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Cat Bucyrus RH120E Hydraulic Excavator Operating Instructions Manual BI651419 – PDF DOWNLOAD
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Description
Cat Bucyrus RH120E Hydraulic Excavator Operating Instructions Manual BI651419 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus RH120E Hydraulic Excavator Operating Instructions Manual BI651419 – PDF DOWNLOAD
Language : English
Pages : 280
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus RH120E Hydraulic Excavator Operating Instructions Manual BI651419 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH120E
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 construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel. The Bucyrus HEX 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 Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX 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 Bucyrus HEX 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 RH120E Hydraulic Excavator Operating Instructions Manual BI651419 – PDF DOWNLOAD
1 INTRODUCTION................................................................................................................................................................ 11 PREFACE .................................................................................................................................................................. 13 WARRANTY ................................................................................................................................................................. 14 FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................................................................................... 15 Warnings and symbols ................................................................................................................................................. 15 DESIGNATED USE ........................................................................................................................................................... 16 ORGANIZATIONAL MEASURES .................................................................................................................................................. 17 Personal protective equipment and the working clothing ............................................................................................................... 17 Selection and qualification of personnel; basic responsibilities ..................................................................................................... 18 Safety instructions governing specific operational phases ............................................................................................................ 18 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 19 Warning of special dangers ........................................................................................................................................... 20 Gas, dust, steam and smoke ........................................................................................................................................... 21 Hydraulic equipment .................................................................................................................................................. 21 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 22 NOTES .................................................................................................................................................................... 23 2 OPERATION................................................................................................................................................................... 25 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 27 Operating Instructions, where to store it in the driverβs cab ........................................................................................................ 28 OPERATION, 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 Central Management System (CMS) ...................................................................................................................................... 32 Demand control / Zero-flow regulation ................................................................................................................................ 33 Automatic engine speed reduction ..................................................................................................................................... 33 Board-Control-System (BCS) ........................................................................................................................................... 33 Electrical system .................................................................................................................................................... 33 Signs and labels ..................................................................................................................................................... 35 Entering and leaving the machine, Safety instructions................................................................................................................. 36 Access ladder lighting ............................................................................................................................................... 36 Folding ladder (optional) ............................................................................................................................................ 37 Swinging ladder (optional) ........................................................................................................................................... 38 Switching the cab interior lighting on and off ....................................................................................................................... 39 Switching the maintenance lights on and off .......................................................................................................................... 40 Illuminating the control column ...................................................................................................................................... 40 EMERGENCY STOP switch ................................................................................................................................................ 41 Windscreen washer .................................................................................................................................................... 41 Driverβs seat ....................................................................................................................................................... 42 Fire extinguisher .................................................................................................................................................... 44 Fire extinguisher (option) ........................................................................................................................................... 44 Automatic fire-extinguishing system (optional)........................................................................................................................ 45 Harness (optional) ................................................................................................................................................... 46 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 50 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 82 Refuelling ........................................................................................................................................................... 82 Service station (tanklift) ........................................................................................................................................... 82 Switching the electrical system on and off ........................................................................................................................... 88 STARTING AND STOPPING THE ENGINES ........................................................................................................................................ 89 Starting the engines ................................................................................................................................................. 89 Starting the engines at low temperatures ............................................................................................................................. 90 AIR CONDITIONER (OPTION).................................................................................................................................................. 92 Back-up heating (option) ............................................................................................................................................. 93 DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................. 95 TRAVELLING ............................................................................................................................................................... 96 Superstructure basic position ........................................................................................................................................ 96 Travelling forwards/backwards ........................................................................................................................................ 96 Emergency machine drive ..............................................................................................................................................100 Superstructure holding brake .........................................................................................................................................102 Track parking brake ..................................................................................................................................................102 TRANSPORTING THE MACHINE .................................................................................................................................................103 Transport - Safety instructions ......................................................................................................................................103 WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................104 Running-in instructions for hydraulic cylinders ......................................................................................................................104 Warming-up phase for the hydraulic system ............................................................................................................................104 Avoid extreme positions of the working equipment .....................................................................................................................105 WORKING OPERATION ........................................................................................................................................................106 Before starting work .................................................................................................................................................106 Switching on the electronic excavator control ........................................................................................................................106 Swinging the superstructure ..........................................................................................................................................106 Braking the superstructure ...........................................................................................................................................106 Working movements ....................................................................................................................................................107 After daily operation ................................................................................................................................................108 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................109 Securing the machine .................................................................................................................................................111 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................112 NOTES ....................................................................................................................................................................113 3 INSPECTION AND SERVICING....................................................................................................................................................115 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................117 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................123 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................125 Intervals.............................................................................................................................................................125 Change of engine oil l................................................................................................................................................125 Air-intake system ....................................................................................................................................................125 Oils / Greases .......................................................................................................................................................125 Cleaning jobs ........................................................................................................................................................125 Components ...........................................................................................................................................................125 Plan V ...............................................................................................................................................................127 Plan N ...............................................................................................................................................................129 Plan T and W .........................................................................................................................................................131 Plan A β E ...........................................................................................................................................................133 LUBRICATING CHART β GREASE (LOADING BUCKET) ..............................................................................................................................140 Lubricating chart β Grease (legend) ..................................................................................................................................141 Filling quantities - Grease...........................................................................................................................................141 INSPECTION PLAN - OIL ....................................................................................................................................................142 Inspection plan β Oil (legend) .......................................................................................................................................143 Filling quantities - oil .............................................................................................................................................144 Filling quantities - other............................................................................................................................................144 LUBRICANTS ...............................................................................................................................................................145 Notes on the selection of oils and greases ...........................................................................................................................145 I. Oils for combustion engines .......................................................................................................................................146 II. Oils for hydraulic system ........................................................................................................................................147 III.a Oils for pump gearboxes ........................................................................................................................................148 III.b Oils for swing gearboxes .......................................................................................................................................149 III.c Oils for travel gearboxes ......................................................................................................................................150 V. Greases for bearings and swing rings ..............................................................................................................................151 SERVICING WORK ...........................................................................................................................................................152 Hose line for oil and cooling liquid changes .........................................................................................................................152 ENGINE ...................................................................................................................................................................153 Engine - Safety instructions .........................................................................................................................................153 Checking the engine oil level / Topping up ..........................................................................................................................154 Changing the engine oil ..............................................................................................................................................155 Replacing the oil filters ............................................................................................................................................157 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................158 COOLING SYSTEM ...........................................................................................................................................................159 Radiators ............................................................................................................................................................159 Cooling liquid, change ...............................................................................................................................................161 AIR-INTAKE SYSTEM ........................................................................................................................................................162 Dust trap, cleaning .................................................................................................................................................162 Main filter elements .................................................................................................................................................163 Safety filter element ................................................................................................................................................165 Air-intake lines .....................................................................................................................................................165 FUEL SYSTEM ..............................................................................................................................................................166 Fuel system - Safety instructions ....................................................................................................................................166 Replacing the fuel filter ............................................................................................................................................166 Primary fuel filter, drain water .....................................................................................................................................167 Replacing the primary fuel filter ....................................................................................................................................167 Venting the fuel system ..............................................................................................................................................168 Cleaning the fuel tanks ..............................................................................................................................................168 Water trap (option)...................................................................................................................................................170 ELECTRICAL SYSTEM .......................................................................................................................................................172 Electrical system - Safety instructions ..............................................................................................................................172 Alternator - Instructions ............................................................................................................................................172 Battery ..............................................................................................................................................................173 Switchgear cabinet aeration ..........................................................................................................................................175 Equipotential bonding ................................................................................................................................................177 Floodlight projector, replacing the lamp .............................................................................................................................179 HYDRAULIC SYSTEM .........................................................................................................................................................181 Hydraulic system - Safety instructions ...............................................................................................................................181 Depressurizing the hydraulic system ..................................................................................................................................181 Checking the hydraulic oil level .....................................................................................................................................182 Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................184 Bypass valves (hydraulic oil reservoir) ..............................................................................................................................186 Replacing the hydraulic oil return-flow filters (filter housing) .....................................................................................................187 Bypass valves (filter housing - cooling system) ......................................................................................................................188 Breather filter ......................................................................................................................................................189 Filter (servo circuit)................................................................................................................................................190 High-pressure filter for working hydraulics ..........................................................................................................................191 High-pressure filters for swing circuit ..............................................................................................................................192 Filter pump control, clean ...........................................................................................................................................193 Changing the hydraulic oil ...........................................................................................................................................194 Venting the hydraulic system..........................................................................................................................................197 Cleaning the hydraulic oil cooler.....................................................................................................................................198 Electronic excavator control..........................................................................................................................................199 Pressure accumulator - Emergency lowering ............................................................................................................................200 PUMP TRANSFER GEARBOX ....................................................................................................................................................201 Checking the gearbox oil level / Topping up with oil .................................................................................................................201 Gearbox venting ......................................................................................................................................................203 Pump transfer gearbox lube oil filters ...............................................................................................................................204 SWING GEARBOX ............................................................................................................................................................205 Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................205 Swing gearbox - Changing the gearbox oil .............................................................................................................................205 Swing gearbox, venting ...............................................................................................................................................206 SWING GEARBOX ............................................................................................................................................................207 Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................207 Swing gearbox, changing oil ..........................................................................................................................................208 Swing gearbox, venting ...............................................................................................................................................209 TRAVEL GEARBOX ...........................................................................................................................................................210 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................210 Travel gearbox - Changing oil ........................................................................................................................................211 Pre-chamber - Changing the oil .......................................................................................................................................211 Brake chamber - Changing oil .........................................................................................................................................212 Breather filter ......................................................................................................................................................212 CRAWLER TRACKS ...........................................................................................................................................................213 Track roller, Support roller .........................................................................................................................................214 Track tensioner ......................................................................................................................................................215 Pressure-accumulator inspection regulations ..........................................................................................................................216 Checking the gas charging pressure in the pressure accumulator........................................................................................................216 SWING RING ...............................................................................................................................................................217 Swing ring β Instructions ............................................................................................................................................217 Bearing races.........................................................................................................................................................217 CENTRAL LUBRICATING ......................................................................................................................................................219 Design ...............................................................................................................................................................219 Function .............................................................................................................................................................220 Filling up the grease container ......................................................................................................................................221 Breather filter ......................................................................................................................................................221 Checking the greasing pressure .......................................................................................................................................222 Unblocking a grease line..............................................................................................................................................223 Oilfilter (hydraulic circuit grease pump) )...........................................................................................................................224 Grease filter (Filling the grease container) .........................................................................................................................225 Grease filter (Grease lines) .........................................................................................................................................226 OTHER MAINTENANCE ........................................................................................................................................................227 Other maintenance, engine ............................................................................................................................................227 Heating and air conditioning .........................................................................................................................................227 HYDRAULIC LADDER .........................................................................................................................................................228 Pressure-accumulator inspection regulations .........................................................................................................................229 Extract from the German regulations...................................................................................................................................229 Checking the gas charging pressure in the pressure accumulator .......................................................................................................229 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................230 Monitoring, warning and control elements .............................................................................................................................230 Checking the on-board crane...........................................................................................................................................230 Drive unit ...........................................................................................................................................................231 On-board crane........................................................................................................................................................231 On-Board crane, checking tightness of fastening bolts ................................................................................................................232 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................233 Putting the excavator out of operation ...............................................................................................................................233 Battery storage ......................................................................................................................................................233 Recommissioning ......................................................................................................................................................234 NOTES ...................................................................................................................................................................235 4 REPAIR WORK.................................................................................................................................................................237 REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................239 REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................241 REPAIR WORK, ENGINE.......................................................................................................................................................242 ELECTRICAL SYSTEM ........................................................................................................................................................243 Assisted starting (with jumper cables) β Safety instructions .........................................................................................................243 Assisted starting (with jumper cables)................................................................................................................................243 Starting the engine with jumper cables (external batteries ...........................................................................................................243 HYDRAULIC SYSTEM..........................................................................................................................................................245 Repair instructions ..................................................................................................................................................245 Hydraulic hoses β Instructions ......................................................................................................................................245 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................246 WELDING OPERATIONS - SAFETY INSTRUCTIONS .................................................................................................................................247 NOTES ....................................................................................................................................................................249 5 ANNEX.......................................................................................................................................................................251 TROUBLESHOOTING ..........................................................................................................................................................253 Instructions on troubleshooting ......................................................................................................................................253 Layout of the fault table ............................................................................................................................................253 Possible causes ......................................................................................................................................................253 Measures .............................................................................................................................................................253 Section ..............................................................................................................................................................253 FAULT TABLES .............................................................................................................................................................254 Combustion engine - Fault table ......................................................................................................................................254 Working hydraulics β Fault table .....................................................................................................................................255 Track drive β Fault table ............................................................................................................................................256 Swing mechnism β Fault table .........................................................................................................................................257 Central lubricating system β Fault table .............................................................................................................................258 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................259 ABBREVIATIONS ............................................................................................................................................................261 ABBREVIATIONS.........................................................................................................................................................262 ENGINE MONITORING, CONTROL LAMPS .........................................................................................................................................263 TECHNICAL DATA ...........................................................................................................................................................264 NOTES ....................................................................................................................................................................273 6 INDEX.......................................................................................................................................................................275
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