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Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651438 – PDF DOWNLOAD
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Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651438 – PDF DOWNLOAD
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Description
Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651438 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651438 – PDF DOWNLOAD
Language : English
Pages : 247
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651438 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 120-E Electric
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
- The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
ο§ operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
ο§ maintenance (inspection, servicing, repair) and / or
ο§ transport
In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the mining- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified Terex O&K mechanic or by attending an Terex O&K training course for operators or maintenance personnel. The service personal responsible for you will be pleased to deal with any queries you may have after reading through the operating instructions.
- 1 Complies with VDMA recommendation “Operating instructions” All Terex O&K operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Terex O&K will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the responsible service personal.
- 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 INSTRUCTIONS MANUAL BI651438 – 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 Transporting and recommissioning..................................................................................................................................... 21 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS ..................................................................................................... 22 Safety instructions for excavators with electric motor .............................................................................................................. 23 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 24 NOTES ................................................................................................................................................................... 25 2 OPERATION.................................................................................................................................................................. 27 OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 29 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 31 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 32 Excavator layout..................................................................................................................................................... 33 Undercarriage........................................................................................................................................................ 34 Superstructure....................................................................................................................................................... 34 Drive................................................................................................................................................................ 34 Hydraulic system..................................................................................................................................................... 34 Pump Managing System (PMS)........................................................................................................................................... 34 Stored Program Control (SPC) ........................................................................................................................................ 34 Control Management System (CMS) ..................................................................................................................................... 34 Demand control / Zero-flow regulation................................................................................................................................ 35 Board-Control-System (BCS) .......................................................................................................................................... 35 Electrical system ................................................................................................................................................... 35 Signs ............................................................................................................................................................... 39 Entering and leaving the machine, Safety instructions ............................................................................................................... 40 Access lighting ..................................................................................................................................................... 40 Folding ladder (optional) ........................................................................................................................................... 41 Swinging ladder (optional) .......................................................................................................................................... 42 Cab interior lamp ................................................................................................................................................... 43 Servicing lighting .................................................................................................................................................. 44 Illuminating the control column ..................................................................................................................................... 44 EMERGENCY STOP switch ............................................................................................................................................... 45 Servicing switch .................................................................................................................................................... 46 Windscreen washer ................................................................................................................................................... 46 Driver's seat ....................................................................................................................................................... 47 Fire extinguisher.................................................................................................................................................... 49 Automatic fire-extinguishing system (optional)....................................................................................................................... 50 Trainer's / instructor's seat ....................................................................................................................................... 50 Emergency escape device (optional)................................................................................................................................... 51 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 54 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 77 Service station (tanklift) .......................................................................................................................................... 77 Battery main switch, switching on and off ........................................................................................................................... 80 Electrical system (24V), switching on and off ....................................................................................................................... 80 Switching the electric motor on and off ............................................................................................................................. 81 Time-out before restart ............................................................................................................................................. 82 Electric motor can not be switched on ............................................................................................................................... 83 In case of failure .................................................................................................................................................. 83 Circuit breaker, switching on and off ............................................................................................................................... 84 Motor protection relay, function .................................................................................................................................... 86 Air conditioner (option)............................................................................................................................................. 88 TRAVELLING THE MACHINE .................................................................................................................................................. 89 Travelling, Safety Instructions ..................................................................................................................................... 89 Travelling .......................................................................................................................................................... 90 Emergency machine drive ............................................................................................................................................. 94 Locking the superstructure .......................................................................................................................................... 96 Track parking brake ................................................................................................................................................. 96 TRANSPORTING THE MACHINE ................................................................................................................................................ 97 Transport - Safety instructions ..................................................................................................................................... 97 WORKING OPERATION ....................................................................................................................................................... 98 Safety instructions ................................................................................................................................................. 98 Working equipment, avoid extreme positions .......................................................................................................................... 99 WORKING OPERATION .......................................................................................................................................................100 Before starting work ................................................................................................................................................100 Swinging the superstructure .........................................................................................................................................100 Braking the superstructure ..........................................................................................................................................100 Working .............................................................................................................................................................101 Emergency lowering of the working equipment .........................................................................................................................102 After daily operation ..............................................................................................................................................102 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................103 Securing the machine ................................................................................................................................................104 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................105 NOTES ...................................................................................................................................................................107 3 INSPECTION AND SERVICING...................................................................................................................................................109 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ..................................................................................................................111 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................113 FIRE AND EXPLOSION HAZARD................................................................................................................................................119 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................121 Intervals............................................................................................................................................................121 Oils / Greases ......................................................................................................................................................121 Cleaning jobs .......................................................................................................................................................121 Components ..........................................................................................................................................................121 Plan V ..............................................................................................................................................................123 Plan N ..............................................................................................................................................................125 Plan T and W ........................................................................................................................................................127 Plan A β E ..........................................................................................................................................................129 LUBRICATING CHART β GREASE ..............................................................................................................................................134 Lubricating chart β Grease (legend) .................................................................................................................................135 Filling quantities - Grease..........................................................................................................................................135 INSPECTION PLAN - OIL ...................................................................................................................................................136 Inspection plan β Oil (legend) ).....................................................................................................................................137 Filling quantities - oil ............................................................................................................................................138 Filling quantities - other...........................................................................................................................................138 LUBRICANTS ..............................................................................................................................................................139 Notes on the selection of oils and greases ..........................................................................................................................139 II. Oil for hydraulic system ........................................................................................................................................140 III.a Oils for pump gearbox .........................................................................................................................................141 III.b Oils for swing gearboxes ......................................................................................................................................142 III.c Oils for travel gearboxes .....................................................................................................................................143 V. Greases for bearings and slewing rings ...........................................................................................................................144 SERVICING WORK ..........................................................................................................................................................145 Hose line for oil change ............................................................................................................................................145 ELECTRIC MOTOR ..........................................................................................................................................................146 Electric motor - Safety instructions ................................................................................................................................146 Cleaning the electric motor ........................................................................................................................................146 Electric motor, greasing ............................................................................................................................................147 ELECTRICAL SYSTEM ......................................................................................................................................................148 Electrical system - Safety instructions .............................................................................................................................148 Battery .............................................................................................................................................................149 Switchgear cabinet ..................................................................................................................................................151 Slip ring maintenance................................................................................................................................................154 Floodlight projector, replacing the lamp ............................................................................................................................155 HYDRAULIC SYSTEM ........................................................................................................................................................157 Hydraulic system - Safety instructions ..............................................................................................................................157 Depressurizing the hydraulic system .................................................................................................................................157 Checking the hydraulic oil level ....................................................................................................................................158 Changing the hydraulic oil return-flow filter (hydraulic oil reservoir) .............................................................................................160 Bypass valves (hydraulic oil reservoir) .............................................................................................................................162 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................163 Bypass valves (filter housing - cooling system) .....................................................................................................................164 Breather filter .....................................................................................................................................................165 Filter (control circuit and auxiliary control circuit)...............................................................................................................166 High-pressure filter for working hydraulics .........................................................................................................................167 High-pressure filters for slewing circuit ...........................................................................................................................168 High-pressure filters for feeding circuits and slewing pumps ........................................................................................................169 Changing the hydraulic oil ..........................................................................................................................................170 Venting the hydraulic system.........................................................................................................................................173 Cleaning the hydraulic oil cooler....................................................................................................................................174 Electronic excavator control.........................................................................................................................................175 Pressure accumulator - Emergency lowering............................................................................................................................176 Pressure accumulator β Servo control- and feeding circuit ...........................................................................................................176 PUMP TRANSFER GEARBOX ...................................................................................................................................................178 Checking the gearbox oil level / Topping up with oil ................................................................................................................178 Gearbox venting .....................................................................................................................................................180 Pump transfer gearbox lube oil filters ..............................................................................................................................181 SLEWING GEARBOX .........................................................................................................................................................182 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................182 Changing the gearbox oil ............................................................................................................................................182 Gearbox venting .....................................................................................................................................................183 SWING GEARBOX ...........................................................................................................................................................184 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................184 Changing the gearbox oil ............................................................................................................................................185 Gearbox venting .....................................................................................................................................................186 TRAVEL GAERBOX ..........................................................................................................................................................187 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................187 Travel gearbox - Changing oil .......................................................................................................................................188 Pre-chamber - Changing the oil ......................................................................................................................................188 Brake chamber - Changing oil ........................................................................................................................................189 Breather filter .....................................................................................................................................................189 CRAWLER TRACKS ..........................................................................................................................................................190 Track roller, Support roller ........................................................................................................................................191 Track tensioner .....................................................................................................................................................192 Pressure-accumulator inspection regulations .........................................................................................................................193 Checking the gas charging pressure in the pressure accumulator.......................................................................................................193 SWING RING ..............................................................................................................................................................194 Swing ring - Instructions............................................................................................................................................194 Bearing races .......................................................................................................................................................194 CENTRAL LUBRICATING .....................................................................................................................................................196 Design ..............................................................................................................................................................196 Function ............................................................................................................................................................197 Replacing the grease drum ...........................................................................................................................................198 Checking the greasing pressure ......................................................................................................................................199 Unblocking a grease line.............................................................................................................................................199 Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................200 Grease filter (Grease lines) .......................................................................................................................................201 OTHER MAINTENANCE .......................................................................................................................................................202 Cleaning the cooling system .........................................................................................................................................202 Heating and air conditioning ........................................................................................................................................202 Air intake filters ..................................................................................................................................................202 HYDRAULIC LADDER (OPTIONAL) .............................................................................................................................................203 Pressure-accumulator inspection regulations .........................................................................................................................204 Extract from the German regulations..................................................................................................................................204 Checking the gas charging pressure in the pressure accumulator.......................................................................................................204 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................205 Putting the excavator out of operation...............................................................................................................................205 Battery storage......................................................................................................................................................205 Recommissioning......................................................................................................................................................206 NOTES ..................................................................................................................................................................207 4 REPAIR WORK................................................................................................................................................................209 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ..................................................................................................................211 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................213 FIRE AND EXPLOSION HAZARD ...............................................................................................................................................215 HYDRAULIC SYSTEM.........................................................................................................................................................216 Repair instructions .................................................................................................................................................216 Hydraulic hoses β Instructions .....................................................................................................................................216 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................217 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................218 NOTES ...................................................................................................................................................................219 5 ANNEX......................................................................................................................................................................221 TROUBLESHOOTING .........................................................................................................................................................223 Instructions on troubleshooting .....................................................................................................................................223 Layout of the fault table ...........................................................................................................................................223 Possible causes .....................................................................................................................................................223 Measures ............................................................................................................................................................223 Section .............................................................................................................................................................223 FAULT TABLES ............................................................................................................................................................224 Working hydraulics β Fault table ....................................................................................................................................224 Track drive β Fault table ...........................................................................................................................................225 Slewing mechnism β Fault table ......................................................................................................................................226 Central lubricating system β Fault table ............................................................................................................................227 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................228 ABBREVIATIONS ...........................................................................................................................................................229 ABBREVIATIONS ...........................................................................................................................................................230 TECHNICAL DATA ..........................................................................................................................................................231 6 INDEX......................................................................................................................................................................243
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