CAT Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651512 – PDF DOWNLOAD

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CAT Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651512 – PDF DOWNLOAD

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CAT Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651512 – PDF DOWNLOAD

Language : English
Pages : 243
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus RH 90C Hydraulic Excavator Operating Instructions Manual BI651512 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH 90 C
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 GERMANY Germany mechanic or by attending an Terex-Germany training course for operators or maintenance personnel. The Terex-Germany 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 Terex Germany operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Terex Germany will be pleased to answer.
• The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex Germany after- sales 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 BI651512 – PDF DOWNLOAD

TABLE OF CONTENTS..............................................................................................................................................................  5
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
		Noise.................................................................................................................................................................. 21
		Oil, grease and other chemical substances............................................................................................................................. 21
		Transporting and recommissioning...................................................................................................................................... 21
	FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 22
	N.......................................................................................................................................................................... 23
	NOTES...................................................................................................................................................................... 23
OPERATION...................................................................................................................................................................... 25
	OPERATION - SAFETY INSTRUCTIONS............................................................................................................................................ 27
	FIRE AND EXPLOSION HAZARD.................................................................................................................................................. 29
	DESCRIPTION OF THE EXCAVATOR............................................................................................................................................... 30
		Excavator layout....................................................................................................................................................... 31
		Undercarriage.......................................................................................................................................................... 32
		Superstructure......................................................................................................................................................... 32
		Drive.................................................................................................................................................................. 32
		Hydraulic system....................................................................................................................................................... 32
		Pump Managing System (PMS)............................................................................................................................................. 32
		Stored Program Control (SPC)........................................................................................................................................... 32
		Demand control / Zero-flow regulation.................................................................................................................................. 33
		Automatic engine speed reduction....................................................................................................................................... 33
		Board-Control-System (BCS)............................................................................................................................................. 33
		Electrical system...................................................................................................................................................... 33
		Sign................................................................................................................................................................... 35
		Entering and leaving the machine Safety instructions................................................................................................................... 36
		EMERGENCY STOP pushbuttons............................................................................................................................................. 38
		Windscreen washer...................................................................................................................................................... 38
		Driver's seat.......................................................................................................................................................... 39
		Fire extinguisher...................................................................................................................................................... 40
		Automatic fire-extinguishing system (optional)......................................................................................................................... 41
	MONITORING, WARNING AND CONTROL ELEMENTS................................................................................................................................... 42
	PUTTING THE MACHINE INTO OPERATION......................................................................................................................................... 73
		Refuelling............................................................................................................................................................. 73
		Service station (tanklift)............................................................................................................................................. 73
		Switching the electrical system on and off............................................................................................................................. 78
	STARTING AND STOPPING THE ENGINES.......................................................................................................................................... 79
	AIR CONDITIONER (OPTION)................................................................................................................................................... 82
		Back-up heating (option)............................................................................................................................................... 84
	DRIVING SAFETY INSTRUCTIONS................................................................................................................................................ 86
	TRAVELLING................................................................................................................................................................. 87
		Superstructure basic position.......................................................................................................................................... 87
		Travelling forwards/backwards.......................................................................................................................................... 87
		Locking the superstructure............................................................................................................................................. 91
		Track parking brake.................................................................................................................................................... 91
	TRANSPORTING THE MACHINE................................................................................................................................................... 92
		Transport - Safety instructions........................................................................................................................................ 92
	WORKING OPERATION - SAFETY INSTRUCTIONS.................................................................................................................................... 93
	WORKING OPERATION.......................................................................................................................................................... 95
		Before starting work................................................................................................................................................... 95
		Slewing and braking the superstructure................................................................................................................................. 95
		Braking the superstructure............................................................................................................................................. 95
		Working................................................................................................................................................................ 96
		After daily operation.................................................................................................................................................. 97
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS......................................................................................................................... 98
		Securing the machine...................................................................................................................................................100
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS).............................................................................................................101
	NOTES......................................................................................................................................................................103
INSPECTION AND SERVICING.......................................................................................................................................................105
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS.............................................................................................................................107
	FIRE AND EXPLOSION HAZARD..................................................................................................................................................113
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS..............................................................................................................................115
		Intervals..............................................................................................................................................................115
		Change of engine oil l.................................................................................................................................................115
		Air-intake system......................................................................................................................................................115
		Oils / Greases.........................................................................................................................................................115
		Cleaning jobs..........................................................................................................................................................115
		Plan V.................................................................................................................................................................117
		Plan N.................................................................................................................................................................119
		Plan T.................................................................................................................................................................121
		Plan A – E.............................................................................................................................................................123
	LUBRICATING CHART – GREASE (LOADING BUCKET)................................................................................................................................130
		Lubricating chart – Grease / Loading bucket (legend)...................................................................................................................131
		Filling quantities - Grease............................................................................................................................................131
	LUBRICATING CHART – GREASE / BACKHOE BUCKET (LEGEND).......................................................................................................................132
		Lubricating chart – Grease / Backhoe bucket (legend)...................................................................................................................133
		Filling quantities - Grease............................................................................................................................................133
	INSPECTION PLAN - OIL......................................................................................................................................................134
		Inspection plan – Oil (legend) ).......................................................................................................................................135
		Filling quantities - oil...............................................................................................................................................136
		Filling quantities - other.............................................................................................................................................136
	LUBRICANTS.................................................................................................................................................................137
		I.	Oils for combustion engines and compressors (selection).............................................................................................................137
		II.	Oils for hydraulic system (selection)..............................................................................................................................138
		III.	Oils for gearboxes (selection)....................................................................................................................................139
		V.	Greases for bearings and slewing rings..............................................................................................................................140
	SERVICING WORK.............................................................................................................................................................141
		Hose line for oil and cooling liquid changes...........................................................................................................................141
	ENGINE.....................................................................................................................................................................142
		Engine - Safety instructions...........................................................................................................................................142
		Checking the V-belt tension............................................................................................................................................142
		Retensioning the alternator/fan belt...................................................................................................................................142
		Checking and adjusting the valve clearance.............................................................................................................................142
		Checking the engine oil level / Topping up.............................................................................................................................142
		Changing the engine oil................................................................................................................................................144
		Replacing the oil filter...............................................................................................................................................146
		Centrifuge (optional)..................................................................................................................................................147
	COOLING SYSTEM.............................................................................................................................................................148
		Radiators..............................................................................................................................................................148
		Cooling liquid.........................................................................................................................................................150
		Water filter...........................................................................................................................................................151
	AIR-INTAKE SYSTEM..........................................................................................................................................................152
		Main filter elements...................................................................................................................................................152
		Safety filter element..................................................................................................................................................154
		Air-intake lines.......................................................................................................................................................155
		Dust collection........................................................................................................................................................155
	FUEL SYSTEM................................................................................................................................................................156
		Fuel system - Safety instructions......................................................................................................................................156
		Replacing the fuel filter..............................................................................................................................................156
		Venting the fuel system................................................................................................................................................157
		Cleaning the fuel tanks................................................................................................................................................157
		Water trap (option)....................................................................................................................................................159
	ELECTRICAL SYSTEM..........................................................................................................................................................161
		Electrical system - Safety instructions................................................................................................................................161
		Alternator - Instructions..............................................................................................................................................161
		Battery................................................................................................................................................................162
		Switchgear cabinet.....................................................................................................................................................164
	HYDRAULIC SYSTEM...........................................................................................................................................................166
		Hydraulic system - Safety instructions.................................................................................................................................166
		Depressurizing the hydraulic system....................................................................................................................................166
		Checking the hydraulic oil level.......................................................................................................................................167
		Changing the hydraulic oil return-flow (hydraulic oil reservoir).......................................................................................................169
		Bypass valves (hydraulic oil reservoir)................................................................................................................................171
		Breather filter........................................................................................................................................................172
		High-pressure filter for working hydraulics............................................................................................................................173
		High-pressure filters for the servo circuit............................................................................................................................174
		Changing the hydraulic oil.............................................................................................................................................175
		Venting the hydraulic system...........................................................................................................................................178
		Cleaning the hydraulic oil cooler......................................................................................................................................179
		Pressure accumulator - Emergency lowering..............................................................................................................................180
	PUMP TRANSFER GEARBOX......................................................................................................................................................181
		Checking the gearbox oil level / Topping up with oil...................................................................................................................181
		Changing the gearbox oil...............................................................................................................................................181
		Gearbox venting........................................................................................................................................................183
	SLEWING GEARBOX............................................................................................................................................................184
		Gearbox - Checking the oil level / Topping up with oil.................................................................................................................184
		Changing the gearbox oil...............................................................................................................................................184
		Gearbox venting........................................................................................................................................................185
	TRAVEL GAERBOX.............................................................................................................................................................186
		Gearbox - Checking the oil level / Topping up with oil.................................................................................................................186
		Gearbox - Checking the oil level / Topping up with oil.................................................................................................................186
		Breather filter........................................................................................................................................................186
	CRAWLER TRACKS.............................................................................................................................................................187
		Track tensioner........................................................................................................................................................189
		Pressure-accumulator inspection regulations............................................................................................................................190
		Checking the gas charging pressure in the pressure accumulator.........................................................................................................190
		Idlers.................................................................................................................................................................191
	SLEWING RING...............................................................................................................................................................192
		Slewing ring - Instructions............................................................................................................................................192
		Bearing races..........................................................................................................................................................192
	CENTRAL LUBRICATING........................................................................................................................................................194
		Design and function....................................................................................................................................................194
		Lube cycle / Pause period..............................................................................................................................................194
		Lube cycle manual lubricating (optional)...............................................................................................................................194
		Grease container.......................................................................................................................................................195
		Grease container (optional)............................................................................................................................................196
		Filling up the grease container........................................................................................................................................196
		Breather filter........................................................................................................................................................197
		Checking the greasing pressure.........................................................................................................................................197
		Unblocking a grease line...............................................................................................................................................198
		Manual greasing (option)...............................................................................................................................................198
	OTHER MAINTENANCE..........................................................................................................................................................200
		Engine.................................................................................................................................................................200
		Heating and air conditioning...........................................................................................................................................200
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.................................................................................................................201
		Putting the excavator out of operation.................................................................................................................................201
		Battery storage........................................................................................................................................................201
		Recommissioning........................................................................................................................................................202
	NOTES......................................................................................................................................................................203
REPAIR WORK....................................................................................................................................................................205
	REPAIR WORK - SAFETY INSTRUCTIONS..........................................................................................................................................207
	FIRE AND EXPLOSION HAZARD..................................................................................................................................................209
	ENGINE.....................................................................................................................................................................210
	ELECTRICAL SYSTEM..........................................................................................................................................................211
		Assisted starting (with jumper cables) – Safety instructions...........................................................................................................211
		Assisted starting (with jumper cables).................................................................................................................................211
		Starting the engine with jumper cables (external batteries.............................................................................................................211
	HYDRAULIC SYSTEM...........................................................................................................................................................213
		Repair.................................................................................................................................................................213
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................................................................................................214
	WELDING OPERATIONS - SAFETY INSTRUCTIONS...................................................................................................................................215
	NOTES......................................................................................................................................................................217
ANNEX..........................................................................................................................................................................219
	TROUBLESHOOTING............................................................................................................................................................221
		Instructions on troubleshooting........................................................................................................................................221
		Layout of the fault table..............................................................................................................................................221
		Possible causes........................................................................................................................................................221
		Measures...............................................................................................................................................................221
		Section................................................................................................................................................................221
	FAULT TABLES...............................................................................................................................................................222
		Combustion engine - Fault table........................................................................................................................................222
		Working hydraulics – Fault table.......................................................................................................................................223
		Track drive – Fault table..............................................................................................................................................224
		Slewing mechnism – Fault table.........................................................................................................................................225
		Central lubricating system – Fault table...............................................................................................................................226
	HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................228
	TIGHTENING TORQUES AND ANGLES – TABLE......................................................................................................................................231
	ABBREVIATIONS..............................................................................................................................................................233
	TECHNICAL DATA.............................................................................................................................................................235
INDEX..........................................................................................................................................................................239

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