PDF Operating Instructions Cat Bucyrus RH 120E Hydraulic Excavator - 2 MB
This manual contains the official operating instructions for the Cat Bucyrus RH 120E Hydraulic Excavator.
It is designed to help operators understand the machine's controls, systems, and safety features.
Adherence to these instructions ensures efficient and safe operation in demanding mining environments.
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OPERATING INSTRUCTIONS RH 120E
Hydraulic Excavator
RH 120E No.
Bucyrus HEX GmbH
BA RH120E(3 663 730.00)-EN
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OPERATING INSTRUCTIONS RH 120 E
Introduction
1 INTRODUCTION
2804051
Operating instructions Target group
Part 1 INTRODUCTION Operating personnel
+
FUNDAMENTAL Inspection and
servicing personnel
SAFETY INSTRUCTIONS +
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
SERVICING The inspection and servicing personnel must
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(3 663 730.00)-EN 1-1
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OPERATING INSTRUCTIONS RH 120 E
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 Always wear the prescribed ear protectors.
outside;
Oil, grease and other chemical
Do not modify or tamper with the exhaust system
substances
Diesel engine exhaust and some of its constitu-
ents are known to cause cancer, birth defects, and When handling oil, grease or other chemical sub-
other reproductive harm stances, observe the product-related safety regu-
lations (see safety specifications).
Operate fuel-operated heating systems only on
adequately ventilated premises. Before starting Be careful when handling hot consumables (risk of
the machine on enclosed premises, make sure burning or scalding).
that there is sufficient ventilation.
Transporting and recommission-
Observe the regulations in force at the respective
site. ing
Carry out welding, flame-cutting and grinding work The machine must be loaded and transported only
on the machine only if this has been expressly in accordance with the operating instructions.
authorized, as there may be a risk of explosion
and fire. Use only appropriate means of transport and lifting
gear of adequate capacity.
Before carrying out welding, flame-cutting and
grinding operations, clean the machine and its The recommisioning procedure must be strictly in
surroundings from dust and other inflammable accordance with the operating instructions.
substances and make sure that the premises are
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 (hydraulic system) to be removed in accor-
dance with the specific instructions for the unit
concerned before carrying 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
comply with the technical requirements.
BA RH120E(3 663 730.00)-EN 1-11
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OPERATING INSTRUCTIONS RH 120 E
Operation
Excavator layout 35 β Fire-extinguisher
36 β Control cabinet with battery main switch
Fig. 2-1:
37 - Batteries
Undercarriage 38 - Service-station, (tanklift)
1 - Track drive 39 - Ladder
2 β Idler 40 - Ladder
3 - Track roller 41 - Grease container for central lubrica
4 - support roller ting system
5 - Crawler track 42 - Tool cabinet (optional)
6 - Track tensioner 43 - Counterweight
7 - Slewing ring 44 - On-board crane (optional)
8 - Ladder 45 - Drive unit (onboard crane, optional)
Loading bucket
Superstructure
51 β Boom
10 - Engine
52 - TriPower linkage
11 - Radiator (engine cooling liquid)
53 β Stick
11 - Reservoir (cooling liquid)
54 - Bottom-dump bucket
13 - Air-intake system
55 - Boom cylinder
14 - Exhaust system
56 - Stick cylinder
15 - Fuel tank
57 - Tipping cylinder
16 - Hydraulic oil reservoir
58 - Bottom-dump cylinder
17 - Hydraulic oil cooler
64 - Control valves
18 - Engine oil reservoir (optional)
65 - Quick-action valve
19 - Pump transfer gearbox
20 - Working pump Backhoe bucket
21 - Cooling oil pump 53 - Stick
22 - Servo system pump 35 bars 55 - Boom cylinder
23 - Servo system pump 60 bars 56 - Stick cylinder
24 - Gearbox circulating pump 59 - Monoblock boom
25 - Slewing pump 60 - Backhoe bucket
26 - Fan drive pump (cooler, hydraulic oil) 61 - Backhoe cylinder
27 - Fan drive pump (radiator, engine cooling 62 - Toggle link
liquid) 63 - Toggle lever
28 - Air compressor drive (air conditioning 64 - Control valves
system) 65 - Quick-action valve
29 β Slewing gear
30 β Travel block and rotor
31 β Driver`cab
32 β Control stand with BCS
33 β Control cabinet
34 β Air conditioner (optional)
BA RH120E(3 663 730.00)-EN 2-7
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OPERATING INSTRUCTIONS RH 120 E
Operation
Fire extinguisher Extinguishing agent
The excavator is equipped with two fire extin- Each fire-extinguisher is filled with 12 kg Glutex.
guishers (arrow Fig. 2-19:) This extinguishing agent is used for fighting fires
of classes A, B and C. Fires are extinguished fast,
perfectly and without residues.
Handling
Fig. 2-19:
The excavator driver and the maintenance per-
sonnel must informthemselves about how to han-
dle the fire-extinguisher in order to be able to act
Fig. 2-21:
fast and efficiently in case of beginning fires. Such
instruction should be given by a qualified instruc- " Pull out securing pin (2, Fig. 2-21:).
tor.
" Strike knob (3) hard, then release again.
Fire extinguisher (option) " Operate the extinguishing gun.
The fire extinguishers can be installed, for in-
stance, at the places indicated by the arrows (Fig. Inspection
2-20:).
Have the extinguisher inspected at regular inter-
The excavator driver and the maintenance per- vals by an expert. This is required by local authori-
sonnel must inform themselves about how to han- ties and insurance companies and is in the inter-
dle the fire-extinguisher in order to be able to act est of your own safety.
fast and efficiently in case of beginning fires. Such
instruction should be given by a qualified instruc- Have the fire-extinguisher checked
tor. at the prescribed intervals by
authorized testing agencies
Fig. 2-20:
BA RH120E(3 663 730.00)-EN 2-17
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OPERATING INSTRUCTIONS RH 120 E
Operation
Fig. 2-28:
No. Element Function Symbol
41 Warning lamp CELECT warning Lamp is lit up in the event of an Celect fault.
(left engine 1) The lamp moreover indicates the fault code.
Contact Terex Germany after-sales ser-
vice or engine manufacturer.
(see switches 55 and 57)
42 Warning lamp CELECT warning Lamp is lit up in the event of an Celect fault.
(left engine 1) The lamp moreover indicates the fault code.
Shut off the engine
Stop working
Contact Terex Germany after-sales ser-
vice or engine manufacturer.
(see switches 55 and 57)
43 Warning lamp CELECT warning Lamp is lit up (e.g.):
(left engine 1) - when the engine oil pressure is too low
- when the cooling water temperature is too
high
Shut off the engine
44 Warning lamp CELECT warning Lamp is lit up in the event of an Celect fault.
(right engine 2) The lamp moreover indicates the fault code.
Contact Terex Germany after-sales ser-
vice or engine manufacturer.
(see switches 65 and 67)
45 Warning lamp CELECT warning Lamp is lit up in the event of an Celect fault.
(right engine 2) The lamp moreover indicates the fault code.
Shut off the engine
Stop working
Contact Terex Germany after-sales ser-
vice or engine manufacturer.
(see switches 65 and 67)
46 Warning lamp CELECT warning Lamp is lit up (e.g.):
(right engine 2) - when the engine oil pressure is too low
- when the cooling water temperature is too
high
Shut off the engine
47 Indicator lamp Boom/stick angle Lamp is lit up when the boom/stick angle is
(optional) in normal working range.
48 Indicator lamp Boom/stick angle Lamp is lit up when the boom/stick angle is
(optional) in hazard range.
(the tracks may be demaged by the working
equipment)
Increase the angle.
The buzzer (34) sounds until the angle has
resumed the normal working range.
BA RH120E(3 663 730.00)-EN 2-27
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OPERATING INSTRUCTIONS RH 120 E
Operation
Fig. 2-33:
No. Element Function Symbol
91 Switch Emergency Operati- Lowers the boom and stick when actuated in
on Boom/Stick an emergency.
92 Button Counting dumper RESET
93 Switch Stick cylinder
switch-off bypass
(optional)
94 Switch Fuel pre-heating Switches on the the pre-heating system for
(optional) the fuel
95 Switch Lighting Switches on the lighting for servicing work.
96 Switch Lighting Switches the cab lighting on and off.
97 Switch Windscreen wiper Activates permanent wiping
rear window (optio-
nal)
98 Switch Beacon (optional) Switches the beacon on and off.
BA RH120E(3 663 730.00)-EN 2-37
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OPERATING INSTRUCTIONS RH 120 E
Operation
Fig. 2-38: (optional)
No. Element Function Symbol
165 Warning lamp Slewing motor 1 Lights up when the slewing motor is conta-
contaminated minated with metal particles.
166 Warning lamp Slewing motor 2 Lights up when the slewing motor is conta-
contaminated minated with metal particles.
167 Warning lamp free for optional
168 Warning lamp Hydraulic oil filter Lights up when the flow resistance in the
contaminated filter is too high. Replace filter elements if the
warning lamp fails to go out when the oil is at
operating temperature.
169 Warning lamp Min. hydraulic oil Lights up when the hydraulic oil level in the
level hydraulic tank is too low.
170 Warning lamp Electronic excavator Lights up when the electronic excavator con-
control ON trol is switched on.
171 Indicator light Hydraulic oil tank Lights up when one of the shut-off valves of
the hydraulic oil tank is closed
When the left valve is closed, the
LH engine cannot be started.
When the right valve is closed,
the RH engine cannot be started.
When the center valve is closed
none of the two engines can be
started.
When a shutoff valve is closed
with the engines running, the re-
spective engine or both engines
are stopped.
172 Thermometer Hydraulic oil Indicates hydraulic oil temperature in hydrau-
lic tank
181 Control unit Air conditioner
(optional)
182 Control unit Heating (optional)
BA RH120E(3 663 730.00)-EN 2-47
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OPERATING INSTRUCTIONS RH 120 E
Operation
Assemblies resp. Measuring device Remarks
reservoirs
Cooling system Level indicator (4, Fig. 2-53:) Stop filling when the level indicator indicates maximum
reservoir filling level. (cf. chapter "Cooling system - Cooling li-
quid").
Grease container β BCS display (Fig. 2-54:) Stop filling when the BCS indicates ββgrease container is
cental lubricating fullβ.
system Switch on the display system (optional) with the toggle
switch (33, Fig. 2-55:).
Stop filling when the grease container is full.
The indicator lamp (34) lights up.
On completion of filling, switch the display system off
again with the toggle switch (33).
Fig. 2-53:
Fig. 2-55:
Fig. 2-54:
BA RH120E(3 663 730.00)-EN 2-57
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OPERATING INSTRUCTIONS RH 120 E
Operation
TRAVELLING Travelling forwards/backwards
2804916
Travelling forwards:
Superstructure basic position
depress pedals (112 and 113) forwards.
Travel direction and sense of actuation of pedals
(112 and 113, Fig. 2-73:) are identical only when The excavator travels in the direction of the idler
the excavator is in its BASIC POSITION (Fig. (2, Fig. 2-72:).
2-72:).
Travelling backwards:
depress pedals (112 and 113, Fig. 2-73:) back-
wards.
The excavator travels in the direction of the drive
sprocket (4,Fig. 2-72:).
Fig. 2-72:
If the superstructure is slewed out
of its basic position by more than
90Β° (Fig. 2-74:), the excavator mo-
ves in a direction opposite to that
expected when pedals (112 and
113, Fig. 2-73:) are depressed. Fig. 2-74:
The pedals return automatically to their "0" positi-
ons 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 drive must always be at
the rear. Travel only in the basic
position of the excavator and only
forwards.
Fig. 2-73: Be extremely careful on slippery
and greasy ground.
If the operator is not completely sure of the positi-
on of the superstructure with regard to the under-
carriage, pedals (112 and 113) should be de-
All instructions with regard to travelling speed re-
pressed slightly in order to find out which way the
gulation and travel direction control are applicable
excavator moves before initiating the full travelling
only as long as the crawler tracks have sufficient
movement.
grip and do not slip.
BA RH120E(3 663 730.00)-EN 2-67
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OPERATING INSTRUCTIONS RH 120 E
Operation
WORKING OPERATION Slewing and braking the super-
2804917 structure
Before starting work The superstructure can only be slewed if the su-
perstructure holding brake is released.
To slew the superstructure to the right:
shift control lever (115) to the right.
Prior to initial commissioning and
after repairs on the central lubrica- To slew the superstructure to the left:
ting system or the hydraulic cylin- shift control lever (115) to the left.
ders, move the unloaded equip-
ment for abt. 5 minutes. After releasing, the control lever returns automati-
cally to position "0".
This is required to ensure an adequate supply of Braking the superstructure
grease to the cylinder bearings when the work
starts. The superstructure is braked only by setting con-
trol lever (115) into the opposite direction (counte-
Warming up ring).
At low outside temperatures it is necessary to run In an emergency apply parking
the hydraulic system up to operating temperature. brake with switch (82, Fig. 2-92:)
The temperatures at which warming up is neces-
sary depend on the type of hydraulic oil used; cf.
also "Oils for hydraulic systems".
To warm up the system: Run the diesel engines at
ca. 2/3 full speed and start to perform no-load
working movements for abt. 10 minutes with the
excavator.
Fig. 2-91: Fig. 2-92:
Switching on the electronic excavator
control
The electronic excavator control is switched on
and off with switch (105, Fig. 2-91:).
Electronic excavator control activated - operator is
sitting on his seat.
Electronic excavator control deactivated - driver's
seat is empty.
BA RH120E(3 663 730.00)-EN 2-77
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OPERATING INSTRUCTIONS RH 120 E
Inspection and servicing
3 INSPECTION AND SERVICING
2804053
Operating instructions Target group
Part 1 INTRODUCTION Operating personnel
+
FUNDAMENTAL Inspection and
servicing personnel
SAFETY INSTRUCTIONS +
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
SERVICING The inspection and servicing personnel must
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(3 663 730.00)-EN 3-1
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OPERATING INSTRUCTIONS RH 120 E
Inspection and servicing
INSPECTION AND SERVICING indicates. Replace the filter elements after one
year at the latest.
PLANS - INSTRUCTIONS
Oils / Greases
For the specification of oils and greases to be
Intervals used refer to the "Lubricants" section.
The inspection and Servicing plan lists all jobs
The numerals mentioned in the "Oil / Grease"
which have to be done on the machine at regular
column in the inspection and sServicing plans
intervals.
have the following meaning:
The individual inspection and Servicing plans are
marked with letters providing a link between the I Oils for combustion engines and com-
operating hours (OH) recorded by the hours-run pressors
meter of the machine and the inspection and II Oils for hydraulic systems
sServicing plans.
III Oils for gearboxes
V Greases for bearings and slewing
rings
Plan Do all jobs ....
V ...once prior to initial commissioning.
N ...after initial commissioning and du- Cleaning jobs
ring the running-in period.
Cleaning jobs, especially on cooling systems,
T ...every 10 OH or every working shift 1) must be done at shorter intervals if the machine is
2 exposed to severe dust build-up.
W ...every 60 OH or weekly .
A ...after every 250 OH.
Components
B ...after every 500 OH.
C ...after every 1000 OH. The maintenance intervals for components, e.g.
engine and gearbox, are listed in the following
D ...after every 5000 OH. Terex Germany maintenance schedules.
E ...after every 10000 OH.
It is possible that the manufacturer's documentati-
OH = Bh = Operating hours on for these components states intervals deviating
from the above-mentioned intervals.
Change of engine oil l In such case, only the maintenance intervals
specified by Terex Germany shall apply.
The intervals stated for changing the engine oil
apply to fuels with a sulphur content of β€ 0.5% and
a permanent ambient temperature down to β10Β°
C.
In case of higher sulphur content and/or a perma-
nent ambient temperature of below β10Β° C, shor-
ter intervals are required.
If the engine oil change intervals are not reached
within 6 months, the oil must be changed at least
after 6 months.
Air-intake system
The air filter must be serviced only if the BCS so
2
Whichever comes first.
BA RH120E(3 663 730.00)-EN 3-11
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OPERATING INSTRUCTIONS RH 120 E
Inspection and servicing
Plan A - after every 250 OH Plan B - after every 500 OH
(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH
(at 10000, 20000, 30000, ... OH)
Page 3 von 8
Location Servicing work Menge / Plan Plan Plan Plan Plan
No. A B C D E
Engine with centrifuge and Carry out oil analysis 2 # # # # #
engine oil reservoir (optio-
nal)
7
Change oil 2 # # # #
Clean # # #
- Bearing
- Fastening screws Check tightness # # #
- Rubber bearing Check condition # # #
Oil filter Replace 2x2 # # # # #
7
Engine oil reservoir Change oil 2 # # # #
Clean # # #
V-belt Check tension # # # # #
Check condition # # # # #
Centrifuge Clean 2x1 # # # #
- Rotor seal Replace 2x1 # # #
- Casing seal Check /replace 2x1 # # #
Inspection and servicing (cf. Operating and mainte- 2 # # # # #
nance manual for engine)
7
cf. βRefilling quantities β Oilβ table
BA RH120E(3 663 730.00)-EN 3-21
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OPERATING INSTRUCTIONS RH 120 E
Inspection and servicing
Lubricating chart β Grease / Backhoe bucket (legend)
No. Greasing point Number Lubricant Grease every
properties .... operating hours
1 Central lubricating system β grease container 1 18 10
V
3 Ramp-type ladder (optional) V 18
- Deflecting roller 3 1000
- Locking bolt 1 I 18 1000