Cat Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651416 – PDF DOWNLOAD

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Cat Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651416 – PDF DOWNLOAD

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Cat Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651416 – PDF DOWNLOAD

Language : English
Pages : 267
Downloadable : Yes
File Type : PDF

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Cat Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651416 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH200
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

• 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 Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel. The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
• 1 Complies with VDMA recommendation “Operating instructions” All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service.
• 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.

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TABLE OF CONTENTS:

Cat Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651416 – 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
	INTRODUCTION, FIRE AND EXPLOSION HAZARD.................................................................................................................................. 22
	NOTES ................................................................................................................................................................... 23
2 OPERATION.................................................................................................................................................................. 25
	OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 27
		Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 28
	OPERATION, 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
		Signs and labels .................................................................................................................................................... 35
		Entering and leaving the machine, Safety instructions ............................................................................................................... 36
		Access ladder lighting .............................................................................................................................................. 36
		Swinging ladder ..................................................................................................................................................... 37
		Switching the cab interior lighting on and off ...................................................................................................................... 38
		Switching the servicing lighting on and off ......................................................................................................................... 39
		EMERGENCY STOP switch ............................................................................................................................................... 40
		Driver’s seat  ...................................................................................................................................................... 41
		Trainer's / instructor's seat ....................................................................................................................................... 43
		Windscreen washer ................................................................................................................................................... 43
		Fire extinguisher ................................................................................................................................................... 44
		Automatic fire-extinguishing system (optional) ...................................................................................................................... 45
		Harness (optional) .................................................................................................................................................. 46
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 50
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 82
		Refuelling .......................................................................................................................................................... 82
		Service station (tanklift) .......................................................................................................................................... 83
		Switching the electrical system on and off .......................................................................................................................... 89
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 90
		Starting the engines ................................................................................................................................................ 90
		Starting the engines at low temperatures ............................................................................................................................ 91
	AIR CONDITIONER (OPTION)................................................................................................................................................. 93
		Back-up heating (option) ............................................................................................................................................ 94
	DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................ 96
	TRAVELLING .............................................................................................................................................................. 97
		Superstructure basic position ....................................................................................................................................... 97
		Travelling forwards/backwards ....................................................................................................................................... 97
		Locking the superstructure ..........................................................................................................................................101
		Track parking brake .................................................................................................................................................101
	TRANSPORTING THE MACHINE ................................................................................................................................................102
		Transport - Safety instructions .....................................................................................................................................102
	WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................103
		Running-in instructions for hydraulic cylinders .....................................................................................................................103
		Warming-up phase for the hydraulic system ...........................................................................................................................103
		Avoid extreme positions of the working equipment ....................................................................................................................104
	WORKING OPERATION .......................................................................................................................................................105
		Before starting work ................................................................................................................................................105
		Switching on the electronic excavator control .......................................................................................................................105
		Swinging the superstructure .........................................................................................................................................106
		Braking the superstructure ..........................................................................................................................................106
		Working movements ...................................................................................................................................................107
		After daily operation ...............................................................................................................................................108
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................109
		Securing the machine ................................................................................................................................................111
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................112
	NOTES ...................................................................................................................................................................113
3 INSPECTION AND SERVICING...................................................................................................................................................115
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................117
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................123
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................125
		Intervals............................................................................................................................................................125
		Change of engine oil l...............................................................................................................................................125
		Air-intake system ...................................................................................................................................................125
		Oils / Greases ......................................................................................................................................................125
		Cleaning jobs .......................................................................................................................................................125
		Components ..........................................................................................................................................................125
		Plan V ..............................................................................................................................................................127
		Plan N ..............................................................................................................................................................129
		Plan T and W ........................................................................................................................................................131
		Plan A – E ..........................................................................................................................................................133
	LUBRICATING CHART – GREASE ..............................................................................................................................................140
		Lubricating chart – Grease (legend) .................................................................................................................................141
		Filling quantities - Grease..........................................................................................................................................141
	INSPECTION PLAN - OIL ...................................................................................................................................................142
		Inspection plan – Oil (legend) ......................................................................................................................................143
		Filling quantities - oil ............................................................................................................................................144
		Filling quantities - other...........................................................................................................................................144
	LUBRICANTS ..............................................................................................................................................................145
		Notes on the selection of oils and greases ..........................................................................................................................145
		I. Oils for combustion engines ......................................................................................................................................146
		II. Oils for hydraulic system .......................................................................................................................................147
		III.a Oils for pump gearboxes .......................................................................................................................................148
		III.b Oils for swing gearboxes ......................................................................................................................................149
		III.c Oils for travel gearboxes .....................................................................................................................................150
		V. Greases for bearings and swing rings .............................................................................................................................151
	SERVICING WORK ..........................................................................................................................................................152
		Hose line for oil and cooling liquid changes ........................................................................................................................152
	ENGINE ..................................................................................................................................................................153
		Engine - Safety instructions ........................................................................................................................................153
		Checking the engine oil level / Topping up  .........................................................................................................................154
		Changing the engine oil .............................................................................................................................................155
		Replacing the oil filters ...........................................................................................................................................157
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................158
	COOLING SYSTEM ..........................................................................................................................................................159
		Radiators ...........................................................................................................................................................159
		Cooling liquid change ...............................................................................................................................................161
	AIR-INTAKE SYSTEM .......................................................................................................................................................162
		Dust trap, cleaning  ................................................................................................................................................162
		Main filter elements ................................................................................................................................................163
		Safety filter element ...............................................................................................................................................165
		Air-intake lines ....................................................................................................................................................165
	FUEL SYSTEM .............................................................................................................................................................166
		Fuel system - Safety instructions ...................................................................................................................................166
		Replacing the fuel filter ...........................................................................................................................................166
		Venting the fuel system .............................................................................................................................................167
		Cleaning the fuel tanks .............................................................................................................................................167
		Water trap (option)..................................................................................................................................................169
	ELECTRICAL SYSTEM  ......................................................................................................................................................171
		Electrical system - Safety instructions .............................................................................................................................171
		Alternator - Instructions ...........................................................................................................................................171
		Battery .............................................................................................................................................................172
		Switchgear cabinet, filter element ..................................................................................................................................174
		Floodlight projector, replacing the lamp ............................................................................................................................176
	HYDRAULIC SYSTEM ........................................................................................................................................................178
		Hydraulic system - Safety instructions ..............................................................................................................................178
		Depressurizing the hydraulic system .................................................................................................................................178
		Checking the hydraulic oil level ....................................................................................................................................179
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................181
		Bypass valves (hydraulic oil reservoir) .............................................................................................................................183
		Breather filter .....................................................................................................................................................184
		High-pressure filter for working hydraulics .........................................................................................................................185
		High-pressure filters for the servo circuit .........................................................................................................................186
		Filter (control circuit) ............................................................................................................................................187
		Changing the hydraulic oil ..........................................................................................................................................188
		Venting the hydraulic system.........................................................................................................................................191
		Cleaning the hydraulic oil cooler....................................................................................................................................192
		Electronic excavator control.........................................................................................................................................193
		Pressure accumulator - Emergency lowering............................................................................................................................194
	PUMP GEARBOX ............................................................................................................................................................195
		Checking the gearbox oil level / Topping up with oil ................................................................................................................195
		Changing the gearbox oil ............................................................................................................................................195
		Gearbox venting .....................................................................................................................................................197
	SWING GEARBOX ...........................................................................................................................................................198
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................198
		Changing the gearbox oil ............................................................................................................................................198
		Gearbox venting .....................................................................................................................................................199
	TRAVEL GAERBOX ..........................................................................................................................................................200
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................200
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................200
		Breather filter .....................................................................................................................................................200
	CRAWLER TRACKS ..........................................................................................................................................................201
		Track roller, Support roller ........................................................................................................................................202
		Track tensioner .....................................................................................................................................................203
		Pressure-accumulator inspection regulations .........................................................................................................................204
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................204
	SWING RING ..............................................................................................................................................................205
		Swing ring - Instructions............................................................................................................................................205
		Bearing races .......................................................................................................................................................205
	CENTRAL LUBRICATING SYSTEM, STANDARD ....................................................................................................................................207
		Design ..............................................................................................................................................................207
		Function ............................................................................................................................................................208
		Replacing the grease container ......................................................................................................................................209
		Filling up the grease container .....................................................................................................................................209
		Checking the greasing pressure ......................................................................................................................................210
		Unblocking a grease line.............................................................................................................................................210
		Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................211
		 Grease filter (Filling the grease container) .......................................................................................................................212
		Grease filter (Grease lines) ........................................................................................................................................213
	OTHER MAINTENANCE .......................................................................................................................................................214
		Engine ..............................................................................................................................................................214
		Heating and air conditioning ........................................................................................................................................214
	HYDRAULIC LADDER ........................................................................................................................................................215
		Pressure-accumulator inspection regulations  ........................................................................................................................216
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................217
		Putting the excavator out of operation ..............................................................................................................................217
		Battery storage .....................................................................................................................................................217
		Recommissioning .....................................................................................................................................................217
	NOTES ...................................................................................................................................................................219
4 REPAIR WORK................................................................................................................................................................221
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................223
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................225
	ENGINE, REPAIR WORK .....................................................................................................................................................226
	ELECTRICAL SYSTEM .......................................................................................................................................................227
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................227
		Assisted starting (with jumper cables)...............................................................................................................................227
		Starting the engine with jumper cables (external batteries ..........................................................................................................227
	HYDRAULIC SYSTEM ........................................................................................................................................................229
		Repair instructions .................................................................................................................................................229
		Hydraulic hoses – Instructions  .....................................................................................................................................229
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS .............................................................................................................................230
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................232
	NOTES ...................................................................................................................................................................234
5 ANNEX......................................................................................................................................................................237
	TROUBLESHOOTING .........................................................................................................................................................239
		Instructions on troubleshooting .....................................................................................................................................239
		Layout of the fault table ...........................................................................................................................................239
		Possible causes .....................................................................................................................................................239
		Measures ............................................................................................................................................................239
		Section .............................................................................................................................................................239
	FAULT TABLES ............................................................................................................................................................240
		Combustion engine - Fault table .....................................................................................................................................240
		Working hydraulics – Fault table ....................................................................................................................................241
		Track drive – Fault table ...........................................................................................................................................242
		Swing mechnism – Fault table ........................................................................................................................................243
		Central lubricating system – Fault table ............................................................................................................................244
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................245
	ABBREVIATIONS ...........................................................................................................................................................247
		ABBREVIATIONS........................................................................................................................................................248
	TECHNICAL DATA ..........................................................................................................................................................250
	NOTES ...................................................................................................................................................................260
6 INDEX......................................................................................................................................................................263

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