Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651458 – PDF DOWNLOAD
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Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651458 – PDF DOWNLOAD
Language : English
Pages : 271
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Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651458 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH 200 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
-operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
-maintenance (inspection, servicing, repair) and / or
-transport.
- In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified 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. 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus Hydraulic Excavator RH 120E OPERATING INSTRUCTIONS MANUAL BI651458 – 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 Pump Managing System (PMS)........................................................................................................................................... 32 Stored Program Control (SPC) ........................................................................................................................................ 32 Central Management System (CMS) ..................................................................................................................................... 32 Demand control / Zero-flow regulation................................................................................................................................ 33 Automatic engine speed reduction .................................................................................................................................... 33 Board-Control-System (BCS) .......................................................................................................................................... 33 Electrical system ................................................................................................................................................... 33 Sign ................................................................................................................................................................ 35 Entering and leaving the machine Safety instructions................................................................................................................. 36 Ramp-type ladder (optional) ......................................................................................................................................... 37 Ramp-type ladder (optional) ......................................................................................................................................... 38 EMERGENCY STOP switch ............................................................................................................................................... 40 Windscreen washer ................................................................................................................................................... 40 Driver's seat ....................................................................................................................................................... 41 Fire extinguisher................................................................................................................................................... 42 Fire extinguisher (option) .......................................................................................................................................... 42 Automatic fire-extinguishing system (optional)....................................................................................................................... 43 Harness (optional) .................................................................................................................................................. 44 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 48 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 73 Refuelling .......................................................................................................................................................... 73 Service station (tanklift) .......................................................................................................................................... 74 Switching the electrical system on and off .......................................................................................................................... 80 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 81 Starting the engines ................................................................................................................................................ 81 Starting the engines at low temperatures ............................................................................................................................ 82 AIR CONDITIONER (OPTION)................................................................................................................................................. 84 Back-up heating (option) ............................................................................................................................................ 85 DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................ 87 TRAVELLING .............................................................................................................................................................. 88 Superstructure basic position ....................................................................................................................................... 88 Travelling forwards/backwards ....................................................................................................................................... 88 Emergency machine drive ............................................................................................................................................. 92 Locking the superstructure .......................................................................................................................................... 94 Track parking brake ................................................................................................................................................. 94 TRANSPORTING THE MACHINE ................................................................................................................................................ 95 Transport - Safety instructions ..................................................................................................................................... 95 WORKING OPERATION - SAFETY INSTRUCTIONS ................................................................................................................................. 96 WORKING OPERATION ....................................................................................................................................................... 98 Before starting work ................................................................................................................................................ 98 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 SWING GEARBOX ...........................................................................................................................................................200 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................200 Changing the gearbox oil ............................................................................................................................................201 Gearbox venting .....................................................................................................................................................202 TRAVEL GEARBOX ..........................................................................................................................................................203 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................203 Travel gearbox - Changing oil .......................................................................................................................................204 Pre-chamber - Changing the oil ......................................................................................................................................204 Brake chamber - Changing oil ........................................................................................................................................205 Breather filter .....................................................................................................................................................205 CRAWLER TRACKS ..........................................................................................................................................................206 Track roller, Support roller ........................................................................................................................................207 Track tensioner .....................................................................................................................................................208 Pressure-accumulator inspection regulations .........................................................................................................................209 Checking the gas charging pressure in the pressure accumulator.......................................................................................................209 SWING RING ..............................................................................................................................................................210 Swing ring - Instructions............................................................................................................................................210 Bearing races........................................................................................................................................................210 CENTRAL LUBRICATING .....................................................................................................................................................212 Design ..............................................................................................................................................................212 Function ............................................................................................................................................................213 Filling up the grease container .....................................................................................................................................214 Breather filter .....................................................................................................................................................214 Checking the greasing pressure ......................................................................................................................................215 Unblocking a grease line.............................................................................................................................................216 Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................217 Grease filter (Filling the grease container) ........................................................................................................................218 Grease filter (Grease lines) ........................................................................................................................................219 OTHER MAINTENANCE .......................................................................................................................................................220 Engine ..............................................................................................................................................................220 Heating and air conditioning ........................................................................................................................................220 RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................221 Pressure-accumulator inspection regulations .........................................................................................................................222 Extract from the German regulations..................................................................................................................................222 Checking the gas charging pressure in the pressure accumulator.......................................................................................................222 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................223 Monitoring, warning and control elements ............................................................................................................................223 Checking the on-board crane..........................................................................................................................................223 Drive unit ..........................................................................................................................................................224 On-board crane.......................................................................................................................................................224 On-Board crane, checking tightness of fastening bolts ...............................................................................................................225 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................226 Putting the excavator out of operation...............................................................................................................................226 Battery storage......................................................................................................................................................226 Recommissioning......................................................................................................................................................226 NOTES ..................................................................................................................................................................227 4 REPAIR WORK................................................................................................................................................................229 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................231 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................233 REPAIR WORK, ENGINE......................................................................................................................................................234 ELECTRICAL SYSTEM .......................................................................................................................................................235 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................235 Assisted starting (with jumper cables)...............................................................................................................................235 Starting the engine with jumper cables (external batteries ..........................................................................................................235 HYDRAULIC SYSTEM.........................................................................................................................................................237 Repair instructions .................................................................................................................................................237 Hydraulic hoses – Instructions .....................................................................................................................................237 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................238 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................239 NOTES ...................................................................................................................................................................241 5 ANNEX......................................................................................................................................................................243 TROUBLESHOOTING .........................................................................................................................................................245 Instructions on troubleshooting .....................................................................................................................................245 Layout of the fault table ...........................................................................................................................................245 Possible causes .....................................................................................................................................................245 Measures ............................................................................................................................................................245 Section .............................................................................................................................................................245 FAULT TABLES ............................................................................................................................................................246 Combustion engine - Fault table .....................................................................................................................................246 Working hydraulics – Fault table ....................................................................................................................................247 Track drive – Fault table ...........................................................................................................................................248 Swing mechnism – Fault table ........................................................................................................................................249 Central lubricating system – Fault table ............................................................................................................................250 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................251 ABBREVIATIONS ...........................................................................................................................................................253 ABBREVIATIONS........................................................................................................................................................254 TECHNICAL DATA ..........................................................................................................................................................255 NOTES ...................................................................................................................................................................265 6 INDEX......................................................................................................................................................................267
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