Yuchai YC20SR Operation Manual
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Yuchai YC20SR Operation Manual

Hydraulic excavator
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HYDRAULIC EXCAVATOR
YC20SR / YC18SR
U20 / U18
OPERATION MANUAL
GUANGXI YUCHAI HEAVY INDUSTRY COMPANY LIMITED

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  • Page 1 HYDRAULIC EXCAVATOR YC20SR / YC18SR U20 / U18 OPERATION MANUAL GUANGXI YUCHAI HEAVY INDUSTRY COMPANY LIMITED...
  • Page 2 Operators should have been trained in the safe operation of the machine before operating the  machine at the work site. You are responsible for complying with relevant laws and regulations and following Yuchai Heavy Industries' instructions on machine operation and maintenance.

  • Page 3: Table Of Contents

    CATALOGUE Foreword ..................................1 1.1. To Users .................................. 1 1.2. Machine information ............................2 1.3. Machine directions ............................... 4 1.4. Machine components ............................5 1.5. General Operation Information ......................... 6 1.5.1. Specified operations............................ 6 1.5.2. Break-in ................................. 6 1.6. Safety-related information ..........................6 1.7.
  • Page 4 2.6.3. Safety rules when traveling ........................23 2.6.4. Traveling or working on slopes ......................23 2.6.5. Safe excavation operations ........................26 2.6.6. Tip and Skipping Prevention and Countermeasures ................ 30 2.6.7. Transportation and Handling ......................... 31 2.6.8. Downtime maintenance .......................... 32 2.6.9.
  • Page 5 4.3. Enter and exit the machine ..........................55 4.4. Traveling ................................56 4.4.1. Safety principles for traveling ....................... 56 4.4.2. Preparation for traveling ......................... 57 4.4.3. Travel forward............................57 4.4.4. Travel backward ............................58 4.4.5. Stop the machine ............................58 4.5.
  • Page 6 4.14. After operation ............................... 69 4.14.1. Check ................................69 4.14.2. Lock up ............................... 69 4.15. Loading and unloading and transportation ....................69 4.15.1. Safety rules ..............................69 4.15.2. Loading ............................... 70 4.15.3. Fixing the machine on the transport vehicle ..................72 4.15.4.
  • Page 7 5.2.2. Fuel ................................88 5.2.3. Grease ................................. 88 5.2.4. Coolant ................................ 89 5.2.5. Filter element ............................. 89 5.2.6. Hydraulic system ............................89 5.2.7. Electrical System ............................90 5.3. Wear and tear parts............................90 5.4. Mandatory replacement parts.......................... 91 5.5. Oil selection table .............................. 92 5.6.
  • Page 8 5.11.2. Change the engine oil ..........................105 5.11.3. Replace the engine oil filter element ....................106 5.11.4. Oil filter replacement ..........................106 5.12. Engine air intake system ........................... 106 5.12.1. Cleaning of dust collection bin ......................107 5.12.2. Clean the air filter element ........................107 5.12.3.
  • Page 9 5.20. Flushing of the floor mat ........................... 127 Attachment Guide ..............................128 6.1. Safety issues ..............................128 6.1.1. Safe operation of attachments ......................129 6.2. Removing or installing attachments ......................130 6.2.1. Attachment Installation/Removal Procedure ................... 130 6.3. Attachment Operation Guide ........................131 6.3.1.

  • Page 10: Foreword

    Dear users. Greetings! Welcome to use Yuchai excavator and thank you for your great support to Yuchai business. This manual is intended as a safety guide and for the proper use and maintenance of the machine. Before starting and operating the machine for the first time and before servicing the machine, please make sure to read and understand this manual carefully and fully understand the safety procedures, operation and maintenance procedures.For easy access,...

  • Page 11: Machine Information

    1.2. Machine information When you need to know the basic information of the machine, you can view it in the position shown in the picture.  Machine information (Nameplate is located on the right front side of the upper machine) Engine Information ...
  • Page 12 Fill in the form below with the VIN and engine number of your machine. You can provide them to Yuchai when you need to purchase spare parts or request relevant information. Please record these numbers and keep them together with the product certificate. If your machine is stolen, you can submit them to police.

  • Page 13: Machine Directions

    1.3. Machine directions The front, back, left, right, top and bottom on this manual refer to each direction of the illustrated pictures. Down Right Front Back Left...

  • Page 14: Machine Components

    1.4. Machine components Bucket Tracks Bucket Cylinder Travel Reducer Driving Roller Arm Cylinder Carrier Roller Boom Cylinder Chassis Boom Slew Ring Idler Hydraulic Tank Boom Swing Cylinder Fuel Tank Dozer Blade Cylinder Rear Panel Boom Swing Knuckle Upper Platform Dozer...

  • Page 15: General Operation Information

    1.5. General Operation Information 1.5.1. Specified operations This machine is mainly used for the following operations.  Digging  Trenching  Loading  Grading Please refer to operation guide and attachment guide for detailed descriptions of the operating principles. 1.5.2. Break-in The machine has been fully adjusted and checked before delivery.
  • Page 16 WARNING: Indicates that the consequences of the potential hazard may result in death or serious injury if not avoided. CAUTION: Indicates that the consequences of a potential hazard may result in a low or moderate level of injury if not avoided, and may also be used to indicate unsafe practices that may result in injury.

  • Page 17: Technical Specifications

    1.7. Technical specifications 1.7.1. Dimension paragauges YC20SR（E20F51S） Items Unit Working weight 2000（cabin, rubber track) Bucket capacity 0.05 Engine model Yanmar 3TNV76-P Engine power kw/rpm 14.5/2400 Overall length (transportation status) 3750 Total length of grounding 2650 Working device height (to the top of boom)

  • Page 18: Working Paragauges

    Specifications are subject to change without prior notice 1.7.2. Working paragauges YC20SR（E20F51S） Items Unit Max. digging height 3600 Max. dumping height 2485 Max. digging depth 2310 Max. vertical digging depth 1920 working device Min. slewing radius 1690 Max. digging radius on ground level 4060 Max.

  • Page 19: Traveling Mechanism

    Specifications are subject to change without prior notice 1.7.3. Traveling mechanism The traveling system is driven by hydraulic motor through multistage planetary reducer. Traveling speed Gradeability High speed 58%(30 Low speed 1.7.4. Hydraulic system Load sensing hydraulic system. Max. hydraulic flow rate: 61.6L/min （2200 rpm） Working pressure: 24 Mpa (LS=21.5 Mpa, load compensated pressure difference 2.5 Mpa) Slewing pressure: 9 Mpa...

  • Page 20: Interference

    Humidity: <85% Altitute: ≤1500m Transportation and storage temprature: -15~40 1.7.7. Interference Non-standard working devices may interfere with the boom cylinder or the lower cover of the boom. When non-standard working devices are used , attention should be paid to the angle between the boom and the boom when retrieving the bucket to prevent interference with the boom cylinder and damage to the machine body.

  • Page 21: Safety Rules

    2. Safety rules 2.1. General safety rules Following the relevant safety procedures in this manual will prevent most accidents , avoiding endangering operation and maintenance of the machine. Before you operate or service the machine, you should read and understand all the safety information in this book and on the decals for the machine.

  • Page 22: Safety Labels And Instructions

    dangerous work conditions such as underwater, culverts, explosive places and toxic environments. 2.2. Safety labels and instructions 2.2.1. WARNING Symbols In this manual, WARNING sign indicates important information about safety. Seeing this sign, you should read the information and advice in it carefully to avoid injury. 2.2.2.

  • Page 23: Security Signs

    If the sign is broken, lost or unreadable, replace it. If the marker is located on a part that needs to be replaced, make sure that the marker is matched on the new part. Please contact Yuchai agent to obtain new safety markings. 2.4.1. Classification of safety signs Safety signs used in this manual and on the machine are "graphic safety signs"...

  • Page 24: Location Of Safety Signs

    B. Graphic+text safety signs This type of safety sign has a diagram and corresponding explanatory text, and is used where the graphic does not adequately convey the safety message. 2.4.2. Location of safety Signs The sign shown is only the "safety signs" , other type of signs logos are described in later sections.

  • Page 25: Safety Signs And Descripton

    2.4.3. Safety signs and descripton  Stay away from the working device  left signs  Lifting combination signs Moving work equipment can cause injury. Keep a safe distance from the area where the work device is working.  Warning signs ...
  • Page 26 Hydraulic oil refiling sign  Warning sign   Tail signs  Swing center  Safety sign  Control signs  Warning sign  Throttle sign...
  • Page 27  Warning sign  Lubrication oil refill sign  Reading manual sign  High temperature sign  Machine Lift Points  Stop engine sign...
  • Page 28  Warning sign  Maintenance warning  Swing lock sign...

  • Page 29: Workplace Safety

    2.5. Workplace safety Familiarize yourself with the area you will be working in advance. Please check. 1) Location of slopes. 2) Ditches. 3) Falling or hanging objects. 4) Soil conditions (soft or hard). 5) Stagnant water and swampy areas. 6) Tocks and tree stumps. 7) Boundaries of buried foundations, root posts or walls.

  • Page 30: Safe Operations

    15) Confirm the depth of underground gas pipes, cables, telephone lines and water pipes and avoid these areas when working WARNING: If you look in from the end of the damaged cable, the cut fiber will seriously hurt your eyes. 16) It is forbidden to use this machine under the culverts.

  • Page 31: Travel And Swinging

     After the engine is started, check the following 1) Safety belt fastened properly. 2) The working device, bulldozing device, traveling, slewing, working device deflection and other moving parts work normal. 3) There is any abnormality in the sound, vibration, smell or gauge of the machine. 4) Oil or fuel leakage 2.6.2.

  • Page 32: Safety Rules When Traveling

    2.6.3. Safety rules when traveling 1) When traveling on a flat road, the arm must be lowered and the boom retracted to maintain the best position of the center of gravity, and the distance between the bottom of the bucket and the ground should be 40 - 50 cm.
  • Page 33 2) When the machine is working, especially when working up and down slopes and in dangerous areas, fasten the safety belt. 3) When the excavator is going up the slope, drive at low speed, the driving wheel should be in the lower direction of the slope, the arm and bucket should be fully extended parallel to the slope, and the bucket teeth should be 20-30cm away from...
  • Page 34 steel sheets, because there is a danger of the machine slipping even on small slopes. Never turn sharply on an uphill or downhill slope, otherwise the machine will tip over. When stopping on a slope, the front dozer and the bucket must be inserted into the soil and the driver can get off the machine only after stopping the engine and the machine is safely parked.

  • Page 35: Safe Excavation Operations

    13) Do not change direction on the slope. 14) When going up a slope, make sure the engine and hydraulic oil are properly warmed up, otherwise accidents may happen. 15) When the excavator is on a slope with two tracks oriented at 90 degrees to the slope, it is very dangerous to swing.
  • Page 36 trench, etc.), make sure the path is level and clear. 6) When the bucket meets unyielding resistance, do not travel or rotate, otherwise the machine will be damaged. 7) If the hydraulic cylinder is operated to the end of its stroke during operation, the force will push on the internal limit ring of the cylinder, thus reducing the life of the machine.
  • Page 37 14) Do not use the weight of the machine to increase the digging force. 15) Do not use the bucket drop as a hand pick, crusher, or pile driver as this will overload the rear structure of the machine. This will not only damage the machine but is also very dangerous.
  • Page 38 18) Do not use the rotary force to compact the soil or to damage mounds and walls. When turning, do not insert the bucket teeth into the soil, as these actions can damage the working device. 19) Do not dig into the ground with the bucket and use the traveling force to excavate, as this will cause the rear of machine...

  • Page 39: Tip And Skipping Prevention And Countermeasures

    2.6.6. Tip and Skipping Prevention and Countermeasures WARNING: 1) When you have to turn on the ramp, only turn in a big circle. When the machine is to turn to the right, extend the arm and boom to the left, with the bucket about 30cm from the ground, and lock the platform.

  • Page 40: Transportation And Handling

    10）When the machine is digging deep under the machine body. 11）When traveling on frozen ground. 12）When there is oil or lubricant on both tracks, the machine is prone to skid. 2.6.7. Transportation and Handling  The transportation (loading and unloading) of the excavator must strictly observe safety...

  • Page 41: Downtime Maintenance

     Before going up and down the slide, be sure to lock the swing lock of the rotary platform to prevent the platform from rotating.  When going up and down the slide, do not maneuver any handle except the travel handle.

  • Page 42: Fire, Explosion And Poisoning Prevention

    be guarded by a person.  Do not carry loose items in your pockets to prevent them from falling into the moving parts.  High-pressure liquids can hurt eyes or skin and should be handled with great care during maintenance. ...
  • Page 43  Do not leave the machine unattended while refueling.  The fuel must not spill onto overheated surfaces or the electrical parts.  After refueling, wipe off any spilled fuel or oil and tighten the fuel and oil tank cap tightly. ...

  • Page 44: Battery

    2.6.10. Battery  General safety rules for batteries The battery electrolyte contains sulfuric acid, which generates flammable explosive hydrogen gas. Incorrect handling can lead to serious injury or fire, so the following precautions must be observed.  When the indicator shows green, the battery is ready for use. When the indicator shows black, the battery should be charged in time, and when the indicator shows white, it should be replaced immediately.

  • Page 45: Hydraulic System

    3）The terminals of the battery cannot be shorted with metal parts. 4）Welding, grinding or smoking should not be done near the battery. Due to the risk of sparks, the following steps are to be followed.  Firmly mount the battery. ...
  • Page 46 Never weld the machine without isolating the hydraulic oil lines (hoses). If any damage is found to the hose, stop the operation immediately and contact your Yuchai dealer. Replace the hose if the following problems are found.
  • Page 47 D. Release the internal pressure of hydraulic system Between machine operations, the hydraulic oil in the hydraulic lines is at high temperature and pressure. When the oil port is open, oil may spurt out, so rotate the oil filler cap to relieve the internal pressure before removing the cap.
  • Page 48 How to disassemble the pipes of a machine equipped with an accumulator 1) Lower the machine to the ground and turn off the hydraulic hammer or other attachments. 2) Turn off the engine. 3) Turn the key of the starter switch to the ON position again to allow current to flow in the circuit.

  • Page 49: Introduction Of Components

    3. Introduction of Components 3.1. Control Consoles 1 Main power switch 5 Right attachment pedal Left attachment pedal Throttle Travel control pedal Pilot system lock Dozer lever Left travel pedal Left joystick Swing Lock Right travel pedal Right joystick Seat...

  • Page 50: Safety Locking Components

    3.2. Safety locking components WARNING: The working device safety locking mechanism is an important part of the safety system. The safety lockout must be engaged when the operator leaves the cab. If the joystick locking mechanism is not in the locked position, the handle may move and cause the working device to actuate, resulting in an accident.

  • Page 51: Switch Assembly

    plate is placed at the lower box d, and the pin b locks the platform and the bottom frame. When locking, make sure that the locking pin holes on the platform and the bottom frame must be aligned. 3.3. Switch assembly Switch assembly of left control box - 1 1) Out Frame 2) Working light switch...

  • Page 52: Electronics Controls

    the default platform Swinging to the left or right. 7) Chassis telescopic switch Press the rocker switch, the dozing handle switches to the chassis telescopic state. 8) wiper switch Press the wiper switch, the wiper is working. 9) Heater Press the air heater switch, the air heater is working. 10) Cover plate 3.4.

  • Page 53: Cigarette Lighter

    3.4.2. Cigarette lighter 3.5. Monitor...

  • Page 54: Work Device S And Swing Controls

    3.6. Work device s and Swing Controls  Control of excavation work device and platform Swinging A) Left joystick Arm extends out when pushing up, and retracts in when pulling back. Platform slewing: platform turns right when joystick moves right, platform turns left when joystick moves left.

  • Page 55: Travel Control

     Operation of the dozer Push the lever down to push the dozer plate downwards. When pulling up, the dozer plate is lifted.  Operation of the auxiliary work device When the machine is equipped with an auxiliary work device , the auxiliary oil supply is switched on by pressing the foot pedal of the auxiliary work device .

  • Page 56: Driver's Seat

    After the engine is turned off, push the stop handle forward to the end. 3.9. Driver's Seat WARNING: Accidental tilting or sudden movement of the machine may result in injury or even death. Therefore, for safety reasons, remember to fasten the seat belt and adjust the seat before starting the machine. Seat forward-backward adjust handle ①...
  • Page 57 Hold the harness clip, check that it is not twisted, adjust the length of the harness and insert the it firmly into the buckle. Gently pull the seat belt and check that it is properly locked. 2) Remove the seat belt Press the red button on the buckle and remove the clip from the buckle to remove the seat belt.

  • Page 58: Operation Instructions

    4. Operation Instructions 4.1. Preparation before operating the machine 1) The excavator should be operated by a trained driver . The machine should meet the specific requirements of each region for the driver to operate independently. 2) The driver is strictly forbidden to operate the machine until he/she is familiar with the instruction manual.

  • Page 59: Engine Operation

    4.2. Engine Operation WARNING: Before starting the engine, review the safety instructions in this manual. Read all safety signs on the machine. No other people are allowed in the workplace. Before operating, learn and practice safe operation. When operating the machine, you must be clear of and follow the operation and maintenance requirements in the manual.

  • Page 60: Starting The Engine

    provide relevant information for operation. 4.2.2. Starting the engine WARNING: Starting the engine is not allowed when there is a “no engine start” WARNING sign on the joystick. WARNING: Before starting the engine, make sure the safety locking handle is in the locked position to prevent accidental maneuver of the lever during start-up, which could cause the working device to move abruptly and cause an accident.
  • Page 61 key and it will automatically return to the ON position. If the engine does not start. Try again after 30 seconds. B) Starting the engine in cold temperatures When the ambient temperature is below 5 degrees, the engine must be warmed up by turning the key counterclockwise to the HEAT position.
  • Page 62 sparks, flames and fireworks. When charging or using the battery in a confined area, maintain ventilation and wear eye protection when working near the battery. If the jumper cable is connected in a wrong way, it can cause the battery to explode.

  • Page 63: After Starting The Engine

    4.2.3. After starting the engine A) Engine warm-up and machine warm-up The normal operating temperature of hydraulic oil is 50°C~80°C. Operation with hydraulic oil below 20°C will damage the hydraulic components. Therefore, if the oil temperature is below 20°C, the following warm-up procedure must be followed before starting operation.

  • Page 64: Check After Turning Off The Engine

    2) Push the throttle forward to the end and pull the stop handle back to the end. 3) Turn the key switch to OFF position and turn off the engine. Each indicator light goes off. 4) Remove the starter switch key. 5) Push the stop handle forward to the end after the engine is stopped.

  • Page 65: Traveling

    Then use the joystick safety handle to pull up the left control box in a locked position and keep it in this position until the next time the machine is operated. ATTENTION: When leaving, remove the key and lock all doors and windows. Do not climb on top of the fuel tank, engine hood or cab.

  • Page 66: Preparation For Traveling

    operating the steering lever, check the direction of the chassis. 9）If the dozer facing backward, the control of the travel joystick is reversed. 10） Do not allow anyone to be in the area around the machine. 11） Remove all obstacles from the machine's travel path. 12）...

  • Page 67: Travel Backward

    2）Maneuver both travel levers as follows. When the dozer is facing front, slowly push both lever forward to control the machine travel. When the dozer is facing rear ,slowly pull both lever backward to control the machine travel. ATTENTION: In low temperatures, the machine’s travel speed could be abnormal, when the machine is not warmed up thoroughly.

  • Page 68: Steering

    4.5. Steering ATTENTION: Before operating the travel lever, check the position of the dozer. If the dozer is facing back ward, operate the travel lever in the reversed direction. Use the left and right travel joysticks to change the direction of travel. Avoid sudden changes of direction if possible.

  • Page 69: Rotation

    4.6. Rotation  Before rotating the upper, check that the surrounding area is safe.  Make sure that the platform is unlocked from the chassis by lifting the platform locking pin.  The rotating speed is proportionate to the maneuver spin of the left joystick. 1) Lift the platform locking pin to unlock the platform from the chassis before slewing 2) Disconnect the deflection switch.

  • Page 70: Rotation Control

    4.7.2. Rotation control Select the rotation mode on the left joystick first. Operate the leftto rotate the platform. Before rotating, it is necessary to make sure that the machine is in a rotation mode. 4.7.3. Boom control The right joystick Forward-boom is lowed.

  • Page 71: Working On Slope Or Water

    4.8. Working on slope or water WARNING: Working near slopes in the foothills is very dangerous. Rain, mud, snow, ice, loose sand, and soft ground pose potential hazards. Make sure it is completely safe before operate. 4.8.1. Slope  When traveling, raise the bucket about 20~30cm off the ground. ...

  • Page 72: Getting Out Of The Muddy Environment

    Permissible water depth Do not drive the machine in water deeper than the midline of the pallets. Grease parts that have been submerged for a long time until the grease is squeezed out of the zerks. 4.9. Getting out of the Muddy Environment Always operate carefully to avoid getting stuck in the mud.

  • Page 73: General Operations Instruction

    4.10. General Operations instruction 4.10.1. Backhoe operation The backhoe is suitable for digging below the machine. Maximum bucket thrust is achieved when the machine is in the position shown in the diagram to the right, i.e., when the bucket cylinder is at 90° to the connecting rod and the boom cylinder is at 90°...

  • Page 74: Trenching Operations

    4.10.3. Trenching operations Keep the dozer at the rear and anchor it into the soil surface. Extend the arm and boom and insert the bucket teeth into the soil surface. Use the boom cylinder to dig. During the digging process, adjust the cutting and loading angle of the bucket at the right time, or switch to digging with the bucket cylinder.

  • Page 75: Removal And Installation Of Bucket

    1) Excessive debris entering the tracks might cause the tracks to over load, damaging the track motors. 2) Avoid making sudden turns on road with strong friction. 3) Avoid contacting salt water or gas as much as possible. 4) If the tracks are not used for a long period of time, keep them in a cool and dry place.

  • Page 76: Disassembly

    performing this operation. 2) When removing the bucket, keep the bucket in a stable position. 3) If the pin is struck too hard, the pin may fly out and injure people in the surrounding area. Therefore, make sure the surrounding area is safe before striking the pin. 4) When removing the pin, take special care not to stand under the bucket or place your feet or any part of your body under the bucket.

  • Page 77: Parking

    4.13. Parking  Safety principles 1）Avoid sudden stops. Always park in open space. 2）Park the machine on a firm and level surface. Avoid parking the machine on a slope. If the machine must be parked on a slope, put a pad under the tracks and insert the bucket into the ground to prevent the machine from moving.

  • Page 78: After Operation

    7）Lock the platform. 8）Use the pilot valve safety handle to pull up the left control box and put the machine in the locked position. 4.14. After operation 4.14.1. Check Check the engine water temperature, oil pressure, fuel pressure, fuel level, etc. on the digital monitor of the machine.

  • Page 79: Loading

    is recommended that the loading/unloading slope should be less than 15°, or the length of the ramp should be more than 3.5 times its height. When using a mounded slope, the mounded soil should be completely compacted and measures should be taken to prevent the slope from caving in. 6) To prevent the machine from slipping on the ramp, remove all soil and dirt from the tracks before starting.
  • Page 80 2) Apply brakes transport vehicle properly and put pads under the tires to ensure that transport vehicle does not move. 3) Install a ramp between the transport vehicle machine and make sure that both sides of the ramp are on the same level.

  • Page 81: Fixing The Machine On The Transport Vehicle

    dimensions provided in this manual. 4.15.3. Fixing the machine on the transport vehicle 1) Set up the working device. 2) Turn off the engine and remove the key from the starter switch. 3) Lock the platform. 4) Lock the cab and the engine hood. 5) Place pads under the ends of the tracks to prevent the machine from moving during transport and tie the machine securely with wire...

  • Page 82: Lifting Machine

    match the center of the tracks. 4) Remove the rope holding the machine in place. 5) Start the engine. In winter, perform a thorough warm-up operation. 6) Lower the left control box. 7) Lift up the arm and bucket, and lift the dozer. 8) Check that there are no obstacles within the excavator's range of motion.

  • Page 83: Operation In Cold/Hot Climate

    For machines equipped with lifting holes, lift the machine according to the following procedure. 1) Rotate the platform so that the working device is oriented in the same direction as the dozer. Start the engine and set the work device to the position shown on the right, with the boom fully raised and the arm and bucket fully retracted.

  • Page 84: Operating In Hot Weather

    extend the life of the machine. 1) Electrical system: Keep the battery clean and fully charged. Check the battery cables and connectors, clean the terminals and apply a layer of grease to prevent rusting. 2) Lubricant: Use lubricant with suitable viscosity at each joint. Please use the lubricant recommended by this manual.

  • Page 85: Storage Of The Machine

    4.17. Storage of the machine 4.17.1. Preparation before storage When storing the machine for a long time, do the following steps. 1) Clean and rinse the machine before put it indoor. If you have to store the machine outdoor, choose a flat surface and cover the machine with tarp. 2) Apply a thin layer of grease to the metal surface of the piston rod.

  • Page 86: During Storage

    figure to the right to protect the cylinder piston rod from rusting. 4.17.2. During storage 1) During storage, operate the machine once a month to apply a fresh film of oil to the surfaces of the moving parts. Also, charge the battery. 2) Drive the tracks to prevent rusting.

  • Page 87: Causes Of Technical Failures And Solutions

    4.18. Causes of technical failures and solutions  The engine cannot be started or is difficult to start 1) The starter motor is faulty - Fix or replace the starter motor 2) Insufficient battery charge -Charge or replace with new battery 3) Preheat circuit or preheat plug improperly used -Repair or replace the preheat plug 4) Injection timing is not correct -Check the injection timing 5) Fuel delivery line is blocked -Clean the fuel line...
  • Page 88  Engine power drops 1) Fuel mixed with air -Vent air 2) Oil supply is not smooth -Check and clean 3) Injection timing change -Adjust according to the specified value 4) Injectors work poorly -Check the working pressure and oil injection atomization 5) Air filter is blocked -Clean the filter element 6) Incorrect intake and exhaust valve clearance or valve not sealed -Adjust valve clearance...
  • Page 89 4) The engine cooling water temperature is too high - Correctly prepare the coolant mixture ratio or contact the local after-sales service  Grey and black smoke from the engine 1) Poor fuel quality - Use the correct fuel 2) Clogged air filter - Replace filter element 3) Injection timing is not correct -Adjust according to the specified value 4) Nozzle atomization is poor -Check, change parts ...
  • Page 90  Engine running while the generator alarm light is on 1) generator failure - ask after-sales service 2) Faulty electronic regulator -Replacement 3) The wiring is faulty -Servicing  Hydraulic system components too slow 1) Hydraulic oil cold -Operate the machine to heat up the hydraulic oil 2) Pilot system pressure too low -Consult after-sales service 3) Wrong hydraulic oil -Use correct hydraulic fluid 4) The engine speed is too slow -Consult after-sales service...
  • Page 91 4) Oil level is too low – Add oil  Oil pressure too low or no pressure 1) The hydraulic pump is damaged -Check with after-sales service 2) Insufficient oil in the system -Add oil 3) Faulty safety valve -Consult after-sales service ...
  • Page 92 8) The pilot valve is broken or leaking oil -Repair or replace  Two travel motors do not work Oil stringing in the central rotary joint - Consult after-sales service  One travel motor does not work 1) Walking device is damaged -Consult after-sales service 2) The control mechanism is damaged -Repair ...
  • Page 93  Air condition system noise 1) Clutch noise caused by loose electrical connector -Tighten the connector or repair it 2) Loose belt -Tighten moderately, replace if broken 3) Blower fan blade is loose -Reinstall tightly 4) Blower operation is not normal -Repair or replace 5) Electronic fan is not running properly -Repair or replace 6) Compressor bearing damaged -Replace 7) Tension wheel bearing is damaged -Replacement...

  • Page 94: Maintenance

    5. Maintenance 5.1. General knowledge of maintenance 5.1.1. New machine break-in The first 100 hours of the machine is the break-in period. During this period, the machine should be used carefully and should not used with excessive load and high intensity work.

  • Page 95: Timer Readings

    5.1.5. Use genuine parts Using Yuchai Heavy Industry pure parts is an important factor to ensure the normal working of the machine and prolong the service life of the machine. 5.1.6. Waste disposal Promote environmental protection, pay special attention to waste disposal by.

  • Page 96: Periodic Inspection And Maintenance

    5.1.8. Periodic inspection and maintenance Regular inspect and do maintenance according to the items listed in the "Periodic Inspection and Maintenance Schedule" to ensure the normal operation of the machine and extend its service life. Be sure to follow the inspection and maintenance cycle. 5.1.9.

  • Page 97: Maintenance Summary

    5.2. Maintenance Summary 5.2.1. Lubricant  Use oil of the grade and temperature specified in the "Oil Selection Table" in this manual. Change the oil within the specified time, even if it is not dirty.  Take care to prevent contaminants (water, metal particles, dust, etc.) from entering the lubricant.

  • Page 98: Coolant

     Do not recycle cleaned cartridges (cartridge type) again. Replace it with a new one.  When replacing the cartridge, check for metallic particles on the old cartridge. If any metal particles are found, contact your Yuchai dealer.  Do not open the packaging of the spare cartridge before use.

  • Page 99: Electrical System

     Do not install any electronic components other than those specified to be installed by Yuchai Heavy Industries.  When working at the beach, clean the electrical system carefully to prevent corrosion.

  • Page 100: Mandatory Replacement Parts

    Genuine parts can be ordered from Yuchai Heavy Industries dealer according to the part numbers in the table or the part numbers in the parts catalog. Item Part number Part name Quantity Model...

  • Page 101: Oil Selection Table

    5.5. Oil selection table Select oil according to the ambient temperature, operating conditions, and other factors. It is necessary to use oil that meets the following specifications. lubrication Recommended Temperature Viscosity fuel substitute oil Engine lubrication oil CH4 15W/40 -15°C~+40°C -25°C 〜+30°C CH4 5W-30 Cold Region：HS46+...

  • Page 102: Tightening Torque

     Oil capacity data Classification Unit of measure Capacity Fuel tank Engine oil Hydraulic tank 5.6. Tightening Torque The tightening torque of each mounting bolt and nut on the machine should be referred to the values in the table below. If the bolts or nuts are not tightened to the specified torque, the fastened or connected parts will be loosened or even damaged, causing machine failure or affecting operation.

  • Page 103: Tightening Torque For Hydraulic Hoses

    940- 1400- 1700- 2473- 2800- 4111- 10.9 740-880 1120 1650 2000 3298 3350 5481 864- 1098- 1606- 2181- 2968- 3812- 4933- 12.9 1080 1152 1461 2142 2908 3958 5082 6577 5.6.2. Tightening torque for hydraulic Hoses Metric Thread Nuts Thread Tube outer diagauge Torque min./max...
  • Page 104 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 Thread Nut UNF Thread Spec 9/16〜18 11/16-16 13/16〜16 1〜14 1.3/16〜12 1.3/16〜12 1.7/16〜12 1.11/16-12 2〜12...

  • Page 105: Periodic Inspection And Maintenance Table

    5.7. Periodic Inspection and Maintenance Table The machine should be regularly inspected and maintained in accordance with the following table, in conjunction with the operating hours of the machine as indicated by the engine timer. If the machine is in rough working condition, or if it is equipped with attachments such as hydraulic breakers, the inspection and maintenance intervals for certain parts need to be shortened.
  • Page 106 ☆ Cylinder head tightness ▲ ☆ Engine support tightness ▲ Maintenance intervals Check 1000 2000 Engine air intake system Empty the dust accumulation tank ▲ Clean the air filter element ▲ Replace the air filter element ▲ Hydraulic System Check the hydraulic oil level (if necessary, refill) ▲...

  • Page 107: General Checking

    ▲means checking on normal cycle; ☆ means performing first maintenance; ■means to check every year in spring and autumn 5.8. General checking Make general routine inspection of the machine every day or every 10 hours. 1) Leak check to see if there is any oil, water and fuel leakage from all parts of the machine. 2) Check whether there are scratches, fractures or deformations in the elastic connections and Attachments.

  • Page 108: Drain Water And Contaminants From The Tank

    5.9.1. Oil level check and refueling The oil level can be checked with the oil level indicator on the right control box panel or by looking at the oil marker tube. Check daily or every 10 hours. To avoid condensation, the fuel tank should be filled after each day's work.

  • Page 109: Check The Injection Pressure

    5.9.4. Check the injection pressure Check once every 500 hours. The injection pressure should be checked periodically according to the intervals shown in the maintenance table and adjusted if necessary. This check should be carried out by our after-sales team! The efficiency of the engine basically depends on the working condition of the injector nozzle, so it must be maintained regularly to ensure its proper working.

  • Page 110: Replace The Fuel Filter

    and protective clothing should be worn before operation. 5.9.6. Changing the fuel filter Replace the fuel filter element for the first time after 50 hours of operation and every 250 hours or 3 months thereafter. A) Replace the fuel filter 1) Remove the fuel filter.

  • Page 111: Engine Cooling System

    5.10. Engine Cooling System Maintenance Instructions Coolant Level Check------------------------------Every day or every 10 hours of work Check the condition of the rubber hoses and clamps ---Every day or every 10 hours of work Coolant replacement----------------------------------------------Every 500 hours Cleaning the radiator blades---------------------------------Every spring and autumn Coolant concentration check ----------------------------- Every day or every 10 hours of work 5.10.1.

  • Page 112: Clean And Inspect The Radiator Blades

    5.10.2. Check the condition of the rubber hoses and clamps Check every 10 hours or once a day. Check the rubber hose, if it is cracked or hardened due to aging, replace it. Check the hose clamps for tightness and replace them if they are loose or damaged. 5.10.3.

  • Page 113: Check The Coolant Concentration

    minutes, and then stop to release the cleaning fluid. 3）Shut off the drain valve again; 4）Fill the coolant, let the engine idle for a few minutes, so that the coolant go through the entire cooling circuit. 5）Check the coolant level and refill the coolant. WARNING: Do not open the radiator (tank) cap of a hot engine.

  • Page 114: Engine Lubrication System

    5.11. Engine Lubrication System Maintenance instructions Oil quantity-------------3.4 liters Oil level check-----------------Every 10 hours of operation or daily Oil change or oil filter element change------------Every 250 hours of operation 5.11.1. Oil level check Check the oil level before starting the new machine and every 10 hours thereafter.

  • Page 115: Replace The Engine Oil Filter Element

    WARNING: Avoid inhaling oil vapor, swallowing or prolonged contact with used oil. 3）Clean the oil drain plug and reinstall it, if the seal is damaged, replace it. 4）Open the oiling hole. 5）Refill with new oil until the oil quantity reaches the "maximum" mark H of the oil scale.

  • Page 116: Engine Air Intake System

    5.12. Engine air intake system Maintenance Instructions Dust collection tank cleaning cycle ---------------- every 10 hours or daily Air filter cartridge cleaning cycle -------------------- every 100 hours Air filter cartridge replacement cycle -------------- every 500 hours 5.12.1. Cleaning of dust collection bin 1）...

  • Page 117: Replace The Air Filter Element

    3） After drying the cartridge (not to exceed 50°C), reassemble the cartridge. 4） Never clean the cartridge by tapping it on a hard surface. ATTENTION: Before installing the cleaned cartridge or replacing the cartridge with a new one, the cartridge should be checked for damage. Method: Place a light source inside the cartridge to see if there are any holes in the cartridge.

  • Page 118: Other Engine Maintenance

    5.13. Other engine maintenance WARNING: To prevent injury, do not perform maintenance while the engine is running. If maintenance must be performed with the engine running, operate with at least two people and do the following. One person must be in the operator's seat at all times and be ready to shut down the engine.

  • Page 119: Hydraulic System

    5.14. Hydraulic system Maintenance Instructions Hydraulic oil tank capacity ------------- 20 liters Oil level check every -------------------- every10 hours Oil filter change Every ------------------ every 2,000 hours Hydraulic oil change Every ----------- every 2,000 hours Check system pressure Every --------- every 400 hours WARNING: Hydraulic oil or grease, if shot into the skin, can cause serious injury and death.

  • Page 120: Drain The Water And Dirt In The Hydraulic Oil Tank

    The hydraulic oil level is observed through the oil level gauge. It is required that the hydraulic oil gaugue can be clearly seen in the oil level gauge, do not over fill the tank until you cant see the level in the gauge.

  • Page 121: Replace The Hydraulic Oil And Clean The Oil Suction Filter

    5.14.3. Replace the hydraulic oil and clean the oil suction filter Replace the hydraulic oil as shown in Figure 5-31. WARNING: 1) To avoid burns, drain the oil only after the hydraulic oil has cooled down or when the oil is cold before daily work. 2) When removing the flange cover of the oiling port, you need to turn the cover slowly to release the internal pressure, in order to prevent oil from spraying out.

  • Page 122: Vent Air From The Hydraulic System

    ATTENTION: After this last operation is completed, the oil level position in the hydraulic oil tank should be slightly raised.  Replace the hydraulic oil return filter element First replacement after 2000 hours of work, and every 2000 hours thereafter. 1) Fully extended the piston rod of each hydraulic cylinder, and then stop the engine.
  • Page 123 C) Vent air from the cylinder 1) At low engine speed, extend and retract the cylinder to the position that is about 100mm from the end for 4~5 times. (Be sure not to extend or retract to the end of the line) 2) Then, operate each cylinder to the end of its stroke 3~4 times.

  • Page 124: Replace The Return Oil Filter Element

    tighten the screw. 2） Run the engine at idle speed and rotate the work device 90 degrees so that it is on the side of the tracks. (as shown on the right) 3） Raise the machine with the work device so that the track on one side is slightly off the ground and rotate the track for 2 minutes under no load.

  • Page 125: Replace The Pilot Oil Filter Element

    engine. 2） Remove the oil tank bolt 1. 3） Unscrew the filter element 6 and replace the filter element with a new oil return filter (the seal gasket should greased before installation). 4） Operate the digging mechanism. 5） Check the hydraulic oil level and refill it if necessary.
  • Page 126 6） Tighten the oil filter housing and filter head with a torque of 25~35N.m. 7） Connect the pipeline and start the engine at slow speed. Run continuously for 3~5 minutes to vent air from the system. 8） Park the machine on a level surface, stop and check the oil level, and refill if necessary.

  • Page 127: Battery

    5.15. Battery WARNING: 1 The battery contains sulfuric acid liquid, which is highly corrosive, please keep it away from children, users should wear protective glasses and rubber gloves when handling the battery. 2 The battery will emit hydrogen and oxygen when charging, the battery should be far away from open fire and avoid short circuit.

  • Page 128: Installation Of The Battery

    Charge the battery with a current (A) of one-tenth of the rated capacity for 2~4 hours. 2) Constant voltage charging method Charge the battery with 16V at constant voltage for 16 hours (maximum current not exceeding 25A) B）Normal battery charging 1) Charge the battery with a current of one twentieth of the rated capacity at the rate of 20 hours (A) until the terminal voltage of the battery reaches 14.4V, and continue charging for 2~3 hours.

  • Page 129: Battery Maintenance

    (generally more than 15 days), and recharge the battery once every 3~6 months (depending on whether the indicator is black or not). 5） For the questionable battery, please contact with Yuchai Heavy Industry agent in time to solve.

  • Page 130: Speed Reducer

    5.16. Speed Reducer Maintenance instructions Rotary reducer lubricating oil capacity ----------------------- 0.5 liters Travel reducer lubricating oil capacity ---------------------------1 liter (each side) Check lubricant oil level and refueling -----------------------Every 250 hours of operation Change lubricating oil ------------------------------------- 1000 hours per operation Check reducer connecting bolt tightening torque -------------------- 500 hours per operation WARNING: The oil in the reducer will become hot soon after the...

  • Page 131: Check The Tightening Torque Of The Bolts Connecting The Travel Reducer And The Slewing Reducer

    5) If necessary, add oil (follow the procedure below to replace the oil) 6) Clean the screw plug ① and reassemble it. 2. 5.16.2. Replace the lubricant (for each gearbox) Change the oil for the first time after 1000 hours of operation, and every 1000 hours after that.

  • Page 132: Tracks

    5.16.4. Check the solidity of the connecting bolts of the slewing reducer The first inspection will be carried out at 50 hours after commisioning and every 500 hours thereafter. Tighten the bolts connecting the reducer to the platform. 5.16.5. Tracks Check and adjust the tension status of the tracks Check every 10 hours.

  • Page 133: Idler Wheel And Guide Wheel

    5) Remove the cover ① (a in Fig. 2) from each track frame to expose the oiling nozzle of the tensioning device (② in Fig. 2). 6) To loosen the tracks, loosen the joint ② (Fig. 2) to allow the grease to flow out until the correct tension is obtained and then retighten it.
  • Page 134 1) Start the work device and lower the bucket to the ground. 2) Place the dozer on the ground. 3) Stop the engine. 4) Wipe the oil cup nozzle clean. 5) Lubricate each lubrication point and wipe off the excess grease. ○...
  • Page 135 12 Defelecting head uppper pin lubrication point ○ ○ 13 Defelecting head lower pin lubrication point ○ 14 lubrication point of deflection cylinder ○ 15 Lubrication point of rotary motor raceway ○ 16 lubricating point of swing support gear ring ○...

  • Page 136: Replacement Of Bucket Teeth

    5.19. Replacement of bucket teeth Replace the bucket teeth before the bucket teeth socket wears out. WARNING: Accidental movement of the work device during tooth replacement is extremely dangerous due to mishandling. Therefore, before replacing the bucket teeth, turn off the engine and lift the left control box so that the work device is in the locked position.

  • Page 137: Flushing Of The Floor Mat

    5.20. Flushing of the floor mat Clean the floor mats whenever they are dirty to prevent accidents due to slippery floors and falls. WARNING: If the joystick or lever is accidentally touched, the work device or machine may move suddenly, resulting in a serious accident. Therefore, always stop the machine on a firm and level surface before removing the floor mat .

  • Page 138: Attachment Guide

    When installing attachments not approved by Yuchai Heavy Industries, you should contact Yuchai Heavy Industries dealer first. If you do not contact Yuchai Heavy Industries, we will not be responsible for any accident or damage. 6.1.1. Safe operation of attachments 1) Attachments have powerful functions.

  • Page 139: Removing Or Installing Attachments

    WARNING: Certification is required to operate the crane. Unlicensed personnel are not allowed to operate the crane. Please contact your Yuchai Heavy Industries dealer for details on disassembly and installation operations.

  • Page 140: Attachment Installation/Removal Procedure

    6.2.1. Attachment Installation/Removal Procedure A) Removal Procedure 1) Place the attachment on the ground and turn off the engine. 2) Turn the start switch to the ON position and push the left joystick box to the working position. 3) Operate each work device lever and attachment control pedal two to three times with full range to remove internal pressure in hydraulic lines.

  • Page 141: Attachment Operation Guide

    ATTENTION: Select the attachment that is most suitable for the main unit. The machine models that can be fitted with attachments are different. Please contact your Yuchai Heavy Industries dealer for the selection of attachments and machine models. 6.3.1. Hydraulic Hammer A.
  • Page 142 keep the direction of penetration of the rod in a straight line with the body of the hammer. 2) When applying impact, press the brazing rod onto the impact surface so that the base plate is about 5cm above the ground, do not let the machine leave the ground too much.
  • Page 143 1） Use a crushing hammer to push heavy objects or large rocks. 2） Operate with slewing force. 3） Move brazing while performing impact operations 4） Apply impact force horizontally or to the top 5） Swinging the crushing hammer when it has penetrated into the rock...
  • Page 144 6） Pecking operation 7） Crushing operation in water or muddy ground 8） Using the crushing hammer as a tool for lifting heavy objects. 9） The bucket cylinder is fully extended to lift the machine off the ground.

  • Page 145: Daily Inspection Of Hydraulic Hammer

    6.4. Daily inspection of hydraulic hammer The following table carries out the daily inspection and maintenance of hydraulic breaker hammer. Inspection or maintenance Key parts Maintenance method items Check bolts and nuts for Main body bolts and side Tighten bolts or reinstall looseness and loss plate bolts new bolts...

  • Page 146: Quick Coupler

    6.5. Quick coupler Installation 1） Pry up the pry bar○ 1 . 2） Put the bucket pin into○ 2. ○ 3 , put down the pry bar, and the bucket is installed. Disamount 1） Use the pry bar to pry up ○ 1 . 2）...

  • Page 147: Grab Bucket

    6.6. Grab Bucket The grab bucket is used to dig or load on the side of a ditch or restricted space. It is suitable for basic works such as cleaning the sewer and unblocking the access opening of water and sewer. 6.6.1.

  • Page 148: Operation Precasutions Of The Grapple

    the boom and the closing of the grab to carry out excavation work. 6.6.3. Operation precasutions of the grapple 1） For safety reasons, avoid sudden travelling, turning and stopping of the machine. 2） When digging, make the bucket teeth vertical to the ground. 3）...

  • Page 149: Maintenance Of The Grapple

    5） Open the grapple and put it on the ground before leave the machine ATTENTION: When transporting the machine, remove the grapple from the arm. 6.6.4. Maintenance of the grapple  Lubrication 1) Park the machine on a hard horizontal surface, lower the working device to the ground, and turn off the engine.

  • Page 150: Drilling Device

    6.7. Drilling device 6.7.1. Installation of drilling device 1) Remove the bucket or other attachments. 2) Put the attachment on a flat place and connect the arm to the drilling unit and the connecting rod to the drilling unit with pin A and pin B in turn. 3) After confirming that the oil has cooled, remove the screws from the outlet and inlet respectively.

  • Page 151: Precautions For The Operation Of Drilling Device

    2) Press the auxiliary control pedal and start working (rotating) when the drilling tool reaches a certain depth. 3) If there is mud on the drilling tool, the mud will come off by reversing the drilling bit. 6.7.3. Precautions for the operation of drilling device 1) When drilling, make sure that the drill head is oriented perpendicular to the work surface and maintain the able as much as possible at all times.

  • Page 152: Installation

    6.8. Backhoe bucket with scraper 6.8.1. Installation Same with bucket 6.8.2. Operation of the backhoe bucket Turn the right joystick to the right the backhoe bucket scraper will be closed inward and the backhoe bucket will be turned outward. When the joystick is turned to the left, the backhoe bucket scraper will be pushed outward and the backhoe bucket will be closed inward.

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