND SERVICING...................................................................................................................................................117 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................119 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................125 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................127 Intervals............................................................................................................................................................127 Change of engine oil l...............................................................................................................................................127 Air-intake system ...................................................................................................................................................127 Oils / Greases ......................................................................................................................................................127 Cleaning jobs .......................................................................................................................................................127 Components ..........................................................................................................................................................127 Plan V ..............................................................................................................................................................129 Plan N ..............................................................................................................................................................131 Plan T and W.........................................................................................................................................................133 Plan A β E ..........................................................................................................................................................135 LUBRICATING CHART β GREASE ..............................................................................................................................................142 Lubricating chart β Grease (legend) .................................................................................................................................143 Filling quantities β Grease .........................................................................................................................................143 INSPECTION PLAN - OIL ...................................................................................................................................................144 Inspection plan β Oil (legend) ......................................................................................................................................145 Filling quantities - oil ............................................................................................................................................146 Filling quantities - other...........................................................................................................................................146 LUBRICANTS ..............................................................................................................................................................147 Notes on the selection of oils and greases ..........................................................................................................................147 Avoid mixing of different hydraulic fluids ..........................................................................................................................147 I. Oils for combustion engines ......................................................................................................................................148 II. Oils for hydraulic system .......................................................................................................................................149 III.a Oils for pump gearboxes .......................................................................................................................................150 III.b Oils for swing gearboxes ......................................................................................................................................151 III.c Oils for travel gearboxes .....................................................................................................................................152 V. Greases for bearings and swing rings .............................................................................................................................153 SERVICING WORK ..........................................................................................................................................................154 Hose line for oil and cooling liquid changes ........................................................................................................................154 ENGINE ..................................................................................................................................................................155 Engine - Safety instructions ........................................................................................................................................155 Checking the engine oil level / Topping up .........................................................................................................................156 Checking the oil level in the engine oil reservoir / topping up (optional) ..........................................................................................157 Changing the engine oil .............................................................................................................................................158 Draining the oil off the engine oil reservoir (optional) ............................................................................................................160 Replacing the oil filters ...........................................................................................................................................161 Engine oil reservoir, filling in engine oil .........................................................................................................................161 Replacing the oil filters (oil interval prolonging) .................................................................................................................162 Centrifuge (optional) ...............................................................................................................................................163 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................164 COOLING SYSTEM ..........................................................................................................................................................165 Radiators ...........................................................................................................................................................165 Cooling liquid change ...............................................................................................................................................167 Water filter, replace ...............................................................................................................................................168 AIR-INTAKE SYSTEM .......................................................................................................................................................169 Main filter elements ................................................................................................................................................169 Safety filter element, replace ......................................................................................................................................172 Air-intake lines ....................................................................................................................................................173 Dust collection .....................................................................................................................................................173 FUEL SYSTEM .............................................................................................................................................................174 Fuel system - Safety instructions ...................................................................................................................................174 Fuel filters, replace ...............................................................................................................................................174 Venting the fuel system .............................................................................................................................................175 Cleaning the fuel tanks .............................................................................................................................................175 Water trap (option)..................................................................................................................................................177 ELECTRICAL SYSTEM ......................................................................................................................................................179 Electrical system - Safety instructions .............................................................................................................................179 Alternator - Instructions ...........................................................................................................................................179 Battery .............................................................................................................................................................180 Switchgear cabinet ..................................................................................................................................................182 Equipotential bonding ...............................................................................................................................................184 Floodlight projector, replacing the lamp ............................................................................................................................186 HYDRAULIC SYSTEM ........................................................................................................................................................188 Hydraulic system - Safety instructions ..............................................................................................................................188 Depressurizing the hydraulic system .................................................................................................................................188 Checking the hydraulic oil level ....................................................................................................................................189 Hydraulic oil return-flow filters (hydraulic oil reservoir), replace ................................................................................................191 Bypass valves (hydraulic oil reservoir), replace ....................................................................................................................193 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................194 Bypass valves (filter housing - cooling system), replace ............................................................................................................195 Breather filter, replace ............................................................................................................................................196 Filter (servo circuit), replace .....................................................................................................................................197 High-pressure filter for working hydraulics, replace ................................................................................................................198 High-pressure filters for swing circuit, replace ....................................................................................................................199 Filter pump control, clean ..........................................................................................................................................200 Changing the hydraulic oil ..........................................................................................................................................201 Avoid mixing of different hydraulic fluids ..........................................................................................................................201 Venting the hydraulic system.........................................................................................................................................205 Cleaning the hydraulic oil cooler....................................................................................................................................206 Electronic excavator control.........................................................................................................................................207 Pressure accumulators - Emergency lowering and servo circuit ........................................................................................................208 PUMP TRANSFER GEARBOX ...................................................................................................................................................209 Checking the gearbox oil level / Topping up with oil ................................................................................................................209 Gearbox venting .....................................................................................................................................................211 Pump transfer gearbox lube oil filters ..............................................................................................................................212 SWING GEARBOX ...........................................................................................................................................................213 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................213 Changing the gearbox oil ............................................................................................................................................213 Gearbox venting .....................................................................................................................................................214 SWING GEARBOX ...........................................................................................................................................................215 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................215 Changing the gearbox oil ............................................................................................................................................216 Gearbox venting .....................................................................................................................................................217 TRAVEL GEARBOX ..........................................................................................................................................................218 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................218 Travel gearbox - Changing oil .......................................................................................................................................219 Pre-chamber - Changing the oil ......................................................................................................................................219 Brake chamber - Changing oil ........................................................................................................................................220 Breather filter .....................................................................................................................................................220 CRAWLER TRACKS ..........................................................................................................................................................221 Track roller, Support roller ........................................................................................................................................222 Track tensioner .....................................................................................................................................................223 Pressure-accumulator inspection regulations .........................................................................................................................224 Checking the gas charging pressure in the pressure accumulator.......................................................................................................224 SWING RING ..............................................................................................................................................................225 Swing ring - Instructions............................................................................................................................................225 Bearing races........................................................................................................................................................225 CENTRAL LUBRICATING SYSTEM ..............................................................................................................................................227 Design ..............................................................................................................................................................227 Function ............................................................................................................................................................228 Filling up the grease container .....................................................................................................................................229 Breather filter grease container, check / replace ...................................................................................................................229 Checking the greasing pressure ......................................................................................................................................230 Unblocking a grease line ............................................................................................................................................230 Oilfilter replace (hydraulic circuit grease pump) ...................................................................................................................231 Grease filter replace (filling the grease container) ................................................................................................................232 Grease filter replace (Grease lines) ................................................................................................................................232 OTHER MAINTENANCE .......................................................................................................................................................233 Engine ..............................................................................................................................................................233 Heating and air conditioning ........................................................................................................................................233 RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................234 Pressure-accumulator inspection regulations .........................................................................................................................235 Extract from the German regulations..................................................................................................................................235 Checking the gas charging pressure in the pressure accumulator.......................................................................................................235 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................237 Monitoring, warning and control elements ............................................................................................................................237 Checking the on-board crane..........................................................................................................................................237 Drive unit ..........................................................................................................................................................238 On-board crane.......................................................................................................................................................238 On-Board crane, checking tightness of fastening bolts ...............................................................................................................239 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................240 Putting the excavator out of operation...............................................................................................................................240 Battery storage......................................................................................................................................................240 Recommissioning......................................................................................................................................................240 NOTES ..................................................................................................................................................................241 4 REPAIR WORK................................................................................................................................................................243 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................245 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................247 REPAIR WORK, ENGINE......................................................................................................................................................248 ELECTRICAL SYSTEM .......................................................................................................................................................249 Assisted starting (with jumper cables) β Safety instructions ........................................................................................................249 Assisted starting (with jumper cables)...............................................................................................................................249 Starting the engine with jumper cables (external batteries ..........................................................................................................249 HYDRAULIC SYSTEM ........................................................................................................................................................251 Repair instructions .................................................................................................................................................251 Hydraulic hoses β Instructions .....................................................................................................................................251 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................252 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................253 DISPOSAL AT THE END OF THE SERVICE LIFE ................................................................................................................................254 Dismantling and removal instructions ................................................................................................................................254 Risk of deflagrations ...............................................................................................................................................254 Risk of fire ........................................................................................................................................................254 Disposing of the machine without polluting the environment ..........................................................................................................255 Further hazardous substances ........................................................................................................................................255 Appropriate disposal of batteries ...................................................................................................................................256 NOTES ...................................................................................................................................................................257 5 ANNEX......................................................................................................................................................................259 BOARD-CONTROL-SYSTEM ....................................................................................................................................................261 BCS III, whatβs that? ...............................................................................................................................................261 The keys on the front side ..........................................................................................................................................262 Other elements on the front side ....................................................................................................................................262 BCSIII, the start screen ............................................................................................................................................263 Information given on the start screen, top section ..................................................................................................................264 Information given on the start screen, central section ..............................................................................................................265 Information given on the start screen, lower section ................................................................................................................266 Information given on the βServiceβ screen ...........................................................................................................................267 Engine data screen ..................................................................................................................................................269 Hydraulic data screen ...............................................................................................................................................270 Lubrication data screen .............................................................................................................................................271 Controls adjustment data screen .....................................................................................................................................272 View documents screen ...............................................................................................................................................273 Signal table screen .................................................................................................................................................274 Signal table screen, location .......................................................................................................................................275 Signal table screen, diagram ........................................................................................................................................276 Signal table screen, diagram configuration ..........................................................................................................................278 Code table screen ...................................................................................................................................................279 BCS III, interfaces .................................................................................................................................................280 USB interface, data storage .........................................................................................................................................280 Saving data to a USB stick ..........................................................................................................................................281 Saving data to a USB stick, continued ...............................................................................................................................282 Saving data to a USB stick, continued ...............................................................................................................................283 BCSIII, cleaning ....................................................................................................................................................284 BCSIII, disposal ....................................................................................................................................................284 TROUBLESHOOTING .........................................................................................................................................................285 Instructions on troubleshooting .....................................................................................................................................285 Layout of the fault table ...........................................................................................................................................285 Possible causes .....................................................................................................................................................285 Measures ............................................................................................................................................................285 Section .............................................................................................................................................................285 FAULT TABLES ............................................................................................................................................................286 Combustion engine - Fault table .....................................................................................................................................286 Working hydraulics β Fault table ....................................................................................................................................287 Track drive β Fault table ...........................................................................................................................................288 Swing mechnism β Fault table ........................................................................................................................................289 Central lubricating system β Fault table ............................................................................................................................290 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................291 ABBREVIATIONS ...........................................................................................................................................................293 ABBREVIATIONS........................................................................................................................................................294 TECHNICAL DATA ..........................................................................................................................................................295 RH120E_product_spec_sheet............................................................................................................................................297 page_1...........................................................................................................................................................297 page_2 ..........................................................................................................................................................298 page_3...........................................................................................................................................................299 page_4...........................................................................................................................................................300 page_5...........................................................................................................................................................301 page_6...........................................................................................................................................................302 page_7 ..........................................................................................................................................................303 page_8...........................................................................................................................................................304 NOTES ...................................................................................................................................................................305 6 INDEX......................................................................................................................................................................307
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