Page 1 YC310LC-8 H y d r a u l i c YC360LC-8 Excavator Operation Manual This manual comes to you with the Hydraulic excavator. Please preserved carefully.
Page 2 You are responsible for compliance with relevant laws and regulations and to comply with the relevant guidance of Yuchai Heavy Industry Co., Ltd. for operating and maintaining the machine. YUCHAI is registered by Yuchai Heavy Industry Co., Ltd.
Page 3: Table Of Contents
Contents To the Users .............................. Product Information ........................... Direction of the Machine ........................... Composition of the Machine ........................Technical Specifications ..........................General Safety ............................Safety Tips ..............................Safety Equipment ............................Safety Signs .............................. Workplace Safety ............................ Safe Operation ............................Transport and Handling Machine ......................
Page 4 Working Device Operation ........................Working on Slopes or in Water ........................ Out of the Muddy Environment ....................... Construction Operations Guide ....................... Disassembly and Installation of the Bucket ..................... Parking the Machine ..........................After Operation ............................Handling and Transport of the Machine ....................
Page 5 Foreword...
Page 6: To The Users
If the machine failures are caused by the non-genuine accessories, parts or the organization without the authorization of our Company, even in the warranty period, Yuchai Heavy Industry Co., Ltd. does not assume the warranty service.
Page 7: Product Information
Product Information When you need know the basic information of the machine, you can view the location in the picture. Whole Machine Information (the whole machine nameplate is on the left front ● side of the platform) Engine Information ●...
Page 8 Please fill the table below with serial number of your machine and its engine and other data. When you need to buy machine parts or want to obtain the information, you can tell Yuchai these codes. Please record these numbers, and keep them well with the product certification. In case that your machine is stolen, you can submit the information to the local public security organs.
Page 9: Direction Of The Machine
Direction of the Machine The directions of front, back, left, right, up and down in the manual refer to the directions as shown in the following diagram. Down Right Rear Front Left...
Page 11: Composition Of The Machine
Composition of the Machine hydraulic oil tank Bucket oil cylinder 2. fuel tank 8 Bucket 3. Boom Cylinder Guide wheel 4. Boom 10. Track 5. Stick Cylinder 11 Driving wheel 6. Stick...
Page 12: Technical Specifications
Technical Specifications Structure size parameters YC310-8 YC360-8 Code Item Unit Operating Weight 31640 33620 Standard bucket capacity 1.43 1.63 Engine Name Cummins 6C8.3 Cummins 6C8.3 Engine power KW/rpm 186/2200 186/2200 Length 10795 11250 Height 3360 3160 Overall Width 3260 3260 Track width Platform Rotation radius 3364...
Page 14 Operating parameters YC310LC-8 YC360LC-8 Code Item Unit Maximum digging height 10190 10320 Maximum dumping height 7165 7255 Maximum digging depth 7410 7366 Maximum digging radius 10620 11095 Maximum digging distance of 10420 10900 ground level Digging radius of the maximum...
Page 15 Walking structure An independence drive is by a hydraulic motor through the multi-stage planetary reducer. Walking speed (km/h) Maximum traction (kn) Climbing ability High speed Low speed Bucket Bucket Capacity (m 1.43 1.63 Bucket width(mm ) 1463 1605 Weight(kg ) Bucket teeth Bucket work environment Bucket type...
Page 16 X Unavailable Hydraulic system Inverted flux control hydraulic system Main valve: imported multi-pass valve Maximum flow of the system 2 x 260+30（YC310LC-8） 2 x 280+30 （YC360LC-8） Pressure 32.5 Return Line Oil Filters 10µm...
Page 17 Safety Regulations...
Page 18: General Safety
General Safety Follow the relevant safety regulations in this manual, and most of the accidents caused by the dangerous operation and maintenance of the machine will be avoided. Before you operate or maintain your company, please have an understanding of this manual and all of the safety information of the machine in the diagram.
Page 19: Safety Tips
Safety Tips Warning signs In this manual, the warning signs refer to important information about safety. When you see this sign, you should carefully read the information and advice of the signs to avoid possible injury or death. Safety warnings This manual provides the safety precautions, identifications and description of potential hazards, and the operator should read this manual, the safety identity attached to the machine carefully before operation, maintenance, and repair of the machine, and do the work in accordance with relevant...
Page 20: Safety Equipment
Safety Equipment Protective equipments of the operators Before the operation and maintenance, the operators must wear tight-fitting suitable overalls, helmets, shoes and other work- related safety products (such as: ear protection, gloves, protective glasses, belts, etc.). If the operator's hair is too long, please band it, and cover up it with a helmet, which will protect your hair from being entangled in the machine.
Page 21: Safety Signs
If the signs are damaged, lost or cannot be seen clear, you need to change them. If the signs are on the parts which need to be placed, you must ensure the new parts have these signs too. Please contact the Yuchai agents to obtain a new safety signs. Classification of the safety signs There are two kinds of safety signs in this manual, "icon safety signs"...
Page 22 Location of the safety signs The signs shown in the graphics are only the safety signs of all the signs, and other function signs are described in the following chapters.
Page 23 S a f e t y s i g n s a n d t h e i r Please keep safe when getting up or getting down from the machine. descriptions Be away from the working devices Move slowly with facing the machine and grasping The moving working device can bring injury.
Page 24 Sign of reading the manual 10) When adjusting the tension of the track, pay attention to the dangerous high pressure oil that may spray out. Read carefully and keep the content in your mind to prepare for contingencies. Combined hoist mark 11) Sign of slewing center Oiling sign 12) Sign of filling hydraulic oil...
Page 25 13) Do not open container lid of engine 15) Sign of filling fuel coolant at high temperature. There is high pressure in high-temperature coolant. Open at this time, hot oil will squirt out, bringing personal injury. Remove the lid until it cools.
Page 26 18) Mind the high temperature components 12) Be careful of personal injury caused by like engine, water tank and muffler as well engine blower. as engine fan that may cause personal injuries. Do not touch directly. Repair these components after stopping the machine and wait until the temperature is cooled down to a suitable temperature.
Page 27 24) Lifting hook sign 27) Sign of unlocked door 25) Do not split, drill, cut or impact the Accumulators, air spring pressure device and keep them away from open fire and heat. 28) Escaping sign These components contain high-pressure gas, improper handling of which can cause injury.
Page 28 30) Sign of escaping direction 31) Toolbox sign 2-12...
Page 29: Workplace Safety
Workplace Safety To have a prior knowledge of your work area, you should inspect: Position of the slope Ditches Falling or hanging objects Soil conditions (soft and hard) Water and marsh areas Rocks and stumps Boundaries of the buried foundations, pillar and the wall Boundaries of the buried waste and filling soil Holes, obstructions, mud or water...
Page 30: Safe Operation
Safe Operation Warning: Before operating the machine, you must wear seatbelts and honk. After confirming there is nobody around the workplace, you can start your work. Start the engine A. Safety rules of starting the engine You must honk for a warning before starting the engine.
Page 31 Walking and turning The excavator must walk and work on the ground 1.5 times width than itself. Before walking and turning, you should honk to warn the people in the work area. Before walking operation, please turn the upper part to the right position, if the working device is at the same direction of the march sign, then push the walking rod so that the machine can go forward;...
Page 32 Before walking, please close and lock the door of the cab. The cab windows, overturn windows and sunroof are allowed to be open, but must be locked. When the machine is turning or going back, if the rear area cannot be seen, a signal commander must be there.
Page 33 When the machine is walking or in operation, it must keep a safe distance with people, buildings and other machines to prevent access to them. When walking through the limited high places such as the underground tunnels, under bridges or wires, make sure that there is someone to command with gesture, and keep a safe distance with the commander.
Page 34 Do not turn on slopes or cross the slope. Before go uphill, you should first go downhill to a flat place to change the position of the machine. When working on the slope, it must start in the higher place, and gradually dig in the downhill direction, with the blade in the back, and the dumping position is in the uphill direction.
Page 35 2-19...
Page 36 10) Do not walk or work on the slope whose longitudinal gradient is more than 25°. 11) Do not walk or work on the slope whose horizontal gradient is more than 15° 2-20...
Page 37 12) Try to keen the balance of the machine, and do not walk on the rocks or over obstacles. 13) Do not change the direction on the slope. 14) Before going uphill, ensure that he engine and hydraulic oil have been warmed up correctly, otherwise, the accident may happen.
Page 38 16) When working on the slope, the operation of the rotation and work equipment will cause danger of losing balance and overturn to the machine, which will lead to serious injury and equipment damage. Thus, when do these operations, a solid platform must be built with soil to keep the machine in the balance.
Page 39 When the machine in the reverse operation (such as trenching, etc.), you should observe if the shift line is flat and if there are any obstacles. The shift should be in the safe conditions; otherwise, the machine may be caused to overturn. 2-23...
Page 40 When the bucket subjects to a special resistance on the ground do not walk or turn otherwise the machine may be damaged. In the operation, if the hydraulic cylinder is Remainder controlled to the end of the travel, the force will act to the spacing ring inside the hydraulic cylinder, which will reduce the life of the machine.
Page 41 12) Do not dig towards the machine body. 2-25...
Page 42 13) If the tracks are nor on the ground, do not dig, otherwise the structure of the machine may be damaged. 14) Do not increase the machine’s digging force by its own weight. 2-26...
Page 43 15) Do not regard the falling-down force of the bucket as a hands-ho, a breaker, or a hammer, which make the rear of the machine withstand excessive force. It is very dangerous and will cause damage to the machine. 16) Do not build the flat road with the bucket too much, otherwise the machine may be damaged because of the overload operation of the components.
Page 44 17) Do not use the falling-down force of the machine to dig, otherwise the machine will be damaged. 18) Do not use a rotary force to compact the soil, destruct the mound, or damage the wall. When rotating, do not let the bucket teeth into the soil, which will damage the machine.
Page 45 19) Do not use the walking force to dig with the bucket inserted into the soil, which will make the rear of the machine bear too heavy force. 2-29...
Page 46 20) Do not dig the working surface below the vacant part. There will be danger of rock falling or the collapse of the vacant part, which will hit the machine. 21) If the machine is working where there is danger of the objects falling or the splashing, the equipment of preventing the falling of the objects or splashing should be fitted...
Page 47 23) Do not use the excavator to drag other devices or objects. 2-31...
Page 48 Anti-overturn, anti-slipping in the operation and the treatment Warnings: 1) when you have to turn on the slope, it is only sweeping turn. When the machine is to turn right, the boom stick should be toward the left with the bucket about 30cm from the ground, and the platform should be locked.
Page 49 12) If there is engine oil or lubricant oil on the two tracks, then the machine is prone to slipping. Shut down the machine Please refer to the section of “parking machines” in this Chapter 2-33...
Page 50: Transport And Handling Machine
Transport and Handling Machine Excavator transport (handling) should strictly abide by safety principles. When transporting excavator, abide by the ● rules or good habits of safe transport (handling) in national and local industry. When transporting excavator, it’s strictly ● forbidden to take any personnel or other items and it’s strictly forbidden man-machine mixed and mix-carried.
Page 51: Stop The Machine And The Maintenance
Stop the Machine and the Maintenance Warning: When carrying out any repairs on the machine, you must hang the warning signs of “Do not operate” on the operation handle. The excavator must stop on the solid and flat ground. ● After the machine stops steadily, the bucket must be lowered to the ground, the engine must be ●...
Page 52: Fire Prevention, Explosion-Proof And Anti-Poisoning
Fire Prevention, Explosion-proof and Anti-poisoning The excavator should be avoided to contact ● with the electric wires when it is in transportation, walking or digging, otherwise serious injury and death may be caused. Please always check the appliance and ● circuit of the machine.
Page 53: Battery
Battery General safety of battery Battery electrolyte contains sulfuric acid, which will produce flammable and explosive hydrogen gas. Erroneous operation will result in serious injury or fire. Therefore, we must observe the following precautions: The battery is equipped with the battery ●...
Page 54 Note: When you are repair the electrical systems or carrying out the welding operation, you should remove the negative terminal of the battery to prevent the flow of current. 2-38...
Page 55: Hydraulic System
(hoses) are not isolated. And stop operation to have bolts to be tightened to the specified torque. If you find any damages of the hose, please immediately stop the operation, and contact the agents of Yuchai. If the following questions are found, the hose should be replaced: Damage or leakage of hydraulic fittings;...
Page 56 2-40...
Page 57 Releasing the pressure within the hydraulic system When the machine is just stopped, the hydraulic oil is with high temperature and pressure. While disassembling the oil port, the oil may spray out, therefore before disassembly the oil port cover should be turned to relief the pressure inside.
Page 58 Turn off the engine. Turn the starter Switch to the “ON” position, and the circuit current will flow. Adjust the safety locking control rod to a free position, and then control the pilot valve handle and accessories control pedal(if fitted) in all the directions to release the pressure in the control pipelines.
Page 59 Components Description...
Page 60: Overview Of Operating Equipment
Overview of Operating Equipment Monitor Seat Left walking control rod Right pilot valve handle 10. Right walking control rod Command control panel Left pilot valve handle Radio Safety handle...
Page 61: Monitor
Monitor...
Page 62: Main Screen And Basic Operations
Main Screen and Basic Operations Screen layout ● Working time meter and clock ● Machine status display ●...
Page 63 Machine alarm display ● Main screen ● In-time information Fuel oil meter (when the fuel level is low, there’s alarm in the Pump emergency alarming area of the machine) control mode Mode Power modes: mode L, S and H Gear Throttle gears 1〜10 Voltage Rotation...
Page 64 Note: 1. “Accessory control” is only effective for the specific accessories assembled. 2. “Selection of working mode” is different for the machines of different configuration. Operation of the monitor ● Mode Start the electricity power, the display will start and Gear Autom enter the monitoring interface as shown in the...
Page 65 Main screen ● Press the key to enter “main menu”. Display of operation parameters Press the to move the cursor, then press Display of set parameters key to enter each menu for all kinds of Display of failure records operation. Use setting Press the key to return to the upper level...
Page 66 Fuel filling ● Fuel must be filled when the engine is stopped (the key is on the “ON” position) Press the ”Fuel filling pump start/stop key” for 3 seconds and then release, the fuel filling indicator will be on and the fuel filling pump starts to work.
Page 67: Left Dashboard
Left Dashboard Start switch Stopping Working position position Stopping position: stop of the electronic system of the machine Warming- up position Working position: normal working of the Starting electrical appliances of the machine position Starting position: when the key is turned clockwise to the starting position, the engine’s starter motor starts to work Warming-up position: when the key is turned...
Page 68 reset. Throttle knob Igniter 3-10...
Page 69: Command Control Panel (Cab Left)
Command Control Panel (cab left) Boom lamp switch and front working lamp switch Press the marked part of the button to turn on the lamp, and press the other part to turn it off. Cab headlamp switch (OPT) Press the marked part of the button to turn on the lamp, and pres the other part to turn it off. Cab rear lamp switch (OPT) Press the marked part of the button to turn on the lamp, and pres the other part to turn it off.
Page 70: Safety Locking Parts
Safety Locking Parts Safety locking handle Warning: Safe locking mechanism of the working device is an important part of security systems. When the driver is leaving the cab, he must do the safe locking. If the left control box is not in the locking position, the stick may move to cause the movement of the work platform or device, resulting in an accident.
Page 71: Manipulation Of The Working Device And The Rotary Equipment
Manipulation of the Working Device and the Rotary Equipment Manipulation of the working device and the rotary equipment of the excavator A. Left pilot handle operation Stick control: when pushed, the stick extends outside, when pulled, it is retracted. Platform rotation: when deflecting to right, the platform turns to right;...
Page 72: Walking Manipulation
Walking Manipulation Walking and walking direction manipulation Manipulate the left and right control rods to control the walking of the track on both sides of the machine. The unilateral control of control rod enables the machine's unilateral move. Speed control Walking speed can be switched through the “Driving speed”...
Page 73: Throttle Operation
Throttle Operation Throttle knob Turn the throttle knob to the right to increase throttle, and turn left to reduce it. Before the engine is stopped, the throttle knob should be on the MIN position before parking the machine. B. Throttle lever Pulling backward the engine throttle lever can increase the throttle.
Page 74: Driver's Seat
Driver's Seat Warning: Accidental overturn or sudden move of the machine can cause injury and even death. Therefore, for the sake of safety, remember to fasten the seat belts and adjust the seat before starting the machine. Headrest adjusting handle Safety belt slot Backrest angle and adjusting handle...
Page 75: Seat Belt
Seat Belt Warning: Safety belt is an important part of the safety system of the machine. Before the operation, you must wear the seatbelt. If not, when the machine is overturning, the machine cab or the machine may be down to your body, causing damage.
Page 76: Air-Conditioning Control
Air-conditioning Control Air-conditioning control panel is located on the left control panel switch set. Air conditioning control panel Display screen Mode selection key Settings adjustment key Key functions and basic manipulation Power Switch After you press this button, the air-condition system is electric. Open the screen backlight, and have the fan running for 3 seconds (do not accept other operations here).
Page 77 3-19...
Page 78 Heating key Press this button in the ventilation mode to remember the current state (wind speed settings), and the system enters the heating mode. The graphics disappears from the screen (top row), and the system enters the previous ventilation mode. Press this button in the cooling mode to remember the current state (cooling capacity setting, speed setting), and the system enters defrosting mode.
Page 79 Pressing this button means to decrease the wind speed, and the screen shows a corresponding decrease of grid of . Each time you press the button, a grid is reduced, and the wind speed decreases by 1 file. 3-21...
Page 80: Radio
Radio Power button Automatic tuning button Time and frequency shift key Band conversion button Reset button Radio preset buttons Stereo / mono switch key 10. Volume / balance adjustment button Manual down to select radio stations / Minute adjustment button 11.
Page 81 Remembering stations manually When you have searched for stations automatically or manually, press (for 3 seconds) the present buttons (1-6 button) for the memory. The response of the button dictates that the current station has been remembered on this button. In the future, as long as you press the present button (1-6 buttons) after turning on the radio, the original radio station can be played.
Page 82: Doors And Windows
Doors and Windows Cab door The door of the excavator is the only path for the driver to go in and out. When the operator leaves the cab, he should lock the door. Rear window Rear window can be used as an emergency exit. When for some reason, the cab door cannot be opened and the trapped driver cannot go out of the cab normally but need to escape from the...
Page 83 Front window (flip window) If the flip window is opened, the driver can get a better viewing conditions and air circulation. If you want to open the flip window (front window), firstly you need to pull the locks on both sides of the flip window, and then the flip window can slide down and up.
Page 84 Operating Guide...
Page 85: Preparations Before Operating This Machine
Preparations before Operating this Machine The excavator should be operated by the trained driver, who must comply with the specific requirements of the local area before operating independently. Unless the drivers have been read carefully the manual, the operation is strictly prohibited. Drivers must wear tight-fitting clothing and appropriate adaptation of the safety items such as helmets, shoes, gloves, protective glasses, safety belt light before the operation.
Page 86: Engine Operation
Engine Operation Warning：Before starting the engine, please refer to the safety details in this operation manual. Read all the safety signs on the machine. There should not be other people in the workplace. Before the operation, you should learn and practice the safe operation firstly.
Page 87 Starting the engine Warning: When there is warning sign of prohibiting starting engine hanging on the manipulation handle, the engine is not allowed to be started. Warning: Before starting the engine, you must confirm that the safety lock lever is in the locked position to prevent the accidental touch with the manipulation control rod in the starting, which will cause a sudden movement of the working device, leading to the accident.
Page 88 Starting the engine with the auxiliary cable • Warning: When the battery electrolyte is frozen, if you (1) try to charge the battery or (2) make jumper of the engine, the battery will explode. To prevent freezing of the battery electrolyte, please maintain the battery is charged fully. If you do not comply with these instructions, you or someone else will be hurt.
Page 89 After starting the engine A. Warm-up of the engine and the machine The normal operating temperature of hydraulic oil is 50 ℃ -80 ℃. The hydraulic oil whose temperature is below 20 ℃ will damage the hydraulic components in the operation. Therefore, before starting work, if the oil temperature is below 20 ℃, it must be warmed up according to the following heating process Select or cancel the heating mode through pressing the key.
Page 90: Getting In Or Out Of The Machine
Getting in or out of the Machine Make sure to clench the arm of the cab as shown in the picture(shown by the arrow in the picture) Make sure your feet step steadily on the track. When getting on or off the machine, you should not take the control rod as handrails to grasp.
Page 91: Moving Of The Machine
Moving of the Machine Safety principle of moving the machine Before starting the excavator, you should be familiar with the surrounding environment, the availability of pedestrians and obstacles, and the ground bearing capacity and so on. When starting the machine, please honk to warn others. The drivers are strictly prohibited to start or manipulate the machine on the ground.
Page 92 Moving the machine forward Adjust the control box to the free position, and raise the working device 40-50cm off the ground. Manipulate the left and right walking control rods When the march sign is on the front part of the machine: Slowly push forward the front of the control sticks to make the machine walk.
Page 93: Turning The Machine
Turning the Machine Note: Before manipulating the control rod, you should check the position of the March sign. If it is at the back, then the operation of the control rod is to the opposite. Change the direction of the walking with the left and right control rods. Avoid the sudden change as possible as you can.
Page 94 Turning when the machine is stopped 4-11...
Page 95 When turning left (see the right side figure): When the machine is walking forward, push forward the right control rod and the machine will turn left. When the machine is walking backward, pull back the right control rod, and the machine will turn left.
Page 96: Rotation Of The Machine
Rotation of the Machine Before rotating the upper part of the machine, please check if the surrounding area is safe enough. ● If you operate the rotation control rod quickly, the upper structure will rotate quickly. If you operate ● the rotation control rod slowly, the upper structure will rotate slowly.
Page 97: Selection Of Machine Work Mode
Selection of Machine Work Mode The correction selection of work mode is good for the machine to exert its working ability under different work conditions. Switch between automatic and manual mode can be done through selection of mode on the screen. Work mode Manual (HAND ) Automatic (AUTO)
Page 98: Working Device Operation
Working Device Operation If you operate the working device control rod quickly, the working device will rotate quickly. If you operate the working device control rod slowly, the working device will rotate slowly. Working device is operated by the pilot valve. The left control pilot valve controls the stick and rotation (if fitted with the steering head, the left pilot valve also can operate the swinging of the steering head).
Page 99 Bucket control Manipulate the right control pilot valve. The bucket turns outside when it turns right, the bucket turns inside when it turns left. Note: the pause phenomenon may occur in the stick operation, which is not a mechanical failure but a normal phenomenon of the excavator.
Page 100: Working On Slopes Or In Water
Working on Slopes or in Water Warning: Construction near the foothills slope is very dangerous. The different working conditions such as rain, muddy ground, snow on the ground, frozen ground, loose sand and soft ground brings potential danger to the safe operation. Therefore, when constructing in the dangerous sites such as in the foothills or on the slope, you should determine whether the operation is safe for the decision- making.
Page 101: Out Of The Muddy Environment
Out of the Muddy Environment Please always operate carefully to avoid falling into the mud. If the machine falls into the mud, you should drive the machine out of the muddy environment according to the following steps: A. Track of one side into the mud Note: When lifting the machine with boom or stick, be sure to make the bottom of the bucket contact with the ground.
Page 102: Construction Operations Guide
Construction Operations Guide Backhoe operation Backhoe is suitable for the excavation in the position lower than the machine. When the machine is in the state shown in the right picture, that is, when the angles between the bucket cylinder and linkage, the stick and the stick cylinder are both 90°, the push force of the bucket is biggest.
Page 103 Trenching operations Extend the boom and stick, and make the bucket teeth inserted into the soil. In the process of stick cylinder excavation, you should timely adjust the cut angle and the loading angle of the bucket, or carry out the digging with the bucket cylinder. Do not insert the bucket teeth into the soil too much to avoid the machine fail to dig the soil due to the overloading of the hydraulic system.
Page 104: Disassembly And Installation Of The Bucket
Disassembly and Installation of the Bucket Safety principles When you are striking the pin bearing, the metal debris may fly into your eyes, causing serious ● injury. So when doing this, you should always wear goggles, helmets, gloves and other protective equipment.
Page 105: Parking The Machine
Parking the Machine Safety principles Avoid a sudden stop. When you are parking the machine, please leave a space as large as possible. Park the machine on the solid and flat ground and avoid parking the machine on slopes. If the machine must be parked on the slopes, put the pads under the tracks and insert the working device into the ground to prevent the...
Page 106: After Operation
After Operation Inspection Check the engine temperature, oil pressure, fuel pressure, fuel level, etc. On the digital monitor of the machine. Locking Please lock the following places: Cab door (do not forget to shut the windows and the flip window). In any case, if you want to open the flip window, you need to first pull the handle lock on the both sides of the flip window.
Page 107: Handling And Transport Of The Machine
Handling and Transport of the Machine Safety rules of the machine shipment Run the machine at a slow speed, and operate slowly the machine when loading or unloading. During the automatic warm-up operation, do not handle the machine. If the automatic warm-up operation is canceled in the process of the handling operation, then the speed will suddenly change.
Page 108 Loading Loading can only be carried out on the solid and flat ground, with a safe distance to the road edge. Impose appropriate brake to the transport vehicle, and put pads under the tires to ensure that the transport vehicle cannot move.
Page 109 Fixing the machine on the transport vehicle Adjust the working device. Turn off the engine and remove the key from the starter switch. Lift the safety locking lever. Lock the cab and the engine bonnet. Put pads under the both ends of the tracks to prevent the moving of the machine in the transportation, and tether the machine firmly with the wire ropes.
Page 110 slope, and the machine on the way forward. 10) The excavator walk forward slowly to the top of the stab, and now overhang the stick, making the tracks of the machine dump onto the ramp, and then move the machine slowly to the ground. 4-27...
Page 111 Hoisting the machine A. Safety issues You can never hoist the machine when someone is on it. Ensure that the wire ropes used for hoisting the machine has sufficient strength to withstand the weight of the machine. Except the positions provided in the following procedures, do not hoist the machine in any other positions, otherwise the machine will has the risk of losing balance.
Page 112: Operating Under The Hot Or Cold Climate
Operating under the Hot or Cold Climate Operating in the cold climate The cold weather can cause particular problems, so you must pay special attention to the protection to prevent the serious damage of the machine. The maintenance in the cold weather will extend the life of the machine.
Page 113: Storage Of The Machine
Storage of the Machine Preparation before the storage When the machine need as long-term storage, please do according to the following steps: Clean and wash all the parts, then put the machine into the room. If the machine has to be stored outdoors, choose the flat ground and cover up the machine with the drop cloths.
Page 114 During storage During storage, operate the machine once a month to make the surface of the moving parts attached with a layer of the now film and charge the battery at the same time. Run the air conditioning for the machine equipped with the air conditioning. Turn the track.
Page 115: Reasons Of Technical Failures And Solutions
Reasons of Technical Failures and Solutions Failures Reasons Solutions The engine The problem of the starter motor Replace or repair the starter motor ● ● cannot start or is difficult Insufficient battery charge Charge or replace the battery ● ● to start Improper use of the warm-up lines or plugs Repair or replace the plugs...
Page 116 4-33...
Page 117 Failures Reasons Solutions Engine Coolant level is too low Add coolant ● ● overheating Failure of the temperature sensor Replace the sensor ● ● Blockage of the air filter Clean the air filter ● ● Fan belt is loose or faulty Re-tighten or replace ●...
Page 118 Failures Reasons Solutions 12. Hydraulic oil Use the incorrect hydraulic oil Use the correct hydraulic oil ● ● temperature is high Oil lines blockage Consult the agents of the company ● ● Blockage of the hydraulic oil filter Clean or replace ●...
Page 119 Failures Reasons Solutions 19. Abnormal Tracks are too loose or tight Readjust ● ● waling Oil pump performance is dropping. Consult the agents of the company ● ● Track frame deformation Repair or replace ● ● Track chain with gravel or rock Remove and repair ●...
Page 120 Failures Reasons Solutions 25. No meter Fusing of the starter switch safety plate Replace with the safety plate of the same ● ● display size Broken starter switch, wiring errors or Replace the switch; Check the lines, tighten ● ● joint laxity the connector Power Switch Failure...
Page 121 The running speed value display of If the instrument is broken, replace it. ● ● instrument is abnormal. If the sensor is broken, or the connection is ● poor, check the wiring. Check if the number of flywheel teeth set by ●...
Page 122 Failures Reasons Solutions Instrument display of the hydraulic If the instrument is broken, replace it. If ● ● temperature is abnormal the oil temperature sensor is broken or the connection is poor, check the wirings. Instrument display of the water If the instrument is broken, replace it.
Page 123 Maintenance...
Page 124: Maintenance Knowledge
View the timer on the dashboard, and see if it is time for maintenance based on the hours of work. Use the genuine parts The use of the genuine Yuchai parts is an important factor to ensure the normal wok of the machine and extend the life of the machine.
Page 125 Waste disposal Promote environmental protection, paying particular attention to the waste treatment: Put the emissions oil of the engine into the container, but not directly dump it into the ground, or ● into the sewer, or ditch, river, ocean or lake. When handling the hazardous materials, such as oil, fuel, coolant, antifreeze, plastic parts, ●...
Page 126: Maintenance Summary
Maintenance Summary Lubricating oil You should use the oil whose level and temperature meet the requirement of the “oil selection ● table” in this operation manual. Within the prescribed time, even if the oil is not dirty, it also should be replaced.
Page 127 ● of light bulbs; replacement of fuses and relays and so on. Do not install any electronic components other than those required by Yuchai. ● When working on the beach, you should carefully clean the electrical system to prevent corrosion.
Page 128: Parts Of Mandatory Replacement
Parts of Mandatory Replacement With the working time accumulation of the machine, some components playing an important role in safety, mainly include some oil horse, of which the material will change, and prone to aging, wear or deterioration, not only affecting the play of its normal functions, but also forming a potential risk to the safety.
Page 129: Oil Selection Table
Oil Selection Table Choose the applicable fuel according to the ambient temperature, working conditions and other factors. The oil to be used must meet the following requirements: Recommended Lube or Fuel Viscosity temperature replacement oil Chilliness area:CH15W/40 -15℃~+40℃ Lube of the engine General area:CH5W/30 -25℃~+30℃...
Page 130: Tightening Torque
Tightening Torque The following table provides tightening torque for all kinds of bolts, nuts installed on the machine. If the bolt or nut is not tightened to the specified torque, the parts tightened or linked by it will be loosen or even damaged, leading to the machine failure or impacting on the operations.
Page 131 Tightening torque of the hydraulic hose Metric threaded rotating nut Pipe OD Metric thread (outer diameter) Nominal torque Min./max M12X1.5 15~25 M14x1.5 30~45 M16X1.5 8 10 38~52 M18x1.5 10 12 43~85 M20X1.5 50~65 M22X1.5 60~88 M24X1.5 60~88 M26X1.5 85~25 M30X2 115~155 M36X2 140~192...
Page 132 Tightening torque of the hydraulic hose BSP thread and rotating nut BSPP thread Metric torque Min./max G1/4 15~25 G3/8 27~41 G1/2 42~76 G5/8 44~94 G3/4 95~135 115~165 G1.1/4 140~280 G1.1/2 215~365 300~500 ORFS rotating nut UNF thread Lineation specification 9/16~18 11/16~16 13/16~16 1-14...
Page 133: Regular Inspection And Maintenance Table
Regular Inspection and Maintenance Table Carry out regular inspection and maintenance for the machine according to the following table and combined with the working time indicated on the engine timer. If the working conditions of the machine is very poor or the work intensity is very large, or the machine is equipped with the hydraulic hammer and other accessories, the inspection and maintenance cycle should be lessened.
Page 134 Checking the fastening of the cylinder ● ☆ ▲ cover Checking the fastening of the engine ● ☆ ▲ support 5-12...
Page 135: Regular Inspection And Maintenance Table (Continued)
Regular Inspection and Maintenance Table (continued) Maintenance cycle Page Contents of inspection and (total number of the working hour) Number number maintenance 1000 1500 Engine intake system ▲ Emptying cans of dust ● ▲ Cleaning the air filter element ● ▲...
Page 136 5-14...
Page 137: Routine Examination
Routine Examination Every day or every 10 hours, do the general routine examination for the machine. In the leak inspection, check whether there is leakage of engine oil, water and fuel of all the parts. Check whether the elastic connections and the attachments have been scratched, broken or deformed.
Page 138: Engine Fuel System
Engine Fuel System Maintenance instructions Fuel tank capacity ......................... 500 liters Oil level inspection ......................every 10 hours Excluding water and impurities from the tank ..............every 100 hours Cleaning the tank ......................every 250 hours Injection pressure inspection ..................... every 500 hours Replacing the fuel filter element ..................
Page 139 5-17...
Page 140 Cleaning fuel tank Clean once every 250 hours. Prepare a container for the fuel discharged Remove the oil discharge valve and the filter located in the filler. Fill up the half of the tank and discharge again. Clean the fuel filter and put it back. Replace the drain plug and fill the fuel through the filter in the filler.
Page 141 Diesel pre-filter (diesel strainer) After the first 50hours of the new machine, it should be replaced for the first time. And then, replace the filter element every 250 hours (see the section of “Replacing the fuel filter element” in the following). Discharge the water and sediment in the separator every day.
Page 142 Install the fuel filter according to the requirement of the manufactures. Note: To reduce the possibility of fuel leaks, you should ensure that the fuel filter is installed tighten, but not over-tighten, which will damage the fuel filter. After replacing the filter element, start the engine and check if the filter sealing surface has oil spills.
Page 143: Engine Cooling System
Engine Cooling System Maintenance instructions The coolant level inspection ................every day or every 10 hours Checking the state of the rubber hose and clamps ........every day or every 10 hours Cleaning the radiator blade .................. every 500 working hours Coolant replacement ................
Page 144 5-22...
Page 145 Cleaning and checking the radiator blade Clean it every 500 hours. The dust accumulating on the surface of the radiator (radiator) will affect the cooling effect, so it must be cleaned promptly. Open the engine hood; blow out the dust or leaves and other debris on the oil coolant blocking the radiator blade with high pressure water or compressed air.
Page 146 Checking the coolant concentration Before the start of the cold season, you have to check the coolant concentration. Coolant can work at the ambient temperature of -35℃. If the ambient temperature is lower, the proportion of the antifreeze should be increased. Warning: The coolant is toxic.
Page 147: Engine Lubrication System
Engine Lubrication System Maintenance instructions Oil volume ............................19 liters Checking the oil level ................ every 10 working hours or every day Replacing the oil or the oil filter element .............. every 250 working hours Checking the oil level Before the new machine is used, check the oil Upper limit level once, and later on, check it every 10 working hours.
Page 148 Avoid inhalation of oil vapors, swallowing the oil, and prolonged exposure to the used motor oil. 5-26...
Page 149 Clean and re-install the oil drain plug. If the seal is damaged, replace it. Open the filling hole. Re-inject the new oil, until the oil level reaches the position of greatest mark “H” on the oil gauge. Cover the oiling hole, and make the engine idling for five minutes.
Page 150: Engine Intake System
Engine Intake System Maintenance instructions Air filter element cleaning cycle ................every 100 working hours Air filter element replacement cycle ..............every 500working hours Checking of air intake pipeline Check every day whether the air intake tubes are worn or damaged, clip loosen or other phenomena that will cause damage of the engine.
Page 151: Other Maintenance Of The Engine
Other Maintenance of the Engine Warning: To prevent injury, do not carry out maintenance with the engine running if the maintenance must be done in the case that the engine is running, please make sure the operation will be completed by at least two persons, and it will comply with the following provisions.
Page 152: Hydraulic System
Hydraulic System Maintenance instructions Hydraulic Tank Capacity ....................... 264 liters Oil level inspection ......................every 10 hours Oil filter replacement ......................every 500 hours Hydraulic oil change ....................every 1000-1500 hours Checking the system pressure ..................every 500 hours Warning: if the hydraulic oil or grease injects into the skin, it will cause serious injury and damage.
Page 153 Removing the eater and dirt in the hydraulic tank Remove the eater and dirt in the hydraulic tank every 250 hours After the oil temperature has dropped during the shutdown of the machine or before the daily work starting, expel the air in the oil tank. Slowly release the oil drain valve at the bottom of the tank or the drain plug (as shown).
Page 154 5-32...
Page 155 Discharging the air in the hydraulic system A. Discharging the air in the pump Release the air exhaust plug installed at the drain vent, and check if the oil flow out, completing the exhaust. Tighten the bolt after the exhaust completion. Note: If run the pump when it is not full of oil, the pump will become abnormally hot, leading to the premature failure of it.
Page 156 Discharging the air within the walking motor (when the oil in the walking motor has been discharged) Idle the engine and release the exhaust plug. If there is oil flowing out, tighten the bolt. Idle the engine, turn the working device 90°to make it located on one side of the track (as shown in the right picture).
Page 157 Replacing the filter element Replace it for the first time after the first 250 hours of the new machine, and after this, replace it every 500 hours. The return oil filter is in the hydraulic tank, therefore, Unscrew the lid at the top of the tank. Remove the spring, the bypass valve and return oil filter from the tank.
Page 158 5-36...
Page 159 Unscrew the oil filter housing. Remove the filter element. Install the new O-ring in the groove of the filter head. Before the installation of the new filter element, coat the filter seal surface with a layer of hydraulic oil, and then put the filter element into the filter head. Clean the filter shell and the soft magnets, not allowing the dirt, dust or water enter the oil filter housing.
Page 160: Battery
Battery Warning: 1) Battery contains sulfuric acid liquid with a strong corrosive, so please keep it away from children, and the user should wear protective glasses and rubber gloves. Once the eyes, skin and clothing are splashed with sulfuric acid, wash with plenty of water promptly, and if serious, go to hospital for treatment.
Page 161 Before installing the machine, you should first connect the battery positive cathode with the engine positive cathode, and then connect the battery negative cathode with the engine negative cathode. Make the battery flat on the battery rack with the method of upper fixing or lower fixing, to prevent the battery from being damaged due to the looseness.
Page 162: Reducer
Reducer Maintenance instructions Rotating reducer oil capacity ......................5 liters Walking reducer lubricating oil capacity ..................5.4 liter Checking the lubricating oil level and oiling ............every 250 working hours Replacing the lubricating oil ................... every 500 working hour Checking the reducer bolt tightening torque ............
Page 163 Replacing the lubricating oil( for each reducer box) Replace it for the first time after the first 50 working hours of the new machine, and after this, replace it every 250 hours. Prepare an inner hexagon wrench. Stop the excavator on the flat ground. Turn the walking speed reducer, to let the 3 screws on its external end vertical to the ground, then stop the machine.
Page 164 Checking the walking reducer and rotating reducer bolt tightening torque A. Checking the fastening of the walking reducer connecting bolts Check it for the first time after the first 50 hours of the new machine, and after this, check it every 500 hours.
Page 165: Track
Track Checking and adjusting the tension state of the track Check it every 10 hours. Stop the excavator on the flat and solid ground. Take off the cover of each track carrier (No. ① of Figure 2). 3) In order to tension the track, you need to connect the Grease Gun connector with the connector ②(Figure 2).
Page 166 Warning: Do not beat track tension springs, which will explosively fracture due to the enormous pressure, resulting in personal injury. Do not remove the spring under the tension state. 5-44...
Page 167: Supporting Wheel, Under Roller And Idler
Supporting wheel, under roller and idler Checking the tightening torque of supporting the wheel Check it for the first time after the 50 working hours of the new machine, and after this, it should be checked every 500 hours. If there is bolt looseness phenomenon, you need to unscrew the plug and clean the thread locking agent between the bolt and the thread, and coat the thread joints with the thread locking agent,...
Page 168: Lubricating
Lubricating Lubricate each lubrication point of the machine every 50hours. Lubrication steps: Start the working device and put the bucket to the ground. Put the blade to the ground. Turn off the engine. Clean the refueling nozzle of each oil cup. Lubricate all the lubrication points and wipe the excess grease that is squeezed.
Page 169: Air Conditioning
Air Conditioning The machine is equipped with the air conditioning device in the cab, and its operation knob is on the left control box in the cab. As to the specific operation and maintenance of the air conditioning system, you can not only refer to this operation manual, but also the Air conditioning operation manual attached to this machine.
Page 170 Checking the amount of the refrigerant Refrigerant easily frostbites the skin, especially the eyes; in addition, it will emit toxic phosgene in case of meeting the open fire. Therefore, under any situations that the cooling system needs to be demolished, please recover the refrigerant firstly in the case that the refrigerant will not spay to the skin and eyes, and then demolish the cooling system.
Page 171 Air conditioning regularly inspection contents Inspection cycle Inspection items Inspection contents Per month Per season ★ All fasteners Looseness or drop ★ Air conditioning belt Tension and wear ★ Pipelines Wear or cracking ★ Connector Wear of leakage ★ Electric fan If run properly ★...
Page 172: Bucket Teeth Replacement
Bucket Teeth Replacement Replace the bucket teeth before the wear of the bucket seat. Warning: when replacing the bucket teeth, the accidental movement due to the misuse of the working device is very dangerous. Therefore, before replacing the bucket teeth, you have to place the working device in the locked state, shut down the engine and have all the operating stick firmly locked.
Page 173: Washing The Floor Pads
Washing the Floor Pads Clean the floor pads whenever it is dirty to prevent the accidents due to the slipping or falling. Warning: if you hit the stick accidentally, the working device will move suddenly, causing a serious accident. Therefore, before removing the floor pad, you must stop the machine on the flat and solid ground.
Page 174 Accessory Guide...
Page 175: Safety Issues
Safety issues If the accessories or options that have not been approved by Yuchai are installed, this will not only affect the service life of the machine, but also can cause some safety problems. When installing the accessory that has not been approved by Yuchai, please contact Yuchai dealer firstly.
Page 176 Warning: The person who operates the crane must have the operation qualification. The people without qualifications are not allowed to operate the cane. For the details of the removal and installation, Please contact Yuchai dealer.
Page 177: Accessories Installation And Removal Steps
Accessories Installation and Removal Steps Removal procedures Place the accessory on the ground and turn off the engine Turn the starter switch to “ON” position and push the left control box to the free position. Do the full-stroke operation of forward, backward, left and right to all the work units stick and accessory control pedal to eliminate the internal pressure in the hydraulic circuit.
Page 178: Accessories Instruction Guide
This section describes when operating the hydraulic excavators with accessories, the precautions to be observed. Note: Choose the accessory most suitable to the host. The models of the accessory that can be installed are different. For accessories and machine model selection, please contact Yuchai Dealer. Hydraulic Breaking hammers...
Page 179 Maintain the drill rod blow the surface appropriately to prevent the use of the impact when there is no resistance. When the target or rock has been crushed, please stop the blow action of the breaking hammer immediately. Blowing of continuous and aimlessness can only cause the precursor and the main bolt loose and damaged, or even cause damage to the excavator itself.
Page 180 Move the drill pod in the impact operation. Apply impact force in the level or upward. Swing the drill rod when it has been penetrated into the rock. Pecking operation.
Page 181 Operation in the water or in the muddy ground. Use the breaking hammer as a tool for lifting heavy objects. Make the bucket cylinder fully extended and the machine off the ground.
Page 182 Quick-acting Couplings Bucket Installation Pry ① with a crowbar. Place the bucket pin into the position of ②③, put down the crowbar, and the bucket is installed Bucket Removal Pry ① with a crowbar. Remove the bucket.
Page 183: Daily Inspection Of Hydraulic Breaking Hammer
Daily Inspection of Hydraulic Breaking Hammer Do the daily inspection and maintenance for hydraulic breaking hammer according to the following table: Number Inspection or maintenance items Inspection points Maintenance way If bolts and nuts are loose or lost Main bolts and side bolts Tighten the bolts or re-install a new bolt Check hoses parts for looseness,...
Page 184 Yuchai Machinery Guangxi Yuchai Heavy Industry Co., Ltd. Address: No. 168 Bridge Road, Yulin City, Guangxi Province, China (537005) Telephone: (0775) 3289567 3287255 Fax: (0755) 3813592...

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