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Cat Bucyrus RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651427 – PDF DOWNLOAD
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Description
Cat Bucyrus RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651427 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651427 – PDF DOWNLOAD
Language : English
Pages : 298
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus RH 120E Hydraulic Excavator INSTRUCTIONS MANUAL BI651427 – 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 BI651427 – PDF DOWNLOAD
1 INTRODUCTION............................................................................................................................................................... 13 PREFACE ................................................................................................................................................................. 15 WARRANTY ................................................................................................................................................................ 16 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17 Warnings and symbols................................................................................................................................................. 17 DESIGNATED USE........................................................................................................................................................... 18 ORGANIZATIONAL MEASURES.................................................................................................................................................. 19 Selection and qualification of personnel; basic responsibilities..................................................................................................... 20 Safety instructions governing specific operational phases............................................................................................................ 20 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 21 Warning of special dangers........................................................................................................................................... 22 Gas, dust, steam and smoke .......................................................................................................................................... 22 Hydraulic equipment ................................................................................................................................................. 23 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 24 NOTES ................................................................................................................................................................... 25 2 OPERATION.................................................................................................................................................................. 27 OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 29 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 30 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 31 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 32 Excavator layout..................................................................................................................................................... 33 Undercarriage ....................................................................................................................................................... 34 Superstructure ...................................................................................................................................................... 34 Drive ............................................................................................................................................................... 34 Hydraulic system .................................................................................................................................................... 34 Control and Monitoring Platform (CAMP) .............................................................................................................................. 34 Board-Control-System (BCS) .......................................................................................................................................... 35 Demand control / Zero-flow regulation................................................................................................................................ 35 Automatic reset to idling............................................................................................................................................ 35 Electrical system ................................................................................................................................................... 35 Signs ............................................................................................................................................................... 37 Entering and leaving the machine Safety instructions................................................................................................................. 38 Access ladder lighting .............................................................................................................................................. 38 Folding ladder (optional) ........................................................................................................................................... 39 Swinging ladder (optional) .......................................................................................................................................... 40 Escape ladder ....................................................................................................................................................... 41 Switching the cab interior lighting on and off ...................................................................................................................... 42 Switching the maintenance lights on and off ......................................................................................................................... 43 Emergency shut-off function ......................................................................................................................................... 44 Shutting off the supply voltage (battery main switch) ............................................................................................................... 45 Driver’s seat ...................................................................................................................................................... 46 Trainer's / instructor's seat ....................................................................................................................................... 48 Windscreen washer ................................................................................................................................................... 48 Fire extinguisher.................................................................................................................................................... 49 Fire extinguisher (option) .......................................................................................................................................... 49 Automatic fire-extinguishing system (optional) ...................................................................................................................... 50 Harness (optional) .................................................................................................................................................. 51 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 54 Engine 1 (LH), control and monitoring ............................................................................................................................... 61 Engine 2 (RH), control and monitoring ............................................................................................................................... 63 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 80 Refuelling .......................................................................................................................................................... 80 Back-up heating (option), filling in fuel ........................................................................................................................... 81 Service station (tanklift) .......................................................................................................................................... 81 Switching the electrical system on and off .......................................................................................................................... 87 Engines, emergency shut-off ......................................................................................................................................... 87 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 88 Fuel preheating system (optional) ................................................................................................................................... 89 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 90 Starting the engines ................................................................................................................................................ 90 Starting the left-hand engine........................................................................................................................................ 90 Starting the right-hand engine....................................................................................................................................... 90 Engines – adjusting the speed ....................................................................................................................................... 91 Starting the engines at low temperatures ............................................................................................................................ 91 Shutting off the engines ............................................................................................................................................ 92 Shutting off the left-hand engine.................................................................................................................................... 92 Shutting off the right-hand engine................................................................................................................................... 92 AIR CONDITIONER (OPTION) ................................................................................................................................................ 93 Back-up heating driver’s cab (option) ............................................................................................................................... 93 Back-up heating (option) ............................................................................................................................................ 94 TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 95 TRAVELLING .............................................................................................................................................................. 96 Superstructure basic position ....................................................................................................................................... 96 Travelling forwards/backwards ....................................................................................................................................... 96 Superstructure holding brake ........................................................................................................................................100 Track parking brake .................................................................................................................................................100 TRANSPORTING THE MACHINE ................................................................................................................................................101 Transport - Safety instructions .....................................................................................................................................101 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................102 WORKING OPERATION .......................................................................................................................................................104 Before starting work ................................................................................................................................................104 Activating the electronic excavator control .........................................................................................................................104 Swinging the superstructure .........................................................................................................................................105 Braking the superstructure ..........................................................................................................................................105 Working .............................................................................................................................................................106 After daily operation ...............................................................................................................................................107 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................108 Securing the machine ................................................................................................................................................109 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................110 NOTES ...................................................................................................................................................................111 3 INSPECTION AND SERVICING...................................................................................................................................................113 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................115 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................121 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................123 Intervals............................................................................................................................................................123 Change of engine oil l...............................................................................................................................................123 Air-intake system ...................................................................................................................................................123 Oils / Greases ......................................................................................................................................................123 Cleaning jobs .......................................................................................................................................................123 Components ..........................................................................................................................................................123 Plan V ..............................................................................................................................................................125 Plan N ..............................................................................................................................................................127 Plan T and W.........................................................................................................................................................129 Plan A – E ..........................................................................................................................................................131 LUBRICATING CHART – GREASE ..............................................................................................................................................138 Lubricating chart – Grease (legend) .................................................................................................................................139 Filling quantities – Grease .........................................................................................................................................139 INSPECTION PLAN - OIL ...................................................................................................................................................140 Inspection plan – Oil (legend) ......................................................................................................................................141 Filling quantities - oil ............................................................................................................................................142 Filling quantities - other...........................................................................................................................................142 LUBRICANTS ..............................................................................................................................................................143 Notes on the selection of oils and greases ..........................................................................................................................143 I. Oils for combustion engines ......................................................................................................................................144 II. Oils for hydraulic system .......................................................................................................................................145 III.a Oils for pump gearboxes .......................................................................................................................................146 III.b Oils for swing gearboxes ......................................................................................................................................147 III.c Oils for travel gearboxes .....................................................................................................................................148 V. Greases for bearings and swing rings .............................................................................................................................149 SERVICING WORK ..........................................................................................................................................................150 Hose line for oil and cooling liquid changes ........................................................................................................................150 ENGINE ..................................................................................................................................................................151 Engine - Safety instructions ........................................................................................................................................151 Checking the engine oil level / Topping up .........................................................................................................................152 Changing the engine oil .............................................................................................................................................153 Replacing the oil filters ...........................................................................................................................................155 Engine oil reservoir, filling in engine oil .........................................................................................................................155 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................156 COOLING SYSTEM ..........................................................................................................................................................157 Radiators ...........................................................................................................................................................157 Cooling liquid change ...............................................................................................................................................159 AIR-INTAKE SYSTEM .......................................................................................................................................................160 Dust trap, cleaning ................................................................................................................................................160 Main filter elements ................................................................................................................................................161 Safety filter element ...............................................................................................................................................163 Air-intake lines ....................................................................................................................................................163 FUEL SYSTEM .............................................................................................................................................................164 Fuel system - Safety instructions ...................................................................................................................................164 Replacing the fuel filter ...........................................................................................................................................164 Primary fuel filter, drain water ....................................................................................................................................165 Replacing the primary fuel filter ...................................................................................................................................165 Venting the fuel system .............................................................................................................................................166 Cleaning the fuel tanks .............................................................................................................................................166 Water trap (option)..................................................................................................................................................168 ELECTRICAL SYSTEM ......................................................................................................................................................170 Electrical system - Safety instructions .............................................................................................................................170 Alternator - Instructions ...........................................................................................................................................170 Battery .............................................................................................................................................................171 Switchgear cabinet ..................................................................................................................................................173 Equipotential bonding ...............................................................................................................................................175 Floodlight projector, replacing the lamp ............................................................................................................................177 HYDRAULIC SYSTEM ........................................................................................................................................................179 Hydraulic system - Safety instructions ..............................................................................................................................179 Depressurizing the hydraulic system .................................................................................................................................179 Checking the hydraulic oil level ....................................................................................................................................180 Hydraulic oil return-flow filters (hydraulic oil reservoir), replace ................................................................................................182 Bypass valves (hydraulic oil reservoir), replace ....................................................................................................................184 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................185 Bypass valves (filter housing - cooling system), replace ............................................................................................................186 Breather filter, replace ............................................................................................................................................187 Filter (servo circuit), replace .....................................................................................................................................188 High-pressure filter for working hydraulics, replace ................................................................................................................189 High-pressure filters for swing circuit, replace ....................................................................................................................190 Filter pump control, clean ..........................................................................................................................................191 Changing the hydraulic oil ..........................................................................................................................................192 Venting the hydraulic system.........................................................................................................................................195 Cleaning the hydraulic oil cooler....................................................................................................................................196 Electronic excavator control.........................................................................................................................................197 Pressure accumulators - Emergency lowering and servo circuit ........................................................................................................198 PUMP TRANSFER GEARBOX ...................................................................................................................................................199 Checking the gearbox oil level / Topping up with oil ................................................................................................................199 Gearbox venting .....................................................................................................................................................201 Pump transfer gearbox lube oil filters ..............................................................................................................................202 SWING GEARBOX ...........................................................................................................................................................203 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................203 Changing the gearbox oil ............................................................................................................................................203 Gearbox venting .....................................................................................................................................................204 SWING GEARBOX ...........................................................................................................................................................205 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................205 Changing the gearbox oil ............................................................................................................................................206 Gearbox venting .....................................................................................................................................................207 TRAVEL GEARBOX ..........................................................................................................................................................208 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................208 Travel gearbox - Changing oil .......................................................................................................................................209 Pre-chamber - Changing the oil ......................................................................................................................................209 Brake chamber - Changing oil ........................................................................................................................................210 Breather filter .....................................................................................................................................................210 CRAWLER TRACKS ..........................................................................................................................................................211 Track roller, Support roller ........................................................................................................................................212 Track tensioner .....................................................................................................................................................213 Pressure-accumulator inspection regulations .........................................................................................................................214 Checking the gas charging pressure in the pressure accumulator.......................................................................................................214 SWING RING ..............................................................................................................................................................215 Swing ring - Instructions............................................................................................................................................215 Bearing races........................................................................................................................................................215 CENTRAL LUBRICATING SYSTEM ..............................................................................................................................................217 Design ..............................................................................................................................................................217 Function ............................................................................................................................................................218 Filling up the grease container .....................................................................................................................................218 Breather filter grease container, check / replace ...................................................................................................................219 Checking the greasing pressure ......................................................................................................................................219 Unblocking a grease line ............................................................................................................................................220 Oilfilter replace (hydraulic circuit grease pump) ...................................................................................................................221 Grease filter replace (filling the grease container) ................................................................................................................222 Grease filter replace (Grease lines) ................................................................................................................................222 OTHER MAINTENANCE .......................................................................................................................................................223 Engine ..............................................................................................................................................................223 Heating and air conditioning ........................................................................................................................................223 RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................224 Pressure-accumulator inspection regulations .........................................................................................................................225 Extract from the German regulations..................................................................................................................................225 Checking the gas charging pressure in the pressure accumulator.......................................................................................................225 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................226 Monitoring, warning and control elements ............................................................................................................................226 Checking the on-board crane..........................................................................................................................................226 Drive unit ..........................................................................................................................................................227 On-board crane.......................................................................................................................................................227 On-Board crane, checking tightness of fastening bolts ...............................................................................................................228 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................229 Putting the excavator out of operation...............................................................................................................................229 Battery storage......................................................................................................................................................229 Recommissioning......................................................................................................................................................230 NOTES ..................................................................................................................................................................231 4 REPAIR WORK................................................................................................................................................................233 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................235 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................237 REPAIR WORK, 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 instructions .................................................................................................................................................241 Hydraulic hoses – Instructions .....................................................................................................................................241 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................242 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................243 NOTES ...................................................................................................................................................................245 5 ANNEX......................................................................................................................................................................247 BOARD-CONTROL-SYSTEM ....................................................................................................................................................249 BCS III, what’s that? ...............................................................................................................................................249 The keys on the front side ..........................................................................................................................................250 Other elements on the front side ....................................................................................................................................250 BCSIII, the start screen ............................................................................................................................................251 Information given on the start screen, top section ..................................................................................................................252 Information given on the start screen, central section ..............................................................................................................253 Information given on the start screen, lower section ................................................................................................................254 Information given on the “Service” screen ...........................................................................................................................255 Engine data screen ..................................................................................................................................................256 Hydraulic data screen ...............................................................................................................................................257 Lubrication data screen .............................................................................................................................................258 Controls adjustment data screen .....................................................................................................................................259 View documents screen ...............................................................................................................................................260 Signal table screen .................................................................................................................................................261 Signal table screen, location .......................................................................................................................................262 Signal table screen, diagram ........................................................................................................................................263 Signal table screen, diagram configuration ..........................................................................................................................264 Code table screen ...................................................................................................................................................265 BCS III, interfaces .................................................................................................................................................266 USB interface, data storage .........................................................................................................................................266 Saving data to a USB stick ..........................................................................................................................................267 Saving data to a USB stick, continued ...............................................................................................................................268 Saving data to a USB stick, continued ...............................................................................................................................269 BCSIII, cleaning ....................................................................................................................................................270 BCSIII, disposal ....................................................................................................................................................270 TROUBLESHOOTING .........................................................................................................................................................271 Instructions on troubleshooting .....................................................................................................................................271 Layout of the fault table ...........................................................................................................................................271 Possible causes .....................................................................................................................................................271 Measures ............................................................................................................................................................271 Section .............................................................................................................................................................271 FAULT TABLES ............................................................................................................................................................272 Combustion engine - Fault table .....................................................................................................................................272 Working hydraulics – Fault table ....................................................................................................................................273 Track drive – Fault table ...........................................................................................................................................274 Swing mechnism – Fault table ........................................................................................................................................275 Central lubricating system – Fault table ............................................................................................................................276 ENGINE MONITORING, CONTROL LAMPS ........................................................................................................................................277 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................278 ABBREVIATIONS ...........................................................................................................................................................279 ABBREVIATIONS........................................................................................................................................................280 TECHNICAL DATA ..........................................................................................................................................................281 NOTES ...................................................................................................................................................................291 6 INDEX......................................................................................................................................................................293
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