PDF Operation & Maintenance Manual CAT RH120C Hydraulic Shovel - 904 KB
This is the official Operation & Maintenance Manual for the CAT RH120C Hydraulic Shovel.
It contains essential information for the daily operation and routine servicing of this powerful machine.
Adhering to the guidelines within this manual will help maximize performance, ensure operator safety, and extend the equipment's lifespan.
Every owner and operator should be thoroughly familiar with its contents.
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BA 6020B(3 847 000.00)-EN
04 / 2013
Operation and
Maintenance
Manual
6020B
Hydraulic Shovel No.
DNR00101 - DNR00104
--- Page 3 ---
BA 6020B(3 847 000.00)-EN
Table of contents
PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ________________________________ 4-8
OTHER MAINTENANCE WORK ______________________________________________________ 4-9
Windscreen wiper blade – replace ___________________________________________________ 4-9
Seat belt – replace _______________________________________________________________ 4-9
Bucket tip – replace______________________________________________________________ 4-10
Bucket lip shroud – replace ________________________________________________________ 4-11
Bucket wing shroud – replace ______________________________________________________ 4-11
WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS _____________________ 4-12
DISPOSAL AT THE END OF THE SERVICE LIFE _______________________________________ 4-15
Appropriate disposal of batteries____________________________________________________ 4-16
NOTES_________________________________________________________________________ 4-17
5 ANNEX__________________________________________________________________________ 5-1
BOARD-CONTROL-SYSTEM ________________________________________________________ 5-3
BCS III, what’s that? ______________________________________________________________ 5-3
BCSIII screens - Sitemap 1 _________________________________________________________ 5-4
BCSIII screens - Sitemap 2 _________________________________________________________ 5-5
The BCS housing – overview _______________________________________________________ 5-6
BCSIII, the first screen after startup __________________________________________________ 5-7
BCSIII, the start screen ____________________________________________________________ 5-8
Often used symbols and buttons_____________________________________________________ 5-9
Start screen - Information given in the top section ______________________________________ 5-10
Start screen - Information given in the central section ___________________________________ 5-11
Start screen - Information given in the lower section ____________________________________ 5-12
Start screen – Help section ________________________________________________________ 5-13
System status screen - Information given on the screen _________________________________ 5-14
System status – Engine, Information given on the screen ________________________________ 5-15
System status – Hydraulics, Main pump pressure screen ________________________________ 5-16
System status – Hydraulics, Attachment screen ________________________________________ 5-17
System status – Hydraulics, Slewing screen___________________________________________ 5-18
System status – Hydraulics, Oil tank screen ___________________________________________ 5-19
System status – Hydraulics, Travel screen ____________________________________________ 5-20
System status – Grease, Progressive grease system screen______________________________ 5-21
Service – Servosystem screen _____________________________________________________ 5-22
Service – More details screen ______________________________________________________ 5-23
Service – Slew brake test screen ___________________________________________________ 5-24
Help - Viewing PDF™ documents screen _____________________________________________ 5-25
PDF™ reader - functions__________________________________________________________ 5-26
PDF™ reader - settings screen_____________________________________________________ 5-27
PDF™ reader - search screen _____________________________________________________ 5-28
Software version screen __________________________________________________________ 5-29
Event list screen ________________________________________________________________ 5-30
Event list screen - location ________________________________________________________ 5-31
Screenshot - making and storing____________________________________________________ 5-32
Setup menu - login screen ________________________________________________________ 5-33
BCS III - interfaces ______________________________________________________________ 5-34
BCSIII - cleaning ________________________________________________________________ 5-35
BCSIII – replace battery __________________________________________________________ 5-35
BCSIII - disposal ________________________________________________________________ 5-35
1-11
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BA 6020B(3 847 000.00)-EN
Introduction
Special work in conjunction with Keep all handles, steps, handrails, platforms, land-
ings and ladders free from dirt, snow and ice.
utilization of the machine and Clean the machine, especially connections and
maintenance and repairs as well threaded unions, of any traces of oil, fuel or pre-
as troubleshooting during work; servatives before carrying out maintenance/repair.
Never use aggressive detergents. Use lint-free
disposal of parts and consum- cleaning rags.
ables Before cleaning the machine with water, steam jet
Observe the adjusting, maintenance and in- (high-pressure cleaning) or detergents, cover or
spection activities and intervals set out in the oper- tape up all openings which - for safety and func-
ating instructions, including information on the tional reasons - must be protected against water,
replacement of parts and equipment. These activi- steam or detergent penetration. Special care must
ties may be executed by skilled personnel only. be taken with electric motors and switch-gear cabi-
nets.
Brief operating personnel before beginning special
operations and maintenance work, and appoint a Ensure during cleaning of the machine that the
person to supervise the activities. temperature sensors of the fire-warning and fire-
fighting systems do not come into contact with hot
In any work concerning the operation, conversion
cleaning agents as this might activate the fire-
or adjustment of the machine and its safety-
fighting system.
oriented devices or any work related to main-
tenance, inspection and repair, always observe the Exhaust pipes and turbo chargers in the engine
start-up and shut-down procedures set out in the compartments are covered with special heat-
Operation and Maintenance Manual and the infor- insulating material. This material must not be
mation on maintenance work. spray-washed with steam-jet cleaners or high-
pressure cleaners. It will be damaged. Therefore
Ensure that the maintenance area is adequately
cover all the insulating material with plastic foils
secured.
before using steam-jet cleaners or high-pressure
If the machine is completely shut down for mainte- cleaners inside the engine compartments.
nance and repair work, it must be secured against
After cleaning remove all covers and tapes applied
inadvertent starting by:
for that purpose.
removing the ignition key and
After cleaning, examine all fuel, lubricant, brake
attaching a warning sign. and hydraulic fluid lines for leaks, loose connec-
tions, chafe marks and damage. Any defect found
Carry out maintenance and repair work only if the must be rectified without delay.
machine is positioned on stable and level ground Always tighten any screwed connections that have
and has been secured against inadvertent move- been loosened during maintenance and repair.
ments. Any safety devices removed for set-up, main-
To avoid the risk of accidents, individual parts and tenance or repair purposes must be refitted and
large assemblies being moved for replacement checked immediately upon completion of main-
purposes should be carefully attached to lifting tenance and repair work.
tackle and secured. Use only suitable and techni- Ensure that all consumables and replaced parts
cally perfect lifting gear and suspension systems are disposed of safely and with minimum en-
with adequate lifting capacity. Never work or stand vironmental impact.
under suspended loads.
The fastening of loads and the instructing of crane
operators should be entrusted to experienced per-
sons only. The marshaller giving the instructions
must be within sight or sound of the operator.
For carrying out overhead assembly work always
use specially designed or otherwise safety-
oriented ladders and working platforms. Never use
machine parts as a climbing aid
Wear a safety harness when carrying out mainte-
nance work at heights above 1 m.
Wear an approved harness equipped with fall ar-
resters and safety lines.
1-9
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BA 6020B(3 847 000.00)-EN
Operation
FIRE AND EXPLOSION HAZARD
Remove the hydraulic shovel from such an area
where combustible or easily flammable liquids
have spilled from the hydraulic shovel onto the
Safety instructions:
ground.
Prior to commencing work, obtain informatio-
Flying sparks (caused by welding, flame cutting,
non the national and corporate rules for the
grinding, electrical short-circuit) may cause fire on
prevention of accidents and avoiding fires.
the ground that can spread to the hydraulic shovel.
Pay particular attention to hazards caused by
Clean the hydraulic shovel before starting work.
combustible and easily flammable substances.
Place suitable fire guardings (fire barriers) if open
Obtain information on the safe handling of the fire or flying sparks cannot be avoided during re-
fire extinguishers to be used. pair work.
If necessary, also cover the ground with fire-
Avoid smoking and open fire on, next to and below protective blankets.
the hydraulic shovel. Apply special protection to cables, cable ducts as
Combustible and easily or highly inflammable sub- well as to hose and pipe lines.
stances or liquids increase the risk of fire and ex- The engine compartment can be equipped with
plosion pressure vessels containing cold-starting fluid
Do not store or transport flammable substances on (ether). Ether is toxic and highly flammable; the
the hydraulic shovel during the work. This is also vessels are under pressure. These pressure ves-
valid for pressure vessels containing flammable sels can explode if exposed to high temperatures
substances as, for instance, spray oil or cold- (above 49°C / 120°F) or in the event of damage.
starting fluid (ether). They are heat-sensitive and Protect the pressure vessels against damage be-
can explode even if exposed only to intensive fore beginning to work in or close to the engine
sunlight. compartment.
Clean the hydraulic shovel carefully, if oil, grease, Ensure sufficient ventilation.
fuel, detergents or cold-starting fluid have been Do not keep any fire extinguishers that are not
spilt over the machine. If possible, use a steam-jet suitable or have not been tested.
cleaner for cleaning.
Do not extinguish flammable liquids with water.
These substance can also ignite themselves if they Use:
come close to hot units or objects as, for instance,
dry-powder, carbon-dioxide or foam extin-
a turbocharger.
guishing compounds.
Clean rubber or electrical with compressed air
only. When getting into contact with burning substances,
the fire-fighting water would abruptly evaporate
Ensure sufficient ventilation.
and distribute the substance such as oil over a
Even battery gases can ignite in open flames or wide area. Water causes short-circuits in the elec-
fire. trical system thus possibly entailing new hazards.
Avoid parking the hydraulic shovel in places where Call the fire brigade.
combustible substances such as coal dust or Have all your welding, flame cutting and grinding
tar are present. work approved before starting work.
open or smouldering fire may occur.
2-5
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BA 6020B(3 847 000.00)-EN
Operation
Fig. 2-7:
2-15
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BA 6020B(3 847 000.00)-EN
Operation
Machine number plate – location Engine number plate – location
The identification plate with the machine number The serial number plate (1, Fig. 2-34:) for the die-
(Fig. 2-32:) is attached to the front side of the A- sel engine is located on the left side of the diesel
frame (arrow, Fig. 2-33:). engine.
Fig. 2-32:
Fig. 2-34:
Engine information plate – loca-
tion
The engine information plate (2, Fig. 2-35:) is lo-
cated on the right side of the engine. The plate
gives information about the engine like horse-
power, high idle, full load engine speed and others.
Fig. 2-33:
Component numbers – location
Other larger units also have identification plates
indicating, among other things, their serial number.
On steel components, the CGM HMS part number
or the serial number may be stamped into the
Fig. 2-35:
metal at a clearly visible place.
2-25
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BA 6020B(3 847 000.00)-EN
Operation
Emergency shut-off switches, contin- Emergency shut-off pull switch be-
ued tween power module and counter-
weight
Emergency shut-off switch inside the
power module, pump compartment
Fig. 2-62:
Putting the machine back into
operation – reset of emergency
shut-off function
The machine can only be put back into operation
Fig. 2-60: when all emergency shut-off switches listed above
are again in their basic position (i.e. not actuated /
resetted). To reset pull out the red knob. The emer-
Emergency shut-off switch inside the gency shut-off switch on the rear side of the power-
module is resetted after pulling out the blue knob.
power module, engine compartment Additionally the Reset button switch (1, Fig. 2-63:)
has to be pushed. The Reset button switch is located
in the front door of the battery main switch cabinet
(37) at the power module.
After pushing the Reset button switch (1) a green
LED located inside the switch comes on.
Fig. 2-61: Fig. 2-63:
2-35
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BA 6020B(3 847 000.00)-EN
Operation
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2-45
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BA 6020B(3 847 000.00)-EN
Operation
(Fig. 2-87:)
All switches and pushbuttons have an illuminated symbol face.
The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.
No. Element Function Symbol
81 Switch Travelling speed Not actuated:
1st travelling stage
travelling forwards / backwards is possible.
Press the switch face with the symbol:
2nd travelling stage,
only parallel forward travel is possible. In
case of backward travel and cornering, the
machine switches back automatically into the
1st travelling stage.
82 Push-button Central lubricating Reset function of the central greasing sys-
system reset tem control (Press for at least 3 sec.).
Press switch face to the left:
Resets the control of the upper structure.
Press the switch face to the right:
To be decribed.
83 Push-button Emergency lower- Lowering of the working equipment, for in-
ing stance, if the engine has failed.
Press and hold the switch face with the sym-
bol using at the same time the control lever
to lower the working equipment.
84 Not connected.
85 Switch Working light Press the switch face with the symbol:
(optional) Workinglights on the boom / arm are ON.
86 Switch When the machine Press the switch face with the symbol:
has to be manoeu- The machine can be driven and the upper
vered out of dan- structure be slewed although these functions
gerous situations are automatically deactivated.
Use this function only in dangerous situa-
tions to manouever yourself or the ma-
chine out of hazard zones.
Risk of damaging parts of the machine,
e.g. the hydraulic ladder.
87 Not connected.
88 Not connected.
2-55
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BA 6020B(3 847 000.00)-EN
Operation
Assemblies resp. Level measuring device Remarks
reservoirs
Fuel tank BCS fuel indicator (Fig. Remove protective cap from express coupling at the
2-93:) Service-Station (arrow, Fig. 2-94:).
Attach filling hose from the service vehicle to express
coupling.
Fill in fuel.
Stop filling when the fuel tank is full.
Detach filling hose.
Push protective cap back on to express coupling.
Fig. 2-93:
Fig. 2-94:
2-65
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BA 6020B(3 847 000.00)-EN
Operation
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2-75
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BA 6020B(3 847 000.00)-EN
Operation
TRANSPORTING THE MACHINE Transport
The dimensions and the service weight of the fully
Transport - Safety instructions assembled hydraulic shovel do not allow the hy-
The machine must be loaded and transported only draulic shovel to be transported in an undismantled
after all safety regulations have been observed state on a low-bed trailer over public roads.
and complied with. Therefore, the machine must be disassembled into
Entrust loading and transporting of the machine to the transportable field assembly modules before-
a company experienced in the transport of heavy hand.
equipment. Lifting and lashing points as well as the center of
The responsability for loading and transporting lies gravity are marked on the modules (see example,
with the transport company or their representative. Fig. 2-130:).
Remove oil, grease, soil, mud, snow, ice and other Dimensions and weights of the machines modules
materials from the hydraulic shovel's transport can be found in the annex, chapter “Product Speci-
modules and from ramps and loading platforms of fication Sheet” as well as in the “Service Manual”.
the transport vehicle to minimize slipping. In chapter 3 of the Service Manual you can find a
Secure the transport vehicle against rolling away. detailled description about disassembly and as-
sembly procedures.
Use only tying equipment of sufficient strength (the
weights and dimensions of the hydraulic shovel are
set out in the "Product Specification Sheet").
Fig. 2-130:
2-85
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BA 6020B(3 847 000.00)-EN
Operation
Emergency lowering of the work- After daily operation
ing equipment Parking the machine
With the engine not functional, the working equip- Park the machine on level and stable ground.
ment can be lowered to the ground as follows: This is particularly important in winter to avoid
Switch on electrical system (24V) with key- freezing of the tracks.
operated switch (11, Fig. 2-144:). Stand the working equipment on the ground.
Actuate switch (83) and hold. Shut off the engine.
Push control lever (116) forwards. The working Shift both control levers into all directions to
equipment comes to the ground. depressurize the hydraulic cylinders.
Clean the machine of coarse dirt as well as of
combustible and easily flammable substances,
if possible with a stream jet (rubber parts and
electric components with compressed air - re-
fer to information label). Otherwise, the fire and
explosion hazard will exist.
Clean off gross dirt, ice and snow from the fins
and the fan wheel of the hydraulic oil cooler.
Fill up the fuel tank.
Inspect the engine, the hydraulic system, the
track rollers, support rollers, sprockets, idlers
and gearboxes visually for leaks.
Escaping oil pollutes the environment.
Repair leaks immediately (or have them re-
paired).
Report oil accidents to the responsible person.
Check the upper structure, undercarriage and
the working equipment for damage and all
Fig. 2-144: steel components for cracks or fractures.
Report detected damage immediately to the
responsible person.
Withdraw the key from the electrical system
key-switch.
Lock the cab door and all lockable doors,
hatches and covers on the machine.
2-95
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BA 6020B(3 847 000.00)-EN
Inspection and servicing
INSPECTION AND SERVICING - Securing the machine
SAFETY INSTRUCTIONS Carry out servicing work only if the machine is
secured as described in the section "Securing the
Operating manual machine".
No inspection and servicing work must be carried
out until the operating manual has been read and
understood. Climbing onto and off the machine
Pay special attention to: Use only the ladders, steps, platforms and hand-
rails provided when climbing onto or off the ma-
„Fundamental safety instructions" and all warnings
chine.
and safety instructions attached to the machine.
Always keep ladders, steps, platforms and hand-
The operating manual lists all jobs to be done. The
rails in a non-slip, safe state and remove any oil,
descriptions of job sequences, however, provide
grease, soil, clay, snow, ice and other foreign mat-
only
ter immediately.
Experienced personnel with the necessary instruc-
tions. Always face the machine when climbing on and
off.
The operating manual must be kept with the ma-
chine at all times. Always maintain a three point contact with the
steps and grab handles.
Inspection and servicing personnel
Checking the state of tools
Inspection and servicing personnel must have the
necessary know-how on the inspection and servic- Use only fully functional, reliable tools.
ing of this or comparable machines. Select the right tool for the job.
The necessary know-how can be acquired in a Wrenches of the wrong size, for example, may slip
several day's instruction, e.g. by an CGM HMS and cause injury.
mechanic or by attending an CGM HMS training
course.
Cleaning jobs
Personal protective equipment and Prior to commencing work, clean your working
area, if necessary and possible, with a stream jet
working clothes (rubber parts and electric components with com-
Wear closely fitting working clothing when working pressed air - refer to information label).
on the machine. Loose, wide garments may catch Exhaust pipes and turbo chargers in the engine
on machine parts and result in injury. compartments are covered with special heat-
Wear your personal protective equipment: a safety insulating material. This material must not be
helmet, safety goggles, safety footwear and spray-washed with steam-jet cleaners or high-
gloves. pressure cleaners. It will be damaged. Therefore
When carrying out work on the working equipment, cover all the insulating material with plastic foils
f.ex. on the boom, use a fall arrester. Falling down before using steam-jet cleaners or high-pressure
from great hight may cause severe injuries. Con- cleaners inside the engine compartments.
nect the fall arrester to the safety line on the boom. Use only lint-free cleaning rags when working on
the hydraulic system or the engine.
Securing the working equipment Cleaning agents and solvents may give off harm-
ful, readily flammable vapours. Never work with
Stand working equipment on the ground in such a such agents except on well ventilated premises;
way that no movements can be made if mechani- never inhale the vapours and never smoke.
cal or hydraulical connections become detached.
Prevent solvents and cleaning agents from coming
Secure any equipment or component which is to
into contact with your skin.
be mounted or dismantled, or whose position is to
be changed, with hoists or appropriate slinging / Wear gloves.
supporting devices to prevent them from moving, Observe the instructions on the packaging.
slipping or falling inadvertently.
3-3
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BA 6020B(3 847 000.00)-EN
Inspection and servicing
Plan N
Plan N – After initial commissioning and during the running-in period (after approx. 100 OH)
Page 1 of 2
Location Servicing work Quantity Checked
Undercarriage:
LH / RH crawler structure Inspect visually for cracks / damage
Carbody Inspect visually for cracks / damage
- Fastening bolts Check for tightness (see: „Service Manual“)
- Hoses Check for leaks, tightness of flange bolts
Track chain assembly
- Bolts Check for tightness (see: „Service Manual“)
- Chain links Check for cracks / broken pins