CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651524 – PDF DOWNLOAD

CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651524 – PDF DOWNLOAD

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CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651524 – PDF DOWNLOAD

Language : English
Pages : 275
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus RH 120E Hydraulic Excavator Operating Instructions Manual BI651524 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE __ 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS__ 1-5
Warnings and symbols 1-5
DESIGNATED USE_ 1-6
ORGANIZATIONAL MEASURES 1-7
Selection and qualification of personnel; basic responsibilities ________ 1-8
Safety instructions governing specific operational phases __ 1-8
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables ______ 1-9
Warning of special dangers __ 1-10
Gas, dust, steam and smoke _ 1-11
Hydraulic equipment _ 1-11
Noise_ 1-11
Oil, grease and other chemical substances 1-11
Transporting and recommissioning ______ 1-11
FIRE AND EXPLOSION HAZARD ________ 1-12
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS ___ 2-3
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE EXCAVATOR______ 2-6
Excavator layout 2-7
Undercarriage _ 2-8
Superstructure 2-8
Drive __ 2-8
Hydraulic system 2-8
Pump Managing System (PMS) 2-8
Stored Program Control (SPC)_ 2-8
Electronic Hydraulic Servo-Control (EHSC) _ 2-8
Demand control / Zero-flow regulation _____ 2-9
Automatic engine speed reduction ________ 2-9
Board-Control-System (BCS) __ 2-9
Electrical system 2-9
Sign__ 2-11
Entering and leaving the machine Safety instructions ____ 2-12
Ramp-type ladder (optional) __ 2-13
EMERGENCY STOP pushbuttons _______ 2-15
Windscreen washer _ 2-15
Driver’s seat _ 2-16
Fire extinguisher _ 2-17
Fire extinguisher (option) ____ 2-17
Automatic fire-extinguishing system (optional) 2-18
OPERATING INSTRUCTIONS RH 120 E
Table of contents
vi BA RH120E(2 804 910 02)-EN
MONITORING, WARNING AND CONTROL ELEMENTS __ 2-20
PUTTING THE MACHINE INTO OPERATION_ 2-51
Refuelling 2-51
Service station (tanklift) _____ 2-52
Switching the electrical system on and off _ 2-57
STARTING AND STOPPING THE ENGINES 2-58
Starting the engines _ 2-58
Starting the engines with the cold-starting aid 2-60
AIR CONDITIONER (OPTION) _ 2-62
Back-up heating (option)_____ 2-64
DRIVING SAFETY INSTRUCTIONS_______ 2-66
TRAVELLING _ 2-67
Superstructure basic position _ 2-67
Travelling forwards/backwards 2-67
Emergency machine drive ___ 2-71
Locking the superstructure ___ 2-73
Track parking brake _ 2-73
TRANSPORTING THE MACHINE ________ 2-74
Transport – Safety instructions 2-74
WORKING OPERATION – SAFETY INSTRUCTIONS _____ 2-75
WORKING OPERATION______ 2-77
Before starting work _ 2-77
Slewing and braking the superstructure ___ 2-77
Braking the superstructure ___ 2-77
Working _ 2-78
After daily operation _ 2-79
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS___ 2-80
Securing the machine 2-82
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) __ 2-83
NOTES 2-85
3 INSPECTION AND SERVICING _ 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
FIRE AND EXPLOSION HAZARD 3-9
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-11
Intervals _ 3-11
Change of engine oil l 3-11
Air-intake system 3-11
Oils / Greases 3-11
Cleaning jobs 3-11
Components _ 3-11
Plan V 3-13
Plan N 3-15
Plan T 3-17
Plan A – E 3-19
LUBRICATING CHART – GREASE (LOADING BUCKET)__ 3-28
Lubricating chart – Grease / Backhoe bucket (legend) ___ 3-29
Filling quantities – Grease ____ 3-29
BETRIEBSANLEITUNG RH 120 E
Table of contents
BA RH120E(2 804 910 02)-EN vii
Lubricating chart – Grease / Backhoe bucket (legend) ___ 3-31
Filling quantities – Grease ____ 3-31
INSPECTION PLAN – OIL _____ 3-32
Inspection plan – Oil (legend) ) 3-33
Filling quantities – oil _ 3-34
Filling quantities – other______ 3-34
LUBRICANTS _ 3-35
I Oils for combustion engines and compressors (selection) _______ 3-35
II Oils for hydraulic system (selection)___ 3-36
III Oils for gearboxes (selection)______ 3-37
V Greases for bearings and slewing rings 3-38
SERVICING WORK 3-39
Hose line for oil and cooling liquid changes 3-39
ENGINE 3-40
Engine – Safety instructions __ 3-40
Retensioning the alternator/fan belt ______ 3-40
Checking and adjusting the valve clearance _ 3-40
Checking the engine oil level / Topping up _ 3-40
Checking the oil level in the engine oil reservoir / topping up (optional)_ 3-41
Changing the engine oil _____ 3-42
Draining the oil off the engine oil reservoir (optional) _____ 3-44
Replacing the oil filter 3-46
Centrifuge (optional) _ 3-47
COOLING SYSTEM 3-48
Radiators_ 3-49
Cooling liquid 3-51
Water filter __ 3-54
AIR-INTAKE SYSTEM_ 3-55
Main filter elements 3-55
Safety filter element _ 3-57
Air-intake lines 3-58
Dust collection 3-58
FUEL SYSTEM 3-59
Fuel system – Safety instructions ________ 3-59
Replacing the fuel filter ______ 3-59
Venting the fuel system______ 3-60
Cleaning the fuel tanks ______ 3-60
Water trap (option) 3-62
ELECTRICAL SYSTEM 3-64
Electrical system – Safety instructions ____ 3-64
Alternator – Instructions______ 3-64
Battery 3-65
Switchgear cabinet 3-67
Equipotential bonding 3-69
HYDRAULIC SYSTEM 3-71
Hydraulic system – Safety instructions ____ 3-71
Depressurizing the hydraulic system _____ 3-71
Checking the hydraulic oil level 3-72
Changing the hydraulic oil return-flow (hydraulic oil reservoir) ________ 3-74
Bypass valves (hydraulic oil reservoir) ____ 3-76
Replacing the hydraulic oil return-flow filters (filter housing) 3-77
Bypass valves (filter housing – cooling system) 3-78
Breather filter 3-79
OPERATING INSTRUCTIONS RH 120 E
Table of contents
viii BA RH120E(2 804 910 02)-EN
Filter (control circuit) _ 3-80
Filter (auxiliary control circuit) _ 3-80
High-pressure filter for working hydraulics _ 3-81
High-pressure filters for slewing circuit____ 3-82
Changing the hydraulic oil____ 3-83
Venting the hydraulic system _ 3-86
Cleaning the hydraulic oil cooler 3-87
Electronic excavator control __ 3-88
Pressure accumulator – Emergency lowering_ 3-89
PUMP TRANSFER GEARBOX_ 3-90
Checking the gearbox oil level / Topping up with oil______ 3-90
Gearbox venting _ 3-92
Pump transfer gearbox lube oil filters _____ 3-93
SLEWING GEARBOX _ 3-94
Gearbox – Checking the oil level / Topping up with oil ____ 3-94
Changing the gearbox oil ____ 3-94
Gearbox venting _ 3-95
Slewing gear neck 3-95
TRAVEL GAERBOX 3-96
Gearbox – Checking the oil level / Topping up with oil ____ 3-96
Travel gearbox – Changing oil_ 3-97
Pre-chamber – Changing the oil 3-97
Brake chamber – Changing oil 3-98
Breather filter 3-98
CRAWLER TRACKS 3-99
Track roller, Support roller __ 3-100
Track tensioner_ 3-101
Pressure-accumulator inspection regulations 3-102
Checking the gas charging pressure in the pressure accumulator____ 3-102
Idlers 3-103
SLEWING RING _ 3-104
Slewing ring – Instructions___ 3-104
Bearing races 3-104
CENTRAL LUBRICATING____ 3-106
Design__ 3-106
Lube cycle / Pause period___ 3-106
Lube cycle manual lubricating (optional)__ 3-106
Function 3-107
Filling up the grease container 3-108
Breather filter 3-108
Checking the greasing pressure________ 3-109
Checking the greasing pressure________ 3-110
Unblocking a grease line ___ 3-111
Oilfilter (hydraulic circuit grease pump) ) _ 3-112
Grease filter (Filling the grease container) 3-113
Grease filter (Grease lines)__ 3-114
Manual greasing (option) ___ 3-115
OTHER MAINTENANCE_____ 3-117
Engine__ 3-117
RAMP-TYPE LADDER (OPTIONAL) (OPTION) _ 3-118
Guide pulleys and locking bolt 3-118
Pressure-accumulator inspection regulations 3-119
Extract from the German regulations ____ 3-119
Checking the gas charging pressure in the pressure accumulator____ 3-119
BETRIEBSANLEITUNG RH 120 E
Table of contents
BA RH120E(2 804 910 02)-EN ix
ON-BOARD CRANE (OPTIONAL) _______ 3-120
Monitoring, warning and control elements 3-120
Checking the on-board crane 3-120
Drive unit 3-121
On-board crane_ 3-121
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ____ 3-122
Putting the excavator out of operation ___ 3-122
Battery storage _ 3-122
Recommissioning 3-123
NOTES __ 3-125
4 REPAIR WORK_ 4-1
REPAIR WORK – SAFETY INSTRUCTIONS _ 4-3
FIRE AND EXPLOSION HAZARD 4-5
ENGINE_ 4-6
ELECTRICAL SYSTEM_ 4-7
Assisted starting (with jumper cables) – Safety instructions_ 4-7
Assisted starting (with jumper cables) _____ 4-7
Starting the engine with jumper cables (external batteries__ 4-7
HYDRAULIC SYSTEM _ 4-9
Repair _ 4-9
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-10
WELDING OPERATIONS – SAFETY INSTRUCTIONS ____ 4-11
NOTES 4-13
5 ANNEX _ 5-1
TROUBLESHOOTING _ 5-3
Instructions on troubleshooting_ 5-3
Layout of the fault table 5-3
Possible causes 5-3
Measures _ 5-3
Section 5-3
FAULT TABLES_ 5-4
Combustion engine – Fault table 5-4
Working hydraulics – Fault table 5-5
Track drive – Fault table ______ 5-6
Slewing mechnism – Fault table 5-7
Central lubricating system – Fault table ____ 5-8
HYDRAULIC CIRCUIT DIAGRAM 5-10
ABBREVIATIONS _ 5-13
TECHNICAL DATA 5-15
NOTES 5-17
6 INDEX __ 6-1

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