Yuchai YC60-9 Operator's Manual
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Yuchai YC60-9 Operator's Manual

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  • Page 2: Table Of Contents

    INDEX Ⅰ. PROLEGOMENON To user--------------------------------------------------------------------------------1-1 Product Information ---------------------------------------------------------------1-3 Machine description --------------------------------------------------------------1-4 Excavator main parts -------------------------------------------------------------1-5 Data sheet ---------------------------------------------------------------------------1-9 Ⅱ. SAFETY REGULATIONS Safety general information ------------------------------------------------------2-1 Safety tips ---------------------------------------------------------------------------2-2 Protection devices ----------------------------------------------------------------2-3 Safety labels -----------------------------------------------------------------------2-11 Work area safety------------------------------------------------------------------2-12 Safety Operation -----------------------------------------------------------------2-23 Transport, load and unload ----------------------------------------------------2-24 Repair--------------------------------------------------------------------------------2-2 Prevent fire, blast and poisoning ---------------------------------------------2-26...
  • Page 3 Traveling operation---------------------------------------------------------------3-14 Manual throttle and Electric throttle -----------------------------------------3-15 Operator’s seat--------------------------------------------------------------------3-16 Seat belt ----------------------------------------------------------------------------3-17 Air-condition----------- ------------------------------------------------------------3-21 Radio --------------------------------------------------------------------------------3-24 Door and Window ----------------------------------------------------------------3-25 Ⅳ. Operating guide Preparation before working -----------------------------------------------------4-1 Engine operation-------------------------------------------------------------------4-5 Enter & exit machine--------------------------------------------------------------4-6 Machine moving--------------------------------------------------------------------4-8 Machine steering -----------------------------------------------------------------4-9 Machine slewing------------------------------------------------------------------4-10 Operation of working device --------------------------------------------------4-12 Operating on the slope or in the water--------------------------------------4-13 How to escape from Mud-------------------------------------------------------4-14...
  • Page 4 Easy wear parts---------------------------------------------------------------------5-5 Periodical replacement of safety critical parts -----------------------------5-6 Oil choosing list --------------------------------------------------------------------5-8 Standard torque list---------------------------------------------------------------5-11 Periodic Maintenance schedule-----------------------------------------------5-14 General check --------------------------------------------------------------------5-15 Engine Fuel System -------------------------------------------------------------5-19 Engine Coolant System --------------------------------------------------------5-22 Lubricating System of engine--------------------------------------------------5-24 Air Intake System of engine----------------------------------------------------5-25 Other Maintenances of Engine -----------------------------------------------5-26 Hydraulic System ----------------------------------------------------------------5-31 Battery ------------------------------------------------------------------------------5-33...
  • Page 5 ● Keep any other person or object out of the work area. ● It should have a safety operation training before you operate the machine You have the duty to observance the ordinance and the law, follow the directions of YUCHAI operation and maintenance regulations.

  • Page 6: To User

    TO USER Dear users, You are welcome to use YUCHAI excavator, thank you for your support to our business. This manual is for the operator and the service man of YUCHAI excavator. Hope you can read this manual carefully before operating and maintaining, and work strictly as the regulations of safety measures, operating guides, lubrication and periodic maintenance.

  • Page 7: Product Information

    Product information If you want to know the basic information of the machine, please check the following picture: ● Machine Identification plate(The nameplate is on the left-front side of the platform) ● Engine Information(The nameplate is in the middle of the engine...
  • Page 8 ● Machine running Information (working times is showing on instrument which is inside the cab) Machine record Please fill the machine series No. and engine series No. in the following table. If you need to buy the spare parts or related information, please advice YUCHAI these series numbers.

  • Page 9: Machine Description

    Machine Description Front、rear、left、right、top、underside in this manual are same as the direction as follow:...

  • Page 10: Excavator Main Parts

    Excavator main parts 1. Boom 2. Boom cylinder 3. Arm cylinder 4. Arm 5. Bucket cylinder 6. Bucket 7. Dozer blade 8. Dozer cylinder 9. Font Idler 10. Track 11. Travel motor 12. Platform 13. Covering panels 14. Cabin 15. Swing cylinder...

  • Page 11: Data Sheet

    Data sheet 1. Dimension parameter YC60-9 Code Item Unit E60F51 Operating Weight 5700 Standard bucket capacity 0.21 Name of engine KUBOTA V2403-M-DI-E3B Power of engine Kw/rpm 30.7/2200 Machine length 5656 Machine height 2585 Overall width 1920 Crawler width Platform slewing radius...
  • Page 12 2. Operating parameters YC60-9 Code Item Unit E60F51 Max. digging height 5740 Max. Dumping height 4040 Max. digging depth 3720 Max. digging radius 6065 Max. horizontal digging length 5945 Max. digging height radius 2750 Min. slewing radius 2175 Max. depth of Bulldozer 330.2...
  • Page 13 Note: Technical data are subject to replace without prior notice! 3. Buckets Bucket Bucket Capacity(m Bucket teeth . Width(mm) Weight(kg) 0.21...
  • Page 14 4. Traveling system Traveling system combined Hydraulic traveling motor multiple-planetary reducer, reducer is inside the crawler. Walking speed(km/h) Max. pull force Gradeability (kN) High speed 27.5 70%(35 Low speed 5. Hydraulic system Advance throttle hydraulic system Pressure (mpa): 24mpa Oil return filter: 10 um Oil suction filter : Metal Electric system Voltage: 12V...

  • Page 15: Safety General Information

    Safety general information Almost accidents about machines operation and maintenance will be avoided as per the related safety rules of this manual. It is required to read this book and all the safety information before operation and maintenance. The contents of safety operation in this book show the possible situation during normal operation and maintenance, as well as the possible disposal method.

  • Page 16: Safety Tips

    Safety Tips 1. Warning Symbols This warning symbol indicates important security information in this book. When you see this symbol, please read the relevant information and advice carefully to avoid possible casualties. 3. Safety Tips This book provides tips, symbols and description of potential dangerous situation of machine operation.

  • Page 17: Protection Devices

    Protection devices 1. Protective device for Operators 1) Operator must wear snug fitting work suit, safety helmet, footwear and the other relevant safety equipment (protective earplug, gloves, goggle, and safety belt etc.) 2) Please tie up your hair and cover it with helmet if your hair is too long.

  • Page 18: Safety Labels

    Cotton, water and detergent are recommended. If safety labels need to be replaced due to broken, missing or stained, please contact Yuchai for new safety labels. 1. Safety labels classification The “graphics-text safety labels” and “graphics-symbol safety labels” are adopted in this book, as well as on the machine.
  • Page 19 2. Safety labels sticking position The following labels are just part of the all safety labels, the rest of them will be introduced in the following chapters.
  • Page 20 3. Safety labels graphic symbol and illustration 1). Be careful and stay away from working device Moving working device might cause physical injury. Please keep safety distance from moving zone of working device. 2). Please stay safe when going up and down from machine When you go up and down from machine, please move slowly, grab handrail, and face the machine,...
  • Page 21 6). Safety information of operation and maintenance 7). Please pay attention to the danger of high pressure oil spraying when adjusting crawler tension 8). center of Rotation 9). Cable and crane combination 10). Please stay away from working machine Rotating excavator might cause physical hazard to the people in rotating zone, please keep away from the rotating zone.
  • Page 22 12). Please shut down 13). Fuel injection mark engine before internal checking and adjusting. 14). Fireproof mark 15). Hydraulic oil injection mark 16). Don’t open lid of hydraulic oil or coolant container at high temperature The hydraulic oil and coolant at high temperature have...
  • Page 23 17). Manual throttle label 18). Sign of attention and direction of escape 19). Lifting mark 20). Beware of toxic gases Toxic gas or toxic smoke may Cause suffocation 21). High-pressure fluid (injection, leaking/squirting) danger Don’t try to block or cover high-pressure fluid leaking point by any part of your body, or being squirted by high-pressure fluid.
  • Page 24 22). Pay attention to the overhead 23). Fire extinction electric wire 24). No Smoking 25). Waning. Risk of explosion 26). Emergency hammer Read and remember in case of emergency situation 2-10...
  • Page 25 27). The high-pressure parts, such as Accumulator, gas spring etc., are prohibited to dismantle, drilling and cutting; and kept away from fire or high tempreture. These parts contain high-pressure gas may cause physical injury. 28) .Please make reference to operation manual or related instruction. Electronic system is prone to electric shock, please follow maintenance instruction.
  • Page 26 Working area safety Learn the area you are going to work in advance. Please check following items: Position of slope Ditch Falling or suspension object Soil type (soft or hard) Puddle and swamp Rock and stub Buried foundation, root piles or boundary of wall Buried rubbish or the boundary of the fill Hole, obstacle, mud or ice.

  • Page 27: Safety Operation

    Safety Operation Warning: Do not transport or lift people by excavator. Do not hoist heavy object like crane. Warning: before working, please fasten safety belt, honk, and make sure there is nobody in the working zone.. Starting machine Safety rules for engine starting 1) Please honk before starting engine 2) Don’t...
  • Page 28 2. Traveling & Slewing 1) Please rotate excavator platform to proper position. If working device consists with the stick of forward direction, push traveling rod and move; if working device is contrary to the stick of forward direction, operation contrary. 2) Beep before traveling or rotation, and warn the people in the working zone.
  • Page 29 4) When driving and operating excavator, please keep distance from personnel, building and the other machines. 5) When driving through underground tunnel, under bridge or under electric wires, gestures directing from outside must be ensured. And be careful to keep a safe distance from it.
  • Page 30 5) Do not change directions or cross slopes sideways. 6) When excavator works on slope, it must be started from the height and gradually dig to downhill. The unloading position is in the direction of uphill. 7) Please driving excavator on low speed when traveling on meadow, dead leaves or wet steel plate.
  • Page 31 10）It is forbidden to travel or work on slope with a longitudinal gradient greater than 25 degrees 11）It is forbidden to walk or work on slopes with a lateral gradient greater than 15 degrees 12）Please keep the excavator balance, and it is forbidden to travel on rock or obstacles.
  • Page 32 16 ） When working on a slope, the machine might lose its balance and tip over during operating the swing or working device. This can cause serious injury or damage to the equipment. Therefore, it is necessary to use a pile of earth to build a solid platform that will keep the machine when during these operations.
  • Page 33 7) Please move the machine to the place which is a right-angle of berme or cliff and keep the driving wheel at rear direction, this can help you to escape from dangerous situation. 8) Please don’t operate the hydraulic cylinders to the end-point of the piston during operation, this will reduce the using life of the machine, keep a small distance of the piston for each operation.
  • Page 34 16) Do not use the deadweight of the machine to increase the digging power. 17) Do not use the falling power of the bucket as the handle、the knapper or the pile driver. It will make the back of the machine bear over-weight. 18) Do not use the bucket to dig the road surface more.
  • Page 35 20) Do not use the power of rotating to press the soil or destroy the rideau and the wall. When the machine rotates, do not insert the teeth of the bucket into the soil. 21) Do not make the bucket into the soil to use the driving power to dig.
  • Page 36 27) Don’t make demolition operations under the machine. 28) Please check the strength before operated on the top of building or other structure. 29) Don’t break by the impacting force of the working device. 30) It is prohibited to use the dozer blade to increase the stability of the machine during operation.
  • Page 37 which the portrait gradients more than 250, the thing towards the downgrade. 5) The machine operates on the slope which the landscape orientation gradient is more than 15°, the thing is towards the downgrade. 6) On the slope, it is 90° between the two crawlers and the gradient, the rotating platform is more than 90°.

  • Page 38: Transport, Load And Unload

    Transport, Load and Unload Transporting (unloading) excavator must obey the safety rules strictly: ● When the excavator transported, it must obey the safety transport rules of the country (local) trade or the good habit. ● When the excavator transported, the cab can’t hitch anybody or anything.

  • Page 39: Repair

    Repair Warning: Please handing “No operation” sign on the operation handle during repair. ● Machines should stop on the smooth and hard road. ● After the excavator stops, it must put down the bucket, and run the engine 3 minutes with low speed, then stop it and pull out the key. ●...

  • Page 40: Prevent Fire, Blast And Poisoning

    Prevent fire, blast and poisoning ● When the excavator transported 、 driving、digging, it shouldn’t touch the wire. Otherwise, it causes the casualty. ● The wiring and the line needs to check frequently. If it finds the broken、aging part, it must be replaced to avoid the fire.

  • Page 41: Battery

    Battery Safety rules of the Battery The electrolyte of the Battery includes the vitriol and the hydrogen which is flammability and explosive. The wrong operation leads hurt or fire. Do as follow: ● Check the level of the electrolyte timely. Supply the distilled water to make the level of the electrolyte between the “top level”...
  • Page 42 the Battery should fix fast. ● When the Battery electricized, it produces flammability hydrogen. So before electricized, it should unload the Battery from the machine, and put it to the draughty place and remove the cover. ● Screw down the cover of the Battery. Caution: When maintaining the electric system or weld, it should remove the cathode port to avoid the current flowing.

  • Page 43: Hydraulic System

    Hydraulic System 1. Safety rules of high-pressure oil The inside of the hydraulic system always have the pressure. When check or replace the pipeline or the soft pipe, do check whether the pressure has release or not. If there is pressure, it will make a serious hurt or destroy.
  • Page 44 4. Release the pressure of the hydraulic system excavator just stops working, the hydraulic oil of the hydraulic pipeline is in the state of high-temperature and high-pressure. When take down the nozzle, the oil may squirt. So do turn the cover of the nozzle before take down it to release the pressure.

  • Page 45: Description Of Operation Device

    Description of operation device 1. Operator Seat 7. Dozer control lever 2. Left joy stick 8. Cigar lighter 3. Right joy stick 9. Safety locking valve 4. Accessories control pedal 10. Manual throttle 5. Left travel control lever 11. Switches panel 6.

  • Page 46: Instrument

    Instrument 1. Brand name 2. Hour meter 3. Main indicating Area 4. Alarm indicating area 5. Softkey 6. Push buttons 7. Fountain button...
  • Page 47 A. Instrument Display...
  • Page 49 Function selecting buttons and Alarm indicating lamps You can select functions as the indicating on Machine state area. Alarming lamp will indicate in red if machine have alarm B. Instrument indications during operation Instrument indicating as above after turn on, Voltage alarming lamp and Engine oil pressure alarming lamp will disappear after started the engine.
  • Page 50 Press “VIEM” button can see running data Click “SET”, Click “DOWN” or “UP” to choose the menu which you want, click “ENTER” to change. 1. Working hour / Stage time 2. Hydraulic oil auto-preheating function turn on or off, the Hydraulic oil auto-preheating sign will not show on the instrument when it is off.
  • Page 51 1. “User set” is for password reset and clean stage time. 2. “System set” is for factory setting. Alarming parameters are set by factory Click “HELP” to see Model name and Model, and click “DOWN” to check the version no. of hardware and software of Controller...

  • Page 52: Right Control Box Switch Panel

    Right control box switch panel 1. Horn The horn will sound while you push it. Cigar lighter Directly connect the Cigar lighter, or use the cable of cigar lighter to supply the power for the other electrical equipment. Notice: current capacity less 10A Starting switch OFF Position: Insert or pull out the key, the machine is no power in this position, the...
  • Page 53 ON Position: Keep the key in ON position when the engine is running Start Position: Turn the key to Start position to start the engine, and keep the key in this position while starting, and release the key immediately after started, it will back to “ON”...

  • Page 54: Left Control Box Switch Panel

    Left control box switch panel AC control panel (see AC control section) 3-10...

  • Page 55: Safety Lock Lever

    Safety Lock Lever 1. Safety lock lever Warning: The Safety lock lever is an important part of the machine security system. Put the safety lever lock in lock position before you leave. If the system haven’t been locked, the joy stick could be moved and make the movement of working device or platform, and causing accidences.

  • Page 56: Operation Of Working Device And Slewing Part

    Operation of working device and slewing part 1. Digging and Platform swing Control (Without Boom Swing) Control by right/left joy stick, as show in right figure A. Left Joy stick Digging arm movement: Push forward to extend the arm; Push backward to draw back the arm.
  • Page 57 ●Platform slewing and boom swing Selector and control Press the button on left joy stick to switch the function of boom swing and platform slewing. It is platform slewing function in normal condition, press the button switch to boom swing function.
  • Page 58 Travelling Operation 1. Directional Control The left and right lever control the left/right rubber crawler Push one side lever to make one-sided steering of the machine 2. Speed Control Press this switch to change between low speed and high speed 3-14...
  • Page 59 Manual Throttle and Electric throttle 1. Manual throttle Push lever backward accelerate, push the lever forward to extreme position before the engine stop. 2. Electric throttle Turn the throttle knob to right to accelerate, push the knob to left to extreme position before the engine stop.
  • Page 60 Operator Seat The accidental tipping or abrupt movement of a Warning: machine may cause injury or death, remember to fasten seat belts and adjust seats before the machine starts for safety. ●Seat-Forward/Backward Adjust: Control the Seat adjusting handle, the rang of movement is 0~±75mm, five shift. The seat in lock position when release the handle.
  • Page 61 Seat Belt he accidental Warning: Seat belt is the main part of safety system, t tipping or abrupt movement of a machine may cause injury or death, remember to fasten seat belts and adjust seats before operating. Check the seat belt before using, replace if it is wear or Warning: damage.
  • Page 62 Air-Conditioning Control The Air-Conditioning Control panel is on Left Control Box 1. Button function and operation Power switch When power on, A/C system is standby, screen light up, Air-blower running about 3 seconds (can not make any other operations during this time), then the system will restore to the state of last shutdown.
  • Page 63 memorize current status (Heating value and Wind speed). Heating button System into heating mode when press heating button under ventilation mode, memorize current status (Wind speed), this fig. disappear, system is in last ventilation mode status. System into defrosting mode when press this button under cooling mode, memorize current status (cooling value, wind speed), this fig disappear, system is in last ventilation mode status.
  • Page 64 Press this button under cooling mode, the cooling capacity will be reduced and the vertical bar is reducing accordingly. Press this button under defrosting mode, the heating capacity will be reduced and the vertical bar is reducing accordingly, each time this button is pressed, one vertical bar will be reduced.
  • Page 65 by downward arrow to lower setting temperature. Dehumidification/demisting operation There will be mist on the cabin glass when the humidity (the humidity from climate or human being normally) is high. To get rid of the mist, operator should follow the instruction: A .
  • Page 66 Radio Radio Operation 1. PWR/MODE: When the radio is OFF, press this button or insert SD/MMC card, USB flash dish, the radio will be turn on. After the radio is turn on Press this button more than 4 seconds, the radio will be turn off. Press this button shortly, you can switch between radio, MP3(USB/SD card) function.
  • Page 67 4.TU-/-- manual frequency setting, searching automatic, MP3 song selection, play or pause Radio status: Shortly press this button, manual frequency setting downward; long press this button, automatic searching frequency downward. MP3 status: Shortly press this button, play previous song; long press this button, play or pause MP3 song.
  • Page 68 Long press this button to select sys menu, then shortly press key-SEL to switch menu, and use key-8 VOL- and key-9VOL+ to adjust value. 11. Remote control window 12. Information screen 13. USB port—insert USB flash memory, search song on flash memory and play. 14.
  • Page 69 Door and Windows 1. Cabin door The cab door is the only way to entry or exit. Lock the door after the driver left the cab. When the door opened, fix the door with the lock on the right of the door to avoid hurting peoples.
  • Page 70 Preparation before working 1) The excavator operator should qualify for local construction machinery operation requirement, and being trained before using the machine. 2) Operator should read operation manual before starting work. 3) Operator should wear suitable working suit and proper safety protection device, for example, safety helmet, working boots, glove, safety belt etc.
  • Page 71 Engine operation Warning: please read carefully all safety instruction in this manual and safety labels on the machine before starting the engine. There should be no other unrelated person in the working field. Studying and learning of safety operation is necessary before starting working. Understand and follow the instruction of operation and maintenance, abide by the corresponding law.
  • Page 72 2. Starting engine Warning: Do not start the engine when a warning plate of forbidden starting is hung on the joystick. Make sure safety lock level is on “locked” status before Warning: starting engine, in case unforeseen event caused by accidently touch to the joystick.
  • Page 73 Start the engine with an assistant electric cable ● Waning: while the battery electrolyte is frozen, the following operation might cause battery explosive: (1) Attempt to charge the battery; (2) Start the engine by short connection Warning: batteries can produce explosive gas. Keep away from sparks, flames and fireworks.
  • Page 74 3. After the engine started A. Engine preheating excavator warm up The normal working temperature of hydraulic oil is 50 C~80 C. Operating excavator while hydraulic oil temperature is too low (especially if hydraulic oil temperature is lower than 20 C) will cause hydraulic part damaged.
  • Page 75 Enter and exit machine 1) hold the door handrail on cabin door tightly (arrow toward in the picture) 2) Step on crawler stably. 3) Do not use operator joystick as a handrail for getting in or off the excavator. 4) If any mud, greasing oil on handrail or crawler, there might be a risk of slipping.
  • Page 76 Machine moving 1. Safety rules for moving excavator 1) Please check the working site and surrounding environment, obstruction, endurance of ground etc. before starting the excavator. 2) Honk to warm the people around the excavator before starting. 3) Do not start or operate excavator while the operator is not on the seat. 4) Working or walking of excavator or must be on the solid ground which width is at least 1.5 times of the width of excavator.
  • Page 77 3. Machine moving forwards 1) Turn the safety lock lever to position of unlock, lift working device 40~50 cm from the ground. 2) Operate left and right traveling lever according to following steps. When the forward sign is ahead: Push the traveling lever slowly and move forward.
  • Page 78 Machine steering Attention: please check forward direction before operating traveling lever. If the forward sign is behind, operate opposite to forward. Change traveling direction by left and right traveling lever. Try to avoid changing direction while traveling. Especially for opposite direction turning, please stop the machine before operation.
  • Page 79 Machine slewing ●Please check whether the surrounding area is safe before turret rotating. ●When operating the joystick of rotating quickly, turret will rotate quick. If the joystick is operated slowly, turret rotates slowly. 1) If the machine with the boom swing function, push...
  • Page 80 Operation of working device Joystick operating speed will determine working device working speed. Working device is controlled by left and right joystick. Left joystick is responsible for arm and rotating function. Right joystick is responsible for boom and bucket function. When the joystick is released, they will be back to central of pilot valve and working device remains in original place.
  • Page 81 4. Operating bucket Push right joystick to right direction, the bucket extends out; pull right joystick to left direction, the bucket is taken back. 5. Operating boom swing Push right Joystick to the left, boom will swing to the left. Push the Joystick to the right, the boom swing to the right.
  • Page 82 Operating on the slope or in the water Warning: work near piedmont slope is danger. Raining, mud, snowy, icy, sand and soft soil ground will cause potential risk. Please take proper working method when working on piedmont slop area.  when excavator traveling, lift the bucket 20~30 cm up from the ground. ...
  • Page 83 How to escape from Mud Keep away from muddy environment during excavator operation. If the machine sunk into mud, drive the machine out of mud according to following steps: A. One side track sinking into mud Attention: when lifting excavator by boom or arm force, bucket bottom must touch ground (do not use bucket teeth as support).
  • Page 84 Operating guide 1. Backhoe work Backhoe is suitable for digging job which position is lower than the machine.. Bucket will have the biggest digging force if the machine is in the state that bucket cylinder and linkage, arm cylinder and arm are all at 90 The effective use of the angle will optimize the work efficiency.
  • Page 85 3. Ditching work Keep the dozer blade at rear of the machine, and insert the blade into the earth. Stretch out boom and arm, insert bucket tooth in to ground. While digging by arm cylinder, adjust bucket angle of cutting over and loading; or change to dig by bucket cylinder.
  • Page 86 B. Notice for dozer blade. 1) Dozer blade could only be used to push the earth. Do not use it for other purpose, otherwise dozer blade and crawler may be damaged. 2) Dozer blade could not endure huge heavy object. 3) When machine traveling, do not hang any object on the blade.
  • Page 87 Dismantling or installation of bucket Safety rulers  When you hit the pins with hammer to extract them, splinters may be produced and hit you, it may cause severe injure and permanent damage in your eyes. So use protective eyeglasses and heavy gloves.
  • Page 88 Parking Safety rulers 1) Avoid abruptly stop. Keep enough space when you want to stop the machine 2) Stop the machine on a firm and solid ground, avoid dangerous place. If you must park the machine on slope, put some pieces of wood under the crawlers, then trust the bucket under ground.
  • Page 89 Check after completion of work 1. Check Check the water temperature, engine oil pressure, fuel pressure, the level of the fuel on the instrument panel. 2. Lock After completion of work , make sure the follow compartments are locked. 1) Cab’s door. ( And don’t forget the windows). In any condition, if you want to open the front windows, using the handle , can pull the front window up and down to slide the roller inside the guide, then lock it to upthrust till the lock position, whereas, put the front...
  • Page 90 Loading, unloading and transportation 1. Safety rulers of loading machine 1) When loading or unloading the machine, run the engine at the idling speed. 2) Don’t loading or unloading the machine when turn on the heater. 3) If you turn off the heater when operating the machine, the speed of machine’s movement will suddenly change.
  • Page 91 2 . Loading precaution When loading or unloading the machine, park the trailer on a flat, firm road. Keep a fairly long distance between the road shoulder and the machine. Properly apply the brakes on the trailer and insert blocks beneath the tires to ensure that it does not move.
  • Page 92 3．Fix the machine on the trailer 1) Lower the work equipment correctly 2) Stop the engine and remove the start key. 3) Turn the safety lock handle to Locked position. 4) Lock the door and engine hood 5) Place rectangular timber underneath the front and rear track shoes to prevent the machine from moving about.
  • Page 93 5. Lift the machine A. safety rulers 1) Don’t lift the machine when there is somebody on it. 2) It must be sure the chains that use to lift the machine have the enough intensity to carry the weight of the machine. 3) In order to avoid the machine’s unbalance, it must do just like following provided steps.
  • Page 94 Precautions of working in cold or high temperature area 1. Working in cold weather The cold weather may cause some trouble, so the protection is very important at this time. Avoiding the machine to be badly damaged, if maintain machinery adequately, it will extend machinery life. 1) Electrical system: keep the battery clean and charge fully.
  • Page 95 Long time storage 1. Before storage When putting the machine in storage for a long time, do as follow: 1) After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoor. In case it is indispensable to leave it outdoors, park the machine on a flat road and cover it with canvas etc.
  • Page 96 2. During storage Start the engine and travel the machine for a short stretch every month, so a thin coat of grease will cover the moving parts. At the same time, charge the battery. Also run the air condition if it is assembled. Running the crawler.
  • Page 97 Trouble shooting Trouble Cause Solution Engine can’t be There is some trouble with Replace or repair starter   started started starter difficultly Battery isn’t charged enough Charge or replace the battery   Pre-heating line or glow plug is Repair or replace the glow plug ...
  • Page 98 exhaust valve is incorrect or polishing valve isn’t sealed Cylinder cushion is damaged, Replace the cylinder cushion   gas leakage Injection pump work badly Consult with agent   Engine is over heats Check if the coolant is correctly ...
  • Page 99 trouble Generator can’t be charged Consult with agent   The electrolyte of the battery Replace   is expired The electrode plate of the Replace   battery is failure 9.starter doesn’t work Terminals loosen or get rusty Clean or tighten ...
  • Page 100 There is water in the hydraulic Replace oil   Oil level is too slow Refill the oil till the normal level   14.Hydraulic Hydraulic pump is damaged Consult with agent   pressure is too slow Oil level is too slow Refill the oil ...
  • Page 101 Capability of motor lowered Consult with agent   20.Slewing Capability of oil pump lowered Consult with agent   abnormally Slewing motor is damaged Consult with agent   Pilot valve can’t work Consult with agent   21.Air condition make Appliances joint loosen...
  • Page 102 General information of Maintenance Break-in of the new machine The break-in period is the first 100 working hours of the new machine. Cautious use must be taken during this period in order to prevent the machine from heavy load and working intensity. In the first 50 hours in break-in period, only 80% of working intensity is permitted, because the proper use during the break-in period has a deep influence in the service life of machine.
  • Page 103 Use the original parts It is important to use the original spare parts of YUCHAI EXCAVATOR. Environment protection When dealing with the engine oil, fuel, coolant, anti-freeze, plastic, impregnate, filter core and battery which will be harmful to the environment, do abide by the environmental laws.
  • Page 104 ● Change the filter core periodically. ● Do not use the filter core which has been cleaned. ● When changing the filter, contact YUCHAI if you have found that there are metal grains on the filter. ● Do not open the package of the spare filter before usage.
  • Page 105 Hydraulic system ● Check and do the maintenance on the hydraulic system after the temperature is down and release the pressure of the pipeline in the cylinder. ● When loosening the bolts, nuts and tie-in of pipes, do not stand at the front of the spare parts.
  • Page 106 Easy wear parts Seal ring, Filter elements, Bucket tooth and Cutters are easy wear parts, Please do periodic inspection and maintains, replace on time if they are wear to avoid the influence of machine performance.
  • Page 107 Periodical replacement of safety critical parts Safety critical parts are the hydraulic hoses, the hoses can be perished or worn, and affect the normal functioning, It's also a potential safety hazard. These parts must be replaced compulsively after the stipulated duration of use. Replace immediately if there are any abnormality on these parts even it is not due yet.
  • Page 108 Oil choosing list Choose the suitable oil as the temperature and work condition, but please choose the oil according to the following schedule. Lube or Fuel Suitable Viscosity Recommendation temperature Engine oil CH4 15W/40 -15℃～+40℃ CH4 5W-30 -25℃～+30℃ Hydraulic oil Low-temperature area: Above -35...
  • Page 109 ● Oil capacity Sort Unit Value Fuel tank Engine oil Hydraulic oil tank...
  • Page 110 Standard torque list Tighten torque of bolts and nuts are as following table. The tightened parts or connected parts will lose and be damaged if the bolts and nuts don’t tight to the stipulated torque, and will cause machine faulty or affect the operation. The torque list for general parts Intensity Yield...
  • Page 111 The tighten torque of hydraulic hose The Metric Thread Nut Metric Thread Outside diameter of steel tube torque Min./max M12*1.5 15-25 M14*1.5 30-45 M16*1.5 8/10 38-52 M18*1.5 10/12 43-85 M20*1.5 50-65 M22*1.5 14/15 60-88 M24*1.5 60-88 M26*1.5 85-25 M30*2 20/22 115-155 M36*2 25/28...
  • Page 112 ORFS Nut UNF Thread Specification Min (Nm) Max (Nm) 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 5-11...
  • Page 113 Periodic Maintenance schedule Check the machine timely as follow list and the engine time-meter, the maintenance interval for some related parts must be shortened if the machine is working under the poor condition or equipped with Rock breaker or other accessories.
  • Page 114 Periodic Maintenance schedule (continuous) Period of Maintenance Item (Total of the Working Hour) 100 250 500 1000 2000 Lubricate System of Engine & Others ▲ ●Check engine oil level and refueling if needed ☆ 5-22 ●Replacing engine oil ▲ ☆ 5-23 ▲...
  • Page 115 ●Check electrolyte density and Charge ▲ Reducer 5-34 ●Check oil level and refueling ▲ 5-35 ●Replacing engine oil ☆▲ ●Check tighten torque of connecting bolt ☆ ▲ 5-36 Crawler ●Check and adjust the tension of crawler ▲ Idler, upper roller and front Idler 5-37 ●Check the tighten torque of Idler ☆...
  • Page 116 General Check It need do the routine Check to the machine everyday or every 10hours. 1) Check whether the machine leak oil、water or the fuel leaks 2) Check whether the parts and the attachment have the rupture、the nick or the distortion 3) Check the hydraulic device’s fix and connect 4) Check the appearance of the parts 5) Check the working condition of the working device, light , warning light.
  • Page 117 Engine Fuel System Maintenance illustration Capacity of the oil tank---------------------------------------------------102L Check the level of the oil------------------------------------------------10h Vent the water and the impurity from the oil tank------------------100h Clean the oil tank-----------------------------------------------------------250h Check the pressure of the oil injection--------------------------------500h Replace the filter core of the fuel---------------------------------------250h 1.
  • Page 118 Do the periodic inspection for fuel injection pressure as the Maintenance schedule, the fuel injection pressure is 22.56Mpa, adjust if necessary, the adjustment should be done by YUCHAI authorized distributor. The working efficiency of the engine is depended on the working condition of the spray nozzle, so have to do periodic inspection to keep it working normally.
  • Page 119 6. Fuel pre-filter Replace the filter element after 50 hours for new machine, after that replace it after every 250 hours. Drain the water and the precipitate from the oil and water separator everyday. 1) Stop the engine, open the outlet valve, and turn the valve widdershins about three circle till the valve drop down about 25.4mm(1 inch) and start to vent...
  • Page 120 Attention: For reduce the feasibility of the fuel leaks, make sure to install the filter fixed but on too tight, the fuel filter could be damaged if it is too tight. 7) Start the engine after replaced fuel filter element, and check if it is leaking. 5-19...
  • Page 121 Engine Coolant system Maintenance illustration Capacity of the radiator-----------------------------------------------------------------5.7L Check the level of the coolant----------------------------------------Everyday or 10h Check the hoses and the clips----------------------------------------Everyday or 10h Clean the vane of the radiator--------------------------------------------------------500h Replace the coolant------------------------------------------------Spring and Autumn Check the consistency of the coolant ------------------------------Everyday or 10h 1.
  • Page 122 2. Check the hoses and the clips Check it everyday or every 10 hours. Replace the hose if it is crack or become hard because of the aging. Check the clips, replace if it is loose or damaged. 3. Clean and Check the vane of radiator Clean it every 500 hours.
  • Page 123 Then stop the engine and drain the cleaning fluid. 3) Tight the vent valve. 4) Immit the coolant, run the engine several minutes at idle to make the coolant fill the entire cooling loop. 5) Check the level of the coolant and fill if necessary. Warning: Don’t open the cover of the radiator (water tank) with the hot engine except the temperature of the coolant under 50 5.
  • Page 124 Lubricating System of the Engine Maintenance illustration Capacity of engine oil---------------------------------------------------------------------7.6L Check engine oil level-----------------------------------------------------Everyday or 10h Replace the oil or filter element-----------------------------------------Every 250 hours 1. Check the engine oil level Check the oil level for first time, after that check it every 10 hours.
  • Page 125 Replace engine oil filter 1) Clean filter seat and the around area, take-down filter, clean surface of the seal gasket of the filter seat. 2) There are 2 seal gaskets on the filter, lubricate both seal gaskets. 3) Please wipe the engine oil on the seal gasket before install the filter.
  • Page 126 Air Intake System of Engine Maintenance illustration Period of cleaning dust----------------------Every 10hours or everyday Period of cleaning Air filter--------------------------------Every 100 hours Period of replacement of Air filter element------------Every 500 hours 1. Clean and replace the Air filter element Clean the Air filter every 100hours or when the Air filter warning Indicator light. Clean the Air filter frequently will affect it’s performance.
  • Page 127 Other Maintenances of Engine Warning: No maintenance when the engine is running. If the maintenance have to do during engine running, please do it at least by two persons and follow the regulations: One person stays in the cabin, and prepares to stop the engine in any time.
  • Page 128 Hydraulic System Maintenance illustration Capacity of the hydraulic oil tank--------------------------------------------------------77L Check the hydraulic oil level-----------------------------------------------------every 10h Replace the filter element--------------------------------------------every 1000h/2000h Replace the hydraulic oil-------------------------------------------------------every 2000h Check the pressure system----------------------------------------------------every 500h Warning: It brings the serious hurt and death if the hydraulic oil or the axunge rip into the skin.
  • Page 129 2. Vent the water and the dirt from hydraulic oil tank Vent the water and the dirt every 250 hours. 1) Vent the air from the oil tank after the oil is cold or before starting every day. 2) Loose the oil drain bolt (see the picture) 3) Vent the water and the dirt until see the limpid hydraulic oil come out.
  • Page 130 7) Clean the inner of the oil tank. 8) Install the oil suction filter and oil return filter into the flange, then immit the new qualified hydraulic oil (see oil choosing list), the oil level should be at the middle of the oil scale, and install the cover. 4.Vent the air which in the hydraulic system A.
  • Page 131 E. Vent the air from driving motor(when it vent the oil from the shell of the driving motor) 1) Run the engine with low-speed, loose the drain bolt. If it has the oil outflow, screw up the bolt. 2) Run the engine with low-speed, make working device...
  • Page 132 Attention: It must vent the pressure of the hydraulic oil tank before take-down the filter. 1) Screw down the filter shell. 2) Take-down the filter element. 3) Install the new ”O” ring into the groove of the filter head. 4) Wipe the hydraulic oil on the surface of the seal kit before install the new filter element, and put the filter element...
  • Page 133 2) Batteries shall not be inverted or lying, shall not be impacted or pressed. 3) The storage time of the Battery on Yuchai excavator is 6 month, it can be use directly during 6 months, but it need to be charged if the storage time is more than 6 months.
  • Page 134 3. Installation of Battery 1). Read the safety mark carefully before install the Battery, to prevent the accidents. 2). Wipe a small amount of Vaseline on the end of connecting posts to prevent corrupted. Connecting wires should be secure and reliable. Not tap on the end of connecting posts to avoid the leaking.
  • Page 135 Reducer Maintenance illustration Lube capacity of the slewing reducer ---------------------------------1.6L Lube capacity of the travel reducer ----------------------1L (each side) Check the level of the lube and oil filling----------------------every 250h Replace the lube -------------------------------------------------------- 1000h Check the torque of the connect bolt of the reducers-------------500h 1.
  • Page 136 5) Turn the travel reducer make the bolt in ”a” position 6) Fill the lube thought ① till the hole ② has the oil out. 7) Screw up ①and ②, the torque is 12-15Nm. 3. Check the torque of connected bolts of travel reducer and slewing reducer A .
  • Page 137 Tracks Check and adjust the tension of the Tracks Check it every 10 hours. 1) Park the Excavator on flat ground. 2) Take down the cover ① (Fig. 2), expose the lubricating nipple of the tension unit. 3) Loose the tie-in ② (Fig. 2) make lubricating grease come out, and the track will became loose, make the branches f (Fig.
  • Page 138 Bottom roller, upper roller and Front idler 1. Check the torque of the bottom roller Check the torque of bottom roller after first 50 working hours, after that check it every 500hours. If the bolt is loose, it need to screw the bolt down and clean the thread additive which for lock and fix of the bolt.
  • Page 139 Lubricate Lubricating every 50 hours Lubricating steps: 1) Start the machine and place the bucket on the ground 2) Put the bulldozer down to the ground 3) Stop the engine 4) Clean the nipples and the oil cup. 5) Lubricating the parts and wipe nipples. 1.
  • Page 140 Air-condition This excavator is with AC, and the operation switches are placed on the panel of left control box. About the maintenance of the air-condition, please see the user manual and the air-condition user manual. 1. Caution items of the air-condition maintenance 1) The refrigeration system is failure if “...
  • Page 141 the machine for a long time in winter. It is not under the if the heating part is frost crack in winter. If the parts are corrupted or the Warm Water Valve is damaged because nonuse the coolant as the request of the manufacture.
  • Page 142 4. Items of the time-check Check Item Check Content Check Periods Every Month Every Quarter Fastener If loose、fall off ★ Belt of air-condition The tension and fray ★ Pipeline If fray or rupture ★ Tie-in If fray of leak ★ Electric fan Whether run normal ★...
  • Page 143 Replace Bucket and the Teeth Replaces the bucket teeth before the teeth seat is fray. Warning: it is very dangerous if the working device move because of the wrong operation when replace the bucket teeth. Please lock the working device, stop the engine and lock all operation levers before replace the teeth.
  • Page 144 Washing The floor mat Avoid the floor slip、tumble to make the accident, please wash it at any moment if it dirty. Warming: If it touches the joy stick unguarded, the working device or the machine will move and lead the accident. So it must place the machine on the flat ground before take down the floor mat.
  • Page 145 Yuchai. 7. Electrical system can be failure if it has external electrical interference, please contact with YUCHAI distributor if you need to install radio or other wireless equipment. 8. When working on the beach, clean the electrical system carefully to prevent corrosion.
  • Page 146 Not only effect the using time of the machine, but also can cause some safety problem. Please contact YUCHAI distributor if equipped with the accessories. If you do not confirmed with YUCHAI before installation, we will take no responsibility for any accident or damage.
  • Page 147 Warning: The license for operator is very important .It is forbidden to operate the machine without license. Please contact yuchai agent regarding the details of operation when dismantle or installation .
  • Page 148 Installation and dismantle steps of Accessory 1. Step of dismantle 1) Put the accessory on the ground and turn off the machine. 2) Turn start switch to ON and the left control box to free position. 3) Full operate all working equipment which are control stickers and control pedal of accessory in all directions...
  • Page 149 Attention : Choose the optimum accessory for machine,. The model for machine which can be equipped with accessory is different, Regarding the machine and accessory’s model ,please contact yuchai agent. Hydraulic Rock Breaker 1. Operation guide of hydraulic rock breaker.
  • Page 150 strike where near the side of the object. 4) Use rock breaker to impact the surface suitable, avoid no resistance use the wallop stop use the to impact when the rock breaker or the objet crushed crushed. If not stop, it will lead the bolt of the main body loose and mangle.
  • Page 151 4) Inflict the wallop on the level ground or upwards 5) Waver the rock breaker when it penetrate the rock 6) Peck operation 7) Operate it in the water or the muddy ground...
  • Page 152 8) Use the rock breaker hang the heavy thing 9) Throw out the cylinder of the bucket to make the machine leave the ground...
  • Page 153 Quick hitch 1. Install the bucket 1) Use the tommy bar to prize ① 2) Put the axes of the bucket into the②③,down the tommy bar and the bucket installed. 2. Take down the bucket 1) Use the tommy bar to prize ① 2) Take down the bucket.
  • Page 154 Daily Check of Hydraulic rock breaker Check or maintain item Check point Resolve Check whether the bolt/nut Bolt of the main Screw down the bolt or loose or lose body and the install the new bolt again side of the bolt Check whether the parts of Hydraulic Screw...

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