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CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725080 – PDF DOWNLOAD
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CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725080 – PDF DOWNLOAD
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Description
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725080 – PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725080 – PDF DOWNLOAD
Language : English
Pages : 269
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725080 – 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 protec- tion. - 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 Terex O&K mechanic or by attending an Terex O&K training course for
operators or main- tenance 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
transla- tion may give rise to questions which Terex O&K 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 O&K 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 cov- ering 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 i complete and
in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
Contact us: [email protected]
https://vimeo.com/858159689?share=copy
TABLE OF CONTENTS:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instruction Manual 3725080 – PDF DOWNLOAD
1 INTRODUCTION............................................................................................................................................................... 11 PREFACE ................................................................................................................................................................. 13 WARRANTY................................................................................................................................................................. 14 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15 Warnings and symbols................................................................................................................................................. 15 DESIGNATED USE........................................................................................................................................................... 16 ORGANIZATIONAL MEASURES.................................................................................................................................................. 17 Selection and qualification of personnel; basic responsibilities..................................................................................................... 18 Safety instructions governing specific operational phases............................................................................................................ 18 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19 Warning of special dangers........................................................................................................................................... 20 Gas, dust, steam and smoke........................................................................................................................................... 21 Hydraulic equipment.................................................................................................................................................. 21 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 22 NOTES ................................................................................................................................................................... 23 2 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 Control and Monitoring Platform (CAMP) .............................................................................................................................. 32 Board-Control-System (BCS) .......................................................................................................................................... 33 Demand control / Zero-flow regulation................................................................................................................................ 33 Automatic reset to idling............................................................................................................................................ 33 Electrical system ................................................................................................................................................... 33 Sign ................................................................................................................................................................ 35 Entering and leaving the machine Safety instructions................................................................................................................. 36 Access ladder lighting .............................................................................................................................................. 36 Ramp-type ladder (optional) ......................................................................................................................................... 37 Ramp-type ladder (optional) ......................................................................................................................................... 38 Switching the cab interior lighting on and off....................................................................................................................... 39 Switching the maintenance lights on and off ......................................................................................................................... 40 Emergency shut-off function ......................................................................................................................................... 41 Shutting off the supply voltage (battery main switch) ............................................................................................................... 42 Windscreen washer ................................................................................................................................................... 43 Trainer's / instructor's seat ....................................................................................................................................... 43 Driver’s seat ...................................................................................................................................................... 44 Fire extinguisher.................................................................................................................................................... 46 Fire extinguisher (option) .......................................................................................................................................... 46 Automatic fire-extinguishing system (optional) ...................................................................................................................... 47 Harness (optional) .................................................................................................................................................. 48 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 52 (Fig. 249:).......................................................................................................................................................... 59 Engine 1 (LH), control and monitoring ............................................................................................................................... 59 Engine 2 (RH), control and monitoring ............................................................................................................................... 61 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 75 Refuelling .......................................................................................................................................................... 75 Service station (tanklift) .......................................................................................................................................... 76 Switching the electrical system on and off .......................................................................................................................... 82 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 83 Starting the engines ................................................................................................................................................ 83 Starting the left-hand engine........................................................................................................................................ 83 Starting the right-hand engine....................................................................................................................................... 83 Engines – adjusting the speed ....................................................................................................................................... 84 Starting the engines at low temperatures ............................................................................................................................ 84 Shutting off the engines ............................................................................................................................................ 85 Shutting off the left-hand engine.................................................................................................................................... 85 Shutting off the right-hand engine................................................................................................................................... 85 Engines – emergency shut-off ........................................................................................................................................ 86 AIR CONDITIONER (OPTION)................................................................................................................................................. 87 Back-up heating (option) ............................................................................................................................................ 87 DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................ 88 TRAVELLING .............................................................................................................................................................. 89 Superstructure basic position ....................................................................................................................................... 89 Travelling forwards/backwards ....................................................................................................................................... 89 Superstructure holding brake ........................................................................................................................................ 93 Track parking brake ................................................................................................................................................. 93 TRANSPORTING THE MACHINE ................................................................................................................................................ 94 Transport - Safety instructions ..................................................................................................................................... 94 WORKING OPERATION - SAFETY INSTRUCTIONS ................................................................................................................................. 95 WORKING OPERATION ....................................................................................................................................................... 97 Before starting work ................................................................................................................................................ 97 Activating the electronic excavator control ......................................................................................................................... 97 Slewing the superstructure .......................................................................................................................................... 98 Braking the superstructure .......................................................................................................................................... 98 Working ............................................................................................................................................................. 99 After daily operation ...............................................................................................................................................100 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................101 Securing the machine ................................................................................................................................................103 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................104 NOTES ...................................................................................................................................................................105 3 INSPECTION AND SERVICING...................................................................................................................................................107 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................109 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................115 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................117 Intervals............................................................................................................................................................117 Change of engine oil l...............................................................................................................................................117 Air-intake system ...................................................................................................................................................117 Oils / Greases ......................................................................................................................................................117 Cleaning jobs .......................................................................................................................................................117 Components ..........................................................................................................................................................117 Plan V ..............................................................................................................................................................119 Plan N ..............................................................................................................................................................121 Plan T and W.........................................................................................................................................................123 Plan A – E ..........................................................................................................................................................125 LUBRICATING CHART – GREASE (LOADING BUCKET) .............................................................................................................................132 Lubricating chart – Grease / Loading bucket (legend) ................................................................................................................133 Filling quantities - Grease..........................................................................................................................................133 LUBRICATING CHART – GREASE / BACKHOE BUCKET .............................................................................................................................134 Lubricating chart – Grease / Backhoe bucket (legend) ................................................................................................................135 Filling quantities - Grease..........................................................................................................................................135 INSPECTION PLAN - OIL ...................................................................................................................................................136 Inspection plan – Oil (legend) ......................................................................................................................................137 Filling quantities - oil ............................................................................................................................................138 Filling quantities - other...........................................................................................................................................138 LUBRICANTS ..............................................................................................................................................................139 Notes on the selection of oils and greases ..........................................................................................................................139 I. Oils for combustion engines ......................................................................................................................................140 II. Oils for hydraulic system .......................................................................................................................................141 III.a Oils for pump gearboxes .......................................................................................................................................142 III.b Oils for swing gearboxes ......................................................................................................................................143 III.c Oils for travel gearboxes .....................................................................................................................................144 V. Greases for bearings and swing rings .............................................................................................................................145 SERVICING WORK ..........................................................................................................................................................146 Hose line for oil and cooling liquid changes ........................................................................................................................146 ENGINE ..................................................................................................................................................................147 Engine - Safety instructions ........................................................................................................................................147 Checking the engine oil level / Topping up .........................................................................................................................148 Changing the engine oil .............................................................................................................................................150 Replacing the oil filters ...........................................................................................................................................152 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................153 COOLING SYSTEM ..........................................................................................................................................................154 Radiators ...........................................................................................................................................................154 Cooling liquid ......................................................................................................................................................156 AIR-INTAKE SYSTEM .......................................................................................................................................................157 Main filter elements ................................................................................................................................................157 Safety filter element ...............................................................................................................................................159 Air-intake lines ....................................................................................................................................................160 Dust collection .....................................................................................................................................................160 FUEL SYSTEM .............................................................................................................................................................161 Fuel system - Safety instructions ...................................................................................................................................161 Replacing the fuel filter ...........................................................................................................................................161 Venting the fuel system .............................................................................................................................................162 Cleaning the fuel tanks .............................................................................................................................................162 Water trap (option)..................................................................................................................................................164 ELECTRICAL SYSTEM ......................................................................................................................................................166 Electrical system - Safety instructions .............................................................................................................................166 Alternator - Instructions ...........................................................................................................................................166 Battery .............................................................................................................................................................167 Switchgear cabinet ..................................................................................................................................................169 Equipotential bonding ...............................................................................................................................................171 Floodlight projector, replacing the lamp ............................................................................................................................173 HYDRAULIC SYSTEM ........................................................................................................................................................175 Hydraulic system - Safety instructions ..............................................................................................................................175 Depressurizing the hydraulic system .................................................................................................................................175 Checking the hydraulic oil level ....................................................................................................................................176 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................178 Bypass valves (hydraulic oil reservoir) .............................................................................................................................180 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................181 Bypass valves (filter housing - cooling system) .....................................................................................................................182 Breather filter .....................................................................................................................................................183 Filter (control circuit and auxiliary control circuit)...............................................................................................................184 High-pressure filter for working hydraulics .........................................................................................................................185 High-pressure filters for swing circuit .............................................................................................................................186 Changing the hydraulic oil ..........................................................................................................................................187 Venting the hydraulic system.........................................................................................................................................190 Cleaning the hydraulic oil cooler....................................................................................................................................191 Electronic excavator control.........................................................................................................................................192 Pressure accumulator - Emergency lowering............................................................................................................................193 PUMP TRANSFER GEARBOX ...................................................................................................................................................194 Checking the gearbox oil level / Topping up with oil ................................................................................................................194 Gearbox venting .....................................................................................................................................................196 Pump transfer gearbox lube oil filters ..............................................................................................................................197 SWING GEARBOX ...........................................................................................................................................................198 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................198 Changing the gearbox oil ............................................................................................................................................198 Gearbox venting .....................................................................................................................................................199 TRAVEL GEARBOX ..........................................................................................................................................................200 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................200 Travel gearbox - Changing oil .......................................................................................................................................201 Pre-chamber - Changing the oil ......................................................................................................................................201 Brake chamber - Changing oil ........................................................................................................................................202 Breather filter .....................................................................................................................................................202 CRAWLER TRACKS ..........................................................................................................................................................203 Track roller, Support roller ........................................................................................................................................204 Track tensioner .....................................................................................................................................................205 Pressure-accumulator inspection regulations .........................................................................................................................206 Checking the gas charging pressure in the pressure accumulator.......................................................................................................206 SWING RING ..............................................................................................................................................................207 Swing ring - Instructions............................................................................................................................................207 Bearing races........................................................................................................................................................207 CENTRAL LUBRICATING .....................................................................................................................................................209 Design ..............................................................................................................................................................209 Function ............................................................................................................................................................210 Filling up the grease container .....................................................................................................................................211 Breather filter .....................................................................................................................................................211 Checking the greasing pressure ......................................................................................................................................212 Unblocking a grease line.............................................................................................................................................213 Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................214 Grease filter (Filling the grease container) ........................................................................................................................215 Grease filter (Grease lines) ........................................................................................................................................216 OTHER MAINTENANCE .......................................................................................................................................................217 Engine ..............................................................................................................................................................217 Heating and air conditioning ........................................................................................................................................217 RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................218 Pressure-accumulator inspection regulations .........................................................................................................................219 Extract from the German regulations..................................................................................................................................219 Checking the gas charging pressure in the pressure accumulator.......................................................................................................219 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................220 Monitoring, warning and control elements ............................................................................................................................220 Checking the on-board crane..........................................................................................................................................220 Drive unit ..........................................................................................................................................................221 On-board crane.......................................................................................................................................................221 On-Board crane, checking tightness of fastening bolts ...............................................................................................................222 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................223 Putting the excavator out of operation...............................................................................................................................223 Battery storage......................................................................................................................................................223 Recommissioning......................................................................................................................................................224 NOTIZEN ................................................................................................................................................................225 4 REPAIR WORK................................................................................................................................................................227 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................229 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................231 REPAIR WORK, ENGINE......................................................................................................................................................232 ELECTRICAL SYSTEM .......................................................................................................................................................233 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................233 Assisted starting (with jumper cables)...............................................................................................................................233 Starting the engine with jumper cables (external batteries ..........................................................................................................233 HYDRAULIC SYSTEM.........................................................................................................................................................235 Repair instructions .................................................................................................................................................235 Hydraulic hoses – Instructions .....................................................................................................................................235 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................236 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................237 NOTES ...................................................................................................................................................................239 5 ANNEX......................................................................................................................................................................241 TROUBLESHOOTING .........................................................................................................................................................243 Instructions on troubleshooting .....................................................................................................................................243 Layout of the fault table ...........................................................................................................................................243 Possible causes .....................................................................................................................................................243 Measures ............................................................................................................................................................243 Section .............................................................................................................................................................243 FAULT TABLES ............................................................................................................................................................244 Combustion engine - Fault table .....................................................................................................................................244 Working hydraulics – Fault table ....................................................................................................................................245 Track drive – Fault table ...........................................................................................................................................246 Swing mechnism – Fault table ........................................................................................................................................247 Central lubricating system – Fault table ............................................................................................................................248 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................249 ABBREVIATIONS ...........................................................................................................................................................251 ABBREVIATIONS........................................................................................................................................................252 TECHNICAL DATA ..........................................................................................................................................................253 NOTES ...................................................................................................................................................................263 6 INDEX......................................................................................................................................................................265
PLEASE NOTE:
- 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]
S.V
