CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725044 – PDF DOWNLOAD

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CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725044 – PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725044 – PDF DOWNLOAD

Language : English
Pages : 312
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725044 – PDF DOWNLOAD

• 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 min- ing-machine specialist. They cannot provide
  basic know-how. This can be acquired, for example, in several days’ instruction by a
  qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for
  operators or maintenance per- sonnel.
• 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.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725044 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-3
About this Operating Instructions 1-3
Further machine documentation 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
Contents of the Declaration of Conformity 1-5
DESIGNATED USE 1-6
Noise emissions 1-7
Vibration data 1-7
ORGANIZATIONAL MEASURES 1-8
Selection and qualification of personnel; basic responsibilities 1-9
Safety instructions governing specific operational phases 1-9
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-10
Warning of special dangers 1-11
Gas, dust, steam and smoke 1-11
Hydraulic equipment 1-12
FIRE AND EXPLOSION HAZARD 1-13
NOTES 1-15
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’s cab 2-4
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
Control and Monitoring Platform (CAMP) 2-8
Board-Control-System (BCS) 2-9
Demand control / Zero-flow regulation 2-9
Automatic reset to idling 2-9
Electrical system 2-9
Signs 2-11
Entering and leaving the machine Safety instructions 2-12
Access ladder lighting 2-12
Swinging ladder 2-13
Folding ladder (optional) 2-14
Escape ladder (optional) 2-15
Switching the cab interior lighting on and off 2-16
OPERATING INSTRUCTIONS RH120E
Table of contents
vi BA RH120E(3 725 044.00)-EN
Switching the maintenance lights on and off 2-17
Emergency shut-off function 2-18
Shutting off the supply voltage (battery main switch) 2-19
Driver’s seat 2-20
Reducing the operators exposure to vibrations 2-22
Trainer’s / instructor’s seat 2-22
Fire extinguisher 2-23
Fire extinguisher (option) 2-23
Automatic fire-extinguishing system (optional) 2-24
Windscreen washer 2-24
Harness (optional) 2-25
MONITORING, WARNING AND CONTROL ELEMENTS 2-28
Engine 1 (LH), control and monitoring 2-35
Engine 2 (RH), control and monitoring 2-37
PUTTING THE MACHINE INTO OPERATION 2-54
Reducing the operator’s exposure to noise 2-54
Refuelling 2-54
Back-up heating (option), filling in fuel 2-55
Service station (tanklift) 2-55
Switching the electrical system on and off 2-61
Engines, emergency shut-off 2-61
Preheating system for engine and hydraulic oil (optional) 2-62
Fuel preheating system (optional) 2-63
STARTING AND STOPPING THE ENGINES 2-64
Starting the engines 2-64
Starting the left-hand engine 2-64
Starting the right-hand engine 2-64
Engines – adjusting the speed 2-65
Starting the engines at low temperatures 2-65
Shutting off the engines 2-66
Shutting off the left-hand engine 2-66
Shutting off the right-hand engine 2-66
AIR CONDITIONER (OPTION) 2-67
Back-up heating driver’s cab (option) 2-67
Back-up heating (option) 2-68
TRAVELLING, SAFETY INSTRUCTIONS 2-69
TRAVELLING 2-70
Superstructure basic position 2-70
Travelling forwards/backwards 2-70
Superstructure holding brake 2-74
Track parking brake 2-74
TRANSPORTING THE MACHINE 2-75
Transport – Safety instructions 2-75
WORKING OPERATION – SAFETY INSTRUCTIONS 2-76
WORKING OPERATION 2-78
Before starting work 2-78
OPERATING INSTRUCTIONS RH120E
Table of contents
BA RH120E(3 725 044.00)-EN vii
Activating the electronic excavator control 2-78
Swinging the superstructure 2-79
Braking the superstructure 2-79
Working 2-80
After daily operation 2-81
OPTIONAL EQUIPMENT 2-82
Water spraying system 2-82
Additional silencers 2-82
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-83
Securing the machine 2-84
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-85
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
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 and W 3-17
Plan A – E 3-19
LUBRICATING CHART – GREASE 3-26
Lubricating chart – Grease (legend) 3-27
Filling quantities – Grease 3-27
INSPECTION PLAN – OIL 3-28
Inspection plan – Oil (legend) 3-29
Filling quantities – oil 3-30
Filling quantities – other 3-30
LUBRICANTS 3-31
Notes on the selection of oils and greases 3-31
Avoid mixing of different hydraulic fluids 3-31
I. Oils for combustion engines 3-32
II. Oils for hydraulic system 3-33
III.a Oils for pump gearboxes 3-34
III.b Oils for swing gearboxes 3-35
III.c Oils for travel gearboxes 3-36
V. Greases for bearings and swing rings 3-37
SERVICING WORK 3-38
Hose line for oil and cooling liquid changes 3-38
OPERATING INSTRUCTIONS RH120E
Table of contents
viii BA RH120E(3 725 044.00)-EN
ENGINE 3-39
Engine – Safety instructions 3-39
Checking the engine oil level / Topping up 3-40
Checking the oil level in the engine oil reservoir / topping up (optional) 3-41
Changing the engine oil 3-42
Draining the oil off the engine oil reservoir (optional) 3-44
Replacing the oil filters 3-45
Engine oil reservoir, filling in engine oil 3-45
Replacing the oil filters (oil interval prolonging) 3-46
Centrifuge (optional) 3-47
Cold-starting fluid (ether) – Replacing the pressure vessel 3-48
COOLING SYSTEM 3-49
Radiators 3-49
Cooling liquid change 3-51
Water filter, replace 3-52
AIR-INTAKE SYSTEM 3-53
Main filter elements 3-53
Safety filter element, replace 3-56
Air-intake lines 3-57
Dust collection 3-57
FUEL SYSTEM 3-58
Fuel system – Safety instructions 3-58
Fuel filters, replace 3-58
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
Hydraulic oil return-flow filters (hydraulic oil reservoir), replace 3-75
Bypass valves (hydraulic oil reservoir), replace 3-77
Replacing the hydraulic oil return-flow filters (filter housing) 3-78
Bypass valves (filter housing – cooling system), replace 3-79
Breather filter, replace 3-80
Filter (servo circuit), replace 3-81
High-pressure filter for working hydraulics, replace 3-82
High-pressure filters for swing circuit, replace 3-83
Filter pump control, clean 3-84
Changing the hydraulic oil 3-85
Avoid mixing of different hydraulic fluids 3-85
Venting the hydraulic system 3-89
OPERATING INSTRUCTIONS RH120E
Table of contents
BA RH120E(3 725 044.00)-EN ix
Cleaning the hydraulic oil cooler 3-90
Electronic excavator control 3-91
Pressure accumulators – Emergency lowering and servo circuit 3-92
PUMP TRANSFER GEARBOX 3-93
Checking the gearbox oil level / Topping up with oil 3-93
Gearbox venting 3-95
Pump transfer gearbox lube oil filters 3-96
SWING GEARBOX 3-97
Gearbox – Checking the oil level / Topping up with oil 3-97
Changing the gearbox oil 3-97
Gearbox venting 3-98
SWING GEARBOX 3-99
Gearbox – Checking the oil level / Topping up with oil 3-99
Changing the gearbox oil 3-100
Gearbox venting 3-101
TRAVEL GEARBOX 3-102
Gearbox – Checking the oil level / Topping up with oil 3-102
Travel gearbox – Changing oil 3-103
Pre-chamber – Changing the oil 3-103
Brake chamber – Changing oil 3-104
Breather filter 3-104
CRAWLER TRACKS 3-105
Track roller, Support roller 3-106
Track tensioner 3-107
Pressure-accumulator inspection regulations 3-108
Checking the gas charging pressure in the pressure accumulator 3-108
SWING RING 3-109
Swing ring – Instructions 3-109
Bearing races 3-109
CENTRAL LUBRICATING SYSTEM 3-111
Design 3-111
Function 3-112
Filling up the grease container 3-113
Breather filter grease container, check / replace 3-113
Checking the greasing pressure 3-114
Unblocking a grease line 3-114
Oilfilter replace (hydraulic circuit grease pump) 3-115
Grease filter replace (filling the grease container) 3-116
Grease filter replace (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
OPERATING INSTRUCTIONS RH120E
Table of contents
x BA RH120E(3 725 044.00)-EN
ON-BOARD CRANE (OPTIONAL) 3-121
Monitoring, warning and control elements 3-121
Checking the on-board crane 3-121
Drive unit 3-122
On-board crane 3-122
On-Board crane, checking tightness of fastening bolts 3-123
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-124
Putting the excavator out of operation 3-124
Battery storage 3-124
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
Hydraulic hoses – Instructions 4-9
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-10
WELDING OPERATIONS – SAFETY INSTRUCTIONS 4-11
DISPOSAL AT THE END OF THE SERVICE LIFE 4-12
Dismantling and removal instructions 4-12
Risk of deflagrations 4-12
Risk of fire 4-12
Disposing of the machine without polluting the environment 4-13
Further hazardous substances 4-13
Appropriate disposal of batteries 4-14
NOTES 4-15
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
The keys on the front side 5-4
Other elements on the front side 5-4
BCSIII, the start screen 5-5
Information given on the start screen, top section 5-6
Information given on the start screen, central section 5-7
Information given on the start screen, lower section 5-8
Information given on the “Service” screen 5-9
Engine data screen 5-11
OPERATING INSTRUCTIONS RH120E
Table of contents
BA RH120E(3 725 044.00)-EN xi
Hydraulic data screen 5-12
Lubrication data screen 5-13
Controls adjustment data screen 5-14
View documents screen 5-15
Signal table screen 5-16
Signal table screen, location 5-17
Signal table screen, diagram 5-18
Signal table screen, diagram configuration 5-20
Code table screen 5-21
BCS III, interfaces 5-22
USB interface, data storage 5-22
Saving data to a USB stick 5-23
Saving data to a USB stick, continued 5-24
Saving data to a USB stick, continued 5-25
BCSIII, cleaning 5-26
BCSIII, disposal 5-26
TROUBLESHOOTING 5-27
Instructions on troubleshooting 5-27
Layout of the fault table 5-27
Possible causes 5-27
Measures 5-27
Section 5-27
FAULT TABLES 5-28
Combustion engine – Fault table 5-28
Working hydraulics – Fault table 5-29
Track drive – Fault table 5-30
Swing mechnism – Fault table 5-31
Central lubricating system – Fault table 5-32
HYDRAULIC CIRCUIT DIAGRAM 5-33
ABBREVIATIONS 5-35
ABBREVIATIONS 5-36
TECHNICAL DATA 5-37
NOTES 5-39
6 INDEX 6-1

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• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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