Cat Hydraulic Excavator 120E Operating Instructions Manual BI651428 – PDF DOWNLOAD

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Cat Hydraulic Excavator 120E Operating Instructions Manual BI651428 – PDF DOWNLOAD

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Cat Hydraulic Excavator 120E Operating Instructions Manual BI651428 – PDF DOWNLOAD

Language : English
Pages : 282
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Hydraulic Excavator 120E Operating Instructions Manual BI651428 – PDF DOWNLOAD

• 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

• 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

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TABLE OF CONTENTS:

Cat Hydraulic Excavator 120E Operating Instructions Manual BI651428 – PDF DOWNLOAD

1 INTRODUCTION............................................................................................................................................................... 11
	PREFACE.................................................................................................................................................................. 13
	WARRANTY................................................................................................................................................................. 14
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15
		Warnings and symbols................................................................................................................................................. 15
	DESIGNATED USE........................................................................................................................................................... 16
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 17
		Selection and qualification of personnel; basic responsibilities..................................................................................................... 18
		Safety instructions governing specific operational phases............................................................................................................ 18
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19
		Warning of special dangers .......................................................................................................................................... 20
		Gas, dust, steam and smoke........................................................................................................................................... 21
		Hydraulic equipment.................................................................................................................................................. 21
		Noise ............................................................................................................................................................... 21
		Oil, grease and other chemical substances............................................................................................................................ 21
		Ether ............................................................................................................................................................... 21
		Transporting and recommissioning..................................................................................................................................... 21
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 22
	NOTES ................................................................................................................................................................... 23
2 OPERATION.................................................................................................................................................................. 25
	OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 27
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 29
	DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 30
		Excavator layout..................................................................................................................................................... 31
		Undercarriage ....................................................................................................................................................... 32
		Superstructure ...................................................................................................................................................... 32
		Drive ............................................................................................................................................................... 32
		Hydraulic system .................................................................................................................................................... 32
		Pump Managing System (PMS) .......................................................................................................................................... 32
		Programmable Logic Controller (PLC) ................................................................................................................................. 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
		Sign ................................................................................................................................................................ 35
		Entering and leaving the machine Safety instructions................................................................................................................. 36
		Ramp-type ladder (optional) ......................................................................................................................................... 37
		Ramp-type ladder (optional) ......................................................................................................................................... 38
		EMERGENCY STOP pushbuttons .......................................................................................................................................... 40
		Windscreen washer ................................................................................................................................................... 40
		Driver's seat  ...................................................................................................................................................... 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
		Running-in instructions for hydraulic cylinders .....................................................................................................................102
		Warming-up phase for the hydraulic system ...........................................................................................................................102
		Avoid extreme positions of the working equipment ....................................................................................................................103
	WORKING OPERATION .......................................................................................................................................................104
		Before starting work ................................................................................................................................................104
		Slewing the superstructure ..........................................................................................................................................104
		Braking the superstructure ..........................................................................................................................................104
		Working movements ...................................................................................................................................................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
3 INSPECTION AND SERVICING...................................................................................................................................................113
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................115
	INSPECTION AND SERVICING WORK, 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 ..............................................................................................................................................140
		Lubricating chart – Grease (legend) .................................................................................................................................141
		Filling quantities - Grease..........................................................................................................................................141
	INSPECTION PLAN - OIL ...................................................................................................................................................142
		Inspection plan – 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 slewing 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  .........................................................................................................................153
		Checking the oil level in the engine oil reservoir / topping up (optional) ..........................................................................................154
		Changing the engine oil .............................................................................................................................................155
		Draining the oil off the engine oil reservoir (optional) ............................................................................................................157
		Replacing the oil filter ............................................................................................................................................159
		Replacing the oil filter (oil interval prolonging) ..................................................................................................................159
		Centrifuge (optional)................................................................................................................................................160
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................161
	COOLING SYSTEM ..........................................................................................................................................................162
		Radiators ...........................................................................................................................................................162
		Cooling liquid ......................................................................................................................................................164
		Water filter ........................................................................................................................................................165
	AIR-INTAKE SYSTEM .......................................................................................................................................................166
		Main filter elements ................................................................................................................................................166
		Safety filter element ...............................................................................................................................................168
		Air-intake lines ....................................................................................................................................................169
		Dust collection .....................................................................................................................................................169
	FUEL SYSTEM .............................................................................................................................................................170
		Fuel system - Safety instructions ...................................................................................................................................170
		Replacing the fuel filters ..........................................................................................................................................170
		Venting the fuel system .............................................................................................................................................171
		Cleaning the fuel tanks .............................................................................................................................................171
		Water trap (option)..................................................................................................................................................173
	ELECTRICAL SYSTEM  ......................................................................................................................................................175
		Electrical system - Safety instructions .............................................................................................................................175
		Alternator - Instructions ...........................................................................................................................................175
		Battery .............................................................................................................................................................176
		Switchgear cabinet ..................................................................................................................................................178
		Equipotential bonding ...............................................................................................................................................180
		Floodlight projector, replacing the lamp ............................................................................................................................182
	HYDRAULIC SYSTEM ........................................................................................................................................................184
		Hydraulic system - Safety instructions ..............................................................................................................................184
		Depressurizing the hydraulic system .................................................................................................................................184
		Checking the hydraulic oil level ....................................................................................................................................185
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................187
		Bypass valves (hydraulic oil reservoir) .............................................................................................................................189
		Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................190
		Bypass valves (filter housing - cooling system) .....................................................................................................................191
		Breather filter .....................................................................................................................................................192
		Filter (control circuit and auxiliary control circuit)...............................................................................................................193
		High-pressure filter for working hydraulics .........................................................................................................................194
		High-pressure filters for slewing circuit ...........................................................................................................................195
		Changing the hydraulic oil ..........................................................................................................................................196
		Venting the hydraulic system.........................................................................................................................................199
		Cleaning the hydraulic oil cooler....................................................................................................................................200
		Electronic excavator control.........................................................................................................................................201
		Pressure accumulator - Emergency lowering............................................................................................................................202
	PUMP TRANSFER GEARBOX ...................................................................................................................................................203
		Checking the gearbox oil level / Topping up with oil ................................................................................................................203
		Gearbox venting .....................................................................................................................................................205
		Pump transfer gearbox lube oil filters ..............................................................................................................................206
	SWING GEARBOX ...........................................................................................................................................................207
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................207
		Changing the gearbox oil ............................................................................................................................................207
		Gearbox venting .....................................................................................................................................................208
	SWING GEARBOX ...........................................................................................................................................................209
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................209
		Changing the gearbox oil ............................................................................................................................................210
		Gearbox venting .....................................................................................................................................................211
	TRAVEL GEARBOX ..........................................................................................................................................................212
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................212
		Travel gearbox - Changing oil .......................................................................................................................................213
		Pre-chamber - Changing the oil ......................................................................................................................................213
		Brake chamber - Changing oil ........................................................................................................................................214
		Breather filter .....................................................................................................................................................214
	CRAWLER TRACKS ..........................................................................................................................................................215
		Track roller, Support roller ........................................................................................................................................216
		Track tensioner .....................................................................................................................................................217
		Pressure-accumulator inspection regulations .........................................................................................................................218
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................218
	SLEWING RING ............................................................................................................................................................219
		Slewing ring - Instructions..........................................................................................................................................219
		Bearing races........................................................................................................................................................219
	CENTRAL LUBRICATING .....................................................................................................................................................221
		Design ..............................................................................................................................................................221
		Function ............................................................................................................................................................222
		Filling up the grease container .....................................................................................................................................223
		Breather filter .....................................................................................................................................................223
		Checking the greasing pressure ......................................................................................................................................224
		Unblocking a grease line.............................................................................................................................................225
		Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................226
		Grease filter (Filling the grease container) ........................................................................................................................227
		Grease filter (Grease lines) ........................................................................................................................................228
	OTHER MAINTENANCE .......................................................................................................................................................229
		Engine ..............................................................................................................................................................229
		Heating and air conditioning ........................................................................................................................................229
	RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................230
		Pressure-accumulator inspection regulations .........................................................................................................................231
		Extract from the German regulations..................................................................................................................................231
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................231
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................232
		Monitoring, warning and control elements ............................................................................................................................232
		Checking the on-board crane..........................................................................................................................................232
		Drive unit...........................................................................................................................................................233
		On-board crane.......................................................................................................................................................233
		On-Board crane, checking tightness of fastening bolts ...............................................................................................................233
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................235
		Putting the excavator out of operation ..............................................................................................................................235
		Battery storage .....................................................................................................................................................235
		Recommissioning......................................................................................................................................................236
	NOTES  ..................................................................................................................................................................237
4 REPAIR WORK................................................................................................................................................................239
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................241
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................243
	REPAIR WORK, ENGINE......................................................................................................................................................244
	ELECTRICAL SYSTEM .......................................................................................................................................................245
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................245
		Assisted starting (with jumper cables)...............................................................................................................................245
		Starting the engine with jumper cables (external batteries ..........................................................................................................245
	HYDRAULIC SYSTEM.........................................................................................................................................................247
		Repair instructions .................................................................................................................................................247
		Hydraulic hoses – Instructions  .....................................................................................................................................247
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................248
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................249
	NOTES ...................................................................................................................................................................251
5 ANNEX......................................................................................................................................................................253
	TROUBLESHOOTING .........................................................................................................................................................255
		Instructions on troubleshooting .....................................................................................................................................255
		Layout of the fault table ...........................................................................................................................................255
		Possible causes .....................................................................................................................................................255
		Measures ............................................................................................................................................................255
		Section .............................................................................................................................................................255
	FAULT TABLES ............................................................................................................................................................256
		Combustion engine - Fault table .....................................................................................................................................256
		Working hydraulics – Fault table ....................................................................................................................................257
		Track drive – Fault table ...........................................................................................................................................258
		Slewing mechnism – Fault table ......................................................................................................................................259
		Central lubricating system – Fault table ............................................................................................................................260
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................261
	ABBREVIATIONS ...........................................................................................................................................................262
		ABBREVIATIONS .......................................................................................................................................................263
	TECHNICAL DATA ..........................................................................................................................................................265
	NOTES ...................................................................................................................................................................275
6 INDEX......................................................................................................................................................................277

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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