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CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651500 – PDF DOWNLOAD
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CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651500 – PDF DOWNLOAD
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Description
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651500 – PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651500 – PDF DOWNLOAD
Language : English
Pages : 222
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651500 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 120 E
Introduction
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The instruction manual contains 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 instruction manual 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 operator’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.
- 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 construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified GERMANY Germany mechanic or by attending an Terex-Germany training course for operators or maintenance personnel. The Terex-Germany 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 Germany operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Terex Germany 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 Germany after- sales service. The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine.
- On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651500 – PDF DOWNLOAD
TABLE OF CONTENTS.............................................................................................................................................................. 5 INTRODUCTION................................................................................................................................................................... 9 PREFACE.................................................................................................................................................................... 11 WARRANTY................................................................................................................................................................... 12 FUNDAMENTAL SAFETY INSTRUCTIONS............................................................................................................................................ 13 Warnings and symbols................................................................................................................................................... 13 DESIGNATED USE............................................................................................................................................................. 14 ORGANIZATIONAL MEASURES.................................................................................................................................................... 15 Selection and qualification of per sonnel; basic responsibilities...................................................................................................... 16 Safety instructions governing specific operational phases.............................................................................................................. 16 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.... 17 Warning of special dangers............................................................................................................................................. 18 Transporting and recommission ing...................................................................................................................................... 19 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS........................................................................................................ 20 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR..................................................................................................................... 22 FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 23 N.......................................................................................................................................................................... 25 NOTES...................................................................................................................................................................... 25 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 Electronic Hydraulic Servo-Control (EHSC).............................................................................................................................. 34 Demand control / Zero-flow regulation.................................................................................................................................. 35 Board-Control-System (BCS)............................................................................................................................................. 35 Electrical system...................................................................................................................................................... 35 Sign................................................................................................................................................................... 39 Entering and leaving the machine Safety instructions................................................................................................................... 40 Windscreen washer...................................................................................................................................................... 43 EMERGENCY STOP pushswitch.............................................................................................................................................. 44 Driver's seat.......................................................................................................................................................... 45 Fire extinguisher...................................................................................................................................................... 46 Automatic fire-extinguishing system (optional)......................................................................................................................... 47 MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 48 PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 65 Service station (tanklift)............................................................................................................................................. 65 Switching the electrical system on and off............................................................................................................................. 67 Switching the electric motor on and off................................................................................................................................ 68 AIR CONDITIONER (OPTION)................................................................................................................................................... 75 TRAVELLING................................................................................................................................................................. 76 DRIVING SAFETY INSTRUCTIONS............................................................................................................................................ 76 TRAVELLING............................................................................................................................................................. 77 Emergency machine drive................................................................................................................................................ 81 Locking the superstructure............................................................................................................................................. 83 Track parking brake.................................................................................................................................................... 83 TRANSPORTING THE MACHINE................................................................................................................................................... 84 Transport - Safety instructions........................................................................................................................................ 84 WORKING OPERATION.......................................................................................................................................................... 85 Safety instructions.................................................................................................................................................... 85 WORKING OPERATION...................................................................................................................................................... 87 Working................................................................................................................................................................ 88 After daily operation.................................................................................................................................................. 89 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 90 Securing the machine................................................................................................................................................... 92 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)............................................................................................................. 93 NOTES...................................................................................................................................................................... 95 INSPECTION AND SERVICING....................................................................................................................................................... 97 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR..................................................................................................................... 99 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................101 FIRE AND EXPLOSION HAZARD..................................................................................................................................................107 INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................109 Intervals..............................................................................................................................................................109 Oils / Greases.........................................................................................................................................................109 Cleaning jobs..........................................................................................................................................................109 Components.............................................................................................................................................................109 Plan V.................................................................................................................................................................111 Plan N.................................................................................................................................................................113 Plan T.................................................................................................................................................................115 Plan A – E.............................................................................................................................................................117 LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................122 Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................123 Filling quantities - Grease............................................................................................................................................123 INSPECTION PLAN - OIL......................................................................................................................................................124 Inspection plan – Oil (legend) ).......................................................................................................................................125 Filling quantities - oil...............................................................................................................................................126 Filling quantities - other.............................................................................................................................................126 LUBRICANTS.................................................................................................................................................................127 I. Oils for combustion engines and compressors (selection).............................................................................................................127 II. Oils for hydraulic system (selection)..............................................................................................................................128 III. Oils for gearboxes (selection)....................................................................................................................................129 V. Greases for bearings and slewing rings..............................................................................................................................130 SERVICING WORK.............................................................................................................................................................131 Hose line for oil and cooling liquid changes...........................................................................................................................131 ELECTRIC MOTOR.............................................................................................................................................................132 Electric motor - Safety instructions...................................................................................................................................132 Electric motor.........................................................................................................................................................132 ELECTRICAL SYSTEM..........................................................................................................................................................134 Electrical system - Safety instructions................................................................................................................................134 Battery main switch....................................................................................................................................................134 Battery................................................................................................................................................................135 Switchgear cabinet.....................................................................................................................................................137 Slip ring..............................................................................................................................................................140 HYDRAULIC SYSTEM...........................................................................................................................................................141 Hydraulic system - Safety instructions.................................................................................................................................141 Depressurizing the hydraulic system....................................................................................................................................141 Checking the hydraulic oil level.......................................................................................................................................142 Changing the hydraulic oil return-flow filter (hydraulic oil reservoir)................................................................................................144 Bypass valves (hydraulic oil reservoir)................................................................................................................................146 Replacing the hydraulic oil return-flow filters (filter housing).......................................................................................................147 Bypass valves (filter housing - cooling system)........................................................................................................................148 Breather filter........................................................................................................................................................149 Filter (control circuit and auxiliary control circuit).................................................................................................................150 High-pressure filter for working hydraulics............................................................................................................................151 High-pressure filters for slewing circuit..............................................................................................................................152 High-pressure filters for feeding circuits and slewing pumps...........................................................................................................153 Changing the hydraulic oil.............................................................................................................................................154 Venting the hydraulic system...........................................................................................................................................157 Cleaning the hydraulic oil cooler......................................................................................................................................158 Electronic excavator control...........................................................................................................................................159 Pressure accumulator - Emergency lowering..............................................................................................................................160 Pressure accumulator – Servo control- and feeding circuit..............................................................................................................160 PUMP TRANSFER GEARBOX......................................................................................................................................................162 Checking the gearbox oil level / Topping up with oil...................................................................................................................162 Gearbox venting........................................................................................................................................................164 Pump transfer gearbox lube oil filters.................................................................................................................................165 SLEWING GEARBOX............................................................................................................................................................166 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................166 Changing the gearbox oil...............................................................................................................................................166 Gearbox venting........................................................................................................................................................167 TRAVEL GAERBOX.............................................................................................................................................................168 Gearbox - Checking the oil level / Topping up with oil.................................................................................................................168 Travel gearbox - Changing oil..........................................................................................................................................169 Pre-chamber - Changing the oil.........................................................................................................................................169 Brake chamber - Changing oil...........................................................................................................................................170 Breather filter........................................................................................................................................................170 CRAWLER TRACKS.............................................................................................................................................................171 Track roller, Support roller...........................................................................................................................................172 Track tensioner........................................................................................................................................................173 Pressure-accumulator inspection regulations............................................................................................................................174 Checking the gas charging pressure in the pressure accumulator.........................................................................................................174 SLEWING RING...............................................................................................................................................................175 Slewing ring - Instructions............................................................................................................................................175 Bearing races..........................................................................................................................................................175 CENTRAL LUBRICATING........................................................................................................................................................177 Design.................................................................................................................................................................177 Lube cycle / Pause period..............................................................................................................................................177 Function...............................................................................................................................................................178 Fig. 3 102.............................................................................................................................................................178 Replacing the grease drum..............................................................................................................................................179 Checking the greasing pressure.........................................................................................................................................183 Unblocking a grease line...............................................................................................................................................183 Oilfilter (hydraulic circuit grease pump) )............................................................................................................................184 Grease filter (Grease lines)...........................................................................................................................................185 OTHER MAINTENANCE..........................................................................................................................................................186 Heating and air conditioning...........................................................................................................................................186 Intake filter..........................................................................................................................................................186 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................187 Putting the excavator out of operation.................................................................................................................................187 Battery storage........................................................................................................................................................187 Recommissioning........................................................................................................................................................188 NOTES......................................................................................................................................................................191 REPAIR WORK....................................................................................................................................................................193 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR.....................................................................................................................195 REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................197 FIRE AND EXPLOSION HAZARD..................................................................................................................................................199 HYDRAULIC SYSTEM...........................................................................................................................................................200 Repair.................................................................................................................................................................200 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................201 WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................202 NOTES......................................................................................................................................................................203 ANNEX..........................................................................................................................................................................205 TROUBLESHOOTING............................................................................................................................................................207 Instructions on troubleshooting........................................................................................................................................207 Layout of the fault table..............................................................................................................................................207 Possible causes........................................................................................................................................................207 Measures...............................................................................................................................................................207 Section................................................................................................................................................................207 FAULT TABLES...............................................................................................................................................................208 Working hydraulics – Fault table.......................................................................................................................................208 Track drive – Fault table..............................................................................................................................................209 Slewing mechnism – Fault table.........................................................................................................................................210 Central lubricating system – Fault table...............................................................................................................................211 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................212 ABBREVIATIONS..............................................................................................................................................................213 TECHNICAL DATA.............................................................................................................................................................215 INDEX..........................................................................................................................................................................219
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