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CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3664460 – PDF DOWNLOAD
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CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3664460 – PDF DOWNLOAD
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Description
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3664460 – PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3664460 – PDF DOWNLOAD
Language : English
Pages : 242
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3664460 – PDF DOWNLOAD
PREFACE:
- These operating instructions are designed to fa- miliarize the operator with the machine
and its designated use. - The operating instructions contain important in- formation 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 avail- able 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, troubleshoot- ing 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 pre- vention 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 con- struction-machine specialist. They cannot
provide basic know-how. This can be acquired, for exam- ple, in several days’ instruction by
a qualified GERMANY Germany mechanic or by attending an Terex-Germany training course for
operators or maintenance personnel. - The Terex-Germany after-sales service will be pleased to deal with any queries you may
have after reading through the operating instructions. - All Terex Germany operating manuals are issued in German and then translated. Even a good
translation may give rise to questions which Terex Germany will be pleased to answer. - The operating instructions are not work instruc- tions for carrying out major repairs. Such
work is willingly done for you by the Terex Germany af- ter-sales service. - The documentation relating to the machine is listed according to scope, quantity and language in
the shipping note of the machine or in the covering letter if supplied separately. The operating
instruc- tions and spare-parts list are marked with the se- rial number of the machine. - On taking receipt of the consignment, please check that the documentation is
complete and in the language requested by you.
TABLE OF CONTENTS:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3664460 – 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 EMERGENCY STOP pushbuttons............................................................................................................................................. 38 Windscreen washer...................................................................................................................................................... 38 Driver's seat.......................................................................................................................................................... 39 Fire extinguisher...................................................................................................................................................... 40 Automatic fire-extinguishing system (optional)......................................................................................................................... 41 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 42 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 65 Refuelling............................................................................................................................................................. 65 Service station (tanklift)............................................................................................................................................. 66 Switching the electrical system on and off............................................................................................................................. 71 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 72 Starting the engines................................................................................................................................................... 72 AIR CONDITIONER (OPTION)................................................................................................................................................... 75 DRIVING SAFETY INSTRUCTIONS................................................................................................................................................ 76 TRAVELLING................................................................................................................................................................. 77 Superstructure basic position.......................................................................................................................................... 77 Emergency machine drive................................................................................................................................................ 81 Locking the superstructure............................................................................................................................................. 83 Track parking brake.................................................................................................................................................... 83 TRANSPORTING THE MACHINE................................................................................................................................................... 84 Transport - Safety instructions........................................................................................................................................ 84 WORKING OPERATION - SAFETY INSTRUCTIONS.................................................................................................................................... 85 WORKING OPERATION.......................................................................................................................................................... 87 Before starting work................................................................................................................................................... 87 Slewing and braking the superstructure................................................................................................................................. 87 Braking the superstructure............................................................................................................................................. 87 Working................................................................................................................................................................ 88 After daily operation.................................................................................................................................................. 89 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 90 Securing the machine................................................................................................................................................... 92 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)............................................................................................................. 93 NOTES...................................................................................................................................................................... 95 INSPECTION AND SERVICING....................................................................................................................................................... 97 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS............................................................................................................................. 99 FIRE AND EXPLOSION HAZARD..................................................................................................................................................105 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................107 Intervals..............................................................................................................................................................107 Change of engine oil l.................................................................................................................................................107 Air-intake system......................................................................................................................................................107 Oils / Greases.........................................................................................................................................................107 Cleaning jobs..........................................................................................................................................................107 Components.............................................................................................................................................................107 Plan V.................................................................................................................................................................109 Plan N.................................................................................................................................................................111 Plan T.................................................................................................................................................................113 Plan A – E.............................................................................................................................................................115 LUBRICATING CHART – GREASE.................................................................................................................................................122 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................123 Filling quantities - Grease............................................................................................................................................123 INSPECTION PLAN - OIL......................................................................................................................................................124 Inspection plan – Oil (legend) ).......................................................................................................................................125 Filling quantities - oil...............................................................................................................................................126 Filling quantities - other.............................................................................................................................................126 LUBRICANTS.................................................................................................................................................................127 I. Oils for combustion engines and compressors (selection).............................................................................................................127 II. Oils for hydraulic system (selection)..............................................................................................................................128 III. Oils for gearboxes (selection)....................................................................................................................................129 V. Greases for bearings and slewing rings..............................................................................................................................130 SERVICING WORK.............................................................................................................................................................131 Hose line for oil and cooling liquid changes...........................................................................................................................131 ENGINE.....................................................................................................................................................................132 Engine - Safety instructions...........................................................................................................................................132 Retensioning the alternator/fan belt...................................................................................................................................132 Checking and adjusting the valve clearance.............................................................................................................................132 Checking the engine oil level / Topping up.............................................................................................................................132 Checking the oil level in the engine oil reservoir / topping up (optional).............................................................................................133 Changing the engine oil................................................................................................................................................134 Draining the oil off the engine oil reservoir (optional)...............................................................................................................136 Replacing the oil filter...............................................................................................................................................138 Centrifuge (optional)..................................................................................................................................................139 COOLING SYSTEM.............................................................................................................................................................140 Radiators..............................................................................................................................................................140 Cooling liquid.........................................................................................................................................................142 Water filter...........................................................................................................................................................143 AIR-INTAKE SYSTEM..........................................................................................................................................................144 Main filter elements...................................................................................................................................................144 Safety filter element..................................................................................................................................................146 Air-intake lines.......................................................................................................................................................147 Dust collection........................................................................................................................................................147 FUEL SYSTEM................................................................................................................................................................148 Fuel system - Safety instructions......................................................................................................................................148 Replacing the fuel filter..............................................................................................................................................148 Venting the fuel system................................................................................................................................................149 Cleaning the fuel tanks................................................................................................................................................149 Water trap (option)....................................................................................................................................................151 ELECTRICAL SYSTEM..........................................................................................................................................................153 Electrical system - Safety instructions................................................................................................................................153 Alternator - Instructions..............................................................................................................................................153 Battery................................................................................................................................................................154 Switchgear cabinet.....................................................................................................................................................156 Equipotential bonding..................................................................................................................................................158 HYDRAULIC SYSTEM...........................................................................................................................................................160 Hydraulic system - Safety instructions.................................................................................................................................160 Depressurizing the hydraulic system....................................................................................................................................160 Checking the hydraulic oil level.......................................................................................................................................161 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................163 Bypass valves (hydraulic oil reservoir)................................................................................................................................165 Replacing the hydraulic oil return-flow filters (filter housing).......................................................................................................166 Bypass valves (filter housing - cooling system)........................................................................................................................167 Breather filter........................................................................................................................................................168 Filter (control circuit and auxiliary control circuit).................................................................................................................169 High-pressure filter for working hydraulics............................................................................................................................170 High-pressure filters for slewing circuit..............................................................................................................................171 Changing the hydraulic oil.............................................................................................................................................172 Venting the hydraulic system...........................................................................................................................................175 Cleaning the hydraulic oil cooler......................................................................................................................................176 Electronic excavator control...........................................................................................................................................177 Pressure accumulator - Emergency lowering..............................................................................................................................178 PUMP TRANSFER GEARBOX......................................................................................................................................................179 Checking the gearbox oil level / Topping up with oil...................................................................................................................179 Gearbox venting........................................................................................................................................................181 Pump transfer gearbox lube oil filters.................................................................................................................................182 SLEWING GEARBOX............................................................................................................................................................183 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................183 Brake chamber - Checking the oil level / Topping up with oil...........................................................................................................183 Changing the gearbox oil...............................................................................................................................................184 Brake chamber - changing the oil.......................................................................................................................................185 Gearbox venting........................................................................................................................................................185 Brake chamber..........................................................................................................................................................185 TRAVEL GAERBOX.............................................................................................................................................................186 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................186 Travel gearbox - Changing oil..........................................................................................................................................187 Pre-chamber - Changing the oil.........................................................................................................................................187 Brake chamber - Changing oil...........................................................................................................................................188 Breather filter........................................................................................................................................................188 CRAWLER TRACKS.............................................................................................................................................................189 Track roller, Support roller...........................................................................................................................................190 Track tensioner........................................................................................................................................................191 Pressure-accumulator inspection regulations............................................................................................................................192 Checking the gas charging pressure in the pressure accumulator.........................................................................................................192 SLEWING RING...............................................................................................................................................................193 Slewing ring - Instructions............................................................................................................................................193 Bearing races..........................................................................................................................................................193 CENTRAL LUBRICATING........................................................................................................................................................195 Design.................................................................................................................................................................195 Lube cycle / Pause period..............................................................................................................................................195 Lube cycle manual lubricating (optional)...............................................................................................................................195 Function...............................................................................................................................................................196 Replacing the grease drum..............................................................................................................................................197 Checking the greasing pressure.........................................................................................................................................197 Unblocking a grease line...............................................................................................................................................198 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................199 Grease filter (Grease lines)...........................................................................................................................................200 OTHER MAINTENANCE..........................................................................................................................................................201 Engine.................................................................................................................................................................201 Heating and air conditioning...........................................................................................................................................201 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................202 Putting the excavator out of operation.................................................................................................................................202 Battery storage........................................................................................................................................................202 Recommissioning........................................................................................................................................................203 NOTES......................................................................................................................................................................205 REPAIR WORK....................................................................................................................................................................207 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................209 FIRE AND EXPLOSION HAZARD..................................................................................................................................................211 ENGINE.....................................................................................................................................................................212 ELECTRICAL SYSTEM..........................................................................................................................................................213 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................213 Assisted starting (with jumper cables).................................................................................................................................213 Starting the engine with jumper cables (external batteries.............................................................................................................213 HYDRAULIC SYSTEM...........................................................................................................................................................215 Repair.................................................................................................................................................................215 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................216 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................217 NOTES......................................................................................................................................................................219 ANNEX..........................................................................................................................................................................221 TROUBLESHOOTING............................................................................................................................................................223 Instructions on troubleshooting........................................................................................................................................223 Layout of the fault table..............................................................................................................................................223 Possible causes........................................................................................................................................................223 Measures...............................................................................................................................................................223 Section................................................................................................................................................................223 FAULT TABLES...............................................................................................................................................................224 Combustion engine - Fault table........................................................................................................................................224 Working hydraulics – Fault table.......................................................................................................................................225 Track drive – Fault table..............................................................................................................................................226 Slewing mechnism – Fault table.........................................................................................................................................227 Central lubricating system – Fault table...............................................................................................................................228 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................230 ABBREVIATIONS..............................................................................................................................................................231 TECHNICAL DATA.............................................................................................................................................................233 NOTES......................................................................................................................................................................235 INDEX..........................................................................................................................................................................237
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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