CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725023 – PDF DOWNLOAD

Description

CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725023 – PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725023 – PDF DOWNLOAD

Language : English
Pages : 282
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725023 – PDF DOWNLOAD

PREFACE:

• These operating instructions are designed to famil- iarize the operator with the machine and its
  desig- nated 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 Bu- cyrus HEX mechanic or by attending an Bucyrus HEX training course for
  operators or maintenance personnel.
• The Bucyrus HEX after-sales service will be pleased to deal with any queries you may
  have after reading through the operating instructions.
• All Bucyrus HEX operating manuals are issued in German and then translated. Even a good transla-
  tion may give rise to questions which Bucyrus HEX 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 Bucyrus HEX after- 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
  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 Operating Instruction Manual 3725023 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE 1-6
ORGANIZATIONAL MEASURES 1-7
Selection and qualification of personnel; basic responsibilities 1-8
Safety instructions governing specific operational phases 1-8
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-9
Warning of special dangers 1-10
Gas, dust, steam and smoke 1-11
Hydraulic equipment 1-11
Noise 1-11
Oil, grease and other chemical substances 1-11
Ether 1-11
Transporting and recommissioning 1-11
FIRE AND EXPLOSION HAZARD 1-12
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE EXCAVATOR 2-6
Excavator layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Pump Managing System (PMS) 2-8
Programmable Logic Controller (PLC) 2-8
Central Management System (CMS) 2-8
Demand control / Zero-flow regulation 2-9
Automatic engine speed reduction 2-9
Board-Control-System (BCS) 2-9
Electrical system 2-9
Sign 2-11
Entering and leaving the machine Safety instructions 2-12
Ramp-type ladder (optional) 2-13
Ramp-type ladder (optional) 2-14
EMERGENCY STOP pushbuttons 2-16
Windscreen washer 2-16
Driver’s seat 2-17
OPERATING INSTRUCTIONS RH120E
Table of contents
vi BA RH120E(3 725 023.00)-EN
Fire extinguisher 2-18
Fire extinguisher (option) 2-18
Automatic fire-extinguishing system (optional) 2-19
Harness (optional) ) 2-20
MONITORING, WARNING AND CONTROL ELEMENTS 2-24
PUTTING THE MACHINE INTO OPERATION 2-54
Refuelling 2-54
Service station (tanklift) 2-55
Switching the electrical system on and off 2-61
STARTING AND STOPPING THE ENGINES 2-62
Starting the engines 2-62
AIR CONDITIONER (OPTION) 2-65
Back-up heating (option) 2-67
DRIVING SAFETY INSTRUCTIONS 2-69
TRAVELLING 2-70
Superstructure basic position 2-70
Travelling forwards/backwards 2-70
Emergency machine drive 2-74
Locking the superstructure 2-76
Track parking brake 2-76
TRANSPORTING THE MACHINE 2-77
Transport – Safety instructions 2-77
WORKING OPERATION – SAFETY INSTRUCTIONS 2-78
Running-in instructions for hydraulic cylinders 2-78
Warming-up phase for the hydraulic system 2-78
Avoid extreme positions of the working equipment 2-79
WORKING OPERATION 2-80
Before starting work 2-80
Slewing the superstructure 2-80
Braking the superstructure 2-80
Working movements 2-81
After daily operation 2-82
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-83
Securing the machine 2-85
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-86
NOTES 2-87
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-9
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-11
Intervals 3-11
Change of engine oil l 3-11
OPERATING INSTRUCTIONS RH120E
Table of contents
BA RH120E(3 725 023.00)-EN vii
Air-intake system 3-11
Oils / Greases 3-11
Cleaning jobs 3-11
Components 3-11
Plan V 3-13
Plan N 3-15
Plan T 3-17
Plan A – E 3-19
LUBRICATING CHART – GREASE 3-28
Lubricating chart – Grease (legend) 3-29
Filling quantities – Grease 3-29
INSPECTION PLAN – OIL 3-30
Inspection plan – Oil (legend) 3-31
Filling quantities – oil 3-32
Filling quantities – other 3-32
LUBRICANTS 3-33
Notes on the selection of oils and greases 3-33
I. Oils for combustion engines 3-34
II. Oils for hydraulic system 3-35
III.a Oils for pump gearboxes 3-36
III.b Oils for swing gearboxes 3-37
III.c Oils for travel gearboxes 3-38
V. Greases for bearings and slewing rings 3-39
SERVICING WORK 3-40
Hose line for oil and cooling liquid changes 3-40
ENGINE 3-41
Engine – Safety instructions 3-41
Checking the engine oil level / Topping up 3-41
Checking the oil level in the engine oil reservoir / topping up (optional) 3-42
Changing the engine oil 3-43
Draining the oil off the engine oil reservoir (optional) 3-45
Replacing the oil filter 3-47
Replacing the oil filter (oil interval prolonging) 3-47
Centrifuge (optional) 3-48
Cold-starting fluid (ether) – Replacing the pressure vessel 3-49
COOLING SYSTEM 3-50
Radiators 3-50
Cooling liquid 3-52
Water filter 3-53
AIR-INTAKE SYSTEM 3-54
Main filter elements 3-54
Safety filter element 3-56
Air-intake lines 3-57
Dust collection 3-57
FUEL SYSTEM 3-58
Fuel system – Safety instructions 3-58
Replacing the fuel filters 3-58
OPERATING INSTRUCTIONS RH120E
Table of contents
viii BA RH120E(3 725 023.00)-EN
Venting the fuel system 3-59
Cleaning the fuel tanks 3-59
Water trap (option) 3-61
ELECTRICAL SYSTEM 3-63
Electrical system – Safety instructions 3-63
Alternator – Instructions 3-63
Battery 3-64
Switchgear cabinet 3-66
Equipotential bonding 3-68
Floodlight projector, replacing the lamp 3-70
HYDRAULIC SYSTEM 3-72
Hydraulic system – Safety instructions 3-72
Depressurizing the hydraulic system 3-72
Checking the hydraulic oil level 3-73
Changing the hydraulic oil return-flow (hydraulic oil reservoir) 3-75
Bypass valves (hydraulic oil reservoir) 3-77
Replacing the hydraulic oil return-flow filters (filter housing) 3-78
Bypass valves (filter housing – cooling system) 3-79
Breather filter 3-80
Filter (control circuit and auxiliary control circuit) 3-81
High-pressure filter for working hydraulics 3-82
High-pressure filters for slewing circuit 3-83
Changing the hydraulic oil 3-84
Venting the hydraulic system 3-87
Cleaning the hydraulic oil cooler 3-88
Electronic excavator control 3-89
Pressure accumulator – Emergency lowering 3-90
PUMP TRANSFER GEARBOX 3-91
Checking the gearbox oil level / Topping up with oil 3-91
Gearbox venting 3-93
Pump transfer gearbox lube oil filters 3-94
SWING GEARBOX 3-95
Gearbox – Checking the oil level / Topping up with oil 3-95
Changing the gearbox oil 3-95
Gearbox venting 3-96
SWING GEARBOX 3-97
Gearbox – Checking the oil level / Topping up with oil 3-97
Changing the gearbox oil 3-98
Gearbox venting 3-99
TRAVEL GEARBOX 3-100
Gearbox – Checking the oil level / Topping up with oil 3-100
Travel gearbox – Changing oil 3-101
Pre-chamber – Changing the oil 3-101
Brake chamber – Changing oil 3-102
Breather filter 3-102
CRAWLER TRACKS 3-103
Track roller, Support roller 3-104
OPERATING INSTRUCTIONS RH120E
Table of contents
BA RH120E(3 725 023.00)-EN ix
Track tensioner 3-105
Pressure-accumulator inspection regulations 3-106
Checking the gas charging pressure in the pressure accumulator 3-106
SLEWING RING 3-107
Slewing ring – Instructions 3-107
Bearing races 3-107
CENTRAL LUBRICATING 3-109
Design 3-109
Function 3-110
Filling up the grease container 3-111
Breather filter 3-111
Checking the greasing pressure 3-112
Unblocking a grease line. 3-113
Oilfilter (hydraulic circuit grease pump) ) 3-114
Grease filter (Filling the grease container) 3-115
Grease filter (Grease lines) 3-116
OTHER MAINTENANCE 3-117
Engine 3-117
Heating and air conditioning 3-117
RAMP-TYPE LADDER (OPTIONAL) 3-118
Pressure-accumulator inspection regulations 3-119
Extract from the German regulations 3-119
Checking the gas charging pressure in the pressure accumulator 3-119
ON-BOARD CRANE (OPTIONAL) 3-120
Monitoring, warning and control elements 3-120
Checking the on-board crane 3-120
Drive unit 3-121
On-board crane 3-121
On-Board crane, checking tightness of fastening bolts 3-121
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-123
Putting the excavator out of operation 3-123
Battery storage 3-123
Recommissioning 3-124
NOTES 3-125
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
ELECTRICAL SYSTEM 4-7
Assisted starting (with jumper cables) – Safety instructions 4-7
Assisted starting (with jumper cables) 4-7
Starting the engine with jumper cables (external batteries 4-7
HYDRAULIC SYSTEM 4-9
Repair instructions 4-9
OPERATING INSTRUCTIONS RH120E
Table of contents
x BA RH120E(3 725 023.00)-EN
Hydraulic hoses – Instructions 4-9
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-10
WELDING OPERATIONS – SAFETY INSTRUCTIONS 4-11
NOTES 4-13
5 ANNEX 5-1
TROUBLESHOOTING 5-3
Instructions on troubleshooting 5-3
Layout of the fault table 5-3
Possible causes 5-3
Measures 5-3
Section 5-3
FAULT TABLES 5-4
Combustion engine – Fault table 5-4
Working hydraulics – Fault table 5-5
Track drive – Fault table 5-6
Slewing mechnism – Fault table 5-7
Central lubricating system – Fault table 5-8
HYDRAULIC CIRCUIT DIAGRAM 5-9
ABBREVIATIONS 5-10
ABBREVIATIONS 5-11
TECHNICAL DATA 5-13
NOTES 5-15
6 INDEX 6-1

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