Yuchai YC60-9, Operator'S Manual

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Page 2: ...vices 2 3 Safety labels 2 11 Work area safety 2 12 Safety Operation 2 23 Transport load and unload 2 24 Repair 2 2 5 Prevent fire blast and poisoning 2 26 Battery 2 28 Hydraulic System 2 30 Ⅲ PARTS DESCRIPTION Description of operation device 3 1 Instrument 3 7 Right control box switch panel 3 9 Left control box switch panel 3 10 Safety Lock Lever 3 11 Operation of working device and slewing part 3...

Page 3: ...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 Operating guide 4 17 Dismantling or installation of bucket 4 18 Parking 4 19 Check after completion of work 4 20 Loading unloading and transportation 4 24 Precautions of working in cold or high temperature area 4 25 Long time storage 4 27 Trouble shooting 4 32 ...

Page 4: ... System of engine 5 25 Other Maintenances of Engine 5 26 Hydraulic System 5 31 Battery 5 33 Reducer 5 35 Tracks 5 36 Bottom roller upper roller and front idler 5 37 Lubricate 5 38 Air Condition If the match 5 41 Replace Bucket and the teeth 5 42 Washing the floor mat 5 43 Maintenance of electrical system 5 44 Ⅵ Accessories Safety precaution 6 2 Installing and dismantling steps of accessory 6 3 Ope...

Page 5: ...rstand the content about safety operating in the manual Understand familiar all the safety labels on the machine 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: ... office or agent for Important servicing and adjustment and use the original parts supplied by our company It will cause many problems if you install unoriginal parts on our machines even it is not clear effect for beginning We will not supply the warranty service if the machine broken as used the unoriginal parts or repaired by the service department which is not authorized by Yuchai even it is d...

Page 7: ...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: ...es 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: ...1 4 Machine Description Front rear left right top underside in this manual are same as the direction as follow ...

Page 10: ...tor 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: ...rall width Mm 1920 D Crawler width Mm 400 E Platform slewing radius Mm 1520 F Crawler length Mm 2494 G Wheel base Mm 1960 H Min ground clearance Mm 316 I Overall height Mm 1943 J Width of platform Mm 1865 K Height of engine hood Mm 1650 L Height from floor to platform Mm 670 Width of bucket Mm 742 Walking speed low hight Km h 2 2 3 6 Platform slewing speed Rpm 9 11 Cab With swing boom Note Technic...

Page 12: ...0 C Max digging depth Mm 3720 D Max digging radius Mm 6065 D1 Max horizontal digging length Mm 5945 E Max digging height radius Mm 2750 F Min slewing radius Mm 2175 G Max depth of Bulldozer Mm 330 2 H Max height of Bulldozer Mm 363 8 I Boom swing angle Right 55 J Boom swing angle Left 75 Max digging force kN 36 6 ...

Page 13: ...1 8 Note Technical data are subject to replace without prior notice 3 Buckets SN Capacity m3 Bucket Width mm Bucket Weight kg Bucket teeth 1 0 21 742 181 4 ...

Page 14: ...oltage 12V Battery 120AH 7 Environment condition Temperature 15 40 0C Humidity 85 Temperature of transportation and storage 15 40 0C 8 When the excavator equipped with some other accessories it may interfere with the boom cylinder or it s protecting cover so if you install some other accessories please pay attention to the retracted angle of the arm and boom for avoiding the damage of the boom cyl...

Page 15: ...any method or action not recommended or permitted by this book The Forbidden purposes and operations of this manual shall never be done in any circumstance This excavator shall be operated and maintained by trained and qualified persons Please check all the functions of the machine before starting work If you found the machine work improperly please stop immediately and check it Don t continue wor...

Page 16: ... means the consequence of danger will cause death or severe injury if not evading only applicable to the few places where the most serious danger exists Warning It means the potential consequences of danger could cause death or severe injury if not evading Attention It means the potential consequences of danger could cause low or medium level injury if not evading Also it could be indicated the un...

Page 17: ...n normal function or not before operating or maintaining 2 Flee hammer and fire extinguisher Escape hammer is on the left doorpost If you are trapped in the cabin and can t open the door please use the hammer tip against the glass until the glass shattered then escape from cabin Please hit the glass eyes and face Fire extinguisher shall be installed in the driver s Cabs we designed a spare install...

Page 18: ...Please do not clean safety labels with organic solvent or gasoline which will damage 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 mach...

Page 19: ...2 5 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: ...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 use the stepping staircase and the crawler board on the machine 3 Read operation manual carefully Read operation manual carefully before operating maintaining dismantling assembling and transportation 4 Locking mark 5 Grease filling mark ...

Page 21: ...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 11 Please lock front window after opening Unlocked front window might fall down suddenly due to vibration or outside force and cause physical injury ...

Page 22: ... 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 high pressure might cause physical injury Please don t open the lid until hydraulic oil and coolant cooling down ...

Page 23: ... 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: ...2 10 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 ...

Page 25: ... physical injury 28 Please make reference to operation manual or related instruction Electronic system is prone to electric shock please follow maintenance instruction 29 Beware of the physical injury may caused by high temperature parts such as engine radiator and muffler etc Please don t touch these parts during running Maintenance must be waited until machine is shut down and parts temperature ...

Page 26: ...l as the load bearing capacity of floor and ramp if you work inside building Make sure adequate ventilation in the building Inadequate preparation might harm you 14 Please be aware of the precise distance between machine and electric telecom wire between machine and floor Please shut down power supply if possible Otherwise please ask signaler guiding Warning It may cause electric shock when the ex...

Page 27: ...perator 3 It is only allowed to operate the machine when sitting on the seat 4 Please don t start engine by shout circuit starting 5 Please preheat the machine in cold weather Warning please do not starts engine when a warning board of prohibiting is hung on joy stick B After engine starting The following items must be checked after the engine is started 1 Buckle up or not 2 Working device dozer d...

Page 28: ...bin front window and top window is allowed to open but they must be locked 5 Before excavator moving back or rotating an assistant is necessary for blind spot The safety rules for traveling 1 When traveling on level surface excavator s boom must be lowed and arm must be drawn back and kept the best position of centre of gravity The bottom of bucket is kept 40 50cm from ground surface 2 When excava...

Page 29: ...rk on slope It is dangers for excavator travel or work on slope please be especially careful 1 It is recommended not to climb uphill or downhill on long slope over 20 degrees 2 Please ensure buckle up when working on danger zone of uphill or downhill 3 When excavator is uphill the driving wheel should be in the downhill direction and keep boom and arm extending out in the parallel with the slope A...

Page 30: ...w speed when traveling on meadow dead leaves or wet steel plate The excavator might slip even in the case of small gradient 8 It is forbidden to turn excavator sharply when going uphill or downhill otherwise the machine will tip over 9 When stop the machine on the slopes please make sure the dozer has been inserted into the earth as well as the bucket and it s no allow to stop the engine if the ma...

Page 31: ...than 15 degrees 12 Please keep the excavator balance and it is forbidden to travel on rock or obstacles 13 It is forbidden to change direction on slope 14 When climbing uphill make sure that the engine and hydraulic oil are properly warmed up otherwise it may cause accidents 15 Please do not turn from upslope to down slope side when the machine is full load it will cause tip over ...

Page 32: ... Wrong operation will make machine overturn learn this section will help you to keep personal security 1 Before operating all the things and the people should be removed 2 Do confirm the workplace can bear the machine before the machine enters 3 As far as possible the two crawlers are in the same plane then it can operate 4 Do confirm there is no cable no windpipe no water pipe in the workplace be...

Page 33: ... the machine digs deep it needs to avoid the hoses at bottom of the boom or bucket cylinder touch the ground 10 To avoid the boom arm bucket and cabin canopy collide with any nonego 11 When the machine rotates do avoid to colliding the engine hood and the counter weight 12 Don t stop operating suddenly during descending the boom to avoid machine damage 13 Do not dig to the machine body 14 Don t di...

Page 34: ... 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 Otherwise the parts will be overload and broken 19 Do not use the falling power of the machine Otherwise the machine will be broken ...

Page 35: ...ng power to dig It makes the back of the machine bear overweight 22 Do not dig the plane which is under the hanging part It may cause the danger of the rock fall or the collapse 23 Protection guard is requested if the operating site have the danger of falling objects or splashing objects 24 Operating on soft ground or swampland is prohibited 25 Don t use the excavator to draw objects 26 Don t use ...

Page 36: ...e snow the road shoulder and the objects which was buried in snow is invisible machine could be overturned or buried so be careful during operation 6 Prevent overturning sliding and the solution Warning 1 If it needs to swerve on the slope it can only swerve with big radian When the machine turns right turn the lever of the boom to left When the distance to the ground is about 30cm lock the platfo...

Page 37: ...ers and the gradient the rotating platform is more than 90 7 The machine operates on the slope it swerves the platform rotates fast or stops unexpected 8 When the machine turns down about 180 9 It is the uneven road for the back operation 10 The machine digs the underside of the machine when it deeply digs 11 The machine moves on the frost road 12 The two crawlers are with the oil or the lube 7 St...

Page 38: ...ives it from the port it can use two laths which are strong enough to put in the transporter The gradient of the laths should be less than 15 The length of the gradient is 3 5 times of the height The width of the lath is 1 2 1 5times of the crawlers Do put down the orientation handle to avoid the platform rotates when it is up or down the slide When the machine drives up or down the slide do not o...

Page 39: ...ed it should take down the cathode cable of the accumulator Do avoid the current movement After the machine starts do not lubricate or maintain Do not let the motion touch the running part If the machine needs to maintain when the engine runs there should be someone to see it Do not put some small parts into the placket The high pressure liquid can hurt the eyes and the skin Do avoid it when the m...

Page 40: ...lip spill lamina and other flammability thing which is in the engine the vent pipe the muffler the engine room Do not put the dishcloth which is with the oil into the cab There should be fire extinguisher in the cab and put it on the place where can be easily to take from When the machine is welded do segregate the pipeline of the hydraulic oil and the fuel Do avoid the fire caused by the hydrauli...

Page 41: ...ectric torch to check the electrolyte of the Battery The end of the sealed Battery dilates it show the Battery freezing When the Battery freezing do not electricize or connect the starting engine The temperature should be less than 15 when heat up the freezing Battery Otherwise it explodes Explosion proof of the Battery Because it has danger of spark do as follow Please fix the Battery to the righ...

Page 42: ...ty 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: ...on of the high pressure soft pipe If the high pressure leaks it will make the fire or the operation trouble and lead the serious hurt or destroy If the bolt is loose stop the machine and screw it down Do not weld the machine when the hydraulic oil pipeline soft pipe is not separate If the soft pipe is broken do stop operate and contact us If any problems as follow happen do replace the soft pipe 1...

Page 44: ...s Using wrongly will lead to explode Do not take down the Battery no drilling and welding Do not close to the fire Avoid collision and impact It should be managed by professional person The machine is installed Accumulator in the control pipeline It is a device which stores the pressure It can operate the control pipeline for a short time after the engine stops Operating the joy stick can put down...

Page 45: ...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 Right travel control lever 12 Radio ...

Page 46: ...3 2 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: ...3 3 A Instrument Display ...

Page 48: ...3 4 ...

Page 49: ... 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: ...ck 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: ...ssword 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: ...gar 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 3 Starting switch OFF Position Insert or pull out the key the machine is no power in this position the engine is stop ...

Page 53: ...lamp is flashing when the key in HEAT position Release the key after preheated and it will back to ON position turn to START position to start the engine 4 Working lamps switch Switch for boom lamp and front lamp on top the cab 5 Wiper switch a OFF b ON wiper moving in low speed c ON wiper moving in high speed 6 Front window washing switch 7 High Low speed switch 8 Taillight switch Accessories Whe...

Page 54: ...3 10 Left control box switch panel AC control panel see AC control section ...

Page 55: ...d and make the movement of working device or platform and causing accidences LOCK Turn the safety lock lever to vertical position with the control box no hydraulic oil supplying from pilot system when the safety lock lever in lock position working device and the platform are not work UNLOCK Turn the safety lock lever to horizontal position with the control box pilot system and the hydraulic oil sy...

Page 56: ...o rise the boom Bucket movement Push to right bucket extend out Push to left bucket draw back 2 Digging and Platform swing With swing head A Left joy stick Digging arm movement Push forward to extend the arm Push backward to draw back the arm Platform slewing movement Push the Joy stick to left platform will slew to left side push the Joy stick to right platform will slew to right side Boom Swing ...

Page 57: ...ing and platform slewing It is platform slewing function in normal condition press the button switch to boom swing function 3 Blade control Lever Push the lever down the blade lower Pull the lever up blade lift 4 Operation of accessories Use the pilot pedal to control the accessories if the machine with some other accessories ...

Page 58: ...n 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 ...

Page 59: ...nual throttle Push the lever backward to 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: ...osition when release the handle Backrest Adjust Pull the Backrest Adjusting handle up to adjust the Backrest have 5 adjusting position The backrest is lock after released the handle Headrest Adjust Pull backward the Headrest Adjusting handle push and pull the headrest in a proper place Armrest Incline Adjust Turn the Armrest Adjusting handle adjusting the incline of the armrest Notice Must stoppin...

Page 61: ...efore using replace if it is wear or damage Replace the seat belt every 3 years date of manufacture is printed on the label of safety belt Fasten the seat belt during operation Don t twist the seat belt when fasten the seat belt 1 Fasten Seat belt Hold the seat belt clip check if it is twisted adjust the length then buckle up Pull the seat belt to check if it is locked 2 Unfasten Seat Belt Push th...

Page 62: ...utdown Cooling button Cooling mode will be started when press this button this fig indicating on screen restore to the value of last shutdown Press this button under cooling mode system into ventilation mode this fig disappear memorize current status The system into defrosting mode when press this button under Heating mode and appear on the screen and restore to the value of last shutdown The syst...

Page 63: ...ast defrosting mode status System into cooling mode when press this button under defrosting mode memorize current status heating value wind speed defrosting mode is canceled this fig disappear system is in last cooling mode status cooling value wind speed Circulating button System into outer loop mode when press this button appear on screen and press this button under outer loop mode system into i...

Page 64: ...ss wind speed increasing button select the max wind speed press TEMP button by the downward arrow and select the lowest temperature value 2 Normal cooling operation In normal hot climate the operator should select this kind of operation after the A C has work for certain time and the temperature inside cabin is comfortable or a little be cold The method is as follows choose cooling mode press wind...

Page 65: ...In inner loop mode no this on screen the fresh air can t go into cabin In outer loop mode appear on screen heating or cooling efficiency will be affected Please choose the suitable mode according to different working condition Default setting on this machine once the system running mode is changed or system shutting down the A C system will close outer loop automatically If the operator try to use...

Page 66: ...atus Press this button shortly information of song displayed only western character supported Long press this button and enter into song search mode Press key 8 VOL or key 9 VOL to select previous next song Press key 6 CH or key 7 CH to move to 10 songs ahead or after Press key 5 TU or key 4 TU to select the first or final song After the song is selected press this button to confirm 3 CLK MUTE mut...

Page 67: ...ortly to increase or decrease the frequency Or long press key 7 or Key 6 select the frequency which will be saved the frequency will be saved automatically after 3 seconds MP3 status 10 songs backward from current song 7 CH 10 f frequency selection save and MP3 quick search Radio status Shortly press this button to select next saved frequency Long press this button enter into saving mode The frequ...

Page 68: ...djust value 11 Remote control window 12 Information screen 13 USB port insert USB flash memory search song on flash memory and play 14 SD MMC port song on SD MMC card start playing after the card is inserted in the port Attention 1 No Clock on the radio 2 The operation will be a little different for different models of Radio ...

Page 69: ...or 2 Rear window Rear window can be an emergency exit If the cabin door can t be opened the operator should use emergency hammer to break rear window and then escape 3 Front window overturn window If the overturn window is opened operator have better vision and fresh air How to open overturn window front window Unlock the hand lock on both side of overturn window slide the overturn window to the t...

Page 70: ...r not 6 Clean dust and dirties around engine radiator and battery 7 Check hydraulic device oil tank rubber hose and hose connector leaking or not stop the machine and check if any oil mark on the ground 8 Check bolts on chassis parts crawler driving wheel idler wheel fixed or not as well as the bolts that connects chassis and turrets 9 Check instruments monitor works or not 10 Clean and check rear...

Page 71: ... rubber hose for any crack wearing or clearance Please change the parts if anything unusual found 5 Check hydraulic device hydraulic tank rubber hose and connector for leaking 6 Check chassis including track shoe driving wheel and idler wheel for possible damage wearing loosing and leaking 7 Check instruments and working light as well as the electric cable for any short cut or damage 8 Check coola...

Page 72: ...ps on instrument If any alarm information is found please debug and then start engine A Start engine in normal temperature Turn the ignition key to position ON engine can be started normally if alarming light off Turn the ignition key to position START keep it in this position less than 10 seconds After the key is released it will be back to potion ON If the engine can t be start successfully the ...

Page 73: ... persons to operate it one on operator s chair another one for the battery connecting 2 While using another excavator to start the engine keep 2 machines separating 3 Turn both 2 machine s ignition start to position OFF when the assistant electric cable are connected incase the machine moved suddenly 4 While connecting the assistant electric cable the negative pole must be connected finally While ...

Page 74: ...d 1 Check whether all status lights are off 2 Check whether any liquid hydraulic oil fuel and water leaking 3 Check machine s sound vibration heat smell and instruments normal or not If any abnormality is found repair it immediately 4 Engine shout down Attention If the engine is shut down suddenly before it cools down the service life of the engine will be greatly shortened Therefore do not shut d...

Page 75: ...mp up or down the excavator While the excavator is moving do not get in or off the excavator 6 If the operator planned to left the machine please low down the working device to the ground and turn the safety lever to locking position shut down the engine and keep the status to next starting Attention please take out the ignition key and lock all door and window before leaving the machine Do not cl...

Page 76: ...ty on optimal position 7 Do not carry any other person except for the operator while the excavator is mobbing 8 Check chassis direction before turning the excavator s direction 9 When the doze blade is at rear of the machine the operation the travel stick contrarily 10 Keep unrelated people from working site 11 Remove obstacle from the traveling route of excavator 12 It is the blind area at the re...

Page 77: ...hen operate in the cold weather if the machine does not move normally please warm up the machine Clean the chassis if the crawler is blocked by mud 2 The platform maybe moved because of inertia when you take a sudden turn under high speed 4 Machine move backwards 1 Turn the safety lock lever to position of unlock lift working device 40 50 cm from the ground 2 Operate opposite to forward 5 Stop mac...

Page 78: ...ing please stop the machine before operation 1 Turning direction while excavator stop Turn left When traveling forward push right traveling lever then the excavator turns left When traveling backward pull right traveling lever then the excavator turns left Turn right Operate left traveling lever by same method Turn in place When the machine turn in place pull left traveling lever and push right tr...

Page 79: ...rating 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 the button on the left Joystick make sure the machine is under slewing fountain 2 Left joystick is responsible for turret rotating ...

Page 80: ... device could be lowed down to the ground And by operating joystick after shutting down the engine remaining pressure inside hydraulic circuit can be released boom of excavator can be lowed down after loading on the truck 1 Operating digging arm Push left joystick arm extends out pull left joystick arm is taken back 2 Operating platform slewing Push left joystick to left direction turret turns lef...

Page 81: ...k to the right the boom swing to the right If the machine has boom swing function make sure the machine is under boom swing fountain 6 Operating dozer blade Push the dozer control lever down the dozer blade down Draw up the control lever dozer blade lift up Notice operating arm could come across action pause This is not a false state but a normal situation Because when the arm moving self weight a...

Page 82: ...or operate working device of excavator might cause excavator turnover due to imbalance Especially when the machine is with load it is very dangers to rotate the machine toward downhill direction If the rotation is inevitable please pile up a working platform by soil to keep the machine working in balance Do not travel up or down steep slope it might cause turnover When the excavator travels uphill...

Page 83: ...le between arm and boom should be 90 110 degree If only one side of tracks sunk into mud lift the machine by bucket put boar or log under the track drive it out If it is necessary put a boards under the bucket B Both tracks sinking into mud If both tracks sunk into mud and slipping put boar or log under the tracks by the same method mentioned above Insert the bucket into the ground in front of the...

Page 84: ...45o outward and 30o inward Please operate the arm in proper digging range as possible as you can do not pull or push the cylinder to the end of its moving distance Attention before digging on hard rocky ground please break the ground by other means first to ease off damage and save cost 2 Loading work In narrow working site it will have better working efficiency to park the dumping truck in the pl...

Page 85: ...first leave the machine after electric is cut off 4 Backfill and smoothing work To fill up a ditch cut over dozer blade into soil to certain depth then release dozer blade operating lever drive the excavator perpendicular to ditch push soil in to the ditch by dozer blade 5 Clean the soil and sand from the bucket Keep the arm at almost horizon status and bucket at unloading status If sand and soil ...

Page 86: ...h 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 4 When using blade to lift up the machine make sure it is on a flat and reliable ground ...

Page 87: ... the bucket Be careful not to bumps your hands Don t put your hands in the pin which is aim at the o rings rightly Bucket installation Stop the machine on a firm and solid ground Start the machine then operate the arm till the hole of the arm and bucket in a line then put a steel bar into it Raise the arm and bucket dozer the blade Extend the bucket cylinder to align the hole of the arm and bucket...

Page 88: ...osition otherwise accidental action on a lever may cause sudden machine movement and it may cause injury or death Parking 1 Put all levers in neutral position 2 Don t stop the engine abruptly before it is cool enough If the engine is over heated let it run at low speed for 5mins then stop it 3 Lower bucket and dozer blade on the ground 4 Push the throttle handle forward to the end lower the engine...

Page 89: ...u 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 windows down 2 Fuel filling port 3 Hydraulic oil filing port 4 Battery box cover 5 Oil tank and Engine hood Before close the Oil tank and Engine hood please replaced the gas spring by your hand Attention M...

Page 90: ...grease or oil 7 Never change the direction of travel when on the ramps If it is necessary drive off the ramps and correct the direction then drive on to the ramps again 8 Don t use the work equipment to load or unload the machine 9 Don t operate any lever besides walking lever when the machine is on the ramp 10 The machine s focus may be suddenly changed at the joint of the ramp and trailer which ...

Page 91: ...ate any other fountions besides the travel 5 Set in direction of the ramps then stop walking to extend the arm B enable the front of crawler load the trailer s floor Lower the work equipment for fear it hitting the trailer then travel slowly to load or unload the machine correctly in the specified position on the trailer 6 Lower down the arm slowly and make the bucket contact with floor then lower...

Page 92: ...trailer and insert blocks beneath the tires to ensure that it does not move 3 Fix ramps in line with the centre of the trailer and the machine Be sure that two sides are at the same level as one another Make the angle of the gangplank a maximum of 15 Set the distance between the ramps to match the centre of the tracks 4 Remove the chains or ropes on the machine 5 Start the engine If it is winter t...

Page 93: ...ording to different configurations the size the weight and the barycentre are different so the lifting procedure also will be different When lifting the machine it must be on the smooth floor and do as the following procedures 1 Slew the platform of the machin keep the working device at front of Front idler wheel 2 Extend the bucket cylinder and arm cylinder completely and use boom cylinder to low...

Page 94: ...e working every 50 hours each time If there s no water inside extend the inspection cycle or else check the oil tank 4 Cooling system before operating the machine in cold weather it is necessary to check the coolant if it is mixed at a suitable proportion and the coolant must be the right one which is fit for the environment temperature 5 Work equipment before starting the engine put the throttle ...

Page 95: ...l and mix them completely In order to prevent from bringing about condensed water refill the fuel tank with this kind of mixed oil 6 Check the antifreeze function of the coolant By filling with antifreeze its antifreeze ability is at least 20 There is non corrosion inhibitor in coolant because of the climate you should fill with corrosion inhibitor it contains 5 corrosion inhibitor according to MI...

Page 96: ...after starting the engine you should check the oil at all places If the oil mixed with some water the oil at all places should be changed Attention 1 According the climate the machine can be stored for a year by means of above method However after storing for six months you should operate every part for 15mins without load At the same time add the lubricant to every part 2 Before operating the mac...

Page 97: ... plugged Unblock the air intake and exhaust system 2 Engine shock runs irregularly or stops A lot of air run about Consult with agent Fuel filter is plugged Clean the filter There is dirt or air in fuel system Exhaust and clean fuel circuit Oil filter is plugged injector is dirty or trouble See your authorized dealer for repair High pressure pipe is damaged Replace the high pressure pipe Fuel is a...

Page 98: ...ubricant till the standard level 5 Engine oil pressure is too low The lever of the lubricant is too low Refill the lubricant Lubricant filter is plugged Clean the lubricant filter Oil is leak in the circuit Tighten or replace The cooling water temperature of the engine is too high Make up the mixture of cooling water or consult with the agent 6 Black smoke come out from exhaust tube Bad fuel Use b...

Page 99: ...is too slow Consult with agent Hydraulic oil is used incorrectly Use the right hydraulic oil The speed of engine is too slow Consult with agent 12 The temperature of hydraulic oil is too high Hydraulic oil is used incorrectly Use the right hydraulic oil Oil circuit is blocked Consult with agent Hydraulic oil filter is plugged Clean or replace Oil pump is damaged Consult with agent Oil cooler is bl...

Page 100: ...is damaged Consult with agent Main safety valve pressure turns low Readjust the pressure Oil pressure and level is too low Refill oil Oil suction filter is plugged Clean oil filter Oil seal is damaged Repair or replace Piston rod is damaged which cause oil leakage Repair or replace Pilots valve is trouble Replace Pilots pipe damaged or oil leakage Repair or replace 17 Both travel motor don t work ...

Page 101: ...ension unit axletree is damaged Replace 23 Air condition can t refrigerate Electric circuit is damaged Repair or replace Air condition switch is damaged Repair or replace There is no refrigerants Check if the refrigerants leakage repair it and refill The air condition system is blocked Clean or replace Belt is loosen or broken Readjust or replace Compressor work abnormally Repair or replace Pressu...

Page 102: ...s exceeded 20 Working in the dusty worksites When the machine is working on a dusty worksite please follow the below instructions To check whether the air filter is clogged or not with the sensor and frequent cleaning of filter core is required Clean the radiator core frequently to prevent the clogging Frequent cleaning and change of fuel filter are required Clean the electrical equipment especial...

Page 103: ...ill cause the damage to the machine and may bring accidents If something has dropped into the machine take it out immediately Periodical maintenance Periodical maintenance should be undertaken according to the items in the Maintenance Schedule Counter checking Counter checking is important after doing the maintenance every time Please pay attention to the following instructions Whether some parts ...

Page 104: ...e or after refueling for 10 minutes do let the deposits and water out of the tank Exhaust the air in the oil circuit if the fuel of engine has run out or the filter has been changed Grease Grease is used to avoid the scratch wear and noise emission form jointed parts To add grease after the parts are used for a long time When adding the grease do remember to get rid of the old one Coolant Anti fre...

Page 105: ...in of pipes do not stand at the front of the spare parts Release the air in the pipeline when doing the checking and maintenance The maintenance of hydraulic system consists of checking the quantity of hydraulic oil changing the filter and refilling the hydraulic oil When disassembling the tubes the O rings must be changed if they are found broken When install tubes don t contort or bend the tubes...

Page 106: ...sy 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: ...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 When replacing the hose replace the seals at the same time ...

Page 108: ... 2 s When it is 400C Lube of the Traveling reducer Overload use gear oil GL 5 Winter and summer use the same lube SAE80W 90 Lube of the slewing reducer Overload use gear oil GL 5 Winter and summer use the same lube Lube of the Front Idler bottom roller and upper roller SAE85W 140 All the temperatures 20 25 2 s When it is 500C Grease Molybdenum disulfide lithium based Grease No 3 200 C 1600 C Fuel ...

Page 109: ...5 8 Oil capacity Sort Unit Value Fuel tank L 102 Engine oil L 7 6 Hydraulic oil tank L 76 ...

Page 110: ...16 18 20 The Tighten torque Nm 8 8 640 9 12 22 30 45 59 78 104 124 165 193 257 264 354 376 502 10 9 900 13 16 30 36 65 78 110 130 180 210 280 330 380 450 540 650 12 9 1080 16 21 38 51 75 100 131 175 209 278 326 434 448 697 635 847 Intensity of The Bolt Yield Intensity N mm2 Diameter of The Bolt mm 22 24 27 30 33 36 39 The Tighten torque Nm 8 8 640 512 68 3 651 868 952 1269 1293 1723 1759 2345 2259...

Page 111: ...58 50 65 M22 1 5 14 15 74 60 88 M24 1 5 16 74 60 88 M26 1 5 18 105 85 25 M30 2 20 22 135 115 155 M36 2 25 28 166 140 192 M42 2 30 240 210 270 M45 2 35 290 255 325 M52 2 38 42 330 280 380 The tighten torque of hydraulic hose BSP Thread and Nut BSPP Thread Metric torque Nm Min max Nm G1 4 20 15 25 G3 8 34 27 41 G1 2 60 42 76 G5 8 69 44 94 G3 4 115 95 135 G1 140 115 165 G1 1 4 210 140 280 G1 1 2 290 ...

Page 112: ...RFS Nut UNF Thread Specification Min Nm Max Nm 9 16 18 4 14 16 11 16 16 6 24 27 13 16 16 8 43 47 1 14 10 60 68 1 3 16 12 12 90 95 1 3 16 12 14 90 95 1 7 16 12 16 125 135 1 11 16 12 20 170 190 2 12 24 200 225 ...

Page 113: ...0 100 250 500 1000 1 5 14 Routine Check Oil water fuel leakage Appearance of the parts and hoses Fastening of bolt and hydraulic connections Controlling parts work lamp and warning light Engine condition 2 5 15 5 16 5 17 5 18 Fuel System of Engine Check fuel oil level and refueling Vent water and impurity Clean the fuel tank Check oil injecting pressure Replacing filter core 3 5 19 5 20 5 21 Cooli...

Page 114: ...eck gas valve clearance Check fastening of the cylinder cover Check fastening condition of the engine support 5 5 24 Engine Air Intake System Empty the dust collector Cleaning air filter core Replace the air filter core 6 5 26 to 5 31 Hydraulic System Check hydraulic oil level and refueling if need Cleaning hydraulic oil tank Replace the hydraulic oil clean the suction filter Replace hydraulic oil...

Page 115: ...necting bolt 9 5 36 Crawler Check and adjust the tension of crawler 10 5 37 Idler upper roller and front Idler Check the tighten torque of Idler Check the oil level of front Idler and upper roller 11 5 38 Lubricate Immit lube to Lubricating point Ordinary maintenance First maintenance in breaking in period One time in each Spring and Autumn ...

Page 116: ... 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 6 Check the working condition of the engine the color of exit gas noise etc ...

Page 117: ...the oil tank Drain condensation water and the impurity every 100 hours Loose the drain plug to make the condensation water and the impurity out When the fuel out then reinstall the drain plug as soon as the fuel is out Users can adjust the period to vent the condensation water according to the quality of the fuel 3 Clean the oil tank Clean it every 250hours 1 Drain the fuel to the container 2 Take...

Page 118: ...zle A Clash from engine cylinder B Engine overheat C Fuel filter is damaged or dirty D Poor quality of the fuel E Water in the fuel F Air filter is dirty or plugged 5 Exhaust of the fuel loop for Kubota V2403 M DI E3B It need to exhaust the air before start the engine when it replaces filter core of the fuel cut off the pipe of the fuel clean the filter of the fuel and make the air into the fuel l...

Page 119: ... tight Attention Don t screw the valve too tight It will destroy the thread 7 Replace fuel filter element Replace it after 50 hours for new machine after that replace it every 250hours or every 3 months It must use the original parts 1 Take down the fuel filter 2 Use the cloth which not cottony to clean the surface of the sealing gasket 3 Disuse the O loop 4 Install the new O loop Attention Check ...

Page 120: ...ce 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 ...

Page 121: ...day or every 10hours Take out the cover of the radiator water tank check the level of the coolant The level of the coolant should under the water filling port about 20mm when the engine is cold Observe the coolant level in the radiator overflow bottle the level should be at the middle of the highest and lowest mark when the engine is cold The level of the coolant should lie in between the highest ...

Page 122: ...injured if the body hit by compress air high pressure water or the steam so please wear the protective goggles or other protection device Attention The distance between the Radiator and the nozzle of high pressure water or the compress air should be or more then 500mm to avoid the damage of the radiator Damage vane of the radiator can cause the leaking water or overheat Check the radiator everyday...

Page 123: ...nt under 500C 5 Check the consistency of the coolant It need to check the consistency of the coolant before winter The coolant should can be suitable for the weather 200C please increase the proportion of the anti freeze fluid If the temperature is lower then 200C Warning The coolant is the toxicant Avoid the children and the pet touch the coolant Please deal as the local law for no longer used co...

Page 124: ...be caused the injury please wait until the temperature is low before start to maintenance 2 Replace the engine oil Replace the engine oil after first 50 hours after that replace it every 250 hours 1 Parking on the flat ground 2 Take down the vent bolt to drain the engine oil Warning Avoid inhale the oil steam eat or touch the used engine oil long time 3 Clean the vent bolts and reinstall replace t...

Page 125: ...kets on the filter lubricate both seal gaskets 3 Please wipe the engine oil on the seal gasket before install the filter 4 Install the filter as the instruction of filter manufacturer 5 Run the engine with idle check if the oil filter is leaking 6 Stop the engine and wait 15 minutes 7 Check the oil level Immit the engine oil to the H marking if the oil level is too low ...

Page 126: ...r when the Air filter warning Indicator light Clean the Air filter frequently will affect it s performance 2 Replace the filter element Replace the filter element every 500 hours or after cleaned over 6 times When the Air filter warning indicator light very soon after install the cleaned filter element replace it even it is not cleaned over 6 times 3 Check the air intake pipes Check the air intake...

Page 127: ... belt wheel and the alternator belt wheel by 6kg force and the belt can be sank about 5 10mm Replace the Fan belt if it is damaged Please see User Manual for The Diesel Engine for the maintenance period of the other parts of engine and the ways 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 r...

Page 128: ...e pressure to avoid the oil spurt out 1 Check the hydraulic oil level Check it every 10 hours 1 Parking on the flat ground 2 Start the engine and operate the working device to make each cylinder reciprocating motion 3 Draw back the arm cylinder extend the bucket cylinder and drop the bucket on the ground put the dozer blade on the ground then stop the engine see the fig 4 Observe the level of the ...

Page 129: ...to avoid the oil spurt out 3 Not allow water the dir or soil into the oil tank when it replaces the hydraulic oil Replacement steps of Hydraulic oil 1 Parking on a flat ground 2 Press the pressure relief button on the air filter to loose the pressure from Oil tank 3 Prepare a container use a defueling pump or a clean pipe to draw out the hydraulic oil 4 Same as the way which vent the water and the...

Page 130: ...om cylinders 1 Run the engine in low speed operate the working device to make the each cylinders to extend or draw back 4 5 times but don t extend or draw back the cylinder completely keep the piston come out about 10mm for each movement 2 Then operate the cylinders to extend and draw back completely about 7 10 times Caution The seal kit of the cylinder could be damaged if run the engine at high s...

Page 131: ...about 10 times under engine idle to vent the air from accessory pipes Attention 1 If the manufacturer has the way for vent the air it should do it as the way 2 After finish the operation of venting air stop the engine about 5 minutes to clear the air bubble of cylinders before restart 3 Wipe the oil which spill over and check if it has oil leaking 4 After the operation of venting air check the oil...

Page 132: ...r 8 Park on the level ground check the oil level and fill if it is necessary Not allow the oil over the highest limit The replace period of the hydraulic filter element when the machine is installed the accessory Rock Breaker It increase the pollution of the hydraulic system when use the Rock breaker The replaced period of the hydraulic oil and the filter element need to be reduced accordingly to ...

Page 133: ...re than 6 months 2 Charge the battery The battery produces hydrogen and oxygen from electrolyte during charge the lower the charging voltage the more water is lost There is no need to add water to the Battery which is on Yuchai excavator therefore constant voltage charging is recommended to avoid constant current charging as far as possible 1 Constant current charge Charge the battery 2 4 hours by...

Page 134: ...of Battery 1 It has an indicator of Battery capacity on the cover when it indicating green the battery for normal use When it indicating black the battery need to be charged When it indicating white the battery need to be changed 2 Please charge the battery in time when it lost electricity during use to prevent battery degradation due to sulfation 3 Don t overcharge the battery to avoid battery fa...

Page 135: ...out release the air pressure Check it every 250 hours 1 Prepare an inside hexagon spanner 2 Parking excavator on a flat ground 3 Turn the travel reducer make the two bolt of the outboard in a position as the picture then stop the machine 4 Loose the bolt after the oil is cool 5 After release the air pressure use 12 15Nm torque to screw up the bolt 6 Remove the bolt check the oil level The oil leve...

Page 136: ...astness of the connected bolts of travel reducer Take the first check it after 50 hours after that check it every 500 hours The torque is 150 10Nm for the bolt which connect the reducer with Chassis and the driving wheel B Check the fastness of the connected bolts of slewing reducer Take the first check it after 50 hours after that check it every 500 hours The torque is 195 250Nm for the bolt conn...

Page 137: ...tions then tight the bolt again 4 For adjust the track connet the tie in of the greasing gun as the tools sent with machine and the tie in Fig 2 Then use the greasing gun immit till the branches f Fig 1 at 2 4 cm deflections 5 Clean the mud on the tracks every day after work Warning Don t knock the tension spring The spring will rupture when it bear the large pressure And hurt the person Don t tak...

Page 138: ...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 And wipe the additive again then screw up with the regular torque 2 Check the oil level of Upper roller and Front idler Check it every 1000 hours 1 Take out the bolt from upper roller and Front idler 2 Immit the oil 3 When the nipples has the oil out screw up bolt again ...

Page 139: ... dozer and chassis 3 panel point of Linkage rod and connected rod 13 Lubricating point on the end of 4 panel point of Linkage rod and arm dozer cylinder 5 lubricating point on the end of bucket cylinder 14 Lubricating point on the head of 6 lubricating point on the head of arm cylinder dozer cylinder 7 panel point of arm and boom 15 Rollaway lubricating point I 8 lubricating point on the end of ar...

Page 140: ...he AC box must be cleaned often clean it in every month Otherwise the dust will block the dust screen and the air not thought the heat exchanger smoothly then effect the Air Conditioning 5 Under special conditions humidity hot weather outer loop blower running in low speed dust screen is dirty return tuyere is blocked etc some time you will find the air outlet is getting smaller after used the rap...

Page 141: ...mantle the cooling system drain the cryogen before dismantlement and make sure there are no fire during operation The cooling performance will worse if the machine short of the cryogen Check the value of the cryogen every month or every 250 hours To do rapid cooling operation when the engine is running at high speed and judge the value of cryogen according the air bubble in the mirror of the desic...

Page 142: ...Belt of air condition The tension and fray 3 Pipeline If fray or rupture 4 Tie in If fray of leak 5 Electric fan Whether run normal 6 Wires If fray burn 7 Condensator If has the dust stop 8 Electromagnetism clutch If slip 9 Compressor If has the noise 10 Value of cryogen If the view mirror has the air bubble 11 dust screen If stop ...

Page 143: ...ury Replace the Bucket teeth 1 Place the bucket on a heel block for take down the teeth pin Check the stability of the working device and make the bucket place in level Turn the safety lock handle to the lock position then shut down the engine 2 Put the metal stick which the diameter is smaller than the teeth pin on the head of the pin use the hammer knock the stick to take out the pin then take d...

Page 144: ...ll move and lead the accident So it must place the machine on the flat ground before take down the floor mat Please turn the safety lock handle to locked position before you leave the seat Washing steps 1 Take floor mat out from the cab 2 Use the brush to washing the dirt or use the water washing it 3 Use the dry mop to clean the floor inner the cab 4 Take floor mat back to the cab after it is dry...

Page 145: ...r please check the fuse firstly and replace if the fuses are burned do not use the iron wire or other conductors to replace the fuse 5 It is very dangerous if the electrical parts become damp or electrical insulation is damaged it can cause electricity leak so please don t wash the inner of the cab by water And please don t let the water touch electrical parts 6 Do not install any electronic compo...

Page 146: ...lease arrange a guider before operation certaining what signals you will use Please do not act the function of swing side s rotate especial on slope This is very dangerous Comparing with the machine with bucket the machine with rock breaker has even heavier burden in front of working part also not stabilization Please do not operate when the accessory turned to side to prevent overturn The machine...

Page 147: ...Bracket and make sure of it safely When place the dismantled accessory or install accessory please make sure it is stabilization and will not turn over Please do not walk the place where under the crane which is working you should stay in the safety please even the load dropped can not be hurt Warning The license for operator is very important It is forbidden to operate the machine without license...

Page 148: ...f dismantle two shafts and then install the bucket 7 Use clean plastic bag enswathe the two hydraulic breaker s rubber pipes to prevent dust Put the accessory well 2 Step of installation 1 Dismantle bucket 2 Put the accessory to a flat place please use shaft A connect sticker and hydraulic breaker use shaft B connect and hydraulic breaker 3 Make sure the oil cooled down dismantling the bolt from i...

Page 149: ...make sure the top of rock breaker s sticker is plumbed with the surface of rock and keeping all the time or the rock breaker s sticker will slip the sticker will be damages under this condition Please choose the best break point and make sure that the sticker is firm when working The cylinder of sticker must be adjusted all the time when working to keep the force direction of the rock breaker s st...

Page 150: ... it will lead the bolt of the main body loose and mangle 2 Operate tabu of the hydraulic rock breaker For the machine has long use life and the safety operation no operate as follow Caution No operate the cylinder to the end of the driving it should keep the rest about 5cm 1 Push the heavy thing or the big block use the rock breaker 2 Use the rotating operation 3 Move the rock breaker when do the ...

Page 151: ...6 6 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: ...6 7 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: ...hitch 1 Install the bucket 1 Use the tommy bar to prize 2 Put the axes of the bucket into the down the tommy bar and the bucket installed 2 Take down the bucket 1 Use the tommy bar to prize 2 Take down the bucket ...

Page 154: ...re vitta Screw down the part which loose Replace the broken part 3 Lubricate Use the lube 10ml t before the operation and after operate 2 3hours Immit the lube 5 10times Immit the lube thought the sprue which in the foreside of the crush hammer 4 Check the capacity of the hydraulic oil and the pollution circs The circs of the hydraulic oil The change circs of the hydraulic oil is different as the ...