PDF Operating Instruction Manual CAT Bucyrus RH 90C Hydraulic Excavator - 2 MB
This is the factory operating instruction manual for the CAT Bucyrus RH 90C Hydraulic Excavator.
It provides operators with critical information on safety, controls, and proper operating techniques.
Adhering to the guidelines within this manual is essential for maximizing productivity while maintaining a safe work environment.
It is a must-have resource for anyone operating this powerful piece of mining equipment.
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OPERATING INSTRUCTIONS RH 90C
Hydraulic Excavator
RH 90C No.
Bucyrus HEX GmbH
BA RH90C(3 725 028.00)-EN
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OPERATING INSTRUCTIONS RH90C
Introduction
1 INTRODUCTION
Operating instructions Target group
Part 1 INTRODUCTION Operating personnel
+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.
Part 3 INSPECTION AND Inspection and servicing personnel
The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.
Part 4 REPAIR WORK Repair personnel
The repair personnel must have know-how
and experience relevant to the repair of this
or comparable machines.
Part 5 ANNEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
Part 6 INDEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
BA RH90C(3 725 028.00)-EN 1-1
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OPERATING INSTRUCTIONS RH90C
Introduction
Gas, dust, steam and smoke Noise
Always start and operate the engine in a well- During operation, all sound baffles of the machine
vented area; must be closed.
If in an enclosed area, vent the exhaust to the out- Always wear the prescribed ear protectors.
side; Oil, grease and other chemical sub-
Do not modify or tamper with the exhaust system stances
Diesel engine exhaust and some of its constituents When handling oil, grease or other chemical sub-
are known to cause cancer, birth defects, and stances, observe the product-related safety regula-
other reproductive harm tions (see safety specifications).
Operate fuel-operated heating systems only on Be careful when handling hot consumables (risk of
adequately ventilated premises. Before starting the burning or scalding).
machine on enclosed premises, make sure that
there is sufficient ventilation.
Observe the regulations in force at the respective Ether
site. The machine can be equipped with pressure ves-
Carry out welding, flame-cutting and grinding work sels for cold-starting fluid (ether) installed in the
on the machine only if this has been expressly engine compartment. Ether is toxic and highly
authorized, as there may be a risk of explosion and flammable; the vessels are under pressure. These
fire. pressure vessels can explode if exposed to high
temperatures (above 49Β°C / 120Β°F) or in the event
Before carrying out welding, flame-cutting and of damage. Protect the vessels against damage
grinding operations, clean the machine and its and high temperatures.
surroundings from dust and other inflammable
substances and make sure that the premises are Do not store pressure vessels with cold-starting
adequately ventilated (risk of explosion). fluid (ether) on the excavator.
Do not eat, drink or smoke when replacing pres-
CALIFORNIA Proposition 65 Warning
sure vessels with cold-starting fluid (ether). Ob-
Diesel fuel and Diesel engine exhaust and some of
serve the instructions on the pressure vessels.
its constituents are known to the State of California
Provide for sufficient ventilation (see also Part 3
to cause cancer, birth defects, and other reproduc-
"Inspection and servicing").
tive harm.
Do not open empty cold-starting fluid pressure
Hydraulic equipment vessels (ether). Have the vessels disposed of
Check all lines, hoses and screwed connections properly.
regularly for leaks and obvious damage. Repair For further details please refer to the instructions
damage immediately. Splashed oil may cause and safety data-sheets of the manufacturer / sup-
injury and fire. plier of pressure vessels with cold starting fluid
Depressurize all system sections and pressure (ether).
pipes (hydraulic system) to be removed in accor-
dance with the specific instructions for the unit
concerned before carrying out any repair work.
Transporting and recommissioning
The machine must be loaded and transported only
Hydraulic lines must be laid and fitted properly.
in accordance with the operating instructions.
Ensure that no connections are interchanged. The
fittings, lengths and quality of the hoses must com- Use only appropriate means of transport and lifting
ply with the technical requirements. gear of adequate capacity.
The recommisioning procedure must be strictly in
accordance with the operating instructions.
BA RH90C(3 725 028.00)-EN 1-11
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OPERATING INSTRUCTIONS RH90C
Operation
Excavator layout
44 β Grease container of central lubricating sys-
Fig. 2-1:
tem
Undercarriage
45 β Tool cabinet (optional)
1 - Track drive
46 β Ladder
2 β Idler
47 β Ladder
3 - Track roller
48 - Counterweight
4 - support roller
5 - Crawler track Loading bucket
6 - Track tensioner 51 β Boom
7 - Swing ring 52 - TriPower linkage
8 - Ladder 53 β Stick
54 - Bottom-dump bucket
Superstructure
55 - Boom cylinder
11 β Engine
56 - Stick cylinder
12 - Radiator (engine cooling liquid)
57 - Tipping cylinder
13 - Air-intake system
58 - Bottom-dump cylinder
14 - Exhaust system
64 - Control valves
15 - Fuel Tank
65 - Quick-action valve
17 - Hydraulic oil reservoir
18 β Hydraulic oil cooler Backhoe bucket
20 β Pump transfer gearbox 53 - Stick
21 - Working pump 55 - Boom cylinder
22 β Cooling oil pump 56 - Stick cylinder
23 - Servo system pump 59 - Monoblock boom
27 β Swing pump 60 - Backhoe bucket
29 - Swing gear 61 - Backhoe cylinder
30 - Travel block and rotor 62 - Toggle link
31 - Driver's cab 63 - Toggle lever
32 - Control stand with BCS 64 - Control valves
33 - Control-cabinet 65 - Quick-action valve
34 - Air conditioner
35 - Fire-extinguisher
36 - Control-cabinet with battery main switch
37 β Batteries
BA RH90C(3 725 028.00)-EN 2-7
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OPERATING INSTRUCTIONS RH90C
Operation
Driverβs seat Never adjust the seat while driving. Con-
centrate on the road to avoid accidents.
The driverβs seat (Fig. 2-24: and Fig. 2-25:) can be ad-
justed in several positions. Before carrying out any seat adjustments
stop the machine and set the control lev-
ers to "0"
Fig. 2-24:
BA RH90C(3 725 028.00)-EN 2-17
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OPERATING INSTRUCTIONS RH90C
Operation
(Fig. 2-44:)
No. Element Function Symbol
1 BCS Electronic measur- Collection and displaying of essential oper-
ing-data collection ating data of the excavator.
and processing
system
2 Monitor BCS Displays the data collected.
Gives warnings and provides help, if de-
sired.
3 UP button Selects the BCS program,
Positions the Cursor.
4 DOWN button Selects the BCS program,
Positions the Cursor.
5 ENTER button Confirms a program,
Activates a desired program.
6 BACK button Recalls the Service Menu.
7 HOLD button Freezes actual service data.
8 Print button Recalls the Print Menu.
9 SERV. button Recalls the Service Menu.
10 HELP button Recalls the Help Menu.
11 BL + button Adjusts BCS monitor background lighting
brighter.
12 BL - button Adjusts BCS monitor background lighting
darker.
BA RH90C(3 725 028.00)-EN 2-27
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OPERATING INSTRUCTIONS RH90C
Operation
(Fig. 2-49:)
No. Element Function Symbol
51 Switch Starting Starts the engine.
(left engine 1)
52 Switch Stopping Shuts off the engine.
(left engine 1)
53 Switch Idling Shuts off the engine with 5 minutes after run.
(left engine 1)
54 Switch Not connected
55 Switch Diagnostic ON / OFF Not used on this machine.
56 Speed adjustment Potentiometer Adjusting the engine speed -
(left engine 1)
ο§ turn CCW to limit stop: idling speed
ο§ turn CW to limit stop: full-load speed
57 Switch Diagnostic incre- Not used on this machine.
ment / decrement
BA RH90C(3 725 028.00)-EN 2-37
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OPERATING INSTRUCTIONS RH90C
Operation
(Fig. 2-54:)
No. Element Function Symbol
101 Button Counting dumper Reset with switch (92).
102 Button Stick floating posi- If actuated, stick cylinders are pressurized
tion (only for load- when retracted.
ing shovel equip-
ment)
Actuate button (102) only when
control lever (115) is in β0β posi-
tion.
103 Button Boom floating posi- If actuated, boom cylinders are pressurized
tion when retracted.
Actuate button (103) only when
control lever (116) is in β0β posi-
tion.
104 Button Warning signal Activates the horn.
105 Button inside seat Electronic excavator Switches the electronic excavator control on
control and off.
111 Pedal Bottom-dump bu- Opens / closes the bottom-dump bucket.
cket
(only for loading
shovel equipment)
112 Pedal Travelling, left track Pedal onwards β travelling forwards,
Pedal rearwards β travelling backwards.
113 Pedal Travelling, right Pedal onwards β travelling forwards,
track Pedal rearwards β travelling backwards.
114 Foot rest
115 Control lever Lifts and lowers the bucket / backhoe bucket
stick;
Swings and brakes the superstructure.
116 Control lever Raises and lowers the boom;
Tipping and rearward tilting of bucket resp.
backhoe bucket.
117 Button Bottom-dump To the left β opens the bottom-dump bucket.
bucket (only for To the right β closes the bottom-dump bu-
loading shovel cket.
equipment
118 Button By-pass for the To the left β automatically stopped stick-
automatically and/or backhoe cylinders can be driven
switch off for stick- slowly to the limit stopps.
and /or backhoe
To the right β Not connected.
cylinders (Option)
BA RH90C(3 725 028.00)-EN 2-47
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OPERATING INSTRUCTIONS RH90C
Operation
(Fig. 2-59:) (Options. Depending on the options ordered with the machine, the described elements can be
found on different positions on the control column).
No. Element Function Symbol
181 Control elements Air conditioning See chapter: βAIR CONDITIONER (OP-
system TION)β for mor information.
191 Service gauge Air filter (left engine Indicates the vakuum in the air filter.
(vakuum) 1, outside) Underpressure must be less than 635 mm
water column.
192 Service gauge Air filter (left engine Indicates the vakuum in the air filter.
(vakuum) 1, inside) Vakuum must be less than 635 mm water
column.
193 Service gauge Air filter (left engine Indicates the vakuum in the air filter.
(vakuum) 2, inside) Vakuum must be less than 635 mm water
column.
194 Service gauge Air filter (left engine Indicates the vakuum in the air filter.
(vakuum) 2, outside) Vakuum must be less than 635 mm water
column.
BA RH90C(3 725 028.00)-EN 2-57
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OPERATING INSTRUCTIONS RH90C
Operation
Do not run engines at full load unless Starting the engines at low tem-
they have been allowed to run for at peratures
least 3 minutes at idling.
If the machine is used in low temperatures, the
engine may be equipped with a cold-starting de-
Repeat the starting procedure if one of the engines vice.
does not fire. Repeat starting procedure not more The pressure vessel containing the cold-starting
often than three to four times. Do not operate the fluid (ether) can be installed in or near the engine
starter for more than 10 seconds. compartment.
If, after starting, the BCS or the engine monitoring The vessel is screwed into an electro-mechanical
devices (Fig. 2-79:) indicates a fault metering valve. When the engine is started at
ο§ of the PMS temperatures below 0Β°C (32Β°F), this valve is acti-
vated automatically by the engine electronics and
ο§ because of insufficient engine oil pressure
injects a precisely metered amount of cold-starting
ο§ of the alternator fluid into the air intake duct of the engine.
stop the engine concerned immediately. Ether is toxic and highly inflammable. Safety in-
structions and information concerning the handling
Locate the cause of the fault and rectify before of pressure vessels for cold-starting fluids (ether)
restarting the engine. can be found in the following chapters: "Funda-
mental safety instructions", "Inspection and servic-
ing - Safety instructions", "Cold-starting fluid
(ether) - Replacing the pressure vessel".
Fig. 2-79:
BA RH90C(3 725 028.00)-EN 2-67
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OPERATING INSTRUCTIONS RH90C
Operation
Locking the superstructure Track parking brake
The excavator is equipped with two superstructure The excavator is equipped with four track brakes
holding brakes integrated in the swing gearboxes. integrated in the track drives.
The superstructure holding brakes are used to The track brakes are parking brakes which relieve
block the superstructure and the undercarriage. the hydro-static travel drives during working opera-
The superstructure holding brakes are parking tion and which protect the excavator against rolling
brakes. forwards and backwards.
ο Switch the parking brakes on by means of The brakes are controlled by means of the travel
switch (82, Fig. 2-100:): pedals (112 and 113, Fig. 2-101:). In neutral posi-
tion of the pedals, the brakes are applied and the
ο§ when the excavator is parked, excavator is braked. During travelling, the brakes
ο§ when travelling over longer distances. are released.
Fig. 2-101:
The track brakes can also be activated with switch
(72, Fig. 2-100:).
Depending on switch position, the brakes are per-
manently engaged or are automatically applied
after ca. 8 sec. each time the excavator stops.
Fig. 2-100:
With this switch position, the brakes are released
as soon as the "Travel" function is activated.
BA RH90C(3 725 028.00)-EN 2-77
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OPERATING INSTRUCTIONS RH90C
Operation
Secure the machine as described below:
Securing the machine
ο§ before carrying out any fitting and modification
Risk of injury work on the working equipment,
The machine must not be started by unauthorized ο§ before carrying out any servicing and repair
persons. work on the machine.
Therefore, secure the machine.
ο Park the machine on level and stable ground.
Observe the accident prevention regulations.
Protective shrouds of moving machine parts may ο Lock the superstructure.
only be opened or removed when the drive unit is
stationary and protected against inadvertent start- ο Stand the working equipment on the ground.
ing.
ο Shut off the engines.
Before carrying out fitting works, the machine and
the equipment must be protected against inadver- ο Depressurize the hydraulic system.
tent starting by placing chocks under the tracks
and by standing the working equipment on the ο Withdraw the key from the key-switch.
ground.
Hydraulic and lubricating systems
Depressurize pipeline systems, on which work is to
be carried out, by appropriate measures.
Close all open bores, pipe and hose connections
with pressure-resistant plugs.
Refill collected hydraulic oil back into the hydraulic
system only through the return-flow filters. Dispose
of non re-usable oils without polluting the environ-
ment.
All components of Bucyrus HEX machines have
been carefully purpose-coordinated. Trouble-free
operation and a long service life can only be
achieved with original Bucyrus HEX spare parts.
Respect the sequence of working operations when
fitting or replacing the attachments. The sequence
has been determined and tested by qualified ex-
perts.
BA RH90C(3 725 028.00)-EN 2-87
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OPERATING INSTRUCTIONS RH90C
Inspection and servicing
Handling batteries Handling of cold-starting fluid (ether)
Battery Posts, terminals and related accessories The engine compartment can be equipped with
contain lead and lead compounds, chemicals pressure vessels containing cold-starting fluid
known to cause cancer and reproductive harm. (ether).
Wash hands after handling. Ether is toxic and highly flammable; the vessels
Batteries give off explosive gases. are under pressure. These pressure vessels can
explode if exposed to high temperatures (above
Never handle batteries close to naked flames and 49Β°C / 120Β°F) or in the event of damage.
unshielded light sources, never smoke. Protect the pressure vessels against damage be-
Battery acid is toxic and corrosive. fore beginning to work in or close to the engine
compartment.
Avoid any contact with the skin, mouth, eyes and Read and observe the instructions on the pressure
clothing. Avoid spilling battery acid or inhaling the vessels.
vapours.
For further details please refer to the instructions
Wear gloves, firm protective clothing and goggles and safety data-sheets of the manufacturer / sup-
when handling batteries. plier of pressure vessels with cold starting fluid
(ether).
If the skin is splashed with acid, rinse thoroughly
Provide for sufficient ventilation.
with running water and consult a doctor.
Do not eat, drink or smoke when replacing an
If the eyes are splashed with acid, rinse thor- empty vessel.
oughly with running water and consult a doctor
Do not inhale the vapours of escaping cold-starting
immediately.
fluid.
Never set tools down on the battery. They may In contact with the skin, ether can cause frostbites
induce a short circuit, causing irreparable damage and irritations. Avoid skin contact.
to the battery and injuring persons.
Wear suitable protective gloves and goggles.
Never wear metal necklaces, bracelets or watch- Even apparently empty pressure vessels can still
straps when working on the battery. The metal contain rests of ether and therefore explode if they
parts may induce a short-circuit resulting in burns. are damaged or heated up above 49Β°C. They must
therefore be handled in the same way as full pres-
Dispose of used batteries separately from other
sure vessels.
waste in the interests of environmental protection.
ο§ Do not keep them on the machine.
Before working on the electrical system ο§ Do not damage or open the vessels.
Before performing work on the electrical system ο§ Do not expose the vessels to great heat or
where tools, spare parts, etc. can come into con- direct sunlight.
tact with electrical conductors or contacts, the
battery must be disconnected. ο§ Do not dispose of in fire.
Disconnect first the negative and then the positive ο§ Keep the vessels in a place inaccessible to
terminal. unauthorized persons.
ο§ Dispose of the vessels properly.
After the work:
Reconnect first the positive and then the negative
terminal.
BA RH90C(3 725 028.00)-EN 3-7
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OPERATING INSTRUCTIONS RH90C
Inspection and servicing
Plan T and W
Plan T - (Every 10 OH or every working shift
(whichever comes first)
Plan W - Every 60 OH or every working shift
(whichever comes first)
Page 1 of 2
Location Servicing work Quantity/ Plan Plan
No. T W
Engine Check oil level 2 ο¬ ο¬
Engine monitoring
(Board Control System) Check monitoring display ο¬ ο¬
Cooling system
Cooling fluid level Check 2 ο¬ ο¬
Radiator Check / clean 2 ο¬ ο¬
Fuel system
Fuel filter Drain off water 2x1 ο¬ ο¬
Water trap (optional) Drain off water 2x1 ο¬ ο¬
Fuel tank Drain off water and sediment ο¬ ο¬
Air-intake system Check BCS β indication 1 ο¬
Intake and clean-air lines Check for tightness and leaks ο¬
Electrical system
Lighting Check operation ο¬ ο¬
Switchgear cabinet
- Breather filter
- Dust trap Remove dust 1 ο¬
- EMERGENCY OFF button Check function 4 ο¬
Monitoring, warning and control Check function of monitoring, warning ο¬ ο¬
elements and control elements
BCS Check function ο¬ ο¬
Hydraulic system Check function of working and travel- ο¬ ο¬
ling movement
Inspect visually for leaks ο¬
Hydraulic oil reservoir Check oil level 1 ο¬ ο¬
Oil cooler Check / clean 2 ο¬
Fan wheel Check condition 2 ο¬ ο¬
Pump transfer gearbox Check oil level 2 ο¬
BA RH90C(3 725 028.00)-EN 3-17
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OPERATING INSTRUCTIONS RH90C
Inspection and servicing
Lubricating chart β Grease (legend)
No. Greasing point Number Lubricant Grease every
properties .... operating hours
1 Central lubricating system β grease container 1 V 15 10
Hydraulic ladder (optional) 1 V 15 1000
2 Monitoring, warning and control elements
- Joystick 2 x 4 16 V 15 1000
16
- Pedal 3x2 1000
All other greasing points are supplied with grease by the central lubricating system.
Filling quantities - Grease
Greasing point Lubricant Filling quant. in
properties kg lb
Central lubricating system β grease container appr. 180 / appr. 397 /
(different containers available) appr. 500 appr. 1102
Internal gearing β Roller-bearing swing ring V 15 appr. 100 appr. 220.5
Idler (permanent grease filling) 2 x appr. 3,3 2 x appr.
7.3
Track rollers (permanent grease filling) Tribol 16 x appr. 2 16 x appr.
Bucyrus HEX part no. 4.4
2764564
Support rollers (permanent grease filling) 4 x appr. 1.3 4 x appr. 3
Lubricating chart β Grease / Backhoe bucket
15
see: "LUBRICANTS" section.
16
apply a thin layer of low temperature grease
BA RH90C(3 725 028.00)-EN 3-27
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OPERATING INSTRUCTIONS RH90C
Inspection and servicing
V. Greases for bearings and swing rings
Fig. 3-8:
BA RH90C(3 725 028.00)-EN 3-37
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OPERATING INSTRUCTIONS RH90C
Inspection and servicing
Cooling liquid change Draining off cooling liquid
ο Shut off the engines.
Risk of scalding from hot cooling liq-
uid. ο Drain cooling liquid through express coupling
(2, Fig. 3-25:) for the lefthand engine.
Shut off the engines and allow to cool
down. ο Drain cooling liquid through express coupling