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Yuchai U35 Operator's Manual

Hydraulic excavator
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Yuchai U35/YC35SR
Hydraulic Excavator
Operator's Manual
Guangxi Yuchai Heavy Industry Co., Ltd.
GUANGXI YU CHAI HEAVY INDUSTRY CO., LTD.

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  • Page 1 Yuchai U35/YC35SR Hydraulic Excavator Operator’s Manual Guangxi Yuchai Heavy Industry Co., Ltd. GUANGXI YU CHAI HEAVY INDUSTRY CO., LTD.
  • Page 2 You are responsible for complying with relevant laws and regulations and the instructions of Yuchai Heavy Industry on machine operation and maintenance. is the registered trademark of Guangxi Yuchai Heavy Industry Co., Ltd. in China.

  • Page 3: Table Of Contents

    Contents PREFACE ......................1 ................... 1-2 O USERS ................ 1-3 RODUCT NFORMATION ................1-5 ACHINE DIRECTION ..............1-6 OMPOSITION OF THE MACHINE ..............1-7 ECHNICAL SPECIFICATIONS SAFETY REGULATIONS ..................1 ............... 2-2 ENERAL SAFETY RULES ................2-3 AFETY WARNING ................2-4 AFETY EQUIPMENT ................
  • Page 4 ..............4-11 LEWING OF THE MACHINE ............... 4-12 PERATION OF THE ATTACHMENT ..............4-14 ORK ON SLOPES OR IN WATER ............4-15 EEPING AWAY FROM MUDDY ENVIRONMENT ............4-16 PERATION GUIDE FOR CONSTRUCTION ..........4-19 ISASSEMBLY AND INSTALLATION OF THE BUCKET ................

  • Page 5: Preface

    Preface...

  • Page 6: To Users

    To users Dear users, Thanks for selection of the excavator from Yuchai Heavy Industry and thanks for your great support for Yuchai business. This manual is for safety guidance and the correct use and maintenance of the machine. Before starting and operating the machine for the first time and before repairing the machine, please read this manual carefully and fully understand the safety regulations, operation guidelines and maintenance matters until you fully understand them.

  • Page 7: Product Information

    Product Information ⚫ Machine information (the nameplate of the machine is in the right front of the platform) ⚫ Engine information (the engine nameplate is located in the middle of the engine) Model ESN (number)
  • Page 8 Fill in the product serial number and engine serial number of your machine in the table below. When you need to purchase machine parts or want to obtain relevant information, you can inform Yuchai of these codes. Please record these numbers and keep them together with the product certificate. If your machine has been stolen accidentally, you can submit the information to the local public security agency.

  • Page 9: Machine Direction

    Machine direction The front, rear, left, right, up, and down in this manual refer to the various directions of the illustrated state. Down Right Rear Front Left...

  • Page 10: Composition Of The Machine

    Composition of the machine 1. Bucket 2. Bucket cylinder 3. Bucket arm 4, Bucket arm cylinder 5. Boom 6. Boom cylinder 7. Dozer cylinder 8. Drive wheel 9. Track 10. Guide roller 11. Dozer blade...

  • Page 11: Technical Specifications

    Technical specifications 1. Structural size parameters Code Item Unit U35-BF51 Operation weight 3875 Standard bucket 0.12 capacity Engine name 3TNV88F Engine power kW/rpm 18.2/2200 (net) Total length 4630 Total height 2550 Overall width 1800 Track width Platform turning radius Track length...
  • Page 12 2. Work parameters Code Item Unit U35-BF51 Maximum excavation depth 5156 Maximum unloading height 3588 Maximum excavation depth 3170 Maximum excavation 5557 radius Maximum ground level 5438 digging distance Digging radius of the 2948 maximum digging height Minimum radius of gyration...
  • Page 13 3. Bucket series Number of bucket Bucket capacity m3 Width mm Weight Kg teeth 0.12 Climbing capacity Travel speed (km/h) Maximum traction (kN) High speed 35° Low speed 4. Travel mechanism Independent drive is achieved by a hydraulic motor through a multi-stage planetary reducer. The reducer is hidden in the width of the crawler.
  • Page 14 8. Mechanical interference of the machine The working devices of various series of hydraulic excavators may interfere with the boom oil cylinder or the boom lower cover plate when they are equipped with some non-standard working devices. Therefore, the attention should be paid to the angle between the bucket and the boom when retrieving the stick if the machine uses non-standard working devices to prevent interference with the boom oil cylinder and damage to the machine body.

  • Page 15: Safety Regulations

    Safety regulations...

  • Page 16: General Safety Rules

    General safety rules Following the relevant safety regulations in this manual can avoid most accidents that endanger the operation and maintenance of the machine. Before the operation or maintenance of the machine, please read and understand all the safety information and the safety markings of the machine in this instruction.

  • Page 17: Safety Warning

    Safety warning 1. Warning signs In this instruction, this warning marking points out important information about safety. If you find the sign, please carefully read the information and advice to avoid possible casualty accident. 2. Safety reminders This instruction provides precautions, signs and descriptions of potential hazards for the safe use of the machine.

  • Page 18: Safety Equipment

    Safety equipment 1. Protective equipment for operators 1) The operator must wear tight-fitting and suitable work clothes, safety helmets, working leather shoes and other related safety protection equipment (such as: protective earplugs, gloves, protective glasses, seat belts, etc.) before operation or maintenance. 2) If the operator's hair is too long, please tie it up and cover it with a safety cap, which will protect your hair from being entangled by the...

  • Page 19: Safety Signs

    If the signs are damaged, lost or illegible, please replace them. If the label is on the part that needs to be replaced, make sure that the new part is equipped with a sign. Please contact Yuchai agent to obtain a new safety mark. 1. Classification of safety signs The safety marks in this manual and on the machine adopt "graphic safety sign"...
  • Page 20 2. Safety sign pasting location The sign shown in the graphics is only the "safety sign" part of all signs, and the rest of the function signs will be introduced in the following chapters.
  • Page 21 4) Lock sign 3. Safety sign diagram and instructions 1) Pay attention to and stay away from the attachment 5) Grease filling sign Movement of the attachment can cause personal injury. Keep a safety distance away from the attachment area. Note: 1.
  • Page 22 8) Slewing center 12) Lifting sign 9) Cable lifting combination 13) Fuel filling sign Precautions 1. Clean the fuel tank every 200 hours; 2. Clean or replace the diesel filter element every 500 hours; 3. Fuel for choice: #0 light diesel fuel for temperatures 10) Keep staying away from the above 0°...
  • Page 23 16) The container cover of hydraulic oil 20) Beware of toxic gases and engine coolant cannot be opened at high temperature The high temperature hydraulic oil and Toxic gases or toxic fumes can suffocate coolant have high pressure. When opened at people.
  • Page 24 24) No smoking, no fireworks 27) Accumulators and gas spring high-pressure devices are not allowed to be disassembled, drilled, cut or hit, and should be kept away from open flames or high temperatures These parts contain high-pressure gas, improper handling can cause injury. Please 25) Watch out for explosions have it handled by an experienced person.
  • Page 25 29) Be careful of personal injury caused 31) Identification of battery disconnect by high temperature parts such as switch engine, water tank, muffler, and engine Do not touch it directly. When repairing these parts, turn off the flame and wait for their temperature to drop to a suitable temperature.

  • Page 26: Safety In The Workplace

    Safety in the workplace Know the area where you will work as much as possible in advance. Please check: 1. Location of the slope. 2. Open ditch. 3. Falling objects or hanging objects. 3. Soil condition (soft or hard). 4. Standing water and swamp area. 5.

  • Page 27: Safe Operation

    Safe operation Warning: It is strictly prohibited to transport or lift personnel with the excavator. Warning: before operating the machine, you must wear a seat belt, honking the horn, and confirm that there is no one around the working area before starting work.
  • Page 28 2. Traveling and slewing Attachment 1) Before traveling, please turn the upper part of the machine platform to a suitable position, with the attachment in the same direction as the dozer blade. If the attachment is in the opposite direction of the dozer blade, the operation is reversed.
  • Page 29 4) During traveling or operating, it is important to maintain a safe distance from people, buildings, or other machines to avoid contact. 5)When traveling through height-restricted areas such as underground passages, bridges, or power lines, it is necessary to ensure command by a specially designated personnel. In addition, a safety distance must be kept.
  • Page 30 5) Do not turn on slopes or cross slopes. Be sure to go down to a flat area and change the position of the machine before climbing up the slope. 6) When working on a slope, it is necessary to start from a high place and gradually excavate towards the downhill direction, with the dozer blade at the back and pressing against the ground, and the...
  • Page 31 10) It is strictly prohibited to travel on slopes with a longitudinal slope direction greater than 25 degrees. 11) It is strictly prohibited to travel and work on slopes with a transverse slope greater than 15 degrees. 12) Try to maintain machine balance and strictly prohibit traveling on rocks or crossing obstacles.
  • Page 32 16) When working on slopes, there is a risk of the machine losing balance and tipping over when operating for slewing and the attachment. This can cause serious injury or equipment damage, therefore, when performing these operations, it is necessary to pile up a sturdy and level platform with soil.
  • Page 33 6) When the bucket is subjected to special resistance on the ground, do not travel or rotate, otherwise the machine may be damaged. Allowanc 7) During operation, if the hydraulic cylinder is operated to the end of its stroke, the force will act on the limit ring inside the cylinder, thereby reducing the service life of the machine.
  • Page 34 13) Do not carry out excavation operations when the track is off the ground, which may cause damage to the machine and structure. 14) Do not use the weight of the machine to increase its excavation force. 15) Do not use the downward force of the bucket as a hand pick, crusher, or pile driver, which will cause excessive force to be applied to the rear of the machine.
  • Page 35 17) Do not use the downward force of the machine for excavation, as it may damage the machine. 18) Do not use the rotational force to compact soil or damage soil piles and walls. When rotating, do not insert the bucket teeth into the soil, which will damage the attachment.
  • Page 36 20) Do not excavate the working surface below the suspended part, as there is a risk of falling rocks or the suspended part collapsing and hitting the machine. 5. Prevention of tipping, slipping and handling during operation Warning: 1) When you have to turn on a ramp, you can only turn in a large arc.
  • Page 37 10) When the machine excavates deeply under the machine. 11) Traveling on frozen ground. 12) When there is oil or lubricating oil on both tracks, the machine is prone to slipping. 6. Turn off the machine See the section "Park the machine". 2-23...

  • Page 38: Machine Transportation And Handling

    Machine transportation and handling The transportation (loading and unloading) of the excavator must strictly follow the safety principles. ⚫ Transportation of the excavator shall comply with relevant national and local industry safety transportation (loading and unloading) rules or good practice. ⚫...

  • Page 39: Downtime For Maintenance

    Downtime for maintenance Warning: When carrying out any maintenance work on the machine, the warning sign “No Operation” must be hung on thejoystick. ● The machine must be parked on solid and flat ground. ● After the excavator has stopped, it is necessary to lower the bucket to the ground, run the engine at idle for three minutes, stop the machine, and finally remove the switch key.

  • Page 40: Fire, Explosion And Poisoning Prevention

    Fire, explosion and poisoning prevention ⚫ Avoid contact with wires when the excavator is transported, walked, or excavated, otherwise it will cause serious casualties. ⚫ The electrical appliances and wiring of the excavator should be checked frequently. If they are found to be damaged, or aging, they must be replaced in time to prevent a short circuit of electrical wiring and causing fire.

  • Page 41: Battery

    Battery Safety rules for the battery The electrolyte of a battery contains sulfuric acid, which can produce flammable and explosive hydrogen gas. Incorrect operation can cause serious injury or fire, so the following precautions must be followed: ● Regularly check the electrolyte level of the battery and replenish it with distilled water, so that the electrolyte level is between the "upper level"...

  • Page 42: Hydraulic System

    When welding the machine, it is strictly forbidden to do it without isolating the hydraulic oil pipeline (hose). If any damage to the hose is found, stop the operation immediately and get in touch with the Yuchai agent. If the following problems are found, replace the hose: 1) Damaged or leaking hydraulic pipe joints;...
  • Page 43 4. Release the internal pressure of the hydraulic system The hydraulic oil in the hydraulic pipeline is at high temperature and high pressure when the machine is working intermittently. When disassembling the oil port, oil may spray out, so rotate the oil filler cap before removing the cap to release internal pressure. 1) If the attachment is not in the state as shown in the figure, start the engine to run at low speed, extend the bucket cylinder, and...

  • Page 44: Cab Flipping

    Cab flipping When flipping the cab, first lower the boom and bucket arm close to the ground, and then perform the flipping operation. Otherwise, if the attachment is not placed on a horizontal surface, flipping up the cab may cause the front window of the cab to touch the boom and damage the glass.

  • Page 45: Introduction Of Components

    Introduction of components...

  • Page 46: Overview Of Controls

    Overview of controls 1. Driver seat 6. Travel left joystick 11. Control panel 2. Joystick of the left attachment 7. Dozer blade joystick 12. Radio 3. Joystick of the right 8. Cigarette lighter attachment 9. Pilot safety lock lever 4. Pedal cover of auxiliary 10.

  • Page 47: Digital Combination Instrument

    Digital combination instrument Parameters Setting Menu Help 1. Machine trademark 2. Machine status display area 3. Main display area 4. Alarm display area 5. Soft key area 6. Keys (corresponding to soft keys) 7. Function keys...
  • Page 48 A. Instrument panel display Slow travel Fast travel Warm-up sign Turn off automatic idle Turn on automatic idle speed function. speed function. Warming up Turn on the automatic warming up function. Timing data, in hours Timing mark (flashing) Machine status display System power supply voltage alarm.
  • Page 49 Voltage Gear Engine coolant temperature gauge. The alarm displays in the machine alarm area when the engine coolant temperature is too high. Gear display value. Throttle gear Voltage display value. Current system voltage in volts Fuel level gauge. The alarm displays in the machine alarm area when the fuel level is too low.
  • Page 50 Cancel buzzer switch key Travel speed change (fast/slow) switch button Automatic idle speed/Cancel automatic idle speed Power mode setting key Function selection key and alarm indicator During the function selection key operation, the selection result can be determined by observing the display of the machine status area.
  • Page 51 Oil pressure Fuel level Select "Parameter" by pressing the key, and the Engine speed monitor will display the operation data of the machine. Coolant high Hydraulic oil temperature Working time Phase working time Select "Set" By pressing the key, and the monitor displays the system setting menu.
  • Page 52 The alarm setting parameters set in the machine will Oil pressure alarm be displayed by selecting "Alarm parameter". (This Fuel level alarm parameter is set before delivery) Coolant temperature alarm Hydraulic oil temperature alarm High voltage alarm Low voltage alarm Flywheel teeth number setting Select "Help"...

  • Page 53: Switch Assembly Of The Right Control Box

    Switch assembly of the right control box 1. Horn button switch 2. Cigarette lighter 3. Start switch 4. Work lamp switch 5. Rear work lamp switch 6. Warning light switch 7. Radio 1. Horn button switch When the electric horn button switch at the top of the right attachment joystick is pressed, the horn sounds.
  • Page 54 At which the key can be inserted or removed, all switches in the electrical system are turned off, and the engine is stopped. When the engine is running, keep the start switch key in the ON position. START This is the engine starting position. When starting the engine, hold the key in this position.

  • Page 55: Switch Assembly Of The Left Control Box

    Switch assembly of the left control box 1. Work lamp switch 2. Two-speed wiper switch 3. Windshield washing switch 4. High/low speed travel switch 5. Air conditioning panel (located on the left side) 1. Work lamp switch Boom work light switch: Press the rocker switch, and the side with a switch mark is ON, while the other side is OFF.

  • Page 56: Safety Lock Parts

    Safety lock parts 1. Safety lock Warning: the safety lock mechanism of the attachment is an important part of the machine safety system. Safety lock must be enabled before the driver leaving the cab. If the left control box is not in the locked position, the handle may move, causing the working device or platform to move, which may result in an accident.

  • Page 57: Operation Of The Attachment And Slewing Mechanism

    Operation of the attachment and slewing mechanism 1. Operation of excavation equipment and platform slewing mechanism (the type of the boom does not swing). Use the direction of left and right work device joysticks, as shown in the right figure. A.
  • Page 58 ⚫ Selection and control of rotation and deflection For models of boom swing type with steering heads, it is necessary to switch between platform slewing or boom swing modes through the switch button on the left attachment joystick in advance to select the platform swing function or boom swing function.

  • Page 59: Travel Control

    Travel control 1. Direction control Operate the left and right travel joysticks to control the left and right tracks of the machine for traveling. Front Front Control of the joystick on one side can achieve single side steering of the machine. Travel left Travel right joystick...

  • Page 60: Mechanical Accelerator And Electronic Accelerator

    Mechanical accelerator and electronic accelerator 1. Mechanical accelerator (for models of mechanical accelerator) Push the engine throttle lever forward to increase the accelerator. Before stopping the engine, push the lever all the way forward. 2. Electronic accelerator (for Gear 1 Gear 10 models of electronic accelerator) Left knob limit...

  • Page 61: Driver Seat

    Driver seat Warning: Accidental tipping or sudden movement of the machine may cause injury or even death. Therefore, for safety reasons, it is important to fasten the seat belt and adjust the seat before starting the machine. 1. Fore and aft seat adjustment lever 2.

  • Page 62: Seat Belt

    Seat belt Warning: the seat belt is an important part of the machine safety system. Before operation, you must wear a seat belt. If you do not wear a seat belt, the cab or the machine may press on your body and cause injury when the machine tipped over. Warning: before using the seat belt, check the installation of the seat belt for abnormalities.

  • Page 63: Air Conditioning Control

    Air conditioning control The air conditioning control panel is located on the switchpack of left control box panel. Air conditioning Display screen control panel Mode selection key Set adjustment key 1. Key functions and basic operations Power switch The air conditioning system is powered when pressed, the screen backlight is turned on, the fan runs at low speed for 3 seconds (no other operation is accepted during this time), and then the state before the last shutdown is restored.
  • Page 64 Heating key Press this key in the ventilation mode to memorize the current status (wind speed setting value), and the system will enter the heating mode. The screen displays (in upper row) graphics disappears, and the system enters the last ventilation state (wind speed setting value). Press this key in the cooling mode to memorize the current status (cooling volume setting value, wind speed setting value), and the system will enter the defrosting mode.
  • Page 65 2. Application of special operations 1) Forced cooling operation This operation should normally be selected in hot weather, especially in the period before the cold air is turned on. The method: select the cooling mode, press the key "Increase wind speed"...
  • Page 66 Machine setting: the system will automatically close the external circulation damper (enter the internal circulation mode) as long as the system operation mode is changed or the machine is shut down. If the operator needs to use the external circulation function after changing the operation mode or just starting the machine, it can only be effective by pressing the key.

  • Page 67: Radio

    Radio 1. TUNING/manual/automatic radio search button for selecting to play MP3 previous/next song 2. CLOCK timer setting key. 3. The VOL -/+volume adjustment button is used in conjunction with CLOCK to set the clock 4. POWER switch and mode switching button. Radio operation instruction 1.
  • Page 68 2. Function description of USB MP3 playback mode buttons In radio operation mode, inserting a USB drive will automatically switch to USB drive playback mode. Press TUNING/ to select the previous/next MP3 song to play; Hold TUNING/to quickly select several previous/next songs, until the button is released to play the selected songs.

  • Page 69: Door And Window

    Door and window 1. Cab door The excavator door is the only path for the driver to get on or off the machine normally. The door must be Door latch locked when the driver leaves the cab. Please fasten the door lock on the door latch when the cab door is open to avoid hurting others.

  • Page 70: Operation Guide

    Operation guide...

  • Page 71: Preparation Before Operating The Machine

    Preparation before operating the machine 1) The excavator should be operated by trained drivers who meet the specific requirements for drivers in each region before independent operation. 2) Drivers are strictly forbidden to manipulate before reading the instruction manual. 3) Drivers must wear tight-fitting and suitable clothing and relevant safety protection equipment adapted to the work before operation, such as safety helmets, leather shoes, gloves, protective glasses, seat belts, etc.

  • Page 72: Engine Operation

    Engine operation Warning: Before starting the engine, please refer to the safety details in this manual. Read all safety signs on the machine. There must be no other people in the workplace. Before operation, learn and practice safe operation. When operating the machine, you must be clear about and follow the relevant operation and maintenance sections of the manual, and comply with the corresponding laws and regulations.
  • Page 73 2. Start the engine Warning: Do not start the engine when there is engine start warning sign on the joystick. Warning: Before starting the engine, it is necessary to confirm that the safety lock lever is in the locked position to prevent accidental contact with the control lever during starting, resulting in sudden action of the attachment and causing accidents.
  • Page 74 ⚫ Start the engine with an auxiliary cable. Warning: When the battery electrolyte freezes, if (1) you try to charge,or (2) jump-start the engine, the battery will explode. To prevent the battery electrolyte from freezing, keep it fully charged. If you do not follow these instructions, you or others will be harmed.
  • Page 75 3. After the engine is started A. Engine warm-up and machine heating The normal working temperature of hydraulic oil is 50° C~80° C. Operating the hydraulic oil below 20° C will damage the hydraulic components. So before starting work, if the oil temperature is below 20 °...

  • Page 76: Get On/Off The Machine

    Get on/off the machine 1) Make sure to hold the handrail (indicated by the arrow) at the door of the cab as shown in the figure. 2) Ensure that the foot is firmly pressed on the track. 3) When getting on and off the machine, it is not allowed to grasp the joystick for security.

  • Page 77: Movement Of The Machine

    Movement of the machine 1. Safety rules for moving the machine 1) Before starting the excavator, it is required to be familiar with the surrounding environment of the site, whether there are pedestrians, obstacles, ground bearing capacity, etc. 2) Before starting the excavator, the horn should be sounded to alert the people nearby to pay attention.
  • Page 78 3. Move the machine forward 1) Adjust the control box to the free position, raise the working device and lift it 40 to 50 cm off the ground. 2) Follow the steps below to operate the left and right travel joystick. When the dozer blade is in front: Slowly push the front of the joystick forward to move the machine.

  • Page 79: Steering Of The Machine

    Steering of the machine Attention: Before operating the travel joystick, check the position of the dozer blade. If the dozer blade is in the rear side, the operation of the travel joystick is reversed. Use the left and right travel joystick to change the direction of travel. Try to avoid sudden changes in direction as much as possible.

  • Page 80: Slewing Of The Machine

    Slewing of the machine ● Before rotating the upper structure, check the surrounding area for safety. ● If you operate the swing joystick quickly, the upper structure will rotate quickly; if you operate the swing joystick slowly, the upper structure will rotate slowly. Pay attention to the operating speed of the joystick. 1) If the machine is equipped with a steering head, operate the selection button on the left attachment joystick to confirm that the machine is in a platform...

  • Page 81: Operation Of The Attachment

    Operation of the attachment If you operate the working device joystick quickly, the working device will move quickly; if you operate the working device joystick slowly, the working device will move slowly. The attachment is operated by the left and right control pilot valves. The left control pilot valve operates the bucket arm and slewing (if equipped with a steering yoke, the left control pilot valve can also control the steering yoke to swing).
  • Page 82 4. Bucket control Swing the right control pilot valve right to turn the bucket out; swing it left to turn it back. Joystick of the right attachment 5. Boom swing (steering yoke) control When the left control pilot valve swings left, the steering yoke turns left;...

  • Page 83: Work On Slopes Or In Water

    Work on slopes or in water Warning: Construction near the foothills and slopes is very dangerous. Different operating conditions such as rainwater, muddy ground, snow covered ground, icy ground, loose sand, and soft ground can pose potential hazards to operational safety. Therefore, when constructing in dangerous areas such as foothills or ramps, it is necessary to make a correct judgment on whether safe operations can be carried out in order to make a decision.

  • Page 84: Keeping Away From Muddy Environment

    Keeping away from muddy environment Always handle with caution to avoid getting stuck in the mud. If the machine gets stuck in mud, follow the steps below to drive the machine out. A. The track on one side stuck Attention: When lifting the machine with a boom or bucket arm, make sure that the bottom of the bucket is in contact with the ground.

  • Page 85: Operation Guide For Construction

    Operation guide for construction 1. Backhoe operation Backhoes are suitable for digging below the machine. When the machine is in the state shown in the right figure, that is, when the bucket cylinder is at a 90° angle to the connecting rod and the bucket arm cylinder is at a 90°...
  • Page 86 3. Trenching operation Position the dozer blade at the rear and anchor it into the soil surface. Extend the boom and bucket arm, and insert the bucket teeth into the soil surface. During the excavation process, adjust the excavation and loading angles of the bucket in a timely manner using the bucket arm cylinder, or switch to using the bucket cylinder for excavation.
  • Page 87 B. Precautions for use of the dozer blade 1) The bulldozer can only be used to move soil, do not use it for digging, otherwise, it will damage the bulldozer or crawler system. (see the right figure.) 2) The dozer blade cannot withstand large or unstable weights, otherwise the dozer blade or track system may be damaged.

  • Page 88: Disassembly And Installation Of The Bucket

    Disassembly and installation of the bucket Safety rules ● When hitting the pin shaft with a hammer, metal shavings may fly into the eyes, causing serious injury. When performing this operation, always wear goggles, safety helmets, gloves, and other protective equipment. ●...

  • Page 89: Park The Machine

    Park the machine Safety rules 1)Avoid sudden stop. When parking the machine, leave as much space as possible. 2) Park the excavator on solid and level ground. Avoid park the machine on a slope. If it is necessary to park the machine on a slope, place a pad under the track and insert the attachment into the ground to prevent the machine from...
  • Page 90 6) After the engine shuts down, reset the shutdown lever. 4-21...

  • Page 91: After Operation

    After operation 1. Check Check the engine water temperature, hydraulic oil temperature, oil pressure, fuel level, etc. on the digital monitor of the machine. 2. Locking The following positions should be locked. 1) Cab door (don't forget to close the window and flip window). In any case, if you want to open the flip window, you need to open the handle lock on both sides of the flip window at first.

  • Page 92: Loading/Unloading And Transport Of The Machine

    Loading/unloading and transport of the machine 1. Safety rules for shipment of the machine 1) Run the engine at a low speed, and operate the machine slowly when loading/unloading. 2) Do not load/unload the machine during automatic warm-up operation. 3) If the automatic warm-up operation is cancelled during the loading/unloading operation, the speed will suddenly change.
  • Page 93 2. Truck loading 1) Truck loading can only allowed on solid and flat ground, and a certain safe distance should be maintained from the edge of the road. 2) Appropriately apply brakes to the transport vehicle, and put a pad under the tire to ensure that the transport vehicle does not move.
  • Page 94 3. Securing the machine on the transport vehicle 1) Well arrange the attachment. 2) Turn off the engine and remove the key from the start switch. 3) Lift the safety lock lever and the above control box 4) Lock the cab and engine hood. 5) Place blocks under both ends of the track to prevent the machine from moving during transportation, and secure the...
  • Page 95 5. Lifting the machine A. Safety Precautions 1) Do not lift the machine when there are people on it. 2) Ensure that the steel wire rope used for lifting the machine has sufficient strength to withstand the weight of the machine. 3) Do not lift the machine in any position other than the one provided in the following procedure, as there is a risk of the machine losing its balance.

  • Page 96: Operation In Cold/Hot Weather

    Operation in cold/hot weather Operation in cold weather Cold weather can cause special problems, so special attention should be paid to protection to prevent serious damage to the machine. Maintenance in cold weather will extend the service life of the machine. 1) Electrical system: Keep the battery clean and fully charged.

  • Page 97: Storage Of The Machine

    Storage of the machine 1. Preparation for the storage To store the machine for a long time, do as follows: 1) Clean and flush all components before placing the machine indoors. If the machine has to be stored outdoors, choose a flat ground and cover it with canvas. 2) Apply a thin layer of lubricating grease to the metal surface of the piston rod.
  • Page 98 2. During the storage 1) During storage, the machine should be operated once a month to apply a new oil film to the surface of the moving parts. At the same time, charge the battery. 2) The air conditioner (if any) on the machine should also be run. 3) Run the track Warning: If rust prevention operations for machine stored indoors are necessary, open the doors and windows to improve the air circulation to...

  • Page 99: Troubleshooting

    Troubleshooting Fault Causes Solutions • Faulty starter motor • Replace or repair the starter motor • Insufficiently charged battery • Charge or replace a new battery • Improper use of preheating lines • Repair or replace the preheating or plugs plug •...
  • Page 100 Fault Causes Solutions • Low coolant level • Add coolant • Faulty temperature sensor • Replace the sensor • Air filter blocked • Clean the air filter 4. Engine • Loose or faulty fan belt • Retighten or replace overheated •...
  • Page 101 Fault Causes Solutions • Incorrect hydraulic oil used • Use the correct hydraulic oil • Consult with dealers of the • Oil path blocked manufacturer • Hydraulic oil filter blocked • Clean or replace • Consult with dealers of the •...
  • Page 102 Fault Causes Solutions • The track is too tight or loose • Re-adjust • Reduced oil pump • Consult with dealers of the performance manufacturer • Crawler frame distorted • Repair or replace • Crushed stones or rocks in the 19.
  • Page 103 conditioning switch cooling degree • Too much water in the system • Replace the drying bottle and internally blocked with ice • The electronic fan or its relay is • Repair or replace damaged 4-34...

  • Page 104: Maintenance

    Maintenance...

  • Page 105: Common Sense For Maintenance

    Check the timer on the dashboard every day to check if it is time for maintenance according to the number of working hours. Use original accessories The use of original Yuchai accessories is an important factor in ensuring the normal operation of the machine and prolonging the service life of the machine.
  • Page 106 Waste disposal For environmental protection, special attention should be paid to the disposal methods of waste: ● Put the oil discharged from the machine into a container. Do not discharge the oil directly onto the ground, or pour it into sewers, drains, rivers, oceans or lakes. ●...

  • Page 107: Maintenance Outline

    Maintenance outline Lubricating oil ● Oil that meets the grade and temperature given in the "Oil Selection Table" of this manual should be used. Within the specified time, even though the oil is not dirty, it must be replaced. ● Pay attention to preventing impurities (water, metal particles, dust, etc.) from entering the lubricating oil.
  • Page 108 ● When replacing the filter element, check if there are metal particles adhering to the old filter element. If metal particles are found, please contact your Yuchai dealer. ● Do not open the packaging of the spare filter element before use.

  • Page 109: Mandatory Replacement Parts

    Mandatory replacement parts With the accumulation of machine working time, some parts that play an important role in safety, mainly some oil hoses, will age, wear or deteriorate in material, affecting their normal function and also becoming potential safety hazards. Such phenomena are not easy to determine.

  • Page 110: Oil Selection Table

    Chilliness area: CJ4 -15° upwards Lube of the engine 15W/40 -25° upwards General area: CJ4 5W/30 Hydraulic oil that meets the requirements of 41.5-50.5 Yuchai Enterprise -35° upwards centipoise Hydraulic oil HS46+ Standard "Technical (When it is Specification for Hydraulic Oil of Construction Machinery"...

  • Page 111: Tightening Torque

    Tightening torque The tightening torque of each bolt and nut on the machine shall refer 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 become loose or even damaged, causing machine failure or affecting operation.
  • Page 112 Tightening torque of hydraulic hose Metric threaded rotary nut Outer diameter Metric thread of steel pipe Nominal moment min./max 15 〜25 M12X1.5 30 〜45 M14X1.5 38 〜52 M16X1.5 M18X1.5 43-85 M20X1.5 50-65 60 〜88 M22X1.5 60 〜88 M24X1.5 M26X1.5 85-25 M30x2 115-155 M36x2...
  • Page 113 Tightening torque of hydraulic hose BSP thread and swivel nut BSPP min./ max Metric torque thread 15 ～25 G1/4 27 〜41 G3/8 42 〜76 G1/4 G5/8 44-94 G3/4 95〜135 115〜165 G1.1/4 140〜280 G1.1/2 215-365 300-500 ORFS rotary nut Marking thread specifications 9/16〜18 11/16〜16...

  • Page 114: Regular Inspection And Maintenance Schedule

    Regular Inspection and Maintenance Schedule According to the table below, regularly inspect and maintain the machine according to the working hours indicated by the engine timer. If the machine is in poor working condition or has high working intensity, or is equipped with accessories such as hydraulic crushing hammers, the inspection and maintenance interval of certain components needs to be reduced.

  • Page 115: Regular Inspection And Maintenance Schedule (Contd.)

    Regular Inspection and Maintenance Schedule (contd.) Maintenance period (total working hours) Page Inspection and maintenance details 1000 2000 Engine air intake system • Empty the dust accumulation tank ▲ • Clean the air filter element ▲ • Replace the air filter element ▲...

  • Page 116: Routine Inspection

    Routine inspection Perform a general routine inspection of the machine every day or every 10 hours. 1) Leakage inspection to check for oil, water, and fuel leaks in various parts of the machine. 2) Check for scratches, breaks or deformations on the elastic connectors and accessories. 3) Check the fixation and connection of the hydraulic devices.

  • Page 117: Engine Fuel System

    Engine fuel system Maintenance instructions Tank capacity ....................100 liters Oil level inspection ..................10h Drain water and impurities from the tank ............ 100h Clean the tank ..................... 250h Replace the fuel filter element ..............500 hours 1. Oil level check and refilling The fuel level shall be checked through the fuel gauge on the side of the fuel tank or the fuel level indicator on the combined...
  • Page 118 4. Exhaust of the fuel circuit If air flows into the fuel line due to replacing the fuel filter element, disconnecting the fuel pipeline, cleaning the fuel filter or inadvertently emptying the fuel tank, the air shall be removed before restarting the engine. Discharge the fuel circuit 1) Fill the fuel tank and open the fuel filter control lever;...

  • Page 119: Engine Cooling System

    1) Turn off the engine, open the drain valve by hands, turn the valve counterclockwise for about three and a half turns, until the valve drops at 25.4 mm (1 in) and begins to drain; 2) Drain the water from the separator until the clean fuel is visible.
  • Page 120 Radiator capacity ..............5.7 liters Coolant level check ............every day or every 10 hours of operation Check the condition of rubber hoses and clamps ....every day or every 10 hours of operation Clean the radiator blades ........... every 500 hours of operation Coolant replacement ............
  • Page 121 Open the engine hood and use high-pressure water or compressed air to blow away debris such as dust or leaves that clog the radiator fins, oil cooler fins. At the same time, clean the protective strainer in front of the oil cooler. For machines equipped with air conditioning, it is also necessary to clean the condenser fins.
  • Page 122 Warning: The coolant is toxic. Avoid children and pets coming into contact with the coolant. If no longer used, dispose of it in accordance with local environmental regulations. Warning: Antifreeze shall be used in any weather. Do not use only water as coolant. Otherwise, it may be damaged due to corrosion.

  • Page 123: Engine Lubricating System

    Engine lubricating system Maintenance instructions Oil volume ..................7L Oil level check ................. Every 10 operation hours or every day Change the oil or replace the fuel filter element ....... Every 500 hours of operation 1. Check the oil level Before starting a new engine, check the oil level once, and thereafter check every 10 hours.
  • Page 124 3) Clean the drain plug and reinstall it. If the seal ring is damaged, replace it. 4) Open the oil filler port. Oil filler port 5) Refill with new oil until the oil reaches the "Maximum" mark H on the oil dipstick. 6) Cover the oil filler cap and allow the engine to idle for 5 minutes.

  • Page 125: Engine Air Intake System

    Engine air intake system Maintenance instructions Air filter element replacement frequency........Every 500 operation hours 1. Replace the air filter element When the air filter blockage alarm indicator light on the digital detector is on Air filter blockage alarm or for every 500 hours, the air filter should indicator be replaced.

  • Page 126: Other Maintenance Of The Engine

    Other maintenance of the engine Warning: To prevent injury, do not perform maintenance while the engine is running. If maintenance must be carried out with the engine running, it should be carried out with at least two people and in accordance with the following regulations: There must always be one person sitting in the operator's seat and ready to turn off the engine at any time.

  • Page 127: Hydraulic System

    Hydraulic system Maintenance instructions Hydraulic oil tank capacity ................…………..50L Oil level inspection ..................…. Every 10h Change filter ................... Every 1000/2000 hours Hydraulic oil change ................. Every 2000 hours Check the system pressure ............... Every 500 hours Warning: If hydraulic oil or grease is injected into the skin, it can cause serious injury and death.
  • Page 128 after the oil cools. If the oil gauge shows that the liquid level is too low or the liquid level is not visible, oil shall be refilled in time through the oil filler port on the top of the hydraulic oil tank. Attention: The hydraulic oil level will change with the increase of oil temperature during operation.
  • Page 129 2. Remove water and dirt from the hydraulic oil tank dipstick Drain the water and dirt from the hydraulic oil tank every 250 hours. 1) After stopping the machine until the oil temperature drops or before starting work every day, discharge the air from the oil tank.
  • Page 130 tank to reach the middle of the oil dipstick. 11) Install the oil suction filter and cover the air filter. 5-27...
  • Page 131 4. Exhaust the air in the hydraulic system A. Exhaust the air in the pump 1) Loosen the exhaust screw plug in the exhaust port, and check whether there is oil flowing out. The exhaust is completed. 2) Tighten the screw plug after the exhaust is completed. Note: If the pump is operated if the pump is not full of oil, it will be abnormally heated and cause premature damage to the pump.
  • Page 132 E. Discharge the air in the walking motor (when the oil in the casing of the walking motor is discharged) 1) Run the engine at idle speed and loosen the exhaust plug. If oil comes out, tighten the screw plug. 2) Run the engine at idling speed and rotate the working device 90 degrees so that it is located on the side of the crawler.
  • Page 133 5. Replace the oil return filter element Air filter After that, replace every 1000 hours. The Cover Cover oil return filter is in the hydraulic oil tank, O-ring O-ring Spring 1) Unscrew the cap on the top of the tank. Spring 2) Remove the spring, bypass valve, and Bypass...
  • Page 134 Attention: If the pressure of the main oil line, dozer oil line, and pilot oil line can not meet the requirements, please contact Yuchai service agency. 5-31...

  • Page 135: Travel Reducer

    Travel reducer Maintenance instructions Lubricating oil capacity of rotary reducer ..........1.6L Lubricating oil capacity of walking reducer ..........2.5L (each side) Check the lubricating oil level and add oil ..........every 250 hours Replace the lubricating oil ............... every 1000 hours of operation Check the tightening torque of the reducer connecting bolts ....
  • Page 136 2. Replace the lubricating oil (for each reducer) After that, replace every 1000 hours. 1) Park the excavator on level ground. 2) Rotate the reducer so that the screw plug is in the position shown in the previous section 3) Drain the oil when the reducer oil is hot. Note: Don't burn yourself by hot oil.

  • Page 137: Track

    Track Check and adjust the tension of the track A. Rubber track Check every 10 hours. 1) Park the excavator on a level and solid ground. 2) Put the bulldozing blade at the back and extend the piston rod of the bulldozing cylinder until the crawler is slightly lifted.
  • Page 138 Check and adjust the tension of the track B. Steel track Check every 10 hours. 1) Park the excavator on a level and solid ground. 2) Correctly tension the track so that the branch amount f on the track is controlled at a deflection of 15-25 cm (a in Fig.1).

  • Page 139: Track Roller, Support Roller, And Guide Roller

    Track roller, support roller, and guide roller 1. Check the tightening torque of the track roller The first inspection after working for 50 hours and then every 500 hours. The tightening torque of bolt ① shall be 420 N· m. If the bolts loose, unscrew the bolts, remove the thread locking agent between the bolt threads, and then apply the...

  • Page 140: Lubrication

    Lubrication Lubricate the lubrication points of the machine every 50 hours. Lubrication steps: 1) Start the working device and put the bucket on the ground. 2) Put the bulldozing shovel on the ground. 3) Stop the engine. 4) Wipe clean the filling nozzles of each oil cup. 5) Lubricate each lubrication point and wipe off excess grease squeezed out.

  • Page 141: Air Conditioner (If Provided)

    Air conditioner (if provided) For the air conditioning equipped for the cab of this machine, its operating knob is set on the left control box panel of the cab. For the specific operation and maintenance of the air conditioning system, please refer to the operation manual of the air conditioner attached to the machine while referring to this manual.
  • Page 142 3. Check and adjust the tension of the air conditioning compressor belt Compressor belt pulley Check and adjust the tension of the air conditioning compressor belt every 250 hours. Drive pulley A. Inspection Press the belt in the middle between the drive pulley and the compressor pulley with a finger force of about 12N and check that its deflection is about 5-7mm.
  • Page 143 4. Regular inspection contents of air conditioning Inspection cycle Inspection Inspection items Every Every contents month season Whether there is ★ All fasteners looseness and falling off ★ Air conditioning belt Tension and wear Whether there is ★ Pipeline abrasion or crack Any abrasion or ★...

  • Page 144: Bucket Teeth Replacement

    Bucket teeth replacement Replace the bucket teeth before the bucket teeth base is worn. Warning: When replacing the bucket teeth, it is very dangerous if the working device moves accidentally due to wrong operation. Therefore, before replacing the bucket teeth, turn off the engine and then lift the left control box to place the attachment in a locked state.

  • Page 145: Washing Of Floor Mats

    Washing of floor mats If the floor rubber mats are dirty, clean them at any time to prevent accidents due to slipping and falling of the floor. Warning: If you accidentally touch the joystick, the working device or machine will suddenly move, causing serious accidents.

  • Page 146: Maintenance Of Electrical System

    Do not wash the inside of the cab with water. During flushing the machine, prevent the water from flowing into the electrical parts. 6. Do not install any electronic components other than those specified by Yuchai Heavy Industry.

  • Page 147: Accessories Guide

    Accessories guide...

  • Page 148: Safety Precautions

    Safety Precautions If you install accessories or options that are not approved by Yuchai, it will not only affect the service life of the machine, but also cause some safety problems. During installing accessories that are not approved by Yuchai, please contact Yuchai dealer in advance.
  • Page 149 ● Do not walk under the load lifted by the crane. Stand in a safe place where there is no danger even if the load falls. Warning: A qualification certificate is required to operate a crane. Unqualified personnel are not allowed to operate the crane. For details on disassembly and assembly operations, please contact Yuchai Heavy Industry dealer.

  • Page 150: Assembly/Disassembly Steps Of Accessories

    Assembly/disassembly steps of accessories 1. Disassembly steps 1) Put the accessories on the ground and turn off the engine. 2) Turn the start switch to the ON position and push the left control box to the free position. 3) Operate each working device joystick and accessory control pedal 2 to 3 times forward, backward, left and right full stroke to eliminate the internal pressure in the hydraulic oil circuit.
  • Page 151 Note: Select the most suitable accessory for the main engine. The models of machines that can install accessories are different. For the selection of accessories and machine models, please contact your Yuchai dealer. Hydraulic breaker hammer 1. Guidelines for the use of hydraulic breaker hammer Hydraulic breaker hammer is the most common work accessory.
  • Page 152 4) Make sure that the drill rod always impact the surface properly to prevent the impact force from being used if there is no resistance. If the rock or the target has been crushed, stop the action of the breaker hammer immediately.
  • Page 153 3) The drill rod is moved during impact operation. 4) Apply impact force horizontally or upward 5) Swing the breaker after it has penetrated the rock 6) Pecking operation...
  • Page 154 7) Carry out crushing operations in water or muddy ground 8) Use the breaking hammer as a tool for lifting heavy objects. 9) The bucket cylinder is fully extended to lift the machine off the ground.
  • Page 155 Quick coupler 1. Bucket installation 1) Pry up ① with a crowbar. 2) Put the bucket pin into ②③, put down the crowbar, and the bucket is installed. 2. Unloading the bucket 1) Pry up ① with a crowbar. 2) Unload the bucket.

  • Page 156: Daily Inspection Of Hydraulic Breaker Hammer

    Daily inspection of hydraulic breaker hammer Carry out the daily inspection and maintenance of the hydraulic breaker hammer according to the following table. Serial Inspection or Check points Maintenance method number maintenance items Check whether the bolts Body bolts and side Tighten the bolts or reinstall and nuts are loose or plate bolts...
  • Page 157 Guangxi Yuchai Heavy Industry Co., Ltd. SJ008/E35BF51S-2019 Publication Date: Aug. 2021 Address: No. 168, Tianqiao Road, Yulin City, Guangxi, China (537005) Phone: 95105432...

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