PDF Operating Instruction Manual Cat Bucyrus RH120E Electric Hydraulic Shovel - 816 KB
Master the operation of the powerful Cat Bucyrus RH120E Electric Hydraulic Shovel with this official operating instruction manual.
It covers all aspects of the machine's functions, from start-up to shutdown, including critical safety protocols.
This guide is essential for training operators and ensuring the massive shovel is used productively and safely in demanding mining environments.
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OPERATING INSTRUCTIONS RH120E Electric
Hydraulic Excavator
RH120E Electric No.
Bucyrus HEX GmbH
BA RH120E(3 725 055.01)-EN
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OPERATING INSTRUCTIONS RH120E Electric
Introduction
1 INTRODUCTION
Operating instructions Target group
Part 1 INTRODUCTION Operating personnel
+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.
Part 3 INSPECTION AND Inspection and servicing personnel
The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.
Part 4 REPAIR WORK Repair personnel
The repair personnel must have know-how
and experience relevant to the repair of this
or comparable machines.
Part 5 ANNEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
Part 6 INDEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
BA RH120E(3 725 055.01)-EN 1-1
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OPERATING INSTRUCTIONS RH120E Electric
Introduction
Gas, dust, steam and smoke Noise
Always start and operate the engine in a well- During operation, all sound baffles of the machine
vented area; must be closed.
If in an enclosed area, vent the exhaust to the out- Always wear the prescribed ear protectors.
side;
Do not modify or tamper with the exhaust system
Oil, grease and other chemical sub-
Diesel engine exhaust and some of its constituents stances
are known to cause cancer, birth defects, and
other reproductive harm When handling oil, grease or other chemical sub-
stances, observe the product-related safety regula-
Operate fuel-operated heating systems only on
tions (see safety specifications).
adequately ventilated premises. Before starting the
machine on enclosed premises, make sure that Be careful when handling hot consumables (risk of
there is sufficient ventilation. burning or scalding).
Observe the regulations in force at the respective
site.
Transporting and recommission-
Carry out welding, flame-cutting and grinding work
on the machine only if this has been expressly ing
authorized, as there may be a risk of explosion and The machine must be loaded and transported only
fire. in accordance with the operating instructions.
Before carrying out welding, flame-cutting and Use only appropriate means of transport and lifting
grinding operations, clean the machine and its gear of adequate capacity.
surroundings from dust and other inflammable The recommisioning procedure must be strictly in
substances and make sure that the premises are accordance with the operating instructions.
adequately ventilated (risk of explosion).
Hydraulic equipment
Check all lines, hoses and screwed connections
regularly for leaks and obvious damage. Repair
damage immediately. Splashed oil may cause
injury and fire.
Depressurize all system sections and pressure
pipes to be removed in accordance with the spe-
cific instructions for the unit concerned before car-
rying out any repair work.
Hydraulic lines must be laid and fitted properly.
Ensure that no connections are interchanged. The
fittings, lengths and quality of the hoses must com-
ply with the technical requirements.
BA RH120E(3 725 055.01)-EN 1-9
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OPERATING INSTRUCTIONS RH120E Electric
Operation
Place suitable fire guardings (fire barriers) if open
FIRE AND EXPLOSION HAZARD fire or flying sparks cannot be avoided during re-
Safety instructions pair work.
Prior to commencing work, obtain Apply special protection to cables, cable ducts as
information on the national and corpo- well as to hose and pipe lines.
rate rules for the prevention of acci- If necessary, also cover the ground with fire-
dents. protective blankets.
Pay particular attention to hazards Ensure sufficient ventilation.
caused by combustible and easily Clean the excavator before starting a job.
flammable substances.on the safe Do not keep any fire extinguishers that are not
handling of the fire extinguishers to suitable or have not been tested.
be used.
Do not extinguish flammable liquids with water.
Use:
Avoid smoking and open fire on, next to and below ο§ dry-powder,
the excavator.
ο§ carbon-dioxide or
Combustible and easily flammable substances or
liquids increase the fire and explosion hazard. ο§ foam extinguishing compounds.
Do not store or handle any flammable substances When getting into contact with burning substances,
during operation. the fire-fighting water would abruptly evaporate
Clean the excavator thoroughly, if possible, with a and distribute the substance such as burning oil
steam jet (rubber parts and electric components over a wide area. Water causes short-circuits in
with compressed air - refer to information label), the electrical system thus possibly entailing new
when, for example, oil, grease, solvent or cleaner hazards.
was spilled. DANGER TO LIFE
Such substances may spontaneously ignite if they Call the fire brigade.
get into the vicinity of hot units or objects. Have all your welding, flame cutting and grinding
Even battery gases can ignite in open flames or work approved.
fire.
Avoid parking the excavator in places where
ο§ combustible substances such as coal dust or
tar are present.
ο§ open or smouldering fire may occur.
Remove the excavator from such an area where
combustible or easily flammable liquids have
spilled from the excavator onto the ground.
Flying sparks (caused by welding, flame cutting,
grinding, electrical short-circuit) may cause fire on
the ground that can spread to the excavator.
BA RH120E(3 725 055.01)-EN 2-5
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OPERATING INSTRUCTIONS RH120E Electric
Operation
Swinging ladder Lowering the swinging ladder (from the upper
carriage)
Raising resp. lowering the swinging ladder (Fig. ο Start electric motor.
2-12:).
ο Push lever (1, Fig. 2-13:) on control valve (2)
downwards to position β II β.
The swinging ladder is lowered (Fig. 2-12:).
The swinging ladder can also be lowered when the
electric motor ist stopped.
Fig. 2-12:
Raising the swinging ladder (from the upper
carriage)
ο Start electric motor.
ο Pull lever (1, , Fig. 2-13:) on control valve (2)
Fig. 2-14:
upwards to position β I β.
The swinging ladder is raised (Fig. 2-14:). Lowering the swinging ladder (from the bottom)
ο Pull down rope (3, Fig. 2-15:).
The swinging ladder is lowered (Fig. 2-12:).
Fig. 2-13:
The upper carriage can only be swung
when the folding ladder is raised Fig. 2-15:
completely (Fig. 2-14:).
BA RH120E(3 725 055.01)-EN 2-15
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OPERATING INSTRUCTIONS RH120E Electric
Operation
Emergency escape device (op-
tional)
Elements of the harness
(Fig. 2-36:- Fig. 2-38:)
Pos. Designation
1 Back support
2 Shoulder belt
3 Shoulder belt
4 Loop (chest belt)
5 Loop (chest belt)
6 Loop (back support)
11 Holding device
12 Fall arrester
13 Guidance line
Fig. 2-37:
14 Hanging up line
15 Handbag with harness
16 Snap hook
17 Hook safety device
Fig. 2-38:
See Description of the supplier.
Fig. 2-36:
Important hints
Before using operator shall have received adequate
training.
The harness must be used by one person only.
He is responsible for the appropriate use and main-
tenance.
Visual inspection is recommended prior to each
use; if necessary it must be checked by an expert.
Harness must be checked annualy (every 12
month) by an expert.
BA RH120E(3 725 055.01)-EN 2-25
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OPERATING INSTRUCTIONS RH120E Electric
Operation
(Fig. 2-50:)
No. Element Function Symbol
41 Indicator lamp Medium voltage Lamp is lit up when the circuit breaker is
switched on. Medium voltage 6.3 kV applied.
42 Indicator lamp Rotary field monito- Lamp is lit up when the rotary field (phas-
ring ing) is correct.
51 Button Electric motor ON Switches on the electric motor.
52 Button Electric motor OFF Switches off the electric motor.
BA RH120E(3 725 055.01)-EN 2-35
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OPERATING INSTRUCTIONS RH120E Electric
Operation
(Fig. 2-55:) Optional equipment
No. Element Function Symbol
121 Rotary switch Fan Selects the intensity level of the blower (3
levels).
122 Rotary switch Mode Selects the desired control function (heating,
cooling, ventilation, defrosting).
123 Knob Thermostat Sets the desired temperature inside the cab.
125 Control Additional heating Controlling the additional heating device via
(optional equip- touch screen, see Back-up heating manufac-
ment) turers manual.
126 Momentary switch Switches additional heating control OFF.
127 Momentary switch Switches additional heating control ON.
128 Momentary switch Not used on this machine.
129 Momentary switch Not used on this machine.
130 Momentary switch Reset fault monitoring.
BA RH120E(3 725 055.01)-EN 2-45
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OPERATING INSTRUCTIONS RH120E Electric
Operation
Switching the electric motor on
and off
Before switching on the electric motor
Before switching on the electric mo-
tor, check that nobody is working on
the electrical system or on the excava-
tor itself.
Switch on the electric motor only
when all these work on the excavator
is finished and all persons leave the
danger area.
ο Switch on battery main switch (see: "Battery
main switch, switching on and off").
ο Switch on electrical system (24V) (see: "Elec-
trical system (24V), switching on and off").
Fig. 2-66:
ο Check telltales (14 and 16, Fig. 2-66:), they
must lit up in green colour.
If so, electric motor can be switched on (see:
"Switching the electric motor on").
If telltales didn`t lit up in green colour, BCS has
detected critical operating conditions or faults
which prohibit starting the electric motor. BCS indi-
cates this case with telltales (for instance 15, Fig.
2-66:) as well as by displaying corresponding text.
Switching the electric motor on
ο Actuate switch-key (51, Fig. 2-67:), the electric
motor is switched on.
During starting period the electric motor heavily
warm up. Therefore it is not allowed to switch it on
and off at will. By means of an electronical time-out
circuit (PLC) the electric motor can be switched on
only three times a hour (time-out period is 30 min-
utes).
Fig. 2-67:
BA RH120E(3 725 055.01)-EN 2-55
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OPERATING INSTRUCTIONS RH120E Electric
Operation
Travelling Travelling forwards/backwards
ο Travelling forwards:
Superstructure basic position depress pedals (112 and 113) forwards.
The excavator travels in the direction of the
Travel direction and sense of actuation of pedals idler (2, Fig. 2-83:).
(112 and 113, Fig. 2-84:) are identical only when
the excavator is in its BASIC POSITION (Fig. ο Travelling backwards:
2-83:). depress pedals (112 and 113, Fig. 2-84:) back-
wards.
The excavator travels in the direction of the
drive sprocket (4,Fig. 2-83:).
During travelling, an acoustic warning signal
sounds (Travel Alarm).
Fig. 2-83:
If the superstructure is slewed out of
its basic position by more than 90Β°
(Fig. 2-85:), the excavator moves in a
direction opposite to that expected Fig. 2-85:
when pedals (112 and 113, Fig. 2-84:)
are depressed.
The pedals return automatically to their "0" posi-
tions when released.
Reverse the excavator only over short distances
and with the assistance of marshallers because of
restricted rear-view conditions.
Do not travel across slopes.
When travelling uphill or downhill, the
travel gears must always be at the
rear. Travel only in the basic position
of the excavator and only forwards.
Be extremely careful on slippery and
greasy ground.
All instructions with regard to travelling speed
Fig. 2-84: regulation and travel direction control are applica-
ble only as long as the crawler tracks have suffi-
If the operator is not completely sure of the posi- cient grip and do not slip.
tion of the superstructure with regard to the under-
carriage, pedals (112 and 113) should be de-
pressed slightly in order to find out which way the
excavator moves before initiating the full travelling
movement.
BA RH120E(3 725 055.01)-EN 2-65
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OPERATING INSTRUCTIONS RH120E Electric
Operation
WORKING OPERATION
Before starting work Swinging the superstructure
The superstructure can only be swung if the su-
Prior to initial commissioning and perstructure holding brake is released.
after repairs on the central lubricating ο To swing the superstructure to the right:
system or the hydraulic cylinders, shift control lever (115) to the right.
move the unloaded equipment for abt.
5 minutes. ο To swing the superstructure to the left:
This is required to ensure an adequate shift control lever (115) to the left.
supply of grease to the cylinder bear-
ings when the work starts. After releasing, the control lever returns automati-
cally to position "0". But the superstructures mo-
Warming up tion will not be braked automatically then. To bring
the superstructure to standstill, shift control lever
At low outside temperatures it is necessary to run
(115) into the opposite direction of superstructures
the hydraulic system up to operating temperature.
motion (countering).
The temperatures at which warming up is neces-
sary depend on the type of hydraulic oil used; see
also "Oils for hydraulic systems".
Braking the superstructure
ο Switch on the electric motor and start to per-
form no-load working movements for abt. 10 After releasing, the control lever returns automati-
minutes with the excavator. cally to position "0". But the superstructures mo-
tion will not be braked automatically then.
The superstructure is braked only by setting con-
trol lever (115) into the opposite direction (counter-
ing).
In an emergency apply parking brake
with switch (82, Fig. 2-100:)
Fig. 2-99:
Switching on the electronic excavator
control
You can only move the working equipment after
the electronic excavator control is switched on via
switch (74, Fig. 2-99:) and the switch inside the
driverβs seat (105).
Electronic excavator control activated - operator is
sitting on his seat.
Electronic excavator control deactivated - driver's
seat is empty.
Fig. 2-100:
BA RH120E(3 725 055.01)-EN 2-75
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OPERATING INSTRUCTIONS RH120E Electric
Inspection and servicing
SAFETY INSTRUCTIONS FOR
EXCAVATORS WITH ELECTRIC Connect the earthing kit (8) to the
earthing points (2, 3 and 4) only by
MOTOR means of extension (5).
Maintenance and inspection work on electrical
The earthing points may still carry
systems may only be performed by qualified elec-
residual voltages.
tricians or by workshops employing such person-
nel.
A qualified electrician for the purpose of this regu-
lation is a person who has the corresponding tech-
nical training, know-how and experience as well as
knowledge of the pertinent prescriptions and who
is therefore in a position to judge the work en-
trusted to him and the potential dangers in connec-
tion therewith.
Before carrying out any maintenance and inspec-
tion work on the electrical system, the following
precautions must be taken:
In the transformer station
ο Cut out the supply voltage.
ο Secure against switching on; apply a warning Fig. 3-1:
sign.
ο Check that the electrical system is off circuit.
ο Connect to earth and short-circuit.
ο Protect adjacent and live parts against acci-
dental contact.
On the excavator
ο Cut out the switch-disconnector
(see the " Switching off the circuit breaker "
chapter in part 2 of the present operating in-
structions)
ο Secure the circuit breaker against switching
on, e.g. seal in the actuating lever in a cabinet.
ο Apply a warning sign.
Fig. 3-2:
ο Remove the cover (1, Fig. 3-1:).
ο Check that the electrical system is off circuit
and dead.
ο§ Connect to earth and short-circuit:
(connect the earthing and short-circuiting line
(8, Fig. 3-2:) in the following order to points (1
β 4):
first to the fixed point (1), then
one after another to the earthing points (2, 3
and 4).
ο Slide partition (6, Fig. 3-3:) into guide (7).
Fig. 3-3:
BA RH120E(3 725 055.01)-EN 3-3
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OPERATING INSTRUCTIONS RH120E Electric
Inspection and servicing
INSPECTION AND SERVICING Oils / Greases
PLANS - INSTRUCTIONS For the specification of oils and greases to be used
refer to the "Lubricants" section.
Intervals The numerals mentioned in the "Oil / Grease" col-
The inspection and Servicing plan lists all jobs umn in the inspection and Servicing plans have the
which have to be done on the machine at regular following meaning:
intervals. I Oils for combustion engines and
The individual inspection and Servicing plans are compressors
marked with letters providing a link between the II Oils for hydraulic systems
operating hours (OH) recorded by the hours-run IIIa, b, c Oils for gearboxes
meter of the machine and the inspection and sSer- V Greases for bearings and slewing
vicing plans. rings
Plan Do all jobs ....
V ...once prior to initial commissioning.
Cleaning jobs
N ...after initial commissioning and du- Cleaning jobs, especially on cooling systems, must
ring the running-in period (after 100OH). be done at shorter intervals if the machine is ex-
T ...every 10 OH or every working shift 1) posed to severe dust build-up.
2
W ...every 60 OH or weekly .
B ...after every 500 OH.
C ...after every 1000 OH.
Components
D ...after every 5000 OH. The maintenance intervals for components, e.g.
E ...after every 10000 OH. electric motor and gearboxes, are listed in the fol-
OH = Bh = Operating hours lowing Bucyrus HEX maintenance schedules.
It is possible that the manufacturer's documenta-
tion for these components states intervals deviat-
ing from the above-mentioned intervals.
In such case, only the maintenance intervals speci-
fied by Bucyrus HEX shall apply.
2
Whichever comes first.
BA RH120E(3 725 055.01)-EN 3-13
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OPERATING INSTRUCTIONS RH120E Electric
Inspection and servicing
Plan A - after every 250 OH
(at 250, 750, 1250 ... OH)
Plan B - after every 500 OH Plan C - after every 1000 OH
(at 500, 1500, 2500 ... OH) (at 1000, 2000, 3000, 4000 ... OH)
Plan D - after every 5000 OH Plan E - after every 10000 OH
(at 5000, 15000, 25000 ... OH) (at 10000, 20000, 30000, ... OH)
Page 3 of 5
Location Servicing work Menge / Plan Plan Plan Plan Plan
No. A B C D E
Hydraulic system Check pressure (cf. Technical ο¬ ο¬ ο¬
handbook)
Oil cooler
- Bearing
- Fastening screw Check for tightness ο¬ ο¬ ο¬
- Rubber bearing Check condition ο¬ ο¬ ο¬
Return-flow filter Replace 7 ο¬ ο¬ ο¬
Return-flow filter (cooling Replace 2 ο¬ ο¬ ο¬
circuit)
Bypass valve Check / clean filter sieve 4 ο¬ ο¬ ο¬
Bypass valve (cooling circuit) Check / clean filter sieve 1 ο¬ ο¬ ο¬
Magnetic rod Check / clean 1 ο¬ ο¬ ο¬ ο¬
High-pressure filter Check / clean 4 ο¬ ο¬ ο¬
Replace 4 ο¬ ο¬
High-pressure filter (control Check / clean 1 ο¬ ο¬ ο¬
circuit)
Replace 1 ο¬ ο¬
High-pressure filter (auxiliary Check / clean 1 ο¬ ο¬ ο¬
control circuit)
Replace 1 ο¬ ο¬
High-pressure filter (slewing Check / clean 2 ο¬ ο¬ ο¬
circuit)
Replace 2 ο¬ ο¬
High-pressure filter (feeding Check / clean 2 ο¬ ο¬ ο¬
circuit)
Replace 2 ο¬ ο¬
Breather filter Replace 4 ο¬ ο¬ ο¬
Hydraulic oil reservoir Carry out oil analysis 1 ο¬ ο¬ ο¬ ο¬
Change oil 167 ο¬
Pressure accumulator Check pressure (cf. Technical 1 ο¬
handbook)
Cylinder (seals and guide Replace ο¬
rings)
6
cf. βRefilling quantities β Oilβ table
7
Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the
latest
BA RH120E(3 725 055.01)-EN 3-23
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OPERATING INSTRUCTIONS RH120E Electric
Inspection and servicing
III.a Oils for pump gearbox
Fig. 3-10:
BA RH120E(3 725 055.01)-EN 3-33
--- Page 18 ---
OPERATING INSTRUCTIONS RH120E Electric
Inspection and servicing
Charging the batteries Switchgear cabinet
The batteries are charged by the battery charger (
Fig. 3-23:) only if the electrical system with the Breather filter
circuit breaker is switched on. In the switchgear cabinet
The battery main switch (Fig. 3-24:) must be in ο§ For the 6.3 kV power supply (2, Fig. 3-25:),
position I "ON". ο§ For the 400 V system (1, Fig. 3-25:),
ο§ For the 24 V system (3, Fig. 3-26:).
The air is drawn in and cleaned by a ventilator with
filter.
Fig. 3-23:
Fig. 3-25:
Fig. 3-24:
Fig. 3-26:
BA RH120E(3 725 055.01)-EN 3-43
--- Page 19 ---
OPERATING INSTRUCTIONS RH120E Electric
Inspection and servicing
ο Loosen screws (13, Fig. 3-47:) and take off If metal filings are detected, locate cause and rec-
spring clip (14) and disk (15). tify.
Contact the Bucyrus HEX Service, if required.
ο Remove basket (12) and clean in paraffin oil.
ο Install basket (12).
ο Insert filter element (9) together with sealing
ring (11) and cap (8) with sealing ring (10).
ο Refit cover (3).
ο Clean the magnetic rod
The magnetic rod is located under cap (19).
Fig. 3-47:
BA RH120E(3 725 055.01)-EN 3-53
--- Page 20 ---
OPERATING INSTRUCTIONS RH120E Electric
Inspection and servicing
Drawing off hydaulic oil Cleaning the hydraulic oil reservoir
The hydraulic oil can also be drawn off through the Explosion hazard.
service station (Fig. 3-64:).
ο Bring hydraulic oil to operating temperature Do not use white spirit, paraffin oil or
(ca. 50Β° C / 122Β°F). other solvents for cleaning.
Use diesel fuel or a special flushing
ο Retract hydraulic cylinders as far as possible oil.
and stand working equipment on the ground.
Read and observe the "Inspection and
ο Switch off the electric motor. servicing - Safety instructions" chap-
ter.
ο Unscrew cap of express coupling (10).
ο Connect hose line of the service vehicle. Switch off the electric motor.
Skin contact with hydraulic oil may cause skin in-
The hose line and its use are described in the
jury.
"Hose line for oil change" section.
ο Remove hose line. The coupling closes auto- Avoid skin contact.
matically. Wear protective gloves and firm working clothing.
Dispose of contaminated hydraulic oil without pol-
ο Screw on protective cap.
luting the environment and separately from other
waste.
ο Drain off hydraulic oil as described under
"Draining off the hydraulic oil".
ο Remove cap (3, Fig. 3-65:).
ο Detach the return-flow filter.
Fig. 3-64: