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Cat Bucyrus RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651393 – PDF DOWNLOAD
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Cat Bucyrus RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651393 – PDF DOWNLOAD
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Cat Bucyrus RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651393 – PDF DOWNLOAD
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Cat Bucyrus RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651393 – 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 RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651393 – 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
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
Lube cycle manual lubricating (optional)……………………………………………………………………………………………………………….216
Function……………………………………………………………………………………………………………………………………………217
Filling up the grease container……………………………………………………………………………………………………………………….218
Breather filter……………………………………………………………………………………………………………………………………..218
Checking the greasing pressure………………………………………………………………………………………………………………………..219
Unblocking a grease line……………………………………………………………………………………………………………………………..220
Oilfilter (hydraulic circuit grease pump) )…………………………………………………………………………………………………………….221
Grease filter (Filling the grease container)……………………………………………………………………………………………………………222
Grease filter (Grease lines)………………………………………………………………………………………………………………………….223
OTHER MAINTENANCE……………………………………………………………………………………………………………………………………….224
Engine……………………………………………………………………………………………………………………………………………..224
Heating and air conditioning………………………………………………………………………………………………………………………….224
RAMP-TYPE LADDER (OPTIONAL) (OPTION)……………………………………………………………………………………………………………………..225
Guide pulleys and locking bolt………………………………………………………………………………………………………………………..225
Pressure-accumulator inspection regulations…………………………………………………………………………………………………………….226
Extract from the German regulations……………………………………………………………………………………………………………………226
Checking the gas charging pressure in the pressure accumulator……………………………………………………………………………………………226
ON-BOARD CRANE (OPTIONAL)………………………………………………………………………………………………………………………………..227
Monitoring, warning and control elements……………………………………………………………………………………………………………….227
Checking the on-board crane…………………………………………………………………………………………………………………………..227
Drive unit………………………………………………………………………………………………………………………………………….228
On-board crane………………………………………………………………………………………………………………………………………228
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING…………………………………………………………………………………………………..229
Putting the excavator out of operation…………………………………………………………………………………………………………………229
Battery storage……………………………………………………………………………………………………………………………………..229
Recommissioning……………………………………………………………………………………………………………………………………..230
NOTIZEN………………………………………………………………………………………………………………………………………………..231
REPAIR WORK………………………………………………………………………………………………………………………………………………..233
REPAIR WORK – SAFETY INSTRUCTIONS…………………………………………………………………………………………………………………………235
FIRE AND EXPLOSION HAZARD………………………………………………………………………………………………………………………………..237
ENGINE…………………………………………………………………………………………………………………………………………………238
ELECTRICAL SYSTEM……………………………………………………………………………………………………………………………………….239
Assisted starting (with jumper cables) – Safety instructions……………………………………………………………………………………………..239
Assisted starting (with jumper cables)…………………………………………………………………………………………………………………239
Starting the engine with jumper cables (external batteries……………………………………………………………………………………………….239
HYDRAULIC SYSTEM………………………………………………………………………………………………………………………………………..241
Repair……………………………………………………………………………………………………………………………………………..241
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS………………………………………………………………………………………………………………..242
WELDING OPERATIONS – SAFETY INSTRUCTIONS…………………………………………………………………………………………………………………..244
NOTES………………………………………………………………………………………………………………………………………………….246
ANNEX……………………………………………………………………………………………………………………………………………………..249
TROUBLESHOOTING…………………………………………………………………………………………………………………………………………251
Instructions on troubleshooting……………………………………………………………………………………………………………………….251
Layout of the fault table…………………………………………………………………………………………………………………………….251
Possible causes……………………………………………………………………………………………………………………………………..251
Measures……………………………………………………………………………………………………………………………………………251
Section…………………………………………………………………………………………………………………………………………….251
FAULT TABLES……………………………………………………………………………………………………………………………………………252
Combustion engine – Fault table……………………………………………………………………………………………………………………….252
Working hydraulics – Fault table………………………………………………………………………………………………………………………253
Track drive – Fault table…………………………………………………………………………………………………………………………….254
Slewing mechnism – Fault table………………………………………………………………………………………………………………………..255
Central lubricating system – Fault table……………………………………………………………………………………………………………….256
HYDRAULIC CIRCUIT DIAGRAM………………………………………………………………………………………………………………………………..258
ABBREVIATIONS…………………………………………………………………………………………………………………………………………..261
TECHNICAL DATA………………………………………………………………………………………………………………………………………….263
NOTES………………………………………………………………………………………………………………………………………………….265
INDEX……………………………………………………………………………………………………………………………………………………..267
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