Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651413 – PDF DOWNLOAD

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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651413 – PDF DOWNLOAD

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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651413 – PDF DOWNLOAD

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Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651413 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH120E
Introduction
PREFACE
About this Operating Instructions

• 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 mining- 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.

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TABLE OF CONTENTS:

Cat Bucyrus 120E Hydraulic Excavator OPERATING INSTRUCTIONS MANUAL BI651413 – PDF DOWNLOAD

Title page...................................................................................................................................................................  1
1 INTRODUCTION............................................................................................................................................................... 13
	PREFACE ................................................................................................................................................................. 15
		About this Operating Instructions ................................................................................................................................... 15
		Further machine documentation ....................................................................................................................................... 15
	WARRANTY ................................................................................................................................................................ 16
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17
		Warnings and symbols ................................................................................................................................................ 17
		Contents of the Declaration of Conformity ........................................................................................................................... 17
	DESIGNATED USE........................................................................................................................................................... 18
		Noise emissions ..................................................................................................................................................... 19
		Vibration data ...................................................................................................................................................... 19
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 20
		Selection and qualification of personnel; basic responsibilities..................................................................................................... 21
		Safety instructions governing specific operational phases............................................................................................................ 21
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 22
		Warning of special dangers........................................................................................................................................... 23
		Gas, dust, steam and smoke .......................................................................................................................................... 23
		Hydraulic equipment ................................................................................................................................................. 24
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 25
	NOTES ................................................................................................................................................................... 27
2 OPERATION.................................................................................................................................................................. 29
	OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 31
		Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 32
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 33
	DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 34
		Excavator layout..................................................................................................................................................... 35
		Undercarriage ....................................................................................................................................................... 36
		Superstructure ...................................................................................................................................................... 36
		Drive ............................................................................................................................................................... 36
		Hydraulic system .................................................................................................................................................... 36
		Control and Monitoring Platform (CAMP) .............................................................................................................................. 36
		Board-Control-System (BCS) .......................................................................................................................................... 37
		Demand control / Zero-flow regulation................................................................................................................................ 37
		Automatic reset to idling............................................................................................................................................ 37
		Electrical system ................................................................................................................................................... 37
		Signs ............................................................................................................................................................... 39
		Entering and leaving the machine Safety instructions................................................................................................................. 40
		Access ladder lighting .............................................................................................................................................. 40
		Swinging ladder ..................................................................................................................................................... 41
		Folding ladder (optional) ........................................................................................................................................... 42
		Escape ladder (optional) ............................................................................................................................................ 43
		Switching the cab interior lighting on and off ...................................................................................................................... 44
		Switching the maintenance lights on and off ......................................................................................................................... 45
		Emergency shut-off function ......................................................................................................................................... 46
		Shutting off the supply voltage (battery main switch) ............................................................................................................... 47
		Driver’s seat  ...................................................................................................................................................... 48
		Reducing the operators exposure to vibrations ....................................................................................................................... 50
		Trainer's / instructor's seat ....................................................................................................................................... 50
		Fire extinguisher.................................................................................................................................................... 51
		Fire extinguisher (option) .......................................................................................................................................... 51
		Automatic fire-extinguishing system (optional) ...................................................................................................................... 52
		Windscreen washer ................................................................................................................................................... 52
		Harness (optional) .................................................................................................................................................. 53
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 56
		Engine 1 (LH), control and monitoring ............................................................................................................................... 63
		Engine 2 (RH), control and monitoring ............................................................................................................................... 65
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 82
		Reducing the operator's exposure to noise ........................................................................................................................... 82
		Refuelling .......................................................................................................................................................... 82
		Back-up heating (option), filling in fuel ........................................................................................................................... 83
		Service station (tanklift) .......................................................................................................................................... 83
		Switching the electrical system on and off .......................................................................................................................... 89
		Engines, emergency shut-off ......................................................................................................................................... 89
		Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 90
		Fuel preheating system (optional) ................................................................................................................................... 91
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 92
		Starting the engines ................................................................................................................................................ 92
		Starting the left-hand engine........................................................................................................................................ 92
		Starting the right-hand engine....................................................................................................................................... 92
		Engines – adjusting the speed ....................................................................................................................................... 93
		Starting the engines at low temperatures ............................................................................................................................ 93
		Shutting off the engines ............................................................................................................................................ 94
		Shutting off the left-hand engine.................................................................................................................................... 94
		Shutting off the right-hand engine................................................................................................................................... 94
	AIR CONDITIONER (OPTION) ................................................................................................................................................ 95
		Back-up heating driver’s cab (option) ............................................................................................................................... 95
		Back-up heating (option) ............................................................................................................................................ 96
	TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 97
	TRAVELLING .............................................................................................................................................................. 98
		Superstructure basic position ....................................................................................................................................... 98
		Travelling forwards/backwards ....................................................................................................................................... 98
		Superstructure holding brake ........................................................................................................................................102
		Track parking brake .................................................................................................................................................102
	TRANSPORTING THE MACHINE ................................................................................................................................................103
		Transport - Safety instructions .....................................................................................................................................103
	WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................104
	WORKING OPERATION .......................................................................................................................................................106
		Before starting work ................................................................................................................................................106
		Activating the electronic excavator control .........................................................................................................................106
		Swinging the superstructure .........................................................................................................................................107
		Braking the superstructure ..........................................................................................................................................107
		Working .............................................................................................................................................................108
		After daily operation ...............................................................................................................................................109
	OPTIONAL EQUIPMENT ......................................................................................................................................................110
		Water spraying system ...............................................................................................................................................110
		Additional silencers ................................................................................................................................................110
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................111
		Securing the machine ................................................................................................................................................112
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................113
	NOTES ...................................................................................................................................................................115
3 INSPECTION AND SERVICING...................................................................................................................................................117
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................119
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................125
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................127
		Intervals............................................................................................................................................................127
		Change of engine oil l...............................................................................................................................................127
		Air-intake system ...................................................................................................................................................127
		Oils / Greases ......................................................................................................................................................127
		Cleaning jobs .......................................................................................................................................................127
		Components ..........................................................................................................................................................127
		Plan V ..............................................................................................................................................................129
		Plan N ..............................................................................................................................................................131
		Plan T and W.........................................................................................................................................................133
		Plan A – E ..........................................................................................................................................................135
	LUBRICATING CHART – GREASE ..............................................................................................................................................142
		Lubricating chart – Grease (legend) .................................................................................................................................143
		Filling quantities – Grease .........................................................................................................................................143
	INSPECTION PLAN - OIL ...................................................................................................................................................144
		Inspection plan – Oil (legend) ......................................................................................................................................145
		Filling quantities - oil ............................................................................................................................................146
		Filling quantities - other...........................................................................................................................................146
	LUBRICANTS ..............................................................................................................................................................147
		Notes on the selection of oils and greases ..........................................................................................................................147
		Avoid mixing of different hydraulic fluids ..........................................................................................................................147
		I. Oils for combustion engines ......................................................................................................................................148
		II. Oils for hydraulic system .......................................................................................................................................149
		III.a Oils for pump gearboxes .......................................................................................................................................150
		III.b Oils for swing gearboxes ......................................................................................................................................151
		III.c Oils for travel gearboxes .....................................................................................................................................152
		V. Greases for bearings and swing rings .............................................................................................................................153
	SERVICING WORK ..........................................................................................................................................................154
		Hose line for oil and cooling liquid changes ........................................................................................................................154
	ENGINE ..................................................................................................................................................................155
		Engine - Safety instructions ........................................................................................................................................155
		Checking the engine oil level / Topping up  .........................................................................................................................156
		Changing the engine oil .............................................................................................................................................157
		Replacing the oil filters ...........................................................................................................................................159
		Engine oil reservoir, filling in engine oil .........................................................................................................................159
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................160
	COOLING SYSTEM ..........................................................................................................................................................161
		Radiators ...........................................................................................................................................................161
		Cooling liquid change ...............................................................................................................................................163
	AIR-INTAKE SYSTEM .......................................................................................................................................................164
		Dust trap, cleaning  ................................................................................................................................................164
		Main filter elements ................................................................................................................................................165
		Safety filter element ...............................................................................................................................................167
		Air-intake lines ....................................................................................................................................................167
	FUEL SYSTEM .............................................................................................................................................................168
		Fuel system - Safety instructions ...................................................................................................................................168
		Replacing the fuel filter ...........................................................................................................................................168
		Primary fuel filter, drain water ....................................................................................................................................169
		Replacing the primary fuel filter ...................................................................................................................................169
		Venting the fuel system .............................................................................................................................................170
		Cleaning the fuel tanks .............................................................................................................................................170
		Water trap (option)..................................................................................................................................................172
	ELECTRICAL SYSTEM  ......................................................................................................................................................174
		Electrical system - Safety instructions .............................................................................................................................174
		Alternator - Instructions ...........................................................................................................................................174
		Battery .............................................................................................................................................................175
		Switchgear cabinet ..................................................................................................................................................177
		Equipotential bonding ...............................................................................................................................................179
		Floodlight projector, replacing the lamp ............................................................................................................................181
	HYDRAULIC SYSTEM ........................................................................................................................................................183
		Hydraulic system - Safety instructions ..............................................................................................................................183
		Depressurizing the hydraulic system .................................................................................................................................183
		Checking the hydraulic oil level ....................................................................................................................................184
		Hydraulic oil return-flow filters (hydraulic oil reservoir), replace ................................................................................................186
		Bypass valves (hydraulic oil reservoir), replace ....................................................................................................................188
		Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................189
		Bypass valves (filter housing - cooling system), replace ............................................................................................................190
		Breather filter, replace ............................................................................................................................................191
		Filter (servo circuit), replace .....................................................................................................................................192
		High-pressure filter for working hydraulics, replace ................................................................................................................193
		High-pressure filters for swing circuit, replace ....................................................................................................................194
		Filter pump control, clean ..........................................................................................................................................195
		Changing the hydraulic oil ..........................................................................................................................................196
		Avoid mixing of different hydraulic fluids ..........................................................................................................................196
		Venting the hydraulic system.........................................................................................................................................200
		Cleaning the hydraulic oil cooler....................................................................................................................................201
		Electronic excavator control.........................................................................................................................................202
		Pressure accumulators - Emergency lowering and servo circuit ........................................................................................................203
	PUMP TRANSFER GEARBOX ...................................................................................................................................................204
		Checking the gearbox oil level / Topping up with oil ................................................................................................................204
		Gearbox venting .....................................................................................................................................................206
		Pump transfer gearbox lube oil filters ..............................................................................................................................207
	SWING GEARBOX ...........................................................................................................................................................208
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................208
		Changing the gearbox oil ............................................................................................................................................208
		Gearbox venting .....................................................................................................................................................209
	SWING GEARBOX ...........................................................................................................................................................210
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................210
		Changing the gearbox oil ............................................................................................................................................211
		Gearbox venting .....................................................................................................................................................212
	TRAVEL GEARBOX ..........................................................................................................................................................213
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................213
		Travel gearbox - Changing oil .......................................................................................................................................214
		Pre-chamber - Changing the oil ......................................................................................................................................214
		Brake chamber - Changing oil ........................................................................................................................................215
		Breather filter .....................................................................................................................................................215
	CRAWLER TRACKS ..........................................................................................................................................................216
		Track roller, Support roller ........................................................................................................................................217
		Track tensioner .....................................................................................................................................................218
		Pressure-accumulator inspection regulations .........................................................................................................................219
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................219
	SWING RING ..............................................................................................................................................................220
		Swing ring - Instructions............................................................................................................................................220
		Bearing races........................................................................................................................................................220
	CENTRAL LUBRICATING SYSTEM ..............................................................................................................................................222
		Design ..............................................................................................................................................................222
		Function ............................................................................................................................................................223
		Filling up the grease container .....................................................................................................................................224
		Breather filter grease container, check / replace ...................................................................................................................224
		Checking the greasing pressure ......................................................................................................................................225
		Unblocking a grease line ............................................................................................................................................225
		Oilfilter replace (hydraulic circuit grease pump) ...................................................................................................................226
		Grease filter replace (filling the grease container) ................................................................................................................227
		Grease filter replace (Grease lines) ................................................................................................................................227
	OTHER MAINTENANCE .......................................................................................................................................................228
		Engine ..............................................................................................................................................................228
		Heating and air conditioning ........................................................................................................................................228
	RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................229
		Pressure-accumulator inspection regulations .........................................................................................................................230
		Extract from the German regulations..................................................................................................................................230
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................230
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................231
		Monitoring, warning and control elements ............................................................................................................................231
		Checking the on-board crane..........................................................................................................................................231
		Drive unit ..........................................................................................................................................................232
		On-board crane.......................................................................................................................................................232
		On-Board crane, checking tightness of fastening bolts ...............................................................................................................233
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................234
		Putting the excavator out of operation...............................................................................................................................234
		Battery storage......................................................................................................................................................234
		Recommissioning......................................................................................................................................................234
	NOTES  ..................................................................................................................................................................235
4 REPAIR WORK................................................................................................................................................................237
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................239
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................241
	REPAIR WORK, ENGINE......................................................................................................................................................242
	ELECTRICAL SYSTEM .......................................................................................................................................................243
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................243
		Assisted starting (with jumper cables)...............................................................................................................................243
		Starting the engine with jumper cables (external batteries ..........................................................................................................243
	HYDRAULIC SYSTEM ........................................................................................................................................................245
		Repair instructions .................................................................................................................................................245
		Hydraulic hoses – Instructions  .....................................................................................................................................245
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................246
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................247
	DISPOSAL AT THE END OF THE SERVICE LIFE  ................................................................................................................................248
		Dismantling and removal instructions ................................................................................................................................248
		Risk of deflagrations ...............................................................................................................................................248
		Risk of fire ........................................................................................................................................................248
		Disposing of the machine without polluting the environment ..........................................................................................................248
		Further hazardous substances ........................................................................................................................................249
		Appropriate disposal of batteries ...................................................................................................................................250
	NOTES ...................................................................................................................................................................251
5 ANNEX......................................................................................................................................................................253
	BOARD-CONTROL-SYSTEM ....................................................................................................................................................255
		BCS III, what’s that? ...............................................................................................................................................255
		The keys on the front side ..........................................................................................................................................256
		Other elements on the front side ....................................................................................................................................256
		BCSIII, the start screen ............................................................................................................................................257
		Information given on the start screen, top section ..................................................................................................................258
		Information given on the start screen, central section ..............................................................................................................259
		Information given on the start screen, lower section ................................................................................................................260
		Information given on the “Service” screen ...........................................................................................................................261
		Engine data screen ..................................................................................................................................................262
		Hydraulic data screen ...............................................................................................................................................263
		Lubrication data screen .............................................................................................................................................264
		Controls adjustment data screen .....................................................................................................................................265
		View documents screen ...............................................................................................................................................266
		Signal table screen .................................................................................................................................................267
		Signal table screen, location .......................................................................................................................................268
		Signal table screen, diagram ........................................................................................................................................269
		Signal table screen, diagram configuration ..........................................................................................................................270
		Code table screen ...................................................................................................................................................271
		BCS III, interfaces .................................................................................................................................................272
		USB interface, data storage .........................................................................................................................................272
		Saving data to a USB stick ..........................................................................................................................................273
		Saving data to a USB stick, continued ...............................................................................................................................274
		Saving data to a USB stick, continued ...............................................................................................................................275
		BCSIII, cleaning ....................................................................................................................................................276
		BCSIII, disposal ....................................................................................................................................................276
	TROUBLESHOOTING .........................................................................................................................................................277
		Instructions on troubleshooting .....................................................................................................................................277
		Layout of the fault table ...........................................................................................................................................277
		Possible causes .....................................................................................................................................................277
		Measures ............................................................................................................................................................277
		Section .............................................................................................................................................................277
	FAULT TABLES ............................................................................................................................................................278
		Combustion engine - Fault table .....................................................................................................................................278
		Working hydraulics – Fault table ....................................................................................................................................279
		Track drive – Fault table ...........................................................................................................................................280
		Swing mechnism – Fault table ........................................................................................................................................281
		Central lubricating system – Fault table ............................................................................................................................282
	ENGINE MONITORING, CONTROL LAMPS ........................................................................................................................................283
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................284
	ABBREVIATIONS ...........................................................................................................................................................285
		ABBREVIATIONS........................................................................................................................................................286
	TECHNICAL DATA ..........................................................................................................................................................287
		Product_Specification_Sheet.pdf......................................................................................................................................  0
			RH120E_DataSheet_english_page_1..................................................................................................................................289
			RH120E_DataSheet_english_page_2..................................................................................................................................290
			RH120E_DataSheet_english_page_3..................................................................................................................................291
			RH120E_DataSheet_english_page_4..................................................................................................................................292
			RH120E_DataSheet_english_page_5..................................................................................................................................293
			RH120E_DataSheet_english_page_6..................................................................................................................................294
			RH120E_DataSheet_english_page_7..................................................................................................................................295
			RH120E_DataSheet_english_page_8..................................................................................................................................296
	NOTES ...................................................................................................................................................................297
6 INDEX......................................................................................................................................................................299

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