Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651400 – PDF DOWNLOAD

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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651400 – PDF DOWNLOAD

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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651400 – PDF DOWNLOAD

Language : English
Pages : 269
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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651400 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH 120-E
Introduction
PREFACE

• These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
• The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as

• They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Terex O&K mechanic or by attending an Terex O&K training course for operators or maintenance personnel. The Terex O&K after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. 1 Complies with VDMA recommendation “Operating instructions” All Terex O&K operating manuals are issued in German and then translated.
• Even a good translation may give rise to questions which Terex O&K will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex O&K aftersales service.
• The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately.
• The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

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TABLE OF CONTENTS:

Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651400 – 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
	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
		Control and Monitoring Platform (CAMP) .............................................................................................................................. 32
		Board-Control-System (BCS) .......................................................................................................................................... 33
		Demand control / Zero-flow regulation................................................................................................................................ 33
		Automatic reset to idling............................................................................................................................................ 33
		Electrical system ................................................................................................................................................... 33
		Sign ................................................................................................................................................................ 35
		Entering and leaving the machine Safety instructions................................................................................................................. 36
		Access ladder lighting .............................................................................................................................................. 36
		Ramp-type ladder (optional) ......................................................................................................................................... 37
		Ramp-type ladder (optional) ......................................................................................................................................... 38
		Switching the cab interior lighting on and off....................................................................................................................... 39
		Switching the maintenance lights on and off ......................................................................................................................... 40
		Emergency shut-off function ......................................................................................................................................... 41
		Shutting off the supply voltage (battery main switch) ............................................................................................................... 42
		Windscreen washer ................................................................................................................................................... 43
		Trainer's / instructor's seat ....................................................................................................................................... 43
		Driver’s seat  ...................................................................................................................................................... 44
		Fire extinguisher.................................................................................................................................................... 46
		Fire extinguisher (option) .......................................................................................................................................... 46
		Automatic fire-extinguishing system (optional) ...................................................................................................................... 47
		Harness (optional) .................................................................................................................................................. 48
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 52
		(Fig. 249:).......................................................................................................................................................... 59
		Engine 1 (LH), control and monitoring ............................................................................................................................... 59
		Engine 2 (RH), control and monitoring ............................................................................................................................... 61
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 75
		Refuelling .......................................................................................................................................................... 75
		Service station (tanklift) .......................................................................................................................................... 76
		Switching the electrical system on and off .......................................................................................................................... 82
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 83
		Starting the engines ................................................................................................................................................ 83
		Starting the left-hand engine........................................................................................................................................ 83
		Starting the right-hand engine....................................................................................................................................... 83
		Engines – adjusting the speed ....................................................................................................................................... 84
		Starting the engines at low temperatures ............................................................................................................................ 84
		Shutting off the engines ............................................................................................................................................ 85
		Shutting off the left-hand engine.................................................................................................................................... 85
		Shutting off the right-hand engine................................................................................................................................... 85
		Engines – emergency shut-off ........................................................................................................................................ 86
	AIR CONDITIONER (OPTION)................................................................................................................................................. 87
		Back-up heating (option) ............................................................................................................................................ 87
	DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................ 88
	TRAVELLING .............................................................................................................................................................. 89
		Superstructure basic position ....................................................................................................................................... 89
		Travelling forwards/backwards ....................................................................................................................................... 89
		Superstructure holding brake ........................................................................................................................................ 93
		Track parking brake ................................................................................................................................................. 93
	TRANSPORTING THE MACHINE ................................................................................................................................................ 94
		Transport - Safety instructions ..................................................................................................................................... 94
	WORKING OPERATION - SAFETY INSTRUCTIONS ................................................................................................................................. 95
	WORKING OPERATION ....................................................................................................................................................... 97
		Before starting work ................................................................................................................................................ 97
		Activating the electronic excavator control ......................................................................................................................... 97
		Slewing the superstructure .......................................................................................................................................... 98
		Braking the superstructure .......................................................................................................................................... 98
		Working ............................................................................................................................................................. 99
		After daily operation ...............................................................................................................................................100
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................101
		Securing the machine ................................................................................................................................................103
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................104
	NOTES ...................................................................................................................................................................105
3 INSPECTION AND SERVICING...................................................................................................................................................107
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................109
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................115
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................117
		Intervals............................................................................................................................................................117
		Change of engine oil l...............................................................................................................................................117
		Air-intake system ...................................................................................................................................................117
		Oils / Greases ......................................................................................................................................................117
		Cleaning jobs .......................................................................................................................................................117
		Components ..........................................................................................................................................................117
		Plan V ..............................................................................................................................................................119
		Plan N ..............................................................................................................................................................121
		Plan T and W.........................................................................................................................................................123
		Plan A – E ..........................................................................................................................................................125
	LUBRICATING CHART – GREASE (LOADING BUCKET) .............................................................................................................................132
		Lubricating chart – Grease / Loading bucket (legend) ................................................................................................................133
		Filling quantities - Grease..........................................................................................................................................133
	LUBRICATING CHART – GREASE / BACKHOE BUCKET .............................................................................................................................134
		Lubricating chart – Grease / Backhoe bucket (legend) ................................................................................................................135
		Filling quantities - Grease..........................................................................................................................................135
	INSPECTION PLAN - OIL ...................................................................................................................................................136
		Inspection plan – Oil (legend) ......................................................................................................................................137
		Filling quantities - oil ............................................................................................................................................138
		Filling quantities - other...........................................................................................................................................138
	LUBRICANTS ..............................................................................................................................................................139
		Notes on the selection of oils and greases ..........................................................................................................................139
		I. Oils for combustion engines ......................................................................................................................................140
		II. Oils for hydraulic system .......................................................................................................................................141
		III.a Oils for pump gearboxes .......................................................................................................................................142
		III.b Oils for swing gearboxes ......................................................................................................................................143
		III.c Oils for travel gearboxes .....................................................................................................................................144
		V. Greases for bearings and swing rings .............................................................................................................................145
	SERVICING WORK ..........................................................................................................................................................146
		Hose line for oil and cooling liquid changes ........................................................................................................................146
	ENGINE ..................................................................................................................................................................147
		Engine - Safety instructions ........................................................................................................................................147
		Checking the engine oil level / Topping up  .........................................................................................................................148
		Changing the engine oil .............................................................................................................................................150
		Replacing the oil filters ...........................................................................................................................................152
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................153
	COOLING SYSTEM ..........................................................................................................................................................154
		Radiators ...........................................................................................................................................................154
		Cooling liquid ......................................................................................................................................................156
	AIR-INTAKE SYSTEM .......................................................................................................................................................157
		Main filter elements ................................................................................................................................................157
		Safety filter element ...............................................................................................................................................159
		Air-intake lines ....................................................................................................................................................160
		Dust collection .....................................................................................................................................................160
	FUEL SYSTEM .............................................................................................................................................................161
		Fuel system - Safety instructions ...................................................................................................................................161
		Replacing the fuel filter ...........................................................................................................................................161
		Venting the fuel system .............................................................................................................................................162
		Cleaning the fuel tanks .............................................................................................................................................162
		Water trap (option)..................................................................................................................................................164
	ELECTRICAL SYSTEM  ......................................................................................................................................................166
		Electrical system - Safety instructions .............................................................................................................................166
		Alternator - Instructions ...........................................................................................................................................166
		Battery .............................................................................................................................................................167
		Switchgear cabinet ..................................................................................................................................................169
		Equipotential bonding ...............................................................................................................................................171
		Floodlight projector, replacing the lamp ............................................................................................................................173
	HYDRAULIC SYSTEM ........................................................................................................................................................175
		Hydraulic system - Safety instructions ..............................................................................................................................175
		Depressurizing the hydraulic system .................................................................................................................................175
		Checking the hydraulic oil level ....................................................................................................................................176
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................178
		Bypass valves (hydraulic oil reservoir) .............................................................................................................................180
		Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................181
		Bypass valves (filter housing - cooling system) .....................................................................................................................182
		Breather filter .....................................................................................................................................................183
		Filter (control circuit and auxiliary control circuit)...............................................................................................................184
		High-pressure filter for working hydraulics .........................................................................................................................185
		High-pressure filters for swing circuit .............................................................................................................................186
		Changing the hydraulic oil ..........................................................................................................................................187
		Venting the hydraulic system.........................................................................................................................................190
		Cleaning the hydraulic oil cooler....................................................................................................................................191
		Electronic excavator control.........................................................................................................................................192
		Pressure accumulator - Emergency lowering............................................................................................................................193
	PUMP TRANSFER GEARBOX ...................................................................................................................................................194
		Checking the gearbox oil level / Topping up with oil ................................................................................................................194
		Gearbox venting .....................................................................................................................................................196
		Pump transfer gearbox lube oil filters ..............................................................................................................................197
	SWING GEARBOX ...........................................................................................................................................................198
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................198
		Changing the gearbox oil ............................................................................................................................................198
		Gearbox venting .....................................................................................................................................................199
	TRAVEL GEARBOX ..........................................................................................................................................................200
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................200
		Travel gearbox - Changing oil .......................................................................................................................................201
		Pre-chamber - Changing the oil ......................................................................................................................................201
		Brake chamber - Changing oil ........................................................................................................................................202
		Breather filter .....................................................................................................................................................202
	CRAWLER TRACKS ..........................................................................................................................................................203
		Track roller, Support roller ........................................................................................................................................204
		Track tensioner .....................................................................................................................................................205
		Pressure-accumulator inspection regulations .........................................................................................................................206
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................206
	SWING RING ..............................................................................................................................................................207
		Swing ring - Instructions............................................................................................................................................207
		Bearing races........................................................................................................................................................207
	CENTRAL LUBRICATING .....................................................................................................................................................209
		Design ..............................................................................................................................................................209
		Function ............................................................................................................................................................210
		Filling up the grease container .....................................................................................................................................211
		Breather filter .....................................................................................................................................................211
		Checking the greasing pressure ......................................................................................................................................212
		Unblocking a grease line.............................................................................................................................................213
		Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................214
		Grease filter (Filling the grease container) ........................................................................................................................215
		Grease filter (Grease lines) ........................................................................................................................................216
	OTHER MAINTENANCE .......................................................................................................................................................217
		Engine ..............................................................................................................................................................217
		Heating and air conditioning ........................................................................................................................................217
	RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................218
		Pressure-accumulator inspection regulations .........................................................................................................................219
		Extract from the German regulations..................................................................................................................................219
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................219
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................220
		Monitoring, warning and control elements ............................................................................................................................220
		Checking the on-board crane..........................................................................................................................................220
		Drive unit ..........................................................................................................................................................221
		On-board crane.......................................................................................................................................................221
		On-Board crane, checking tightness of fastening bolts ...............................................................................................................222
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................223
		Putting the excavator out of operation...............................................................................................................................223
		Battery storage......................................................................................................................................................223
		Recommissioning......................................................................................................................................................224
	NOTIZEN  ................................................................................................................................................................225
4 REPAIR WORK................................................................................................................................................................227
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................229
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................231
	REPAIR WORK, ENGINE......................................................................................................................................................232
	ELECTRICAL SYSTEM .......................................................................................................................................................233
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................233
		Assisted starting (with jumper cables)...............................................................................................................................233
		Starting the engine with jumper cables (external batteries ..........................................................................................................233
	HYDRAULIC SYSTEM.........................................................................................................................................................235
		Repair instructions .................................................................................................................................................235
		Hydraulic hoses – Instructions  .....................................................................................................................................235
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................236
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................237
	NOTES ...................................................................................................................................................................239
5 ANNEX......................................................................................................................................................................241
	TROUBLESHOOTING .........................................................................................................................................................243
		Instructions on troubleshooting .....................................................................................................................................243
		Layout of the fault table ...........................................................................................................................................243
		Possible causes .....................................................................................................................................................243
		Measures ............................................................................................................................................................243
		Section .............................................................................................................................................................243
	FAULT TABLES ............................................................................................................................................................244
		Combustion engine - Fault table .....................................................................................................................................244
		Working hydraulics – Fault table ....................................................................................................................................245
		Track drive – Fault table ...........................................................................................................................................246
		Swing mechnism – Fault table ........................................................................................................................................247
		Central lubricating system – Fault table ............................................................................................................................248
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................249
	ABBREVIATIONS ...........................................................................................................................................................251
		ABBREVIATIONS........................................................................................................................................................252
	TECHNICAL DATA ..........................................................................................................................................................253
	NOTES ...................................................................................................................................................................263
6 INDEX......................................................................................................................................................................265

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