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Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651470 – PDF DOWNLOAD
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Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651470 – PDF DOWNLOAD
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Description
Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651470 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651470 – PDF DOWNLOAD
Language : English
Pages : 267
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651470 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 120 E
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
! operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables, !
maintenance (inspection, servicing, repair) and / or
transport.
- 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 construction- 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 Terex|O&K after-sales service 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 Terex|O&K aftersales service.
- The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus RH 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651470 – PDF DOWNLOAD
TABLE OF CONTENTS.............................................................................................................................................................. 5 INTRODUCTION................................................................................................................................................................... 11 PREFACE.................................................................................................................................................................... 13 WARRANTY................................................................................................................................................................... 14 FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 15 Warnings and symbols................................................................................................................................................... 15 DESIGNATED USE............................................................................................................................................................. 16 ORGANIZATIONAL MEASURES.................................................................................................................................................... 17 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 18 Safety instructions governing specific operational phases.............................................................................................................. 18 Special work in conjunction with utilization of the machine and mainten ance and repairs as well as trouble shooting during work; disposal of parts and consumables.... 19 Warning of special dangers............................................................................................................................................. 20 Gas, dust, steam and smoke............................................................................................................................................. 21 Hydraulic equipment.................................................................................................................................................... 21 Noise.................................................................................................................................................................. 21 Oil, grease and other chemical sub stances............................................................................................................................. 21 Transporting and recommission ing...................................................................................................................................... 21 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22 NOTES...................................................................................................................................................................... 23 OPERATION...................................................................................................................................................................... 25 OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 27 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 29 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 30 Excavator layout....................................................................................................................................................... 31 Undercarriage.......................................................................................................................................................... 32 Superstructure......................................................................................................................................................... 32 Drive.................................................................................................................................................................. 32 Hydraulic system....................................................................................................................................................... 32 Pump Managing System (PMS)............................................................................................................................................. 32 Stored Program Control (SPC)........................................................................................................................................... 32 Electronic Hydraulic Servo-Control (EHSC).............................................................................................................................. 32 Demand control / Zero-flow regulation.................................................................................................................................. 33 Automatic engine speed reduction....................................................................................................................................... 33 Board-Control-System (BCS)............................................................................................................................................. 33 Electrical system...................................................................................................................................................... 33 Sign................................................................................................................................................................... 35 Entering and leaving the machine Safety instructions................................................................................................................... 36 Ramp-type ladder (optional)............................................................................................................................................ 37 EMERGENCY STOP pushbuttons............................................................................................................................................. 39 Windscreen washer...................................................................................................................................................... 39 Driver's seat.......................................................................................................................................................... 40 Adjusting the control consoles......................................................................................................................................... 41 Fire extinguisher...................................................................................................................................................... 42 Fire extinguisher (option)............................................................................................................................................. 42 Automatic fire-extinguishing system (optional)......................................................................................................................... 43 Harness (optional)..................................................................................................................................................... 44 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 48 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 78 Refuelling............................................................................................................................................................. 78 Service station (tanklift)............................................................................................................................................. 79 Switching the electrical system on and off............................................................................................................................. 85 STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 86 Starting the engines................................................................................................................................................... 86 AIR CONDITIONER (OPTION)................................................................................................................................................... 89 Back-up heating (option)............................................................................................................................................... 91 DRIVING SAFETY INSTRUCTIONS................................................................................................................................................ 93 TRAVELLING................................................................................................................................................................. 94 Superstructure basic position.......................................................................................................................................... 94 Travelling forwards/backwards.......................................................................................................................................... 94 Emergency machine drive................................................................................................................................................ 98 Locking the superstructure.............................................................................................................................................100 Track parking brake....................................................................................................................................................100 TRANSPORTING THE MACHINE...................................................................................................................................................101 Transport - Safety instructions........................................................................................................................................101 WORKING OPERATION - SAFETY INSTRUCTIONS....................................................................................................................................102 WORKING OPERATION..........................................................................................................................................................104 Before starting work...................................................................................................................................................104 Slewing and braking the superstructure.................................................................................................................................104 Braking the superstructure.............................................................................................................................................104 Working................................................................................................................................................................105 After daily operation..................................................................................................................................................106 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS.........................................................................................................................107 Securing the machine...................................................................................................................................................109 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................110 NOTES......................................................................................................................................................................111 INSPECTION AND SERVICING.......................................................................................................................................................113 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................115 FIRE AND EXPLOSION HAZARD..................................................................................................................................................121 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................123 Intervals..............................................................................................................................................................123 Change of engine oil l.................................................................................................................................................123 Air-intake system......................................................................................................................................................123 Oils / Greases.........................................................................................................................................................123 Cleaning jobs..........................................................................................................................................................123 Components.............................................................................................................................................................123 Plan V.................................................................................................................................................................125 Plan N.................................................................................................................................................................127 Plan T.................................................................................................................................................................129 Plan A – E.............................................................................................................................................................131 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................140 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................141 Filling quantities - Grease............................................................................................................................................141 Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................143 Filling quantities - Grease............................................................................................................................................143 INSPECTION PLAN - OIL......................................................................................................................................................144 Inspection plan – Oil (legend) ).......................................................................................................................................145 Filling quantities - oil...............................................................................................................................................146 Filling quantities - other.............................................................................................................................................146 LUBRICANTS.................................................................................................................................................................147 I. Oils for combustion engines and compressors (selection).............................................................................................................147 II. Oils for hydraulic system (selection)..............................................................................................................................148 III. Oils for gearboxes (selection)....................................................................................................................................149 V. Greases for bearings and slewing rings..............................................................................................................................150 SERVICING WORK.............................................................................................................................................................151 Hose line for oil and cooling liquid changes...........................................................................................................................151 ENGINE.....................................................................................................................................................................152 Engine - Safety instructions...........................................................................................................................................152 Retensioning the alternator/fan belt...................................................................................................................................152 Checking and adjusting the valve clearance.............................................................................................................................152 Checking the engine oil level / Topping up.............................................................................................................................152 Checking the oil level in the engine oil reservoir / topping up (optional).............................................................................................153 Changing the engine oil................................................................................................................................................154 Draining the oil off the engine oil reservoir (optional)...............................................................................................................156 Replacing the oil filter...............................................................................................................................................158 Replacing the oil filter (oil interval prolonging).....................................................................................................................158 Centrifuge (optional)..................................................................................................................................................159 COOLING SYSTEM.............................................................................................................................................................160 Radiators..............................................................................................................................................................160 Cooling liquid.........................................................................................................................................................162 Water filter...........................................................................................................................................................163 AIR-INTAKE SYSTEM..........................................................................................................................................................164 Main filter elements...................................................................................................................................................164 Safety filter element..................................................................................................................................................166 Air-intake lines.......................................................................................................................................................167 Dust collection........................................................................................................................................................167 FUEL SYSTEM................................................................................................................................................................168 Fuel system - Safety instructions......................................................................................................................................168 Replacing the fuel filters.............................................................................................................................................168 Venting the fuel system................................................................................................................................................169 Cleaning the fuel tanks................................................................................................................................................169 Water trap (option)....................................................................................................................................................171 ELECTRICAL SYSTEM..........................................................................................................................................................173 Electrical system - Safety instructions................................................................................................................................173 Alternator - Instructions..............................................................................................................................................173 Battery................................................................................................................................................................174 Switchgear cabinet.....................................................................................................................................................176 Equipotential bonding..................................................................................................................................................178 HYDRAULIC SYSTEM...........................................................................................................................................................180 Hydraulic system - Safety instructions.................................................................................................................................180 Depressurizing the hydraulic system....................................................................................................................................180 Checking the hydraulic oil level.......................................................................................................................................181 Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................183 Bypass valves (hydraulic oil reservoir)................................................................................................................................185 Replacing the hydraulic oil return-flow filters (filter housing).......................................................................................................186 Bypass valves (filter housing - cooling system)........................................................................................................................187 Breather filter........................................................................................................................................................188 Filter (control circuit and auxiliary control circuit).................................................................................................................189 High-pressure filter for working hydraulics............................................................................................................................190 High-pressure filters for slewing circuit..............................................................................................................................191 Changing the hydraulic oil.............................................................................................................................................192 Venting the hydraulic system...........................................................................................................................................195 Cleaning the hydraulic oil cooler......................................................................................................................................196 Electronic excavator control...........................................................................................................................................197 Pressure accumulator - Emergency lowering..............................................................................................................................198 PUMP TRANSFER GEARBOX......................................................................................................................................................199 Checking the gearbox oil level / Topping up with oil...................................................................................................................199 Gearbox venting........................................................................................................................................................201 Pump transfer gearbox lube oil filters.................................................................................................................................202 SLEWING GEARBOX............................................................................................................................................................203 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................203 Changing the gearbox oil...............................................................................................................................................203 Gearbox venting........................................................................................................................................................204 TRAVEL GAERBOX.............................................................................................................................................................205 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................205 Travel gearbox - Changing oil..........................................................................................................................................206 Pre-chamber - Changing the oil.........................................................................................................................................206 Brake chamber - Changing oil...........................................................................................................................................207 Breather filter........................................................................................................................................................207 CRAWLER TRACKS.............................................................................................................................................................208 Track roller, Support roller...........................................................................................................................................209 Track tensioner........................................................................................................................................................210 Pressure-accumulator inspection regulations............................................................................................................................211 Checking the gas charging pressure in the pressure accumulator.........................................................................................................211 SLEWING RING...............................................................................................................................................................212 Slewing ring - Instructions............................................................................................................................................212 Bearing races..........................................................................................................................................................212 CENTRAL LUBRICATING........................................................................................................................................................214 Design.................................................................................................................................................................214 Lube cycle / Pause period..............................................................................................................................................214 Lube cycle manual lubricating (optional)...............................................................................................................................214 Function...............................................................................................................................................................215 Filling up the grease container........................................................................................................................................216 Breather filter........................................................................................................................................................216 Checking the greasing pressure.........................................................................................................................................217 Unblocking a grease line...............................................................................................................................................218 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................219 Grease filter (Filling the grease container)...........................................................................................................................220 Grease filter (Grease lines)...........................................................................................................................................221 OTHER MAINTENANCE..........................................................................................................................................................222 Engine.................................................................................................................................................................222 Heating and air conditioning...........................................................................................................................................222 RAMP-TYPE LADDER (OPTIONAL) (OPTION)......................................................................................................................................223 Guide pulleys and locking bolt.........................................................................................................................................223 Pressure-accumulator inspection regulations............................................................................................................................224 Extract from the German regulations....................................................................................................................................224 Checking the gas charging pressure in the pressure accumulator.........................................................................................................224 ON-BOARD CRANE (OPTIONAL)..................................................................................................................................................225 Monitoring, warning and control elements...............................................................................................................................225 Checking the on-board crane............................................................................................................................................225 Drive unit.............................................................................................................................................................226 On-board crane.........................................................................................................................................................226 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................227 Putting the excavator out of operation.................................................................................................................................227 Battery storage........................................................................................................................................................227 Recommissioning........................................................................................................................................................228 NOTIZEN....................................................................................................................................................................229 REPAIR WORK....................................................................................................................................................................231 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................233 FIRE AND EXPLOSION HAZARD..................................................................................................................................................235 ENGINE.....................................................................................................................................................................236 ELECTRICAL SYSTEM..........................................................................................................................................................237 Assisted starting (with jumper cables) – Safety instructions...........................................................................................................237 Assisted starting (with jumper cables).................................................................................................................................237 Starting the engine with jumper cables (external batteries.............................................................................................................237 HYDRAULIC SYSTEM...........................................................................................................................................................239 Repair.................................................................................................................................................................239 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................240 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................242 NOTES......................................................................................................................................................................244 ANNEX..........................................................................................................................................................................247 TROUBLESHOOTING............................................................................................................................................................249 Instructions on troubleshooting........................................................................................................................................249 Layout of the fault table..............................................................................................................................................249 Possible causes........................................................................................................................................................249 Measures...............................................................................................................................................................249 Section................................................................................................................................................................249 FAULT TABLES...............................................................................................................................................................250 Combustion engine - Fault table........................................................................................................................................250 Working hydraulics – Fault table.......................................................................................................................................251 Track drive – Fault table..............................................................................................................................................252 Slewing mechnism – Fault table.........................................................................................................................................253 Central lubricating system – Fault table...............................................................................................................................254 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................255 ABBREVIATIONS..............................................................................................................................................................256 ABBREVIATIONS..........................................................................................................................................................257 TECHNICAL DATA.............................................................................................................................................................259 NOTES......................................................................................................................................................................261 INDEX..........................................................................................................................................................................263
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