Yuchai YC135-7 Owners Manual

YYUUCCHHAAII EENNGGIINNEEEERRIINNGG MMAACCHHIINNEERRYY CCOO.. LLTTDD..
IIssssuuee:: 22000055
ATTENTION!!!
A dangerous use of the machine may cause serious injure to the
operators and to the people near the working zone. So it is essential
that, who will use the machine, follows all is written in the manual.
The operators and the maintainers have to read this manual before to
perform any services on the machine. This manual must be kept on
board to allow to the operators further consultation and periodical
reading by who will use the machine.
Is absolutely forbidden use the machine inside tunnels, mines and
fields with slope that exceed 30 °.
Duplication, total or partial, with any device of this manual is

forbidden because it is exclusive property of the Yuchai Engineering
Machinery Co. Ltd.
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INDEX
1. INTRODUCTION AND GENERAL INFORMATION ............................... 9

1.1 Machine serial number ........................................................................................12
1.2 Yuchai engineering machinery co. ltd. data ......................................................13
2. GENERAL PRECAUTION AND SAFETY MEASURES....................... 15
3. PRECAUTION AND SAFETY MEASURES DURING WORK.............. 23
3.1 Precautions before engine start .........................................................................23
3.2 Precaution when the machine is working..........................................................26
3.3 Transport precaution...........................................................................................37
3.4 Precaution when operate with battery ...............................................................38
3.5 Pulling precaution................................................................................................39
4. MAINTENANCE PRECAUTIONS......................................................... 41
4.1 Precautions before staring maintenance...........................................................41
4.2 Precaution during maintenance .........................................................................44
5. MACHINE DESCRIPTION .................................................................... 49
5.1 Excavator main parts description ......................................................................49
5.2 Data sheet.............................................................................................................50
5.2.1. Transport blocked .........................................................................................51
5.3 Warning plates .....................................................................................................52
5.4 Identification plate ...............................................................................................54
6. INSTRUMENT AND COMMAND DESCRIPTION ................................ 55
6.1 Operators seat description .................................................................................55
6.1.1. Lever and pedal ............................................................................................56
6.2 Instrument panel and switches...........................................................................60
6.2.1. Instrument and Switches...............................................................................60
6.2.2. Heating and air conditioning..........................................................................66
6.3 Fuses ....................................................................................................................66
6.4 Operator seat........................................................................................................67
6.4.1. Operator seat adjusting.................................................................................67
6.4.2. Seat belt........................................................................................................68
6.5 Cabin.....................................................................................................................68
6.5.1. Open / Close side door .................................................................................68
6.5.2. Front window opening...................................................................................69
6.5.3. Side window opening ....................................................................................70
6.5.4. Cab light........................................................................................................70
6.5.5. Emergency exit .............................................................................................70
7. STARTING MACHINE .......................................................................... 71
7.1 Check before start ...............................................................................................71
7.1.1. Check coolant, refill it....................................................................................71
7.1.2. Check and replacing engine oil .....................................................................72
7.1.3. Inspecting and adjusting the fan belt.............................................................72
7.1.4. Fuel level and refuelling ................................................................................73
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7.1.5. Check hydraulic oil and refill .........................................................................73
7.1.6. Check air filter ...............................................................................................74
7.1.7. Check electrical circuit ..................................................................................75
7.2 Starting .................................................................................................................76
7.2.1. Precaution.....................................................................................................76
7.2.2. Engine starting ..............................................................................................76
7.2.3. Start engine in cold weather..........................................................................77
7.3 Operations and controls after starting...............................................................77
7.3.1. Engine heating ..............................................................................................77
7.3.2. Instrument panel check .................................................................................78
7.3.3. Safety lock lever check .................................................................................78
7.3.4. Noise and exhaust check ..............................................................................78
8. MACHINE MOVING RULES................................................................. 79
8.1 Forward movement..............................................................................................79
8.2 Backwards movement .........................................................................................80
8.3 Changing direction (steering) .............................................................................81
8.4 Machine stop and park ........................................................................................84
8.5 Swinging...............................................................................................................85
8.6 Forbidden movement and forbidden use ..........................................................86
8.7 Precaution for operating .....................................................................................89
8.8 Work possible using hydraulic excavator .........................................................92
8.8.1. Backhoe work ...............................................................................................92
8.8.2. Ditching work ................................................................................................93
8.8.3. Loading work.................................................................................................93
8.8.4. Operations in confined spaces......................................................................93
8.9 How to escape from mud ....................................................................................94
9. COLD WEATHER OPERATION........................................................... 96
9.1 Precaution for fuel, lubricants and coolant in low temperature ......................96
9.1.1. Fuel and lubricants........................................................................................96
9.1.2. Coolant .........................................................................................................96
9.1.3. Battery ..........................................................................................................97
9.2 Engine starting in cold weather..........................................................................97
9.3 Precaution at work end in cold weather ............................................................97
9.4 Cabin heater .........................................................................................................98
10. CHECK AFTER COMPLETION OF WORK ......................................... 99
11. USING RUBBER SHOES (ONLY FOR MACHINE WITH RUBBER
SHOES) ...................................................................................................... 101
11.1 Rubber shoes guarantee...................................................................................101
11.2 Precautions when using rubber shoes ............................................................102
12. TRANSPORTATION........................................................................... 105
12.1 Loading unloading work ...................................................................................105
12.2 Load precaution .................................................................................................107
12.3 Precaution for transportation ...........................................................................107
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13. MACHINE TOWING............................................................................ 109
14. LONG TERM STORAGE .................................................................... 111
14.1 Before storage....................................................................................................111
14.2 During storage ...................................................................................................112
14.3 After storage.......................................................................................................112
15. STARTING MACHINE WITH JUMP-START CABLES (BATTERY
DISCHARGED!) ......................................................................................... 113
15.1 Precaution for jump-start cable connection and staring................................116
15.2 Precaution for jump-start cables disconnecting.............................................117
15.3 Precaution for battery charging while it is onboard .......................................117
16. PHENOMENA THAT ARE NOT FAILURE......................................... 119
17. THE BUCKET ..................................................................................... 121
17.1 Bucket removing................................................................................................121
17.2 Bucket assembling ............................................................................................123
18. MAINTENANCE.................................................................................. 125
18.1 Guides to maintenance .....................................................................................125
18.2 Controls table and maintenance schedule ......................................................128
18.3 Maintenance during Breaking-in period ..........................................................129
18.4 Lubricants (oil and grease), coolant, fuel characteristics..............................130
18.4.1. Engine oil and hydraulic oil .........................................................................131
18.4.2. Fuel.............................................................................................................131
18.4.3. Coolant .......................................................................................................132
18.4.4. Grease ........................................................................................................132
18.4.5. Oil and fuel storage.....................................................................................132
18.5 Filter ....................................................................................................................133
18.6 Electrical wiring .................................................................................................134
18.7 Maintenance tools and torque list ....................................................................135
18.7.1. Needed tools for maintenance ....................................................................135
18.7.2. Standard torque list.....................................................................................136
19. PERIODICAL REPLACEMENT OF SAFETY CRITICAL PARTS...... 137
19.1 Daily checking or every 10 hours .....................................................................137
19.1.1. General check.............................................................................................137
19.1.2. Check, Clean and Replace air filter.............................................................138
19.1.3. Check coolant level and pipe preservation..................................................139
19.1.4. Check bolt torque of the sprocket ...............................................................139
19.1.5. Checking and adjusting rubber shoes tension (for machine with rubber shoes
only) 139
19.1.6. Checking and adjusting steel track tension (for machine with steel track only)
146
19.2 Maintenance every 50 hours .............................................................................149
19.2.1. Lubricating ..................................................................................................149
19.2.2. Check electrolyte level ................................................................................150
19.3 Maintenance every 100 hours ...........................................................................151
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19.3.1. Cleaning fuel filter and water separator ......................................................151
19.3.2. Fan belt adjusting........................................................................................152
19.4.1. Replacing oil engine and oil filter cartridge .................................................153
19.4.2. Check and refill oil in the sprocket ..............................................................155
19.4.3. Oil level in swing gear .................................................................................156
19.4.4. Cleaning water separator filter ....................................................................156
19.5.1. Check intake pressure ................................................................................158
19.5.2. Fuel filter cartridge replacement..................................................................159
19.5.3. Check and clean radiator fins......................................................................159
19.5.4. Replacing the hydraulic oil return filter ........................................................160
19.5.5. Replacing pilot filter cartridge......................................................................161
19.5.6. Engine bolts supports tightening .................................................................162
19.5.7. Replacing the air filter cartridge ..................................................................162
19.5.8. Sprocket bolts fastening..............................................................................162
19.5.9. Oil level in the front idler .............................................................................163
19.6.1. Cleaning and replacing cooling system.......................................................164
19.6.2. Replacing the hydraulic oil and cleaning the suction strainer......................166
19.6.3. Replacing the travel motor gear oil .............................................................168
19.6.4. Replacing swing system oil .........................................................................168
19.6.5. Check the engine valves clearance, adjusting them ...................................168
20. HYDRAULIC SCHEME....................................................................... 169
21. ELECTRICAL SCHEME ..................................................................... 171
22. TROUBLE SHOOTING....................................................................... 173
23. OPTIONAL ACCESSORIES............................................................... 177
23.1 Safety precaution...............................................................................................177
24. NOTICE............................................................................................... 179
25. ANALYTIC INDEX .............................................................................. 181
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1. INTRODUCTION AND GENERAL INFORMATION
This manual provide regulations and orientations which

will help you to use correctly your machine without any
risk.
Keep the manual easy to read to allow all operators to
read it periodically.
If the manual will miss or become unreadable, please ask
for a copy to YUCHAI ENGINEERING MACHINERY CO.
LTD.
If you sell the machine, deliver the manual to new owner.
Machine project improvement could cause changing on the machine without

manual updating. Check from YUCHAI ENGINEERING MACHINERY CO.
LTD. For the latest information about your machine o for any question about
information inside this manual.
GENERAL INFORMATION
• the improperly use and maintenance of the machine
may cause hazards e could cause serious injury or
death.
• Machine’s operators and maintainers have to read this
manual from the first to the last page, before to start
any work.
• Some action relative the machine’s functioning and
maintenance may cause serious injures if they aren’t
carried out likewise is described in this manual.
• Procedure and precaution described in this manual are
applicable only at the expected machine use. If you use
the machine for any different scope here mentioned but
doesn’t specifically forbidden, you have to be sure that
it is safe for you and all others.
• Never you can use the machine for any scope
specifically forbidden in this manual.
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Most of the accident and injuries that happens in the factories, agricultural
firms, homes or on the roads are due to the lack of attention to any simple but
basic rule of caution and safety. For this reason, most of them could be
avoided: just forecast all predictable cause and act with the necessary
caution.
With any kind of machine, anyhow projected and assembled, it is impossible
to exclude an accident without negative interference on some essential
characteristics (accessibility, efficient working, etc.).
Pay attention to all warnings written on the followed chapters and to all
“PRECAUTION AND SAFETY MEASURES”.
An operator who pay attention at his work is the best guarantee against
injuries.
The most representative of the safety rule is:
Never clean, lubricate or make service if the machine or part of it are
working.
To avoid injuries read, comprehend and forward all precautions and warnings
written in this manual and on board.
To identify the safety message, they will be highlight with the follows symbols.
DANGER
This picture is used where a residual risk with concrete
possibility of permanent injury or death will remain. The
messages describe safety cautions which have to be taken
to avoid residual risk. The fail of comply with all is written
here can, also, damage the machine.
ATTENTION
This picture is used where a residual risk with concrete
possibility of moderate injury will remain.
This picture could be used also where the only residual
risk is to damage the machine.
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The YUCHAI ENGINEERING MACHINERY CO. LTD. cannot predict each
circumstance which may cause a residual risk during work and/or
maintenance, therefore the safety messages written in the manual can not
include all safety precaution.
If you decide to make any action which is not specifically allowed o forbidden,
you must evaluate every consequence to the action in order to avoid
damages to people, machine or object around.
If the machine is used for a work which is not listed in this manual, the
YUCHAI ENGINEERING MACHINERY CO. LTD. will not assume any
responsibility about damage or injury to people and/or object.. All safety
aspect in those action are under user responsibility.
All forbidden action in this manual never have to be made in any
circumstance.
SPECIFIC USE:
This hydraulic excavator made by YUCHAI ENGINEERING MACHINERY CO.
LTD. is drawing and realized to be used for followed jobs:
• Excavator jobs (ditches and/or canals, foundation excavation, etc.);
• Loading jobs.
The YUCHAI ENGINEERING MACHINERY CO. LTD. deny liability for

possible damage to people and/or object due to different use from those
above mentioned or anyway do not specifically mentioned in this
manual.
MACHINE RUNNING IN PERIOD:

Your machine has been regulated and checked by YUCHAI ENGINEERING
MACHINERY CO. LTD. Anyway, start with hard jobs and critical condition
may have a negative influence on the machine’s performance and reduce the
lifetime.
Be sure to respect the running in period for the first 100 hours (like is showed
on the hours meter).
During the running in period:

• do run the engine at the low idling speed for 5 minutes before start work;
• avoid jobs with heavy load or high speed;
• avoid starts, braking, manoeuvres and unexpected stop except for
emergency.
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1.1 MACHINE SERIAL NUMBER
Fill the serial number of your machine into the followed form. If you need
assistance please contact the YUCHAI ENGINEERING MACHINERY CO.
LTD. service, then specify model kind and serial number of you machine.
MACHINE KIND AND REGISTRATION NUMBER
KIND/MODEL:
REGISTRATION No.:
The plate where is written the machine registration number is installed on

front side.
ENGINE KIND AND REGISTRATION NUMBER
KIND/MODEL:
REGISTRATION No.:
HYDRAULIC MOTORS KIND AND REGISTRATION NUMBER
TRAVELLING ENGINE
MODEL:
REGISTRATION No.:
ROTATING ENGINE
MODEL:
REGISTRATION No.:
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1.2 YUCHAI ENGINEERING MACHINERY CO. LTD. DATA
YUCHAI ENGINEERING MACHINERY CO. LTD.

Manufacturing Base:
168 Tianqiao Road, Yulin, Guangxi, 537005 P.R. China
Export Department Office:

36 Cuizhu Road, Guilin, Guangxi, 541002 P.R. China
Tel: 0086-773-5588521 5588522 5588523

Fax: 0086-773-5588530
E-mail: [email protected]
Web-site: www.yuchai-excavator.com
YUCHAI EUROPE:
Address: V. Del Fonditore, 14 40138 Bologna, Italy
Tel:0039
Fax:0039
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2. GENERAL PRECAUTION AND SAFETY MEASURES
FOLLOWS THE SAFETY REGULATIONS
• ONLY trained, qualified, and authorized operator can drive the machine
and make maintenance.
• Follow all safety regulations, precaution and instruction written in this
manual when you use or make service on the machine.
• When you work with a person who assigned to working zone traffic, be
sure that he understand all hand signal used.
SAFETY CHARACTERISTICS
• Be sure that all protections and cover will be on their correct position. If
the protections or cover are damaged they must be repaired and/or
replaced.
• Use correctly all safety system and device installed on the machine, like
the lock lever and the seat belt.
• NEVER remove any safety system and/or devices.
• Be sure that they will remain EVER in good condition.
• Unexpected use of the safety system and/or devices may cause serious
injuries or death.
NON ALLOWED MODIFICATION
• Each modify made without YUCHAI ENGINEERING MACHINERY CO.

LTD. authorization may cause risk.
• YUCHAI ENGINEERING MACHINERY CO. LTD. deny liability for
possible injures or damage to people or objects due to non allowed
modification.
15
CLOTHES AND INDIVIDUAL PROTECTION DEVICES
• Avoid swirling clothes, jewels and streaming hair. They could trap
themselves on the lever or floating part and cause serious injures. Also
do not wear oiled clothes because they are flammable.
When drive or make service on the machine, wear a tight cap, protective
eyeglass, safety shoes, filter mask, and heavy gloves. Wear always
safety glasses, hard hat and heavy gloves if your job entails metal flakes
or tiny materials, specially when you are hammering a hinge or are
cleaning the air filter with compressed air. Also make sure that nobody
stand close the machine.
• In order that the machine work in total safety is necessary the full
operator’s attention. Do not wear headphones for radio or music during
work.
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INDIVIDUAL PROTECTION DEVICES (IPD)
If you do not follow these safety precautions it may cause
severe accident.
SET THE SAFETY LOCK LEVER BEFORE LEAVING THE SEAT
• When you are leaving the operator’s seat, set the safety lock lever
securely to the lock position. If any controls should be touched
accidentally when the safety lock lever has not be locked, the machine
will move suddenly and cause severe injury or death.
• When you are leaving the operator’s seat, low the bucket on the ground
(see paragraph “MACHINE STOP AND PARK”) then set the safety lock
lever in lock position. Then turn off the engine and lock the cabin door (if
your machine has a cabin). Take off the start key and keep it always with
you.
Lock
Unlock
17
MOUNTING AND DISMOUNTING FROM THE MACHINE
• NEVER jump on or off the machine.

• NEVER attempt to mount or dismount from a moving machine.
• When mounting or dismounting the cab, always face the access system
and maintain the contact with hand holds and steps while getting on or off
the machine.
• Never use the safety lock lever or control levers as hand holds.
• Always maintain three contact with hand holds and steps.
• Always clean out oil or mud from hand holds and steps. If they are
damaged then repair them, also close every bolt slackened.
• NEVER climb on the engine bonnet. It can put you in danger.
18
OIL AND FUEL FIRE PREVENTION
• Fuel, oil and antifreeze liquid may burst into flames if become in touch
with a flame. Specially, the fuel can be very DANGEROUS because it is
highly FLAMMABLE.
• Keep the flammable liquids off from the free flames.
• Turn off the engine and do not smoke while refuelling.
• Screw down as well the oil and fuel top.
• Fuel and oil refuelling must be done in well aired place.
• Take shelter oil and fuel and keep them out of reach of unauthorized
people.
PREVENT ASBESTOS INHALATION HAZARD
Asbestos inhalation may cause lungs cancer.

If asbestos fibres are in your working area, follow these rules:
• NEVER use compressed air to clean anything.
• Use water to keep down the dust.
• If possible, work with blow wind from your rear.
• If possible, use a mouth-mask approved.
19
PRECAUTION WITH HIGH TEMPERATURE WORK
• The engine, muffler, radiator, hydraulic lines, sliding parts and many other
parts of the machine are hot and under pressure directly after the engine
is stopped. Touching these parts will cause burns so wait for the
temperature drop before oil, fuel and water screw cap opening.
• To avoid hot water splash out:

1. turn off the engine;
2. waiting for the water temperature drop;
3. slowly open the screw cap to reduce the internal pressure.
• To avoid hot oil splash out:

1. turn off the engine;
2. waiting for the oil temperature drop;
3. slowly open the screw cap to reduce the internal pressure.
20
PREVENT CUTTING AND/OR CRUSHING
• do not put you hands, arms or other body parts between moving parts.
I.e. between work equipment and machine body or between cylinder and
moving parts or between upper structure and undercarriage or tracks. If
the work equipment is moving, the free space around it is changeable it
may cause severe injure or death.
FIRE EXTINGUISHER AND FIRST AID KIT
• Make sure that fire extinguisher is on board and where it is located and
make sure you are able to use it.
• Make sure that first aid kit is on board.
• Known how to do in case of fire.
• Make sure to know all phone number to contact emergency assistance
and first aid help.
21
ACCESSORIES PRECAUTION
• When you will use an optional accessory, first read the accessory’s
operating manual and follow the instruction written in it.
• NEVER use accessories listed in this operating manual or do not
authorized from YUCHAI ENGINEERING MACHINERY CO. LTD.. The
non authorized accessories use may cause safety hazards and may have
a negative influence on the machine’s performance and reduce the
lifetime.
• Each possible injury, accident or machine bad working due to use
of the unauthorized accessory, will not be responsibility of the
PAY ATTENTION DO NOT CRASH THE CABIN GLASS
If the cabin glass is damaged, it is dangerous use the machine. Always

change the broken glass immediately.
22
3. PRECAUTION AND SAFETY MEASURES DURING WORK
3.1 PRECAUTIONS BEFORE ENGINE START
WORKING AREA SAFETY
• Before turning on the engine check the working area, evaluate if there are
abnormal condition which cause hazardous.
• Before turning on the engine check the ground condition in the working
area. Choose the best working method.
• Before start work, reduce the ground slope.
• Before start work under water or run through a river, check the depth and
the water flow. NEVER immerse the machine in water if the depth exceed
the allowed level.
• If your work is on the road or near people passing, put a rigid repair to
protect people and object also appoint a person to control the working
zone.
23
• If you know that water pipe, gas pipe or electrical line were been lay
underground you have to contact the owner society to identify correctly
the position. Pay attention: do not cut off the pipes.
FIRE PREVENTION
• Remove wood splinter, leaves, paper and any flammable materials

accumulated into the engine compartment. They may cause fire.
• Check if there are fuel, lubricant oil and/or hydraulic oil leakage. Use a
clean sheet to dry oil, fuel excess or other flammable liquids escaped.
• Make sure that there is a fire extinguisher and that it works.
INSIDE THE CABIN
• Do not leave tools or spare parts on the cabin floor. They may damage or
break the levers or instrument panel. Put them always into the tool box.
• Keep clean: cabin floor, instrument panel, steps, hands hold. Remove oil,
grease and dirt accumulation.
24
CLOSED WORKING ZONE VENTILATION
• If it necessary turn on the engine inside a room, provide to adequate

ventilation. Exhaust gas can KILL.
LIGHT AND WINDOWS PRECAUTION
• Clean out the windows and lights. Make sure to see well!
• Check if the headlamp are correctly installed for the job to do. Check if
they work properly.
25
3.2 PRECAUTION WHEN THE MACHINE IS WORKING
WHEN TURN OF THE ENGINE
• before start work, walk around your machine to verify that no people or
object are in the working zone.
• NEVER start the machine if any plate is put on the instrument panel.
• Play the horn before turn on the engine.
• Turn on and drive your machine from the operator’s seat only, and after
have fastened your seat belt.
• Do not allow anyone to ride on any part of the machine at any time while
travelling.
• Do not allow anyone to be on any part of the machine while operating.
26
• Before start work, check the seat belt. If any part is damaged or worn,
change the seat belt.
• Before start work, sit down on the operator seat and fast the seat belt.
• Stand on the seat with the seat belt fastened all the time, during work, to
reduce injury if case of accident.
CHECK THE POSITION OF THE TRACKS BEFORE TRAVELLING
• Before operating the travel levers, check to make sure that the dozer
blade is to the front of the operator’s seat. BE AWARE that when the
dozer blade is to the rear the travel lavers operate in the opposite
direction to when the dozer blade in the front.
27
BEFORE GO TO THE REVERSE MOTION OR SWING, BE SURE THAT
NOBODY IS AROUND THE WORKING ZONE
• In dangerous zone o where there is incomplete view, put always a signal.

• Make sure that nobody is inside the radius swing or rear the machine.
• Before start motion, play the horn to warn people standing or walking
around the machine.
• There are blind spots to the rear of the machine, so swing the cab around
before backing up to check that the area is safe and clear.
MOTION PRECAUTION
• Travel with the dozer blade folded as shown on the diagram and the
bucket raised 40 ÷ 50 cm. from the ground.
• Do not slew (swing) while travelling. If you must operate the hoe
attachment while travelling, operate at speeds slow enough so you have
complete control at all times.
• On uneven ground, travel at low speed and avoid accelerating, stopping
or changing directions abruptly.
• Avoid crossing over obstacles whenever possible. If you must do so,
keep the hoe attachment close to the ground and travel slowly. Never
cross obstacles if they will seriously tilt the machine (to an angle of 10° or
greater).
28
Motion Position WRONG!
TRAVELLING ON SLOPES
• Motion up and down the hill with severe slope (greater then 30°) IS
FORBIDDEN. Great slope may cause machine roll over or slide.
• When travelling on slopes or grades, lower the bucket to a height from 20
to 30 cm off the ground. In emergencies, lower the bucket to the ground
and stop the machine.
• Do not change directions or cross slopes sideways. First return to a flat
surface then redirect the machine.
• On grass, dead leaves, wet metal or frozen surfaces, the machine may
slide sideways even on very gentle slopes. Make sure the machine never
faces sideways with respect to the slopes.
Downhill Uphill WRONG CORRECT
29
FORBIDDEN OPERATION
• Never undercut a high bank. Be particularly alert for the possibility of a

cave-in.
• Do not operate in places where there is a danger of falling rocks.
WRONG WRONG
FORBIDDEN OPERATION
• Do not extend or move back the hydraulic cylinders for all them length,
keep a small distance.
• Do not undercut when the trucks are not leant on the ground, otherwise
you may damage the machine.
• Keep machine well back from the edge of an excavation. Avoid
undercutting the machine.
30
IS FORBIDDEN LIFTING LOADS
• Is forbidden to use the excavator lake a load’s lifter.
DO NOT PASS WITH THE BUCKET OVER PEOPLE
• Do not rise, move or swing the bucket over people or trucks cab.
Materials which will drop off may cause severe injure to people or
damage to the machine.
31
DO NOT APPROACH ELECTRICAL POWER LINE
• Touching electrical power line may will cause short circuit, so keep a safe
distance between the machine and electrical line power.
• The follow rules may safe your life:
1. Wear safety shoes with rubber sole;
2. Put a signaller on the machine to alert you if the machine approach the
electrical line power.
• If the machine should come in contact with a live electrical source, do not
leave the operator’s seat.
• Do not allow anyone to approach or touch the machine.
• Before start working check from the supply society the electrical line
voltage.
Voltage Safe clearance

(kV) m
6,6 3
33 4
66 5
154 8
275 10
32
DO NOT HIT THE BOOM OR ARM
• When you work under bridge, in tunnels, near power lines or indoor be
careful not to hit the boom or arm against overhead objects.
ENSURE GOOD VIEW
• When you work in dark place install work lamp and headlamp and
regulate the working area lighting.
• In case of poor illumination, like it is foggy, cloudy, snowing or raining you
must stop operating and waiting for weather clear up.
OPERATE ON SNOW OR ICE WITH EXTRA CARE
• When travelling on snow or frozen surface, keep the machine travel

speed down and avoid accelerating, stopping or changing directions
abruptly.
• Remember that the road shoulder, fences, etc. may be buried in the snow
and not visible.
OPERATE ON RAMBLING SURFACE
• Keep the machine well back from crags, projections, depth ditch, etc. if
the edge fall down the machine can fall itself and roll down it may cause
severe injure or death. Remember that the ground is weak after rain or
explosions.
• The ground near the rambling edge may collapse under the machine
weight or operating vibrations.
33
OPERATE ON SLOPES
• When operate on slope surface, there is a risk of machine lose stability

and tip over. Always pay attention when operate on slopes.
• Avoid swinging the loaded bucket in a downhill direction. This will reduce
the machine stability (see follow design).
• If it is possible level off the working zone (see follow design).
WRONG CORRECT
FILL
34
MACHINE PARK
• If possible, park the machine on firm, level ground, otherwise block the
crawler, thrust the bucket in the ground.
• When parking on streets, use barriers, caution signs, lights, etc. so that
the machine can easily be seen even at night to avoid collision with other
vehicles.
• Before leave the machine lower the bucket and dozer blade to the
ground, place the safety lock lever in the lock position, stop the engine
and remove the key, lock the cab and covers.
CORRECT
Block
Dig in
35
POSSIBILITY OF OBJECT FALLING DOWN
CRUSHING RISK
Is forbidden use the machine in zones where is a concrete
risk of object falling down.
• If is not possible avoid place with falling down object YUCHAI

ENGINEERING MACHINERY CO. LTD. will reject any responsibility
for operators injure or machine damage.
• So the owner will provide for suitable structure for operator’ safety.
36
3.3 TRANSPORT PRECAUTION
LOAD AND UNLOAD
• Load and unload the machine into trucks may cause injure. Due to this
you ALWAYS MUST PAY ATTENTION.
• During load or unload operation, put the engine at low idle then operate
slowly with travelling levers.
• Load and/or unload the machine always on firm, level surface. Keep
clearance from road edge.
• ALWAYS lock the trucks’ tires with wood stoppers and put some strong
piece of wood under the ramps (see the follow design).
• ALWAYS use loading ramps of adequate strength and size. Maintain the
slope of loading ramps within 15°.
• Be sure that the ramps are been secured on the truck’s bed.
• Keep the truck bed and ramps clean of oil, clay, ice, snow and other
materials which can become slippery.
• NEVER correct you travelling on the ramps: the machine can tip over. If it
necessary come back and restart the manoeuvre.
• Do not move cabin or arm on the trailer it may cause lose of stability.
• After machine load lock the crawler then fasten the machine with suitable
belt.
CORRECT
Ram
Lock
Max 15° Lock
Ramp distance
37
SENDING
• When send the machine on a trailer, you must know the Country
legislation about the weight, width and length of the load. Obey to road
code into force.
• When you choose the journey take in mind all machine dimension
(weight, width and length).
3.4 PRECAUTION WHEN OPERATE WITH BATTERY
BATTERY RISK PREVENTION
• Batteries contain sulphuric acid which will damage eyes or skin on

contact, and lungs on inhalation.
9 If acid contact eyes, flush immediately with clean water and get prompt
medical attention.
9 If acid contact skin or clothes, wash off immediately with clean water
and get prompt medical attention.
9 If acid is accidentally swallowed, drink large quantity of water or milk
and call emergency first aid or anti poisoning unit immediately.
• Wear safety glass and gloves when work with batteries.
• Batteries generate flammable and explosive gasses (Hydrogen). Keep
arcs, sparks, flames and lighting away.
• Stop engine and shut off electrical equipment while inspecting or handling
batteries.
• Do not short circuit the battery posts with metal item.
• Loose battery’s terminal may result in sparks. Be sure to fasten terminals
tightly.
• Always unfasten the negative (-) battery cable first when disconnecting
the battery. Always connect the negative (-) battery cable last when
fastening the battery. Be sure which is negative cable (-) usually black
and which is positive (+) cable usually red.
• Make sure the vent caps are tightened securely.
38
STARTING WITH ASSISTANCE CABLES
• When starting the machine with assistance cables wear ALWAYS safety
glass.
• When use assistance cables connected to another vehicle avoid contact
with both machines.
• When connect two batteries with assistance cables first connect the
positive ones (+). When disconnect the batteries first remove the negative
cable (–).
• If positive cable (+) and frame become in contact sparks will be
generated. It is dangerous so pay attention in your work.
• When you two batteries to help starting make sure to connect the positive
cable from one battery to the positive cable from the other ones.
• When connect the negative cable to the machine’s frame make sure that
it is the most far as it possible to the battery.
3.5 PULLING PRECAUTION
WHEN PULL THE MACHINE CONNECT THE CABLE ON THE FRAME
• If your machine will be pulled use ALWAYS a steel rope or cable with
enough pull capability.
• NEVER pull a non-working machine on a slope.
• Do not use a steel rope twisted or worn.
• Do not ride on the rope or cable.
• When connect a truck and the machine do not allow nobody to cross or
stay between two vehicle.
• Set the truck, the ropes and the machine in same line.
• Put a piece of wood between the ropes and the contact point to protect
the machine from wearing o damaging.
39
40
4. MAINTENANCE PRECAUTIONS
4.1 PRECAUTIONS BEFORE STARING MAINTENANCE
ATTENTION
• Before make any maintenance operation, regulation or reparation on

machine with accessories hydraulically or mechanically driven, make sure
that the accessory is lay on the ground. If it is necessary work under the
accessory keep it lifted with auxiliary mechanical device different from
machine commands.
• Be sure to block the machine crawls.
• NEVER work under the machine if you are not sure about how it is lifted.
WARNING PLATE
• If other people will start the machine while you are make the maintenance
or are lubricating some part, you may suffer severe injure or die.
• Put always the WARNING PLATE on a command lever, inside the cab,
to inform other people that you are working on the machine.
• These plates are available from YUCHAI ENGINEERING MACHINERY
CO. LTD.
DO NOT OPERATE
MACHINE
UNDER SERVICE
Date
Sign
41
SUITABLE TOOLS
• Use only tools suitable for the job. To use damage or weakened tools or
do not suitable may injure yourself.
PERIODICAL SAFETY PART SUBSTITUTION
• Replace periodically the follow part, which are related with fire hazard:
1. Fuel pipeline: fuel sleeve (muff), tank cap.
2. hydraulic pipeline: pump sleeve, pump derivations sleeves (from
pump and back pump).
• Periodically replace these part with new ones, even they do not seem
damaged, their physical characteristics go down with age.
• If you find out some defects replace or repair it, even they are not out of
age.
STOP ENGINE BEFORE MAKE INSPECTION AND MAINTENANCE
• Always stop the machine on a solid and level ground, then stop the
engine before make inspections and maintenance.
• If it is necessary that the engine runs during maintenance, i.e. radiator
cleaning, set the safety lock lever in the lock position then take help from
another operator. Operator who make maintenance must pay attention to
avoid to be trapped between moving parts.
42
PRECAUTION WHEN REFILL OIL AND FUEL
• Keep clearance from sparks and flames when refuelling or refill oil.
• Oil or fuel leakage may slide you, so dry them with a cloth duster.
• Make sure to fasten tightly both tank cap and oil tank cap.
• NEVER use fuel to clean any part.
• Refill oil and fuel only in well aired place.
RADIATOR WATER LEVEL
• If it necessary add water inside the radiator. Before you open the cap wait
for engine and water cooling.
• Unfasten slowly the cap to reduce the pressure inside the radiator.
LIGHTING TO USE
• When check fuel, oil, cooling liquid or battery acid always use ant
explosive fixture and lights. These substances may explode or catch fire.
43
DO NOT STAY ON MOTOR COVER
• NEVER climb on the motor cover. You may slide or roll off.
4.2 PRECAUTION DURING MAINTENANCE
OPERATORS
• Only authorized operators can make service on the machine. Particular

attention must be used in welding or using a sledgehammer.
ACCESSORIES
• All parts you will remove from your machine must be put in a safe place
to avoid to through them away or miss them. Also if they roll down may
cause injuries to you or other people.
44
KEEP THE MACHINE CLEAN
• Oil or grease, tools and small parts scattered every where could stumble
across them. Keep your machine clean and tidy.
• Cover electrical parts when washing the machine, water on electrical
parts could cause short circuit or malfunctioning. Do not use water or
steam to wash battery, sensors, connectors, or the operator’ seat area.
PRECAUTION WITH BATTERY
• When you have to repair some electrical part or have to make welding,
disconnect the battery’s negative cable (-) to stop current circulation.
45
MUFF UNDER HIGH PRESSURE HANDLING
• Do not bend and/or hit, with hard piece, muff under high pressure.
• Do not use any pipe, tube or muff bent or damaged. They may explode!
• Always replace every fuel or oil muff if it is damage and be sure to fast it
tightly: fuel or oil leakage may cause fire.
PRECAUTION WITH OIL UNDER HIGH PRESSURE
• Do no forget that pipeline in arms and working accessories are under

pressure.
• Realise all pressure before working on the hydraulic system.
• Hydraulic fluid under pressure can penetrate skin and eyes and cause
injury, blindness or death. Use safety glass and heavy gloves.
• Fluid escaping from a small hole can be almost invisible so use a piece of
paper to find leaks.
• If you will be hit from high pressure fluid call immediately a doctor.
PRECAUTION WITH HOT OR PRESSURIZED COMPONENTS
• The engine, muffler, radiators, hydraulic lines, sliding parts and many
other parts of the machine are hot directly after the engine is stopped.
Touching these parts will cause burns. So after stopping the engine allow
the machine to cool down before performing inspection and maintenance.
46
PRECAUTION WHEN USE PRESSURIZED GREASE
TO SET CRAWLS TENSION
• In the pipeline of the crawls tension regulation, grease is pumped at high

pressure. If the tension is adjusted without following the correct
procedure, the grease discharge valve may fly off, resulting in injury.
• Loosen the grease discharge valve slowly. Do not unfasten it more than
one full turn.
• Do not put your face, arms, legs or body in front of the grease discharge
valve.
47
FAN AND “V” BELT
• Keep clear from moving and rotating parts, pay attention do not trap
anything between them.
• Hand, arms, skin and clothes may be damaged by blade fan or fan belt
so never touch them if they are moving.
WASTE MATERIALS
• NEVER through away lubricant or hydraulic waste oil into seas, rivers,
lakes and drain.
• NEVER drip waste oil in the ground always use a box to collect the oil.
• Follow law and normative to dispose of dangerous materials like waste
oil, fuel, cooling liquid, solvent, filters, batteries, etc.
WRONG
48
5. MACHINE DESCRIPTION
5.1 EXCAVATOR MAIN PARTS DESCRIPTION
10
4
12
3 11
2 6 13
10
9 7
1
8
No ITEM No ITEM
1 Bucket 8 Idler
2 Arm 9 Rubber crawler
3 Bucket cylinder 10 Work light
4 Boom 11 Operator seat
5 Arm cylinder 12 Canopy
6 Boom cylinder 13 Engine hood
7 Sprocket
49
5.2 DATA SHEET
Model YC 135
Machine weight (kg) 13300

Bucket capacity (m3) 0.52
Maximum digging force (bucket) (kN) 80.4
Maximum digging force (arm) (kN) 69.6
Maximum slewing speed (rpm) 11
Maximum travelling speed (km/h) 4.6
Maximum pulling force (kN) 63
Grade ability (degree) 30
Pressure on ground (kPa) 38
Pump flow rate (l/min) 2 x 130
Working pressure (MPa) 31.9
Battery: voltage (V) / Current (Ah) 24 / 2 x 120
Noise emission on operator seat (dB) 83.1
Engine
Diesel, 4 STROKES
Type
liquid coolant
Kind/Model CUMMINS
Power (kW) / rpm 82 / 2200
50
5.2.1. Transport blocked
All dimensions are in mm, they may change without notice.
51
5.3 WARNING PLATES
Hit people danger during slewing

Make sure that people standing around
working zone, keep enough clearance
from the boom range, before starting
work. Play the horn when start.
Run over people danger during reverse travelling

Make sure do not run over people
standing in the working zone, during
reverse movement. Play the horn before
moving.
Hit people danger with bucket

Make sure that people around working
zone, keep clearance from the bucked
range, before moving it or other
accessories. Play the horn before
moving.
52
Fire extinguisher position
Inform you where is positioned the fire
extinguisher.
ESTINTORE
Emergency exit
Inform you where you can escape in case

of emergency. Usually you have to crash
the window to run out.
Noise emission plate

Inform you about the acoustic power
emitted LwA from your machine during
functioning. Noise is evaluate in
conformity with the Directive 2000/14 CE.
53
5.4 IDENTIFICATION PLATE
Yuchai Engineering Machinery Co., Ltd.

168 Tianqiao Road,Yulin,Guangxi,P.R.537005 China
MODEL
SERIAL No.
YEAR
WEIGHT (kg)
POWER (kW)
54
6. INSTRUMENT AND COMMAND DESCRIPTION
6.1 OPERATORS SEAT DESCRIPTION
5 2
4 3 1
No ITEM
1 Throttle lever
2 Starter key
3 Right operating lever
4 Travel speed levers
5 Left operating lever
6 Safety lock lever
7 Door unlock lever
8 Slewing lock lever
9 Accessories pedal
55
2
10
No ITEM
2 Start key
10 Monitor
6.1.1. Lever and pedal
(7) SAFETY LOCK LEVER
this lever is necessary to prevent unexpected

both machine or accessories movement during
operators mounting and dismounting. This lever
make impossible to use each command.
Lock
Unlock
56
SAFETY LOCK LEVER USE
• When park your machine, always lie down the bucket
then put the safety lever lock in lock position.
• Before dismounting (for breakfast or end shift) turn off
the engine, then put the safety lever lock in lock
position.
• When load the machine on a truck put the safety lever
lock in lock position.
• Be sure that the safety lock lever is in lock position
before start the engine.
(1) THROTTLE LEVER
This lever is used to adjust the engine

speed.
(A) Accelerate: push forward the lever.
(B) Low idling: pull back the lever.
B A
HORN
The horn switch is on the right operating lever. The horn

will sound while you keep it pushed.
57
(4) TRAVELLING LEVERS
The travelling levers control the machine translation.

Push forward the levers to move the machine in the
blade direction, pull them back to move the
machine in the sprocket direction.
READ THE OPERATING MANUAL

Before operate with the travelling levers, read carefully the
chapter “MACHINE MOVING RULES” e “PRECAUTION AND
SAFETY MEASURES DURING WORK”.
(8) SLEWING LOCK LEVER

This lever is used to lock the turret swing
(slewing). This is useful when the machine will
loaded on a truck for transport.
To lock slewing, align the turret with crawler,
A
then insert this lock lever in the slot, so it will
remain locked in this position.
B
58
(9) ACCESSORIES PEDAL
This pedal is used when an additional accessory
is connected to the machine at the power takeoff.
If you use an accessory with double action
(i.e. a bucket with a joint) you can control
both movements pushing the pedal in both
directions.
If you use an accessory with single action (i.e.
a hammer) you must push in one direction
only.
(3, 5) OPERATING LEVERS
(5) LEFT LEVER

When the lever is in central position, the
boom will remain in the start position.
Digging arm movement:

(1) digging arm in.
(2) digging arm out.
Swinging movement:
(3) Turret left rotation.
(4) Turret right rotation.
(3) RIGHT LEVER

When the lever is in central position, the
boom will remain in the start position.
Arm movement:
(5) Boom lower.
(6) Boom raise.
Bucket movement:
(7) Bucket load.
(8) Bucket dump.
It is possible combine the previous movements sliding all levers in diagonal

way.
59
6.2 INSTRUMENT PANEL AND SWITCHES
6.2.1. Instrument and Switches
11 12
13 14
18 22 19
17
20
16 21
23
15
24 25 26 27
28 2
29
60
No ITEM No ITEM
2 Start key 20 Hydraulic oil filter obstruction
warning lamp
11 Coolant temperature warning 21 Battery charge warning lamp
gauge
12 Fuel gauge 22 Hour meter
13 Hydraulic oil temperature gauge 23 Rev counter / voltmeter
14 Engine oil pressure gauge 24 Push button indication
changer
15 Engine oil pressure warning lamp 25 Push button clock setup
16 Coolant temperature warning 26 Push button clock setup
lamp
17 Hydraulic oil temperature warning 27 Push button confirmation
lamp
18 Glow lamp 28 Light switch
19 Air filter obstruction warning lamp 29 Screen wiper switch
(11) COOLANT TEMPERATURE GAUGE

It indicates the engine coolant temperature. It works only with the start key in
ON position. Under normal condition, when the engine run, le gauge bars
must be in green zone. When the gauge bars are in yellow zone it means that
the engine does not reach the normal temperature: so do not put the engine
under heavy work. When the gauge bars are in red zone: the engine is in
over heating, stop work and leave the engine run in idle until the gauge bars
drop down the green zone.
(12) FUEL GAUGE
This gauge indicates the amount of fuel in the tank. Be sure to top off the tank
to avoid running out the fuel.
Pay attention: refuelling with diesel fuel before the gauge reach the “E”
(Empty).
(13) HYDRAULIC OIL TEMPERATURE GAUGE

This gauge indicates the hydraulic temperature. It works only with the start
key in ON position. Under normal condition, when the engine run, le gauge
bars must be in green zone. When the gauge bars are in yellow zone it
means that the engine does not reach the normal temperature: so do not put
the engine under heavy work. When the gauge bars are in red zone: the
engine is in over heating, stop work and leave the engine run in idle until the
gauge bars drop down the green zone.
61
(14) ENGINE OIL PRESSURE GAUGE
This gauge indicates the engine pressure. It works only with the start key in
ON position. Under normal condition, when the engine run, le gauge bars
must be in green zone. When the gauge bars are in red zone the engine oil
has low level, lower then the minimum pressure allowed (0.2 MPa): stop the
engine immediately.
(15) ENGINE OIL PRESSURE LAMP
It flash when the engine oil pressure is low. Suddenly stop the
engine. Check the engine and the oil level. Under normal
condition this lamp must be off.
NOTICE: Cold oil, low level or travel in heavy slope may cause
lamp flash.
(16) COOLANT TEMPERATURE WARNING LAMP
This lamp flash in case of abnormal coolant malfunctioning.

Under normal functioning with the engine turn on it must be off.
The lamp flash if the engine temperature raise too much, so turn
off the engine and wait for cool down.
Carry out the checks listed in the trouble shooting table.
(17) HYDRAULIC OIL TEMPERATURE WARNING LAMP
This lamp flash in case of abnormal hydraulic oil temperature.

Under normal functioning with the engine turn on it must be off.
The lamp flash if the hydraulic temperature raise too much, so
turn off the engine and wait for cool down.
Carry out the checks listed in the trouble shooting table.
(18) GLOW LAMP
This lamp flash when the engine is in the preheating mode, alias
when the start key is in HEAT mode, and turns off when the
preheating is completed.
62
(19) AIR FILTER OBSTRUCTION WARNING LAMP
This lamp flash if the air filter is obstructed, so the air flow is too
low. As soon as possible clean and/ or replace the air filter.
(20) HYDRAULIC OIL FILTER OBSTRUCTION WARNING LAMP
I This lamp flash if the air filter is obstructed, so the oil flow to the
pump is too low. As soon as possible clean and/ or replace the
air filter.
(21) BATTERY CHARGE LAMP
This lamp flashes if a problem arises in the charging system while

the engine is running. Under normal condition the lamp flash for
some seconds, when the start key is in ON position.
(22) HOUR METER / CLOCK
This 6 figures’ meter indicates the amount of worked hours of the

machine or the clock, also it may be used to see coolant
temperature and the hours worked in failure check.
It will count any hour in which the engine is turned on.
When the meter show the clock the time is expressed in 24 hours.
(23) REV COUNTER / VOLTMETER

This 4 figures’ meter indicates the engine rpm or the battery voltage. Also it is
used to see the hydraulic oil temperature or the Error code in failure check.
(24) PUSH BUTTON INDICATION CHANGER

Push this button until the meter (22) or (23) will show the information that you
are searching. All possible combination are: time and rev counter, hour meter
and Volt meter, coolant and hydraulic oil temperature.
(25) E (26) CLOCK SETUP PUSH BUTTON

This two push button allow you to set p the clock, or to see the failure code
list.
63
Clock setup
Push the (25) button to change from hours to minutes and vice versa.
Push the (26) button to increase the value.
Push the (27) button to confirm the set up.
Failure list
To see the failure list, push more times the (24) button until you can see the
failure code on the meter.
To choose the failure code type (Er 0x-5x) push more time the (25) button. To
scroll the list type (x0-x9) push the (24) button.
The failure code list is showed forward.
(27) PUSH BUTTON CONFIRMATION

Push this button 2 times within 3 s, to confirm the time in clock set up,
otherwise the time will not change.
FAILURE CODE LIST

For each kind of failure mode are stored the 10 last vents. If more the 10
events are occurred the first ones are overwrited.
Code Failure mode

Er00–Er09 Hydraulic oil pressure
Er10–Er19 Electrical circuit over voltage
Er20–Er29 Coolant temperature
Er30–Er39 Hydraulic oil temperature
Er40–Er49 Hydraulic oil filter
Er50–Er59 Air filter
If a lot of failure occurred carry out the controls listed in the trouble shooting
table (Chap. 22).
(28) ARM LIGHT SWITCHES
When the start key is in ON position, each switch will control the arm and roof
light ON/OFF.
NOTICE: Do not leave the light turned ON for too much time with the engine
OFF otherwise the battery will discharge.
64
(29) WINDOW WIPER SWITCH
When the key is in ON position, this switch control the window wiper on the
front cabin’s window. (It is not present for canopy setting).
NOTICE: Do not turn ON the window wiper when the window is dry,
otherwise the rubber will be damaged.
(2) START KEY

OFF Position (0):
In this set the machine is totally OFF, so you can
remove the key from the socket.
Run Position:
In a position the current may through in the line
and the buzzer ring.
ON Position (I):
After starting, the key came back in I position;
meanwhile the engine is running, leave the key in ON position.
Preheating position (HEAT):
Before start the engine, specially in winter, put the key in position so the
preheating lamp (21) will flash. Leave the key in this position until the lamp
turn off, then start the engine.
Start Position:
To start the engine move the key in position. While staring the engine
keep the key in this position, when the engine run suddenly release the key,
which came back in I position.
65
BATTERY DISCONNECTING SWITCH
To disconnect the battery from the electrical circuit, move

this switch in 0 position. Before use the machine be sure
that the switch will be in I position.
6.2.2. Heating and air conditioning
TEMPERATURE CONTROL
Move the selector to regulate the temperature inside the cab: towards blue
zone to keep fresh air; towards red zone to warm the cab. All position from
side to side are allowed.
FAN SWITCH
Move the selector to regulate the fan speed: it is possible choose some
different speed and it is possible stop it at all, by putting the selector in 0
position (OFF).
6.3 FUSES
Fuses protect electrical equipments and line from overloaded and/or sudden
change in voltage or current.
To inspect the fuses box is necessary open the
cover near the hydraulic oil tank, in the right side
of the machine.
Replace the fuse if it is “open”, if it is corroded or
if see white dust. Replace the fuse with an
equivalent one, but be sure to eliminate the
cause.
REPLACING FUSE
Before replace the fuses, be sure to put the start key in 0
position.
66
FUSE CAPABILITY
ITEM Capability
Starter switch 10 A
Electromagnet 20 A
Top lamp 5A
Main circuit 40 A
Starter motor 20 A
Horn 5A
Lights 10 A
Wiper 5A
6.4 OPERATOR SEAT
6.4.1. Operator seat adjusting
SEAT ADJUSTING
Before start job or every time change the operator be sure
that the seat is in suitable position for you figure.
The seat allow three setting to ensure operator complete comfort:

1. longitudinal position set
2. front side seat’s vertical set
3. back side seat’s vertical set
4. backrest reclining set
5. reclining arm
It is possible that your excavator does not have

all these setup.
The seat can not be adjusted while the
excavator is travelling.
The seat comfort has main important for job
daily course. So that, it is necessary keep it in
good condition, with weekly and useful
maintenance. Specially often check all fastened
screws and fasten them tightly if it necessary.
67
6.4.2. Seat belt
SEAT BELT
Use the seat belt when the machine travel. Before start,
check belt, buckle and fixing point. Replace then if
necessary and do not use the machine without seat belt.
Pay attention that the seat belt is not twisted. Pull

slowly the belt to be sure that the buckle is well
fixed. Set the belt to avoid clearance between it
and body.
Push button (1) to open the belt.
6.5 CABIN
6.5.1. Open / Close side door
From outside:
1. Lift the small cover, insert the key in the
socket and rotate it to unlock the door.
2. Pull the external handle to open the door
completely up to the cabin screen.
3. Unlock the door pulling knob, close the door,

lift the small cover, insert the key and rotate it
clockwise to lock the socket again.
68
From inside:
1. Pull the inside handle to open the door.
6.5.2. Front window opening
1. Stop the machine on a level round, lower down the bucket, turn off the
engine.
2. Put the safety lock lever in lock position.
3. To open the window unlock the pins (A) in
the upper front window’s corner.
4. Using the handle, pull the window the do

slide the roller inside the guide until the
window reach the roof; for more safety
rotate the pins (B) to lock the window in this B
position.
FRONT WINDOW OPENING

When you open the front window, keep both hands on the
handle and lift it. If you use only one hand, it may slide and
remain trapped.
WINDOW LOCK
If the machine travel with the front window open it may fall
down so always lock it with the pins (B).
69
To close the from upper window, follow the previous procedure in reverse
order.
6.5.3. Side window opening
1. Keep the handle and at same time push the

small lever to unlock the window.
2. Slide the side window.
To close the side window slide it reverse direction
and lock the handle.
6.5.4. Cab light
Move the switch up or down to turn on/off inside the

cab.
6.5.5. Emergency exit
In EMERGENCY, if you can not run out the cab

through the door, you can go out through the side
window.
If necessary break out the window using a hammer

or similar.
70
7. STARTING MACHINE
7.1 CHECK BEFORE START
Daily check all parts below listed before start the machine.
7.1.1. Check coolant, refill it
1. Open the engine hood, unlocking it with the lever inside the cab. A shock
absorber keep it open.
BURNS
The radiator top may be hot. Wait until the engine cool down
then open the radiator top.
2. Check if liquid level is between the lines

LOW and FULL. If it is under the LOW line,
add some coolant through the top up to the
correct level.
3. Screw down the top tightly.
4. If the reserve tank is completely empty,
inspect for fluid leakage, the inspect the
radiator coolant level. If it is slow, add water
to the radiator first, then to the reserve tank.
71
7.1.2. Check and replacing engine oil
1. Open the engine hood.

2. Remove the dipstick (1) dry it with a clean duster.
3. Insert the dipstick completely in is tube then
remove it again.
4. On the dipstick you must check the oil level it
have to be in middle between two line. If the oil 1
level is under the low
line (A), replace the oil
up to the middle by put
it through the oil muff 2
(2).
5. If the oil is over the upper line, drain the oil in a pan unfasten the drain plug.
Then check the level again.
6. When oil level is correct insert the dipstick and fast the drain plug tightly,
then close the engine hood.
NOTICE: If the engine has run, wait for 15 minutes before check oil level. If
the machine is on a slope, travel it on a level round before check the oil level.
7.1.3. Inspecting and adjusting the fan belt

2. Press at the centre of the fan pulley and alternator pulley and check the
tension.
Pressure: about 10 kg.
The slack should be about 10 -15 mm.
3. Replace the fan belt if:
- there are cuts or crack;
- the belt is worn and touches the bottom of the V groove in the pulley;
- the belt stretches and cannot be adjusted.
To adjust the tension see the paragraph “FAN BELT ADJUSTING”.
72
7.1.4. Fuel level and refuelling
REFUELLING
When refuelling do not drain it off the tank, it may cause a
fire. If some gasoline drain off dry it immediately with a
duster.
1. Insert the key in the socket the move it in ON position.

2. Check the fuel level in the fuel gauge. If the indicator bars are in red zone
you must refuel the machine.
3. Unlock the top with the key and rotate the top
in anti clockwise to open the tank.
4. Put some diesel inside, then fast the top tightly
and close it with the key.
7.1.5. Check hydraulic oil and refill
REPLACING HYDRAULIC OIL

• When remove the hydraulic oil top, unscrew it slowly, in
order to reduce the pressure inside the tank.
• If to much oil is filled in, stop the engine wait for cooling
down then drain the excess oil.
1. Park the machine on a level ground.

2. Lower down the bucket, start the engine and leave
it run at low idle for some minutes, then lower the
blade and contract the arm and buck after this
lower the boom until the bucket teeth touch the
ground.
3. Leave the engine run for 5 minutes then stop it.
73
4. Check the oil level and watch if it visible in the
circular indicator in the internal side of the
tank. If you can not see the oil you must
replace it through the top under the right
armrest. Do not replace oil if you can see it in
the indicator. It may damage the hydraulic
accessories and will cause oil leakage.
5. If you must replace oil, unscrew the top on

right side of the machine then fill in the oil
through the muff.
6. Check again the oil level if it is good, fast the
top tightly.
NOTICE: The oil level can change by oil temperature. So be carefully:

• When oil temperature is near environment temperature (10 ÷ 30 °C) the oil
level can approach the minimum level.
• When oil temperature is 50 ÷ 80 °C, the oil level can approach the upper
level.
7.1.6. Check air filter
See the instruction listed in the paragraph “CHECK, CLEAN AND REPLACE
AIR FILTER”.
74
7.1.7. Check electrical circuit
ELECTRICAL CABLE
Is fuses burn often or if cable are damaged (burned) you
must find out the cause. You may ask to assistance service
by YUCHAI ENGINEERING MACHINERY CO. LTD.
Check that fuses are not damaged and look for damage or disconnected
cable. Also check terminal and fast them all.
Anyway check these items:
• Liquid battery level (10÷15 mm over
electrode);
• Starter;
• Alternator.
Rotate the start key in a position the check the follow items:
• Instrument panel with care for fuel gauge and warning lamps (contact
insert, water temperature engine oil).
• Verify if buzzer works properly.
• Verify if all switches work properly and also all light.
Contact YUCHAI ENGINEERING MACHINERY CO. LTD. to solve any

trouble with instrument panel.
75
7.2 STARTING
7.2.1. Precaution
1. Verify the safety lock lever is in lock position.

2. Verify that all levers are in neutral position.
3. Check warning lamps in this way: rotate the
start key in position, so the buzzer ring, the

lamp Contact insert, battery charge and engine
oil pressure flashes.
4. Adjust the operator’s seat to reach lever and
pedal correctly. Operator backside must be
leant against the backrest. Fast the seat belt.
Lock
Unlock
STARTING PRECAUTION
Verify that nobody were in the working zone, play horn
then start the machine.
7.2.2. Engine starting
1. Rotate the key in start position . The engine will start.
STARTER
Do not run the starter more then 10 seconds. In engine
does not start rotate the key in OFF position, wait for 30
seconds then try to start the engine again. After a false
start do not rotate the key until the engine is still. (the
starter may damage).
2. When the engine start, release the key, it came back in work position I.
76
7.2.3. Start engine in cold weather
PRECAUTION TO WORK IN COLD WEATHER

Be sure nobody stand in working zone, then play horn and
start engine.
When start the machine in cold weather follow these rules:
1. Keep the key in preheating position .

2. when the preheating procedure is completed (lamp off), then start engine
by rotating the key in position: the engine will start.

3. Move the throttle lever to regulate the engine speed.
ALLOWED WORKING TEMPERATURE

Maximum air temperature 40 °C
Minimum air temperature -20 °C
Coolant temperature 95 °C
Engine oil temperature 88 °C
Hydraulic oil temperature 75 – 80 °C
7.3 OPERATIONS AND CONTROLS AFTER STARTING
After you starter the engine do not travel or move the boom or arm. First of all
let the machine rise temperature (engine, hydraulic oil, ect.) then follow the
rules listed below.
7.3.1. Engine heating
Move the throttle lever in accelerate position then let the engine run at
medium speed for some minutes without any load.
NOTICE:
Do not accelerate the engine suddenly before the heating time is gone.
The heating time depends by air temperature, like showed below:
Environment temperature (°C) Heating time (min)

≤ –20 5
–20 / –10 2
– 10 / +5 1
≥ +5 0.5
77
NOTICE:
working hydraulic oil temperature is 50 ÷ 60 °C. If oil temperature is under
20 °C do not operate with the hydraulic accessories (boom, arm, bucket, etc.)
7.3.2. Instrument panel check
1. The bar gauge must be in centre of the scale.

2. Alternator lamp must be off.
3. Engine oil pressure lamp must be off.
7.3.3. Safety lock lever check
Put the safety lock lever in lock position then

check that moving levers or pedal no action will
result in any hydraulic parts neither the
machine can travel.
Lock
Unlock
7.3.4. Noise and exhaust check
1. Put the safety lock lever in unlock position then pull up the bucket.
2. Operate slowly the bucket lever control and expand totally the cylinder.
Leave the bucket in this position for 5 minutes.
3. Check if exhaust has bad colour, or engine emit strange noise or vibrating.
Exhaust:
• Colourless or light blue: normal (complete combustion);
• Black: abnormal (incomplete combustion);
• White: abnormal (oil drains through cylinders).
78
8. MACHINE MOVING RULES
8.1 FORWARD MOVEMENT
PRECAUTION BEFORE MACHINE OPERATING

• Before operating the travel levers, check to make sure
that the dozer blade is to the front of the operator’s seat.
BE AWARE that when the dozer blade is to the rear the
travel lavers operate in the opposite direction to when
the dozer blade in the front.
• Before operating the travel levers, check that nobody
stands in the working zone, then play horn.
1. Act the throttle lever to accelerate the engine.

2. Put the safety lock lever in unlock position. Bend
the arms like showed in side drawing the pull it up
for 40 ÷ 50 cm.
3. Pull up the dozer blade, acting the appropriate
lever.
4. Act the travel levers (left and right) as written below:

• If the dozer blade is in front side of the machine.
Push forward slowly the travel levers to move the
machine forward.
79
• If the dozer blade is in back side of the machine.
Pull rearwards slowly the travel levers to move the
machine backwards.
8.2 BACKWARDS MOVEMENT

• Be careful when travel backwards, there are blind spots
to the rear of the machine. Before act travel levers check
the dozer blade position, when the dozer blade is to the
rear the travel lavers operate in the opposite direction to
when the dozer blade in the front.
• Before operating the travel levers, check that nobody
stands in the working zone, then play horn.
1. Act the throttle lever to accelerate the engine.

2. Put the safety lock lever in unlock position. Bend
the arms like showed in side drawing the pull it up
for 40 ÷ 50 cm.
3. Pull up the dozer blade, acting the appropriate
lever.
80
4. Act the travel levers (left and right) as written below:
• If the dozer blade is in rear side of the machine.
Pull backward slowly the travel levers to move the
machine forward.
• If the dozer blade is in rear side of the machine.

Push forward slowly the travel levers to move the
machine backward.
8.3 CHANGING DIRECTION (STEERING)

Be careful when travel backwards, there are blind spots to
the rear of the machine. Before act travel levers check the
dozer blade position, when the dozer blade is to the rear
the travel lavers operate in the opposite direction to when
the dozer blade in the front.
Act the travel levers to change direction.

If it is possible, avoid sudden direction change, also before start a rotation in
one direction wait for the machine is stopped.
81
• When the machine still:
LEFT TURNING:
If the machine is travelling forward and you
want turn left push the right travel lever.
Vice versa, to turn left when the machine is
travelling backwards pull the right travelling
lever.
RIGHT TURNING:
If the machine is travelling forward and you
want turn right push the left travel lever.
Vice versa, to turn right when the machine is
travelling backwards pull the left travelling
lever.
82
• When the machine is travelling
(both travelling lever acted at the same time):
LEFT TURNING:
If the machine is travelling forward release
the left travel lever to neutral position.
RIGHT TURNING:
If the machine is travelling forward release
the right travel lever to neutral position.
• Rapid direction change (spin turn):

LEFT TURNING:
When turning left using counter-rotation, pull
the left travelling and steering lever back and
push the right travelling and steering lever
forwards.
RIGHT TURNING:
When turning right using counter-rotation, pull
the right travelling and steering lever back
and push the left travelling and steering lever
forwards.
83
8.4 MACHINE STOP AND PARK
MACHINE STOP AND PARK

• Avoid abruptly stop. Keep enough space when you want
stop the machine.
• When park the machine choose a level and heavy
ground and avoid dangerous place. If you must park the
machine one slope, put some pieces of wood under
crawlers, then thrust the bucket under ground.
Lock
Thrust the bucket
1. If it is possible park the machine on a level ground.

2. Lower bucket and dozer blade on the ground.
3. put all levers in neutral position.
4. Put the safety lock lever in the lock position,
otherwise accidental action on a lever may
cause sudden machine movement and it
may cause injury or death.
Lock
Unlock
5. Put the throttle lever in low idle.
84
6. Rotate the start key in anti clockwise, in 0
position.
NOTICE: Model YC 35-6 has got a lever to stop

the engine.
ENGINE STOP
Do not stop the engine abruptly before it is cool enough, it
may cause fast aging. Only for emergency you can stop it
suddenly. Particularly if the engine is over heated let it run
at medium speed for some minutes then stop it.
7. Remove the start key.

8. Close all windows and cabin door.
9. Close all covers and hood.
8.5 SWINGING
PRECAUTION FOR SWINGING

• When arm or turret swing, always check the clearance
around the machine: make sure nobody and anything
are in machine range.
• Check the swing lock lever (11) is in unlock position.
To swing the turret act the left operating lever as is described in paragraph
6.1.1.
85
8.6 FORBIDDEN MOVEMENT AND FORBIDDEN USE
PRECAUTION IN WORK
If you must act the operating accessory while the machine
is travelling, you have to stop the machine before act the
operating lever.
FORBIDDEN OPERATIONS USING SWING FORCE

Do not use the swing force to compact soil or break earth
mounds or walls.
WRONG
FORBIDDEN OPERATIONS USING TRAVEL FORCE

Do not leave the bucket dug into the round and use the
travel force to excavate.
WRONG
86
PRECAUTIONS WHEN OPERATING HYDRAULIC CYLINDERS
TO END OF STROKE
If the cylinder is operated to the end of its stroke during
operations, force will be brought to bear on the stopper
inside the cylinder, and this will reduce the life of the
machine. To prevent this, always leave a small safety
margin when operating the cylinder.
CORRECT Margin
FORBIDDEN OPERATIONS USING DROPPING FORCE OF

BUCKET
Do not using the dropping force of the bucket as a pickaxe,
breaker, or pile driver. This will bring excessive force to
bear on the rear of the machine, and will not only damage
the machine, but is also dangerous.
WRONG
87
FORBIDDEN OPERATIONS USING DROPPING FORCE OF
MACHINE
Do not use the dropping force of the machine for digging. It
is better to excavate hard rocky ground after breaking it up
by some others means. This will not only reduce damage to
the machine but make for better economy.
WRONG
AVOID HITTING BLADE

Be careful not to hit the blade against rocks or boulders.
This will cause premature damage to the blade or cylinder.
WRONG
88
8.7 PRECAUTION FOR OPERATING
TRAVELLING OVER OBSTACLE

When travelling over obstacle such as boulders or tree
stumps, the machine (in particular the undercarriage) is
subjected to a large shock, so reduce the travel speed and
travel over the obstacle at the centre f the tracks. As far as
possible, remove such obstacle or avoid travelling over
them.
WORONG
PERMISSIBLE WATER DEPTH

When driving the machine out of water, if the angle of the
machine exceeds 15°, the rear of the upper structure will go
under water, and water will be thrown up by the radiator
fan. This may cause the fan break. Be extremely careful
when driving the machine out of water.
CORRECT
89
PERMISSIBLE WATER DEPTH
Do not immerse the machine in water by more then the
permissible depth (under centre of carrier roller (1)).
Also, for parts that have been immersed in water for long
time, pump in grease until the old grease comes out from
the bearings (around the bucket pins).
CORRECT
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS

• When travelling, raise the bucket approx. 20 ÷ 30 cm
from the ground.
• If the machine slide down or loss stability, lower down
the bucket and brake the machine.
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS

• Do not travelling downhill in reverse.
• IT IS DANGEROUS to turns on slopes or to travel across
slopes. Always go down to a flat place to perform these
operations.
• Turning or operating the work equipment when working
on slopes may cause the machine to lose its balance
and turn over, so avoid such operations. It is particularly
dangerous to swing downhill when the bucket is loaded.
If such operations have to be carried out, pile soil to
make platform on the slope so that the machine can be
kept horizontal when operating.
• Do not travel on slopes of over 25° as there is danger
that the machine may overturn.
90
WRONG
CORRECT
WRONG
CORRECT
Platform
When travelling down steep hills, use

the travel lever and fuel control lever
to keep the travel speed low. When
travelling down slope of more than 15°,
set work equipment in the posture
shown in the figure on the right, and
lower the engine speed.
When travelling up a steep hill of more

than 15°, set the work equipment in
the posture shown in the diagram on
the right.
91
Braking when travelling downhill:
to brake the machine during downhill runs, put the travel lever in the neutral
position. This will cause the brake to be automatically applied.
If shoes slip:
when travelling uphill, if the shoes slip or it is impossible to travel uphill using
the force of the track only, it is possible to use the pulling force of the arm to
help the machine travel uphill.
If engine stops:
if the engine stops when travelling uphill, move the travel levers to neutral
position, lower the bucket to the ground, stop the machine, then start the
engine again.
TRAVELLING UP OR DOWN HILLS

If engine stops when the machine is on slope never use the
left operating lever to make swinging operations.
8.8 WORK POSSIBLE USING HYDRAULIC EXCAVATOR
8.8.1. Backhoe work
When condition of the machine is as

shown in the diagram at right, each
cylinders maximum pushing excavation
force is obtained when the bucket cylinder
and link, arm cylinder and arm t 90°. When
excavating, use this angle effectively to
optimize your work efficiency.
The range for excavating with the arm is
from a 45° angle away from the machine
to a 30° toward the machine.
There may be some differences
depending on the excavation depth, but try
to use within the above range rather than
going all the way to the extreme end of the
cylinder stroke.
92
8.8.2. Ditching work
Ditching work can be performed efficiently

by attaching a bucket to much the width of
the ditch and then setting the tracks
parallel to the line of the ditch to be
excavated.
To excavate a wide ditch, first dig out both
sides and then finally remove the centre
portion.
8.8.3. Loading work
In places where the swing angle is small,

work efficiency can be enhanced by
locating the dump truck in a place easily
visible to the operator.
Loading is easier and capacity greater if
you begin from the front of the dump truck
body than if loading is done from the side.
8.8.4. Operations in confined spaces
When operating in confined space, set the work

equipment in the posture showed in side figure. This
will allow the machine, to swing freely in any area
where it is possible for the tracks to enter.
Moreover you can increase the machine capability, by using different

accessories.
For this excavator are available some original optional, like: drill, jointed
bucket, pickaxe, etc. For more information please contact the assistant
service by YUCHAI ENGINEERING MACHINERY CO. LTD.
93
8.9 HOW TO ESCAPE FROM MUD
Always operate carefully to avoid getting stuck in mud. if the machine does
get stuck in mud, use the following procedures to get the machine out.
When only one side in stuck:

Use the bucket to raise the track, then lay
boards or logs and drive the machine out.
If necessary, put a board under the bucket
also.
SOLLEVAMENTO DELLA MACCHINA

Quando usate il braccio e l’asta per sollevare la macchina,
assicuratevi che la parte della benna a contatto con il
terreno non sia la parte iniziale (denti). Verificate, inoltre,
che l’angolo fra il braccio e l’asta sia compreso tra 90° e
110°.
When both side are stuck:

If the machine will not move, lay boards as
explained above and dig the bucket into
the ground in front. Then pull in the arm
as in normal digging operations and put
the travel levers in the forward position to
pull the machine out.
94
95
9. COLD WEATHER OPERATION
9.1 PRECAUTION FOR FUEL, LUBRICANTS AND COOLANT IN LOW

TEMPERATURE
If the temperature becomes low, it becomes difficult to start the engine, and
the coolant may freeze, so do as follows.
9.1.1. Fuel and lubricants
Change fuel and oils with low viscosity for all components.
Gasoline viscosity:
Class (JIS) Viscosity at °C
JIS nr.2 light oil -10
JIS nr.3 light oil -20
JIS special nr.3 light oil -30
Use lubrcant oil with viscosity less then 5 °C at ambient temperature.
9.1.2. Coolant
IS ABSOLUTELY FORBIDDEN
• Keep the liquid coolant near free flames.
• Smoke meanwhile operate with coolant.
• Using coolant with methanol, ethanol, propane.
• Using any water leak preventing agent irrespective of
whether it is used independently or mixed with an
antifreeze.
Use permanent antifreeze so you do not must change it for a year.

For any doubt about your antifreeze coolant refer to your supply.
Where no permanent antifreeze is available, an ethylene glycol antifreeze
without corrosion inhibitor may be used only for the cold season. In this case,
clean the cooling system twice a year. When refilling the cooling system, add
antifreeze in autumn but do not add anything in spring.
DO NOT MIX DIFFERENT LIQUID

Never mix an antifreeze with another different.
96
9.1.3. Battery
PRECAUTION WITH BATTERY

• Never approach the battery with flames and sparks.
• Acid inside the battery is dangerous. If it drops is your
eyes or skin wash with large quantity of water and call
medical emergency suddenly.
When the ambient temperature drops, the capacity of battery will also drop. If
the battery charge ratio is low, the battery electrolyte may freeze. Maintain the
battery charge as close as possible to 100%, and insulate it against cold
temperature so that the machine can be started easily the next morning.
Measure the specific gravity and calculate the rate of charge from the
following conversion table.
Fluid temperature 20 °C 0 °C -10 °C -20 °C

Rate of charge
100% 1.28 1.29 1.30 1.31
90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
9.2 ENGINE STARTING IN COLD WEATHER
To start engine in cold weather, proceed according to write in the paragraph

“START ENGINE IN COLD WEATHER”.
9.3 PRECAUTION AT WORK END IN COLD WEATHER
To avoid that water and mud will freeze on tracks or on other parts, making
machine travelling impossible, follows these rules:
• Dry carefully hydraulic pistons.

• Remove completely water and mud on the machine frame. Ice and mud
may damage gaskets.
• Park the machine on solid and dry ground. If it is impossible part it on
boards.
• Open the drain valve to remove water in fuel pipe to avoid that will freeze.
• Cover up the battery or take it out the machine and put it indoor.
Remember that battery performance drops when temperature drops.
97
• If electrolyte level is low add distillate water only next morning. Never add
water in the evening at the end of the work.
9.4 CABIN HEATER
When ambient temperature drops use the cabin heater to warm it up.
To start the cabin heater:
1. Rotate in anti clockwise the water pipe valve.
2. Push the fan switch as is described in paragraph 6.2.2
In spring and summer close the pipe valve, rotating it in clockwise.
98
10. CHECK AFTER COMPLETION OF WORK
1. Walk around the machine and check all parts: bucket, arm, boom, tracks,
frame, etc. Also check if there are any oil or water leakage. If you find out
any problem call the assistant service by YUCHAI ENGINEERING
MACHINERY CO. LTD.
PROBLEM FOUND OUT

Do not use the machine if find out some problem and put a
warning plate on the instrument panel.
2. Refuel the tank.

3. Check the engine compartment and remove paper, death leaves, etc.
4. Remove any clod of earth from the track.
99
100
11. USING RUBBER SHOES (ONLY FOR MACHINE WITH
RUBBER SHOES)
Rubber shoes have excellent properties that are not found in metal shoes.
However do not use rubber shoes like metal ones, this use cannot be made
of their advantage.
Rubber shoes vs. Metal shoes:
Rubber shoes Metal shoes

Small vibration Excellent Medium
Smooth travel Excellent Good
Low noise Excellent Medium
No damage to paved surface Excellent Medium
Easy to handle Excellent Medium
Easily damaged Medium Excellent
Strong drawbar pull Excellent Excellent
Their weak point is lack of strength. Therefore it is important to understand

the advantages of rubber shoes and to follow the precaution regarding
handling and forbidden work.
11.1 RUBBER SHOES GUARANTEE
Rubber shoes have not to be used with pavement which may damage them,
like steel board, U cracks, obstacles, rocks, etc. if the customer carries out
prohibited work or does not follow precautions for operation, the damage
resulting from the customer’s mistaken use of the machine shall not be
included in the scope of the warranty.
101
11.2 PRECAUTIONS WHEN USING RUBBER SHOES
FORBIDDEN WORK AND USE WITH RUBBER SHOES

• Carrying out operations and steering on crushed rock,
extremely rough hard rock, steel beams, scrap iron or
near the edges of steel plates will cause damage to the
rubber shoes.
• In places such as riverbeds where there are large
numbers of large and small boulders, the stones may get
caught and damage the rubber shoes or make the shoes
come off. If dozing operations are carried out when the
shoes slip, this will also reduce the life of the rubber
shoes.
• Be careful not to get oil, fuel or chemical solvent on the
rubber shoes. If such a substance should get on the
shoes, remove it immediately, furthermore do not travel
on road surfaces where oil has collected.
• When putting the machine into long-term storage (3
months or more) store the machine indoors where t is
protected from direct sunlight or rain.
• Do not move the machine with the crawler on one side
raised using the work equipment. This will cause damage
to the rubber shoes and may cause the shoes to come
off.
Be careful of the following points when carrying out work:

• Avoid carrying out counter rotation turns on concrete surfaces.
• Avoid making sudden changes in direction. This may cause premature
wear or damage to the rubber shoes.
• Avoid operating the steering when travelling over places where there is a
big difference in height. When travelling over obstacles or places where
there is a difference in height, drive the machine at right angles to the
obstacles to prevent the shoes from coming off.
• If the machine has been raised using the bucket, lower it slowly.
• Avoid doing work with materials that will attack the adhesion of the steel
core such as salt, ammonium sulphate, potassium chloride, potassium
sulphate, calcium super phosphate, or wash the machine after use.
• The adhesion of the core will be attacked by salt, so avoid using the
machine in coastal areas.
• Do not carry out works that involves scraping against walls or concrete
embankments.
102
• Rubber shoes slip extremely easily on snow or frozen roads. Be careful
not to sleep when travelling or working on slopes.
• The properties of rubber shoes change when working in extremely cold
place, and this will reduce the life of the rubber shoes.
• Because of the properties of rubber, use the rubber shoes within a range
of –25 °C ÷ +55 °C.
• When working, be careful not to damage the rubber shoes with the bucket.
To prevent the shoes from coming off, always maintain the correct tension.
If the tracks are slack, the shoes will come off under the following condition.
Even when the tension is correct, be extremely careful when carrying out
these operations:
• When travelling over curbs, rocks or

WRONG
places where there is a big difference in
level (approx. 20 cm), do not turn the
machine. When travelling over such
objects, always travel at right angles to
the object.
• When travelling in reverse up a slope, do

WRONG
not turn when moving from flat ground
onto the slope. If it is necessary to turn on
slopes, be sure to turn gradually.
• Avoid travelling along the edge of a slope

WRONG
or on rough ground with the track on one
side raised (with the machine tilting at
angle of more than approx. 10°) and one
side on the flat ground. To avoid damage
to the rubber shoes, travel with both
tracks on flat ground.
103
• If the rubber track is loose, avoid turning
as is showed in side figure, when travel on
obstacles.
WRONG
• When travelling over an obstacle, a gap is WRONG Rubber shoe

formed between the track roller and the
rubber shoe. In this condition, the rubber Track roller
shoe may come off.
• if the machine travels further in reverse, a WRONG

gap is formed among the track roller, idler Idler
and the rubber shoe.
• If the machine travels in reverse in this

WRONG
condition, the rubber shoe may come off.
• If the machine is turned in this condition, WRONG

the rubber shoe may come off.
104
12. TRANSPORTATION
12.1 LOADING UNLOADING WORK
MACHINE LOAD / UNLOAD

Load and unload the machine is a dangerous operation so
be particularly careful.
MACHINE LOAD / UNLOAD

• Make sure the ramp has sufficient width, length and
thickness to enable the machine to be safely loaded and
unloaded. If ramps sag appreciably reinforce them with
blocks.
• When loading or unloading the machine, run the engine
at the idling speed then travel slowly.
• When loading or unloading the machine, park the trailer
on a flat, firm roadbed. Keep a fairly long distance
between the road shoulder and the machine.
• Remove the mud from the under carriage to prevent the
machine from slipping to the side on slopes.
• 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.
• When turning the machine on trailer, the machine’s
footing is unstable, so carry out the operation slowly.
• Ever check if the cabin door is locked (open or closed).
Never open or close the door when travel on ramps it may
cause a sudden stability change.
105
To load or unload the machine, use always ramps or a platform and follows
these rules:
CORRECT
Ramp
Blocks
Max 15° Block
Distance between ramps
1. Properly apply the brakes on the trailer and insert blocks beneath the
tires to ensure that it does not move.
2. Fix ramps in line with the centres of the trailer and the machine. Be sure
that the two sides are at the same level as one another.
3. Make the angle of the gangplank a maximum of 15°. Set the distance
between the ramps to match the centre of the tracks.
4. Lower the engine speed using the throttle lever.
5. Set the swing lock lever to the lock position.
6. set in direction of the ramps, lower the work equipment as far as
possible without letting it hit the trailer, then travel slowly to load or
unload the machine.
If the work equipment is installed to the machine, load from the front; if the
work equipment is not installed then load from the rear.
NOTICE: when you are on the ramps do not operate any lever than the
travel one.
7. Load the machine correctly in the specified position on the trailer.
106
12.2 LOAD PRECAUTION
After machine load, on a truck, keep it still as written below:

1. Lover down the blade.
2. Extend the bucket and arm cylinders completely, then lower down the
arm slowly.
3. Stop the engine and remove the start key.
4. Put the safety lock lever in lock position.
5. Insert a big beam under the
bucket cylinder, to avoid the
contact with the floor.
6. Place rectangular timber underneath

the front and rear track shoes to
prevent the machine from moving about.
Also, hold it down with chains or ropes.
Be particularly careful to ensure that the
machine does not slip sideways.
12.3 PRECAUTION FOR TRANSPORTATION
PRECAUTION FOR TRANSPORTATION

• Obey all state and local laws governing the weight, width
and length of a load. Observe all regulations governing
wide loads.
• Always check if the door is lock in one position: open or
closed.
• Always remember to retract the car radio antenna.
107
108
13. MACHINE TOWING
PRECAUTION FOR TOWING

• When towing the machine, use a wire rope that has
ample strength for the weight of the machine that is
being towed.
• Do not tow the machine with steel rope damaged.
If the machine sinks in mud and cannot

get out under its own power, or if the
drawbar pull of the excavator is being
used to tow a heavy object, use a rope
as shown in beside figure.
109
110
14. LONG TERM STORAGE
14.1 BEFORE STORAGE
To protect the cylinders rod when the

machine is not being used, set the work
equipment as showed in beside figure.
This to prevent rusting of the cylinder
rod.
When putting the machine in storage

for a long time, do as follow:
• After every part is washed and dried, the machine shall be housed in a dry
building. Never leave it outdoors.
• In case it is indispensable to leave it outdoors, park the machine on the
well-drained concrete and cover it with canvas etc.
• Completely fill the fuel tank, lubricate and change the oil before storage.
• Apply a thin coat of grease to metal surface of the hydraulic piston rods.
• Disconnect the negative terminals of the battery and cover it, or remove it
from the machine and store it separately.
• If the ambient temperature is expected to drop below 0 °C, always add
antifreeze to the cooling water.
• Lock each control lever and pedal with the lock lever and pedal lock.
111
14.2 DURING STORAGE
Every month do as follow:

• Start the engine and travel the machine for a short stretch, so a thin coat
of grease will cover the moving parts.
• Charge the battery.
• Clean the grease on a cylinder rod and operate with the working
equipment. After moving the working equipment put some grease on it
again.
EXHAUST GAS
• Do the previous operations outdoors.
• If you cannot go out, open windows and doors to
improve the ventilation and prevent gas poisoning.
14.3 AFTER STORAGE
When you start the machine after a long term storage, do as follow:
• Remove the excess grease with a duster from cylinder rods.
• Add oil and grease to all places.
112
15. STARTING MACHINE WITH JUMP-START CABLES
(BATTERY DISCHARGED!)
OPERATING WITH BATTERY

• Before operating battery, stop the engine and turn the
starting key to the 0 position.
• When handling battery, always wear protective gloves
and eyeglass.
• When removing the battery, first disconnect the cable
from the ground and remember which is which.
• When installing the battery, first connect the positive
cable. Be careful because the sudden contact between
positive pole and frame will cause sparks.
OPERATING WITH BATTERY

• Battery electrolyte is dilute by sulphuric acid, it will
attack skin and clothes. If sulphuric acid drop on your
clothes immediately take them off and clean the skin
with a large quantity of cold water. If sulphuric acid drop
on your skin immediately clean the skin with a large
quantity of cold water and call for medical emergency.
• If the terminal are loose there is danger that the
detective contact may generate sparks that will cause an
explosion. When installing the terminals, install them
tightly.
113
Disconnect Connect
• When remove the battery first disconnect the negative cable (1).
• When install the battery first connect the positive cable (2).
NOTICE: Never change cables polarity.
WRONG
114
STARING MACHINE WITH JUMP-START CABLES
• When connect the cables be sure to prevent contact
between them.
• When start engine with jump-start cables wear always
protective eyeglass.
• Be sure that both vehicles will not touch each other, to
avoid sparks near the battery, which may catch fire the
sulphur acid gas. Sulphur acid explosion will cause
severe injuries.
• Be sure do not make mistake in cables installing.
• Use care when removing cables from the machine that
has been starter. Do not allow the cable ends to contact
each other or the machine, to avoid hydrogen explosion.
• Jump-start cable must be useful for the purpose.
• Battery used for starting must have the same capacity
of the discharged battery.
• Be sure that cables and terminals are not worn or
damaged.
• Be sure that cables and terminals are tightly fastened.
115
15.1 PRECAUTION FOR JUMP-START CABLE CONNECTION AND
STARING
1. Make sure that the starting switches and key are in OFF position, in both
vehicles.
2. Connect jump-start cables as follow:
• connect one clip of jump-start cable (1) to the positive terminal (+) of
the problem machine,
• connect one clip of jump-start cable (2) to the positive terminal (+) of
the normal machine,
• connect one clip of jump-start cable (3) to the negative terminal (-) of
• connect one clip of jump-start cable (4) to the engine block of the
problem machine.
3. Make sure the clips are firmly connected to the terminals.

4. Start the normal machine engine and keep it at high idling speed.
5. turn on the starting switch of the problem machine and start the engine. If
it does not work try again not more than 2 minutes.
116
15.2 PRECAUTION FOR JUMP-START CABLES DISCONNECTING
After the engine has starter, disconnect the jump-start cables in the reverse
order in which they were connected:
1. disconnect one clip of jump-start cable (4) to the engine block of the
problem machine,
2. disconnect one clip of jump-start cable (3) to the negative terminal (-) of
3. disconnect one clip of jump-start cable (2) to the positive terminal (+) of the
normal machine,
4. disconnect one clip of jump-start cable (1) to the positive terminal (+) of the
problem machine.
15.3 PRECAUTION FOR BATTERY CHARGING WHILE IT IS

ONBOARD
BATTERY CHARGING
• Remove the cables from battery terminals, otherwise the
alternator can be damaged from extra voltage.
• To allow gas produced while charging escape, take off
all top from battery.
• If battery over heat (electrolyte exceed 45 °C) suspend
charging for a while.
• Stop immediately charging when battery is well charged.
If you leave battery under charge too much it may
happen:
a) battery overheat,
b) electrolyte level drop down,
c) battery problem may come in.
• When connect the battery make sure to connect the
cables correctly. Never mix the cable (+ with - ) it will
damage the electrical components and battery.
117
118
16. PHENOMENA THAT ARE NOT FAILURE
Pay attention at follow phenomena that are not failure:
1. When the arm is pulled in, the speed of

movement drop momentarily when the
arm is more o less vertical.
2. The arm speed will drop momentarily

when the bucket teeth are more or less
horizontal.
3. When starting or stopping the swing, noise will be emitted from the brake
valve.
4. When going down a steep slope at low speed, a noise will be emitted from
the travel motor.
119
120
17. THE BUCKET
17.1 BUCKET REMOVING
Standard bucket capacity (m3) 0.52
1. Stop the machine on a firm and solid round.

2. Lower the working equipment with the bucket reverse bent.
BUCKET POSITION
Lower the bucket on round softly, more is ground contact
pressure more difficult is remove the pins from the bucket.
3. Remove the split-pin from pins, the spacer and then the O-ring anti
clearance.
4. Remove bucket pins (2) and (1), in this order.
121
INDIVIDUALS SAFETY DEVICES
When you hit the pins with hammer to extract them,
splinters may be produced and hit you. It may cause severe
injure and permanent damage in your eyes. So use
protective eyeglasses and heavy gloves.
5. Lift the working equipment to remove the bucket.
SAFETY DEVICES
Be sure that spacers and O-rings will not drop down and/or
will not result damaged.
REMOVED BUCKET STORAGE

When remove the bucket from the working equipment put it
in a stable position and recover it in a place where only
allowed people can come in.
122
17.2 BUCKET ASSEMBLING
1. Dry the hub with a clean and dry cloth-duster, take off mud and all other
dusts.
2. Lubricate the sliding pins parts with oil or grease with MoS2 (molybdenum
sulphide) (NLGI no 1 or similar).
3. Lower the working equipment aligning the arm’s
hub hole with the bucket hub to insert the
bucket pin (1).
4. Insert the pin (1) inside the bucket hub, the spacer and the O-rings, in this
order.
5. Lock the pin (1) with the side split-pin.
6. Lift slowly the bucket to be sure that all
components are in the correct position.
7. Extend the bucket cylinder to align the fixing

joint pin (2). (Do not insert the O-ring now!).
8. Insert the pin (2) inside the bucket hub, the spacer, the O-rings and the
joint, in this order. Then insert the pin (2) inside the O-rings (1) and the
bucket hub.
9. Lock the pin (2) with the side split-pin.
123
124
18. MAINTENANCE
18.1 GUIDES TO MAINTENANCE
MAINTENANCE OPERATIONS
• Do not carry out any inspection or maintenance
operation that is not given in this manual.
• Perform maintenance in hard, flat ground.
Check hour meter:

Every day check the hour meter, to see if the time has come out for any
necessary maintenance to be carried out. Carry out all operations with
method and schedule written in this manual. The maintenance carried out
following the instruction given in this manual will prolong the machine life and
performance, reducing problem and operating costs.
Missed respect of the instructions and scheduled operation, also

maintenance performed by inexperienced or not allowed operators, will
lapse the guarantee.
Warning plate:
Put the warning plate on the start key or on some lever where you are sure
that it will be seen, so to avoid that other operator who, do not know you are
performing maintenance, start the machine.
DO NOT OPERATE
MACHINE
UNDER SERVICE
Date
Sign
125
Use only original spare parts by YUCHAI ENGINEERING MACHINERY
CO. LTD.:
Do not using original spare parts will lapse the guarantee.
Use only original lubricants by YUCHAI ENGINEERING MACHINERY CO.

LTD.:
Choose oil and grease with useful characteristics for ambient temperature.
Keep any other material out from oil and grease.
Do not using original oil and grease will lapse the guarantee.
Cleaner fluid:
Use only fluid useful to clean car windows and pay attention that impurity will
not came in.
Keep the machine clean:

Keep always the machine clean. It make easier to inspect and check the
machine. Also keep clean grease fittings, breathers and oil level gauges.
Precaution when washing machine:

• Never spray stream or water directly on the connectors and electrical
components.
• Do not allow water to get on the monitor and controllers inside the
operator’s cab.
• Never spray stream or water directly on the radiator or oil cooler portions.
Pay attention to hot water and oil:

It is dangerous drain oil and/or coolant or unscrew top and filter immediately
after engine stop. Let the temperature cool down!
Checking foreign materials in drained oil:

After oil is changed or filter are replaced, check oil and filters for metallic
particles and foreign materials. If large quantity of them are found ask to
Fuel strainer:
if your machine is equipped with fuel strainer, do not remove it while refuelling.
Oil change:
check or change oil in a place where dust is scarce to keep foreign materials
away from oils.
126
Avoid oil mixing:
Do not mix different kind of oil. If you have got some oil different from which is
inside the machine do not add it but change it all.
Welding instruction:
1. Put the start key in 0 position.
2. do not apply more than 200 V continuously.
3. Connect grounding welder cable within 1 m from the area to be welded.
4. Avoid seals or bearings from being between the area to be welded and the
position of grounding point.
5. Do not use the area around the work equipment pins or hydraulic cylinders
as the grounding point.
Anti fire precautions:

during maintenance use not flames substance to remove grease or oil.
Checking undercarriage:
when working in rocky areas, check for damage to the undercarriage and for
looseness, flaws, wear and damage in bolts and nuts. Loosen the track
tension a little when working in such areas.
Pre and post work checks:

before starting work in mud, rain, snow or at seashore, check plugs and
valves for tightness. Wash the machine immediately after work to protect
components from rusting. Lubricate components more frequently then usual.
Be sure to lubricate work equipment pins daily if they are submerged in water.
Dusty worksites:
When working at dusty worksites, do as follow:
1. Clean the air cleaner at shorter intervals than specified.
2. Clean the radiator core frequently to avoid clogging.
3. Clean and replace the fuel filter frequently.
4. Clean electrical components, especially the starting motor and alternator,
to avoid accumulation of dust.
Objects in your pocket:

Keep your pockets free of loose objects which can fall out and drop into the
machinery, especially when you work on the machinery while bending over it.
127
18.2 CONTROLS TABLE AND MAINTENANCE SCHEDULE
Maintenance intervals
Items to check Total worked hours
10 50 100 200 400 800
Oil, water, fuel leakage ●
Machine cleaning and pipeline
inspections
●
General Bolts and hydraulic connections
fastening
●
Lamps, gauges and light ●
Engine conditions ●
Fuel level and refuelling ●
Fuel tank cleaning ●
Fuel circuit Admission pressure check ●
Fuel filter cleaning ●
Replacing cartridge fuel filter ●
Check the rubber hoses and
clamps
●
Cooling circuit Check coolant level ●
Clean radiator fins ●
Replace coolant U ●
Check the hydraulic oil level ●
Hydraulic Check the hydraulic oil, clean the
system suction filter
●
Replace the oil filter cartridge U ●
Check engine oil level and refilling ●
Replacing engine oil U ●
Replacing filter cartridge U ●
Engine
Check V fan belt tension U ●
Check valves clearance U ●
Check engine support tightness U ●
Empty the dust collector ●
Air filter Cleaning core filter ●
Replace core filter ●
● Ordinary maintenance operation.

U First maintenance in breaking-in period.
128
Maintenance intervals
Items to check Total worked hours
10 50 100 200 400 800
Electrolyte level check and replace ●
Battery Charge check and electrolyte
density check
●
Oil level check and replace ●
Travel engine Oil replace ●
Bolts and hydraulic connections
fastening
●
Crawler Tension check ●
Sprocket and Sprocket bolts fastening U ●
roller idler Oil level check and replace ●
Lubrication Grease fitting lubrication ●
Controls check ●
Controls and Levers check ●
levers Throttle lever check ●
Pedal check ●
● Ordinary maintenance operation.

U First maintenance in breaking-in period.
18.3 MAINTENANCE DURING BREAKING-IN PERIOD
Breaking-in period is 100 hours long as recommended; meanwhile you must

pay attention to avoid over forcing the engine, working equipment and travel
engine, to keep machine life and reliability as long.
Start working only when the engine has reached the correct temperature and
hydraulic oil is up to 20 °C.
Do all maintenance operations with care during breaking-in period, in the
intervals scheduled above and noted with U.
129
18.4 LUBRICANTS (OIL AND GREASE), COOLANT, FUEL
CHARACTERISTICS
If do not differently specified, use only oil, fuel and coolant used for shipping
by YUCHAI ENGINEERING MACHINERY CO. LTD.
When add oil never mix with other different.
TEMPERATURE (°C)
TANKS FLUID
-10 0 10 20 30
SAE 30
SAE 10W
Engine oil pan Engine oil
SAE 10W-30
SAE 15W-40
Swing machinery
case
Oil SAE 80W-90
Travel device
SAE 10W
Hydraulic work
Hydraulic oil SAE 10W-30
equipment
SAE 15W-40
JIS 3
Fuel tank Diesel
JIS 2
Antifreeze
Cooling system Water super coolant
(AF-ACL) 41%
TANK CAPACITY:
Fuel tank (l) 180

Engine oil (with filter) (l) 11
Hydraulic circuit (l) 210
Hydraulic oil tank (l) 120
Slewing system (l) 2.2
Travel engine (l) 2 x 2.5
130
18.4.1. Engine oil and hydraulic oil
• Engine and working equipment oil, are used in critical conditions (high
temperature and high pressure), so they will deteriorate with use.
Therefore use always oil useful for real temperature and pressure like as
written in this manual. If the oil is not dirty, replace it at the interval
scheduled in this manual.
• Pay attention to avoid foreign materials (water, particles, dusts, etc.) drop
into the oil. Most of the problem that will come out depends on contaminant
in oil. Be careful when manipulate oil to storage it or add in the machine.
• Never mix different kind of oil.
• Add only the right quantity of oil. To much oil or lack oil will cause damage.
• If hydraulic oil is not clear, maybe some air or water drop in it. In this case
please contact YUCHAI ENGINEERING MACHINERY CO. LTD.
• When change oil, always change relative filter.
18.4.2. Fuel
• Fuel pump is a precision instruments. If fuel contain water or dust, it may

not work properly.
• Be sure that no impurity will contaminate fuel when storage it or refuelling.
• Always use fuel specified in this manual.
! ATTENZIONE LOW TEMPERATURE

Fuel may freeze below -15 °C, so is necessary change it with one
useful for low temperature.
Never add antifreeze materials to the fuel.
• To avoid air condensation inside the fuel tank, refuelling it all ever day,
when stop work.
• If engine will remain without fuel, or if filters are changed, you must breath
the air inside.
131
18.4.3. Coolant
• Water from river, aqueduct, etc. contain a lot of calcium, so if you use it
engine tube and radiator may are damaged. It will reduce efficiency heat
exchange and engine over heating.
• When use antifreeze fluid, follow always the instruction written in this
manual.
• Machine made by YUCHAI ENGINEERING MACHINERY CO. LTD. are
sent with original antifreeze YUCHAI ENGINEERING MACHINERY CO.
LTD. mixed with coolant. This antifreeze is also useful to reduce the
system corrosion. Antifreeze fluid can be used for 2 years or 4000 worked
hours.
• Antifreeze fluid is inflammable, be careful when handle it.
• Antifreeze fluid quantity mixed with water depends on the ambient
temperature, to know the exact rate see the fluid characteristics.
• If coolant level is low, engine may raise to much the temperature and will
damage.
18.4.4. Grease
• Grease is used to avoid scratch wear and noise emission from jointed part.
• Grease fitter do not included in maintenance section, are used for
reviewing operation, so they do not need grease. When refill new grease
the old one come out, so clean it with a cloth duster, to avoid that it will mix
with dust or sand and damage rotating parts.
18.4.5. Oil and fuel storage
• Keep them always indoors, to avoid that some water or impurity will
contaminate them.
• If you must put the tank outdoors, cover them with waterproof coat, or
something else useful.
132
18.5 FILTER
• Filter are protection device very important. They prevent impurity drop in
fuel, oils, air circuit damaging some important equipments.
• Replace filter, with timing and method written in this manual. If the
machine works in critical areas or extreme weather condition, maybe it is
necessary replace filter more often then is written in the manual, so do that.
FILTERS REPLACEMENT
• Never try to clean filters with cartridge to use them
again.
• Always replace filters with new ones.
• When you replace oil filter, check if there are some foreign material (metal)
inside. If is the case please contact YUCHAI ENGINEERING
MACHINERY CO. LTD.
• Do not open the filter pack to much time before use. Always use original
filter made by YUCHAI ENGINEERING MACHINERY CO. LTD.
133
18.6 ELECTRICAL WIRING
ELECTRICAL WIRING MODIFICATIONS

• Do not remove or change electrical devices installed on
the machine.
• Do not install any electrical device different from the
ones from YUCHAI ENGINEERING MACHINERY CO.
LTD.
• If cables become damp or will damage, the electrical wiring may reduce
machine safety and acting.
• If you wash the machine, be careful to prevent electrical wiring wets.
• To avoid radio interference between control device and walkie-talkie or
radio system please check from YUCHAI ENGINEERING MACHINERY
CO. LTD. before install anything.
• If you work near the seashore, keep clean the electrical wiring o avoid
corrosion.
• If you install a fan or other electrical device connect it to an independent
connector.
• Assistance operations on electrical wiring are:
1. alternator belt tension;
2. alternator belt wear;
3. battery electrolyte level.
134
18.7 MAINTENANCE TOOLS AND TORQUE LIST
18.7.1. Needed tools for maintenance
The tools showed below are needed to make maintenance.
No Tool
1 Socket wrenches (10 ÷ 24 mm) with extension and handle.
2 Bag tool.
3 Wrench set (8 ÷ 32 mm).
4 Screwdriver with interchangeable head.
5 Grease pump.
6 Nozzle.
7 Nozzle for rubber shoes.
8 Grease cartridge.
9 Wrench set (36 e 41 mm).
10 L wrench for socket hexagonal.
11 Wrench engine fuel filter
12 Wrench engine oil filter
135
18.7.2. Standard torque list
Unless otherwise specified, tighten the metric bolts and nuts to the torque
shown in the table. The tightening torque is determined by the width across
the flats (b) of the buts and bolts.
If it is necessary to replace any nut or bolt, always use an original spare part
by YUCHAI ENGINEERING MACHINERY CO. LTD. and of the same size as
the part that was replaced.
Thread diameter Tighten torque (kg ⋅ m)

Width across flat
of bolt (mm)
(mm) (b) Nominal value Admissible value
(a)
M6 10 1.35 1.2-1.5
M8 13 3.2 2.8-3.5
M10 17 6.7 6.0-7.5
M12 19 11.5 10.0-12.5
M14 22 18.0 16.0-20.0
M16 24 28.5 25.0-31.5
M18 27 39.0 35.0-43.5
M20 30 56.0 50.0-62.0
M22 32 76.0 67.5-84.5
M24 36 94.5 84.0-105.0
M27 41 135.0 120.0-150.0
M30 46 175.0 155.0-195.0
M33 50 225.0 200.0-250.0
M36 55 280.0 250.0-310.0
M39 60 335.0 295.0-370.0
NOTICE:
When tightening panels or other parts having tightening fixture made plastics,
be careful not to use excessive tightening torque: doing so will damage the
plastic parts.
136
19. PERIODICAL REPLACEMENT OF SAFETY CRITICAL
PARTS
To ensure safety at all times when operating or driving the machine, the user
of the machine must always carry out periodic maintenance. In addition to
further improve safety, the user should carry out periodic replacement of the
parts given in the table. These parts are particularly closely connected to
safety and fire prevention.
The materials changes as time passed, or they easily wear or deteriorate.
However, it is difficult to judge the condition of the parts simply by periodic
maintenance, so they should always be replaced after a fixed time has
passed, regardless of their condition. This is necessary to ensure that they
always maintain their function completely. However, if these parts show any
abnormality before the replacement interval has passed, they should be
repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking,
replace the clamps at the same as the hoses.
When replacing the hoses, always replace the O-rings, gaskets and other
such parts at the same time.
Ask to YUCHAI ENGINEERING MACHINERY CO. LTD. to replace critical

parts.
19.1 DAILY CHECKING OR EVERY 10 HOURS
19.1.1. General check
• Check for oil, water and fuel leakage (if the case refill all fluid after you
eliminated the defect)
• Check for cutting, cracks or deformations on connection, muffs,
accessories and machine frame.
• Check for tightening and connection of hydraulic equipments.
• Clean and check all controls (lever and pedal), lights and gauges.
• Check engine state, particularly for exhaust colour and noise emission.
• Check fuel level and refuel if necessary.
• Check hydraulic oil level and refill it if necessary.
• Check engine oil level and refill it if necessary.
137
19.1.2. Check, Clean and Replace air filter
AIR FILTER CLEANING

• Do not clean or replace air filter while engine is running.
• If use compressed air to clean air filter always use
protective eyeglasses.
Clean and check:

Upper advanced filter
1. Go up the hood, on the machine rear,
unscrew the top and remove the advanced
filter.
2. Take out the filtering element then use a clean cloth duster to close the air
tube to prevent dust entering. Clean the external pan.
3. Clean the filtering element (5). To do this
blow compressed dried air (less then 700
kPa, 7 kg/cm2, 7 bar) starting from internal
element alongside the holes, the blow the air
outside the element along the creases.
NOTICE:
When you clean the element, do not hit or beat it with anything.
Replace the element that has cleaned 4 times or which has been used for
400 h. Replace the elements if you find out small holes or spoiled part. Do
not use an element which has creases, holes or gaskets damaged.
4. Remove the cloth used like top at point 2.

5. Put the cleaned element inside the case then close the top with his clip.
138
Internal filter
6. Unscrew the bolt which holds the filter inside the engine hood.
7. Follow the instruction from 2 to 5.
19.1.3. Check coolant level and pipe

preservation
When the engine is cold check the coolant level

as is specified in paragraph 7.1.1 and the
preservation of coolant pipeline.
19.1.4. Check bolt torque of the sprocket
Using a dynamometric wrench, check the correct torque of the nuts which fix
together machine frame and sprocket in both machine side. The torque value
is 330 ÷ 430 Nm.
19.1.5. Checking and adjusting rubber shoes tension (for machine with
rubber shoes only)
If rubber shoes are in the following condition must be repaired so contact

YUCHAI ENGINEERING MACHINERY CO. LTD. for repairing or replacing.
Height of lug:
If lug height “a” is reduced by wear, the drawbar Track roller
pull will drop. If “a” is less then 5 mm, replace
with a new part. Rubber shoes
139
If the lug wear and the steel cord inside the shoe
is exposed for two links or more, replace with a
new part.
Steel cord expoesd
If more the half of the steel cord layer on one side

is cut, replace with a new part.
If the rubber core has separated at one place or

more, replace with a new part. Core
separation
Rubber shoe tension:

If the rubber shoes is still slack even when grease is pumped in, replace with
a new part or replace the seal inside the cylinder.
When you want to know if your rubber shoes must be replaced, repaired or
you can use them again please contact YUCHAI ENGINEERING
MACHINERY CO. LTD.
If cracks between the rubber shoe lugs increase to a size of approax. 60 mm

the rubber shoes must be repaired. Even if the track is small and short, if the
steel cord can be seen inside, carry out repairs immediately.
140
CHECK AND ADJUSTING TRACK TENSION:
MACHINE LIFTING
• Two operators must carry out these operations. One
must travel the machine according to signal from the
other. The track tension cam be verified only when the
track is lifted.
• Be careful do not low down the machine while the
operator is checking the tension.
The wear of the rubber shoe will vary with the working conditions and type of
soil. Therefore, it is necessary to inspect the wear and track tension
frequently.
After fitting new parts, be sure to carry out the first inspection after 30 hours
of use. In this while, ad just frequently the tension until the initial slack is
complete, to avoid rubber shoe falling down.
Tension adjustment:
1. Park the machine on a level and solid ground.
2. Put the dozer blade on the
machine’s rear, then extend the
blade cylinder completely until
the track will lift a little.
The standard tension is optimal when the clearance between the roller
surface of the track shoe and the track roller tread at the second track roller
from the sprocket is as showed in the table below:
Standard
20 – 40 mm
Clearance value
Slack track min. 40 mm
SLACKS TRACKS
If the machine works with slack tracks they may drop off or
wear too fast.
141
Tension adjusting:
GREASE UNDER PRESSURE

Grease inside the adjusting mechanism is under high
pressure, if it coming out from lubricator point can penetrate
or hit your body causing injury or death. For this reason:
• do not loosen lubricator (1) more then one turn,
• do not loosen any other part than lubricator.
If the tension is different from what is specified above, do as follow:
Increasing the tension:

1. Prepare a grease gun, remove the lubricator top (1), pump in grease
through lubricator hole (2).
2. Travel the machine backwards and forwards to check if the track tension
has been achieved.
3. If can not ad just the correct tension with this procedure please contact
142
Decrease the tension:

Remove the grease from the strain crawl cylinder only as
shown in procedure below.
1. Open the top (1) then loosen the lubricator (2) gradually on the strain crawl
cylinder to realise the grease.
2. Turn the lubricator a maximum of one turn.
3. If the grease does not come out smoothly, move the machine backwards
and forwards.
4. Tighten the lubricator.
has been achieved.
REPLACE RUBBER SHOES
MACHINE LIFTING
track is lifted.

pressure, if it coming out from lubricator point can
penetrate or hit your body causing injury or death. For this
reason:
What prepare:
• Grease gun;
• Steel pipe.
143
Removal of rubber shoe:

• Remove the grease from the strain crawl cylinder only
as shown in procedure below.
• Check that all the grease has been released before
rotate the sprocket to remove the rubber shoe (item 4).
1. Park the machine on a level and

solid ground.
2. Put the dozer blade on the
machine’s rear, then extend the
blade cylinder completely until
the track will lift a little.
3. Lower down the bucket then extend the boom until the machine frame will
lift a little. When do it operate with the lever slowly.
4. Loosen the lubricator the train crawl
cylinder slowly, to drain the grease. Turn
the lubricator a maximum of one turn.
5. Insert the steel pipes inside the rubber
shoes, rotate the sprocket in reverse, so
that the steel pipes make the rubber
shoes come up from the idler, then slide
to the side to remove.
Steel pipes
Installation of rubber shoes

2. Put the dozer blade on the machine’s rear, then extend the blade cylinder
completely until the track will lift a little.
3. Lower down the bucket then extend the
boom until the machine frame will lift a
little. When do it operate with the lever
slowly.
4. Mesh the rubber shoes with the sprocket
and fit it over the idler.
5. Rotate the sprocket in reverse, then push
in the rubber shoe and stop the rotation.
144
6. Mesh the steel pipes with the rubber
shoe, then rotate the sprocket again and
fit the rubber shoe securely on the idler.
Steel pipe
7. Stop the rotation and check that the

rubber shoe is securely fitted to the
sprocket and idler.
8. Adjust the tension of the rubber shoes.

9. Check that the track tension is correct and that the rubber shoe is correctly
meshed on the sprocket and idler, then lower the machine to the ground.
145
19.1.6. Checking and adjusting steel track tension (for machine with
steel track only)
CHECK AND ADJUSTING TRACK TENSION:
MACHINE LIFTING
track is lifted.
The wear of pins and bushings on

the undercarriage will vary with
the working conditions and soil
properties. Therefore is
necessary check the wear and
tension of the tracks.
Tension adjustment:
2. Put the dozer blade on the machine’s rear, then extend the blade cylinder
completely until the track will lift a little.
3. Lower down the bucket then
extend the boom until the
machine frame will lift a little.
When do it operate with the lever
slowly.
The standard tension is a clearance

of 20 ÷ 40 mm between the roller surface of the track shoe and the track roller
tread at the second track roller from the sprocket.
146
Tension adjusting:

pressure, if it coming out from lubricator point can penetrate
or hit your body causing injury or death. For this reason:
If the tension is different from what is specified above, do as follow:
Increasing the tension:

1. Prepare a grease gun, remove the lubricator top (1), pump in grease
through lubricator hole (2).
has been achieved.
3. Go on with grease pumping until S
become 0 mm. If the tension is too low,
then the pin and the bearing are too
worn, so replace them. Please contact
YUCHAI ENGINEERING MACHINERY
CO. LTD. to purchase the new parts.
147
Decrease the tension:

Remove the grease from the strain crawl cylinder only as
shown in procedure below.
1. Open the top (1) then loosen the lubricator (2) gradually on the strain crawl
cylinder to realise the grease.
2. Turn the lubricator a maximum of one turn.
3. If the grease does not come out smoothly, move the machine backwards
and forwards.
4. Tighten the lubricator.
has been achieved.
148
19.2 MAINTENANCE EVERY 50 HOURS
The maintenances scheduled every 10 hours must be done together

with maintenances every 50 hours.
19.2.1. Lubricating
PRECAUTIONS WHILE LUBRICATING

All lubricating operations must be done with the engine
turned off.
What prepare:
• Grease gun.
1. Bend the work equipment as is showed in

picture beside, the low it down and stop
the engine.
2. Clean the grease fittings.

3. Using a grease pump, pump in grease through
the grease fittings.
4. After greasing, wipe off any old grease that was
pushed out.
149
Grease fittings position:
19.2.2. Check electrolyte level
1. Wipe off any dust from battery covers, to prevent

dust come in.
2. Remove the caps of the battery’s elements.
3. Electrolyte level must be 10 ÷ 15 mm over the
electrode plates.
4. Add only distilled water.
5. Put on the caps.
150
The maintenances scheduled every 10 and 50 hours must be done

together with maintenances every 100 hours.
19.3.1. Cleaning fuel filter and water separator
What prepare:
• a pan to collect drained fuel;
• a wrench for hexagonal nuts.
1. Put the pan under the drain plug (3) which is under
the tank.
2. Open the plug and drain dust and water
accumulated in tank bottom.
3. When clean fuel start to drain, close the plug (3).
4. Remove the top (1) and the filter on the refuelling
muff (2).
5. Clean the filter (2) and put it on again.
6. Check the fuel level in the pipe gauge, and if is
necessary rueful.
7. Close the top (1).
PRECAUTIONS WITH FUEL HANDLING

Be careful to prevent fuel drop on you.
151
19.3.2. Fan belt adjusting
Check the fan belt tension:

the belt tension should normally deflect by 10 ÷ 15 mm when pressed with the
finger at a point midway between alternator pulley and fan pulley.
Adjusting the fan belt tension:

What prepare:
• a metal bar;
• a piece of wood.
1. Put the metal bar between the alternator (3)

and the engine, to keep the alternator fixed.
Put the piece of wood between the metal bar Metal bar
and the alternator, to prevent the latest may be
damaged. Piece of wood
2. Loose bolt (1)and nuts (2).

3. Move the alternator (3) so that the fan belt deflect is in 10 ÷ 15 mm.
4. Tighten bolts and nuts (1) e (2) to fix the alternator (3).
Check that all pulleys are not damaged, also that the V rut is not damaged.
Particularly, check if the belt do not touch the bottom of the V rut.
If the belt can not be adjusted, or if it cut or damaged please contact YUCHAI
ENGINEERING MACHINERY CO. LTD. to replace it.
152
The maintenances scheduled every 10, 50 and 100 hours must be done
together with maintenances every 200 hours.
19.4.1. Replacing oil engine and oil filter cartridge
PRECAUTION WITH PARTS AT HIGH TEMPERATURE

When the engine run, the oil is at high temperature, so wait
for the temperature cool down before operate.
What prepare:
• a wrench for engine oil cartridge filter.
• a pan to collect drained oil.
1. Put the pan under the drain plug below the oil sump.
2. Unscrew the drain plug slowly, to avoid that oil drop on you, the wait for oil
draining.
3. Remove the top and the gasket-tight.
4. Check the drained oil and if there are excessive metal particles or foreign
material, please contact YUCHAI ENGINEERING MACHINERY CO. LTD.
5. Put on the gasket-tight then screw the drain plug.
6. Using a filter wrench, turn filter cartridge (1) in anticlockwise. If this
operation is carried out immediately after stopping the engine a large
amount of oil will come out, so wait for 10 minutes before starting the
operation.
7.
1 3
153
Clean the filter holder.
8. Coat the packing surface of a new filter cartridge with engine oil (or coat
it thinly with grease), then install it to the filter holder. When installing,
tighten until the packing surface contacts the seal surface of the filter
holder, then tighten it up ½ o ¾ of a turn.
9. After replacing the filter cartridge, add engine oil through oil filler (2) until
the oil level on the dipstick (3) is between the two reference lines.
10. Let run the engine at idling for a short time, then stop it and check that
the oil level is between the two reference lines.
FILTER REPLACING
Even the machine does not work for 200 hours, then oil and
cartridge must be replaced after 6 months.
154
19.4.2. Check and refill oil in the sprocket
PRECAUTION WITH OIL AT HIGH TEMPERATURE

After the machine worked, oil is at high temperature, so
wait for temperature cool down before operate.
What prepare:
• a hexagonal wrench.
1. Park the machine on a level and solid ground,

also keep the sprocket in the position showed
beside.
2. Put a container (pan) under the drain plug (2).
3. Using the hexagonal wrench remove the
breathe plug (1) and leave the pressure goes
down.
4. Close the breathe hole and check that the oil
level is near the bottom of the plug hole.
5. If the oil level is low, add engine oil through
the filling hole (3). Add engine oil until the oil
flows out from level plug hole (2).
6. Screw the plugs (2).
155
19.4.3. Oil level in swing gear

After the machine worked, oil is at high temperature, so
wait for temperature cool down before operate.
What prepare:
1. Put a container (pan) under the reduction unit.

2. Check the oil level with the lipstick.
3. If the oil level is low, add it through the filling
hole.
4. Clean the lipstick and check the oil level
again.
19.4.4. Cleaning water separator filter
The water separator filter is installed in the fuel pipeline.
If the ring (A) of the water separator is at the

bottom of case there is no water.
D
If the ring (A) is floating (B), there is water up to C
the bottom of the ring, so drain the water as
follows.
1. Close the tap (C).
2. Unfasten the ring (D), then remove the case
and throw out the water inside.
3. Set the case in position then tighten the ring
(D) to install it.
4. St the tap (C) in open position. B
156
Procedure to breath out the air
1. Check the tightening of the all gaskets in the
fuel pipeline.
2. Loosen the draining screws (3) on the fuel
filter.
3. Turn on the clean pump (1) pushing several
times until no air bubbles come out from the
draining screws.
4. Tighten the drain screws. (3).
FUEL LEAKAGE
After water separator filter changing start the engine and
check for fuel leakage.
NOTICE: If the engine has run without fuel, make the same procedure.
157
The maintenances scheduled every 10, 50,100 and 200 hours must be
done together with maintenances every 400 hours.
19.5.1. Check intake pressure
Engine efficiency is due to the injector’s nozzle state, so keep under control
the follows signal of injector bad working:
• Abnormal noise from one or more cylinder.

• Engine over heating.
• Efficiency reduction.
• Black smoke out the muffler.
• Increasing of fuel consumption.
The trouble above mentioned can come out from:
• Bad tight of the suction / exhaust valves.

• Bad setting of the injection pump.
• Dust inside the fuel filter.
• Bad fuel quality.
• To much water inside the fuel tank.
To inspect and ad just the intake pressure of the injector, or to solve the
problem listed above please contact YUCHAI ENGINEERING MACHINERY
CO. LTD. which has got special tools and know-how to repair the machine.
158
19.5.2. Fuel filter cartridge replacement
What prepare:
• a pan to collect the drained fuel.

2. Put the pan under the fuel filter to prevent fuel
ground drain.
3. Using the appropriate key unlock the ring, then
remove the pan to extract the filter and his O-ring.
4. Clean the filter holder and put inside a new filter.
5. After fuel filter replacing breath out the air from the
fuel pipeline.
Procedure to breath out the air is described in paragraph 19.4.3.
FUEL LEAKAGE
Check fuel leakage after fuel filter replacing, by starting the
engine.
19.5.3. Check and clean radiator fins

2. Use compressed air to remove mud, dust, leaves etc. which obstruct the
radiator fins.
PRECAUTION WHEN USE COMPRESSED AIR

Do not point air gun to yourself, it may cause injuries.
corpo, c’è pericolo di lesione. Wear always protective
eyeglasses, gloves and protective shoes.
PRECAUTION WHEN USE COMPRESSED AIR

To prevent fins damage, keep enough distance between air
gun and fins. If fins will be damaged water leakage is
possible and/or engine over heating.
159
19.5.4. Replacing the hydraulic oil return filter

• After the machine operated, hydraulic oil is at high
temperature, so wait for temperature cool down.
• Unfasten the top slowly to reduce the pressure inside
the oil tank.

2. Start the engine and keep it at he low idling,
lower down the dozer blade, then raise the
boom and extend the arm and bucket
cylinders, until the machine will be as
showed beside.
3. Let the engine run for 5 minutes, then stop it.
4. Demount the 4 bolt on the oil tank top (1).
5. Unscrew the cover (2) of oil tank.
6. Remove the hood (3) of the hydraulic oil tank.
7. Remove the spring (4), the valve (5) and the return filter from the tank.
160
8. Clean the dismantle pieces with the grease remover fluid, install a new
filter.
9. Turn on the engine and move all arms slowly.
10. Check the oil level through the gauge and refill if it is necessary.
19.5.5. Replacing pilot filter cartridge
REPLACING THE PILOT FILTER

Before replacing filter make sure to breathe out the air and
reduce the pressure.
• a wrench for engine oil cartridge.

• a pan to collect the drained oil.
2. Start the engine and keep it at he low idling, lower down the dozer blade,
then raise the boom and extend the arm and bucket cylinders, until the
machine will be as showed below.

4. Unscrew and dismantle the cartridge (5) with its wrench.
5. Clean the keeping cartridge and put a new O-ring (2).
6. Insert a new cartridge (3).
7. Put thin layer of oil on the contact surface and screw by hand.
8. Tight with torque about 25 ÷ 35 Nm.
9. Pressurize the hydraulic tank. To do this start the engine and run it at low
speed, operate the boom, arm and bucket cylinders then let the engine
run for 3 minutes. Refill the oil if necessary.
161
19.5.6. Engine bolts supports tightening
With a dynamometric wrench check the correct torque of the engine supports.
The nominal value is in the range 45 ÷ 55 Nm.
19.5.7. Replacing the air filter cartridge
REPLACING THE AIR FILTER

Do not operate on air filter while the engine runs.
Replacing:
Upper advanced filter
1. Go up the hood, on the machine rear,
unscrew the top and remove the advanced
filter.
Internal filter
2. Unscrew the bolt which holds the filter inside
the engine hood.
3. Install a new filter.
19.5.8. Sprocket bolts fastening
With a dynamometric wrench check the correct torque of the sprocket bolts.
The nominal value is 180 ÷ 210 Nm.
162
19.5.9. Oil level in the front idler

• After the machine operated, oil is at high temperature,
so wait for temperature cool down.
What prepare:

2. Unfasten the bolt (1) and the drain plug (2) for each idler.
3. Unfasten the pin (3) of the front wheels.
4. Check the oil level is just below the refilling hole.
5. Fasten all demounted parts.
163
The maintenances scheduled every 10, 50,100, 200 and 400 hours must
be done together with maintenances every 800 hours.
19.6.1. Cleaning and replacing cooling system
COOLING SYSTEM CLEANING

• The engine, muffler, radiator and many other parts of the
machine are hot directly after the engine is stopped.
• When performing maintenance, be sure to keep your
body and clothing away from moving part. Standing at
the back of the machine while the engine is running is
extremely dangerous, as the machine could move
suddenly. NEVER stand at the back of the machine
while the engine is running.
• Never remove the radiator cap or drain plugs when the
coolant is hot. Stop the engine let the engine and
radiator cool and loosen the radiator cap or drain plugs
slowly.
Clean the cooling system, replace the coolant and anti corrosive fluid s is
showed in table below:
System cleaning and fluid

Coolant Add anticorrosive fluid Kl
replacing schedule
Permanent antifreeze Every year (autumn)
(for all seasons) Or every 800 hours
Every 6 months Every 800 hours or when
Non permanent antifreeze,
(spring, autumn) clean the inner cooling
with ethylene glycol
(remove antifreeze in spring, system and when replace
(winter , cold season).
add it in autumn). the coolant.
Quando non si usa Every 6 months
l’antigelo. Or every 400 hours.
When clean the system or replace the coolant stop the machine on level
ground. Use permanent antifreeze, if it is impossible use antifreeze within
ethylene glycol.
To choose the water/antifreeze ratio you must know the minimum working
ambient temperature and determine the ratio as showed in table below. Set a
temperature less then 10 °C when decide the mixing ratio.
164
Mixing water/antifreeze ratio:
Minimum
ambient °C -5 -10 -15 -20 -25 -30
temperature
Antifreeze
l 1.9 2.4 2.9 3.3 3.8 4.0
quantity
Water
l 6.1 5.6 5.1 4.7 4.2 4.0
quantity
PRECAUTION WHEN HANDLED ANTIFREEZE

Antifreeze can catch fire, keep it away from flames.
Use water from aqueduct. If it is not available and you must use water from
rivers, lakes etc. please contact YUCHAI ENGINEERING MACHINERY CO.
LTD.
What prepare:
• a pan to collect the coolant drained;
• a flexible pipe to refill water.
1. Open the engine hood and unscrew the radiator cop slowly.
2. Put a pan to collect the fluid under the
drain plug (3).
3. To drain the coolant open the tap.
4. After the coolant is drained completely,
close the tap (3), then fill the radiator with
water.
5. Start the engine ad let him run at low
idling, open the tap (3) a wait for 10
minutes while the water running, to clean e
the system. Meanwhile regulate the water
running in and out the system to keep the radiator full. Be careful to
avoid the water pipe fly off the radiator cap (1).
6. After 10 minutes stop the engine and drain all the water inside the
system.
7. Close the drain tap (3).
8. Add coolant for radiators up the radiator opening.
165
9. to remove air inside the system start the engine and let him run for 10
minutes with the radiator cap open (1).
10. Stop the engine, wait for 3 minutes, check the coolant level and if it is
necessary fill up to 20 mm under the cap line, then fasten the cap tightly.
11. Refill also the reserve tank of the coolant.
19.6.2. Replacing the hydraulic oil and cleaning the suction strainer

• After the machine operated, hydraulic oil is at high
• When drain the hydraulic oil be careful to prevent drop
on yourself.
What prepare:

2. Start the engine and keep it at he low idling,
lower down the dozer blade, then raise the
boom and extend the arm and bucket
cylinders, until the machine will be as showed
beside.

4. unscrew the drain plug slowly to breathe out the air, to reduce the pressure.
5. Dismantle the hydraulic oil cover like is written before.
6. Put a pan big enough to collect all the oil and drain it with a pump.
7. Unscrew the drain plug (2) to drain the tank
completely.
8. Clean the tank from the dust on the bottom.
166
9. Dismantle the suction filter (5) by
unscrewing the 4 bolt and clean the dust on
the filter, the wash it with a useful liquid.
10. Set up the cleaned filter or a new one if it is
damaged.
11. Check the gasket then fasten the drain plug
(2)
12. Refill the hydraulic oil tank (see the capacity
table) up the maximum level signed on the
gauge.
13. Set all parts demounted.
14. Turn on the engine and operate the arms.
15. Check the oil level through the gauge and refill if it is necessary.
Procedure to breathe out the air
Breathe out the pump

1. Unscrew the top which is over the pump and refill with hydraulic oil. Then
fasten the top.
2. Start the engine and let it run at 1000 rpm then move each cylinder and
each motor 5 times, then wait at idle for 8 minutes.
3. Unscrew the top slowly until bubble come out, when liquid start to come
out fasten the top.
4. Use a torque to 65 Nm to fasten the top.
Breathe out the hydraulic circuit

1. Start the engine, leave it at idle and move all cylinders and motor for 15
minutes to breathe out the air.
2. Park the machine as is showed in the previous page and stop the engine.
3. Check the hydraulic oil level and refill if it necessary.
NOTICE: If a sledgehammer is installed, hydraulic oil will degenerate faster

then bucket is used. So replace the hydraulic oil as often as you use the
sledgehammer.
167
19.6.3. Replacing the travel motor gear oil

After the machine operated, hydraulic oil is at high
What prepare:
1. Park the machine on a level and solid ground, also keep the sprocket
down.
2. Put a container (pan) under the drain plug (1).
3. Using the hexagonal wrench remove the top (1
and 2) and drain the oil.
4. Close the drain plug (1) fill until the oil flows out
from level hole (2).
5. Screw the plugs (1) e (2).
19.6.4. Replacing swing system oil

What prepare:
1. Put a container (pan) under the machine.

2. Unscrew the drain plug, and wait until the tank is
empty, then fasten the drain plug.
3. Remove the top and add the oil through the
filling hole (1) until it flows out from level plug
hole (2).
4. Fasten both top.
19.6.5. Check the engine valves clearance, adjusting them
To inspect and adjust the engine valves, ask to YUCHAI ENGINEERING

MACHINERY CO. LTD. which has got special tools and know-how to repair
the machine.
168
20. HYDRAULIC SCHEME
169
No Item No Item
1 Right pilot valve 11 Pilot filter
2 Pilot valve pedal 12 Accumulator
3 Throttle valve 13 Hydraulic oil tank
4 Left pilot valve 14 Radiator
5 Rotating valve 15 Left pilot motor
6 Motor 16 Rotating centre
7 Hydraulic oil pump 17 Right pilot motor
8 Slewing motor 18 Multi gear valve
9 Boom cylinder 19 Arm cylinder
10 Bucket cylinder 20 Pump
170
21. ELECTRICAL SCHEME
171
No Item No Item
1 Starting switch 25 Wiper switch
2 Main switch fuse 10A 26 Wiper
3 Parking electromagnetism fuse 20A 27 Assemble meter
4 Wall lamp fuse 5A 28 Water temperature
5 Main electric 40A 29 Hydraulic oil temperature sensor
6 Start motor fuse 20A 30 Engine oil pressure
7 Horn fuse 5A 31 Warning lamp air filter
8 Light fuse 10A 32 Warning lamp hydraulic oil filter
9 Wiper fuse 5A 33 Turning speed sensor
10 Main switch relay 34 Fuel level sensor
11 Parking electromagnetism 35 Start relay
12 Top lamp 36 Parking electromagnetism start relay
13 Battery 37 Air conditioning fuse
14 Start motor 38 Evaporator fan speed switch
15 Alternator 39 Evaporator resistor
16 Horn button 40 Evaporator
17 Horn relay 41 Magnifier fuse
18 Horn 42 Magnifier
19 Work lamp switch 43 Temperature control resistor
20 Light relay 44 High low voltage switch air conditioning
21 Work lamp 45 Air conditioning switch
22 Player 46 Cooler gauge
23 Speaker 47 Air conditioning clutch
24 Wiper reposition device
172
22. TROUBLE SHOOTING
TROUBLE MAIN CAUSE SOLUTION

• There is some trouble with • Replace or repair starter.
starter.
• Battery isn’t charged • Charge or replace battery.
enough.
• Warm-up circuit or the plug • Repair or replace warm-up
is incorrectly used. plug.
Engine couldn’t be • Injection time incorrect. • Contact assistant service.
started or started • There is water, dust or air in • Clean or replace fuel filter.
difficultly fuel system.
• injecting nib is dirty or • Contact assistant service.
injection pressure is too low.
• Injection pump is trouble. • Contact assistant service.
• Fuel leakage. • Contact assistant service.
• Air intake and exhaust • Clean the air intake and
system is plugged. exhaust system.
• Fuel filter is plugged. • Clean the filter.
• There is waste or air in the • Exhaust and clean fuel
fuel system. circuit.
• Oil filter is plugged, injecting • Contact assistant service.
Engine shocking,
nib is dirty or trouble.
running
irregularly or stopping. • Accelerator joining can’t be • Replace the high-pressure
adjusted. oil tube.
• Injecting pump is trouble. • Contact assistant service.
• Injection timing is incorrect or • Contact assistant service.
injecting nibs are plugged.
• There is some gets mix in • Empty the fuel tank and
the fuel. clean filters.
• Fuel circuit supply is • Check and cleaning filters
blocked. and pipes
• Injection timing is incorrect. • Contact assistant service.
• Injectors do not work • Contact assistant service.
The power of the engine
properly.
lowered.
• Air filter is plugged. • Clean filter core.
• The clearance of air intake • Contact assistant service.
and exhaust valve is wrong
or valves are not sealed.
• Washer of cylinder is • Contact assistant service.
damaged, gas leakage.
• Injecting pump badly works. • Contact assistant service.
173
• Engine is over hot. • Check if coolant is used
correct, and if the pump and
The power of the engine the belt is loosen, if so,
lowered. repair or replace and clean
the block object in the
watercourse.
• Fuel bad quality • Use the suitable fuel.
Black smoke come out • The air filter is blocked. • Replace the core filter.
from exhaust tube • Injection timing is incorrect. • Contact assistant service.
• Injecting nibs are plugged. • Contact assistant service.
• Fuel bad quality • Use the suitable fuel.
• The engine oil is overmuch. • Make the regular level.
White smoke come out • The piston’s gasket is • Contact assistant service.
from exhaust tube damaged.
• There is water in the cylinder • Check and replace the fuel.
or in the fuel.
• The coolant level is too low. • Refill.
• Temperature sensor is • Replace the sensor.
trouble.
• Air filter is plugged. • Clean the core filter.
• Fan belt is loosen or • Tighten or replace.
Engine over hot damaged.
• Cooling system dirty. • Clean the cooling system.
• Radiator’s fins are blocked or • Clean or repair the fins.
damaged.
• The engine oil has bad • Replace the engine oil with
quality or is overmuch. better quality and check the
correct level.
• The oil level is too low. • Refill.
• Oil filter is plugged. • Clean the core filter.
Engine oil pressure is • Oil circuit leakage. • Tighten all bolts and replace
too low. gaskets.
• The temperature of cooling • Make the mixture rate of the
water is too high. coolant correctly or consult
with agent.
• Circuit is broken. • Check and repair.
The key in the starting
position, but the starter• There are some problems • Replace the switch.
does not work. with the switch.
• The battery is not charge • Charge or replace battery.
enough.
• Terminals are loosen or rust. • Clean or tighten the
terminals.
Battery can’t be charged • Alternator belt is loosen or • Adjust the tension or replace
damaged. the belt.
174
• Alternator broken. • Contact assistant service.
The lamps are dark • Alternator faulty. • Contact assistant service.
when the engine is • The electric loop is trouble. • Check the loop, connect and
running. repair.
• Hydraulic oil is cold. • Operate with hydraulic
Every part of the equipments to increase the
hydraulic system work oil temperature.
too slow. • The hydraulic pump speed is • Contact assistant service.
too low.
• Oil circuit is blocked. • Contact assistant service.
• Hydraulic oil filter is plugged. • Clean or replace the filter.
• Oil pump is worn. • Contact assistant service.
The temperature of the • Oil radiator is blocked. • Clean.
hydraulic oil is too high. • Main safety valve and over • Contact assistant service.
load valve or over fall valve
pressure is too high.
• Oil is too dirty. • Drain the oil and refill.
• Leakage between oil tank • Check and tighten pipe
Hydraulic oil is and pump. connection.
emulsified or there is • There is water in hydraulic • Replace oil.
foams in the oil. oil.
• Oil level is too low. • Refill.
• Safety valve is broken. • Contact assistant service.
Oil pressure is too low or
• Oil level is too low. • Refill.
no pressure.
• Hydraulic pump is damaged. • Replace the pump.
• Hydraulic pump is damaged. • Replace the pump..
• Main safety valve pressure is • Contact assistant service.
low.
Every cylinder or motor • Oil level is too low. • Refill.
work difficulty or can’t
work. • Oil intake filter is plugged. • Clean the intake filter.
• Gaskets damaged. • Replace gaskets.
• Pilots are damaged and • Repair or replace the
result in oil leakage. damaged pilot.
Both travel units don’t • Oil mixed in the slewing • Contact assistant service.
work. joints central.
One of the travel unit • Travel unit is damaged. • Contact assistant service.
doesn’t work.
• Crawler is too tightly or • Adjust crawlers tension.
loosen.
Abnormal travelling. • Capability of the Oil pump • Contact assistant service.
lowered.
• Crawler frame is damaged. • Repair or replace.
175
• There is rock or crushed in • Remove foreign parts.
the crawler chain.
Abnormal travelling. • Leakage in control valve. • Contact assistant service.
• Capability of motor lowered. • Contact assistant service.
• Front idler, tension unit or • Contact assistant service.
lower roller is trouble.
• Capability of oil pump • Contact assistant service.
lowered.
• Slewing motor is damaged. • Contact assistant service.
• Slewing gear is worn. • Contact assistant service.
Abnormal Slewing.
• The slewing support or the • Contact assistant service.
bead is damaged.
• Oil leakage. • Contact assistant service.
• Oil leakage in control valve. • Contact assistant service.
176
23. OPTIONAL ACCESSORIES
23.1 SAFETY PRECAUTION
FORBIDDEN WORK DURING ACCESSORIES USE

Is absolutely forbidden install on the machine any
accessory which are not listed in this manual and do not
authorized by YUCHAI ENGINEERING MACHINERY CO.
LTD. Because this may reduce the machine work life and
may cause its loss of minimum safety requirements.
The YUCHAI ENGINEERING MACHINERY CO. LTD. deny liability for

possible damage to people and/or object due to installation of non
authorized accessories on the machine.
If you need to install different accessories from which are listed in this manual
please contact YUCHAI ENGINEERING MACHINERY CO. LTD.
FORBIDDEN BEHAVIOUR WHEN WORK WITH ACCESSORIES

A long equipment will reduce the machine stability, so the
machine may loss balance and tip over.
The follow operations are particularly dangerous, so
NEVER work with the machine as follow:
• travel downhill with work equipment raised;
• travel be sure the machine never faces sideways with
respect to the slopes;
• swinging the turret on the slopes.
177
PRECAUTION INSTALL AND UNINSTALL THE ACCESSORIES
• Before install and uninstall accessories park the
machine on level, solid ground.
• If two or more operators will install or uninstall
accessories first define who give orders and who receive
orders.
• If you must move heavy objects use crane with enough
loading capacity.
• Clamp on a crane the heavy objects before uninstall
them.
• When clamp on a crane the heavy objects be careful to
them centre of gravity.
• NEVER walk under lifted loads. Stand always in a
“safety” position far from falling point.
• It is dangerous operate with lifted loads. Always check
the correct clamping then put objects in balanced and
safety position before leave work area.
• When install or uninstall accessories, be sure they are in
balance position to prevent drop over.
PRECAUTION FOR WORKING OPERATION WITH

ACCESSORIES
If heavy equipment is installed, the overrun of the swing
become greater, that is the distance from the point where
the operator operates the control levels to stop the swing
to the point where the upper structure stop completely, so
there is danger of mistaking the distance and hitting
something.
• If long work equipment is installed, the working range
will suddenly become larger, so there is danger of
mistaking the distance and hitting something.
• Always keep enough clearance between the work
equipment and any objects standing in the working area.
178
24. NOTICE
179
180
25. ANALYTIC INDEX
Instrument and command description; 55
B Instrument panel and switches; 60
Instrument panel check; 78
Backhoe work; 92 Introduction and general information; 9
Backwards movement; 80
Battery charge lamp; 63 L
C Left lever; 59
Lever and pedal; 56
Cabin; 68 Load precaution; 107
Changing direction (steering); 81 Loading work; 93
Check after completion of work; 99 Long term storage; 111
Check before start; 71 Lubricants, coolant, fuel characteristics; 130
Check hydraulic oil and refill; 73 Lubricating; 149
Cold weather operation; 96
Coolant temperature warning lamp; 62 M
D Machine description; 49
Machine serial number; 12
Daily checking or every 10 hours; 137 Machine stop and park; 84
Data sheet; 50 Machine towing; 109
Ditching work; 93 Maintenance every 100 hours; 151
Maintenance every 200 hours; 153
E
Electrical circuit; 75 Maintenance every 800 hours; 164
Emergency exit; 70
Engine heating; 77 N
Engine oil pressure lamp; 62
Excavator main parts description; 49 Needed tools for maintenance; 135
Noise and exhaust check; 78
F
O
Filter; 133
Forbidden movement and forbidden use; 86 Operating levers; 59
Forward movement; 79 Operations in confined spaces; 93
Fuse; 66 Operator seat; 67
Optional accessories; 177
G
P
Glow lamp; 62
Guides to maintenance; 125 Periodical replacement of safety critical parts;
137
Phenomena that are not failure; 119
H
Precaution and safety measures; 15
Hour meter; 63 Precaution at work end in cold weather; 97
How to escape from mud; 94 Precaution during maintenance; 44
Precaution for operating; 89
Precaution when operate with battery; 38
I Precaution when the machine is working; 26
Identification plate; 54 Precautions before engine start; 23
Inspecting and adjusting the fan belt; 72 Precautions before staring maintenance; 41
181
Pulling precaution; 39 T
R The bucket; 121

Throttle lever; 57
Right lever; 59 Transport precaution; 37
Transportation; 105
S Travelling levers; 58
Trouble shooting; 173
Safety lock lever; 56
Seat belt; 68 U
Standard torque list; 136
Start engine in cold weather; 77 Using rubber shoes; 101
Start key; 65
Starting; 76 W
Starting machine; 71
Starting machine with jump-start cables; 113 Warning plates; 52
Swinging; 85
Y
Yuchai engineering machinery co., ltd; 13
182
YUCHAI ENGINEERING MACHINERY CO., LTD.
Manufacturing Base:
168 Tianqiao Road, Yulin, Guangxi, 537005 P.R. China
Export Department Office:

36 Cuizhu Road, Guilin, Guangxi, 541002 P.R. China
Tel: 0086-773-5588521 5588522 5588523

Fax: 0086-773-5588530
Web-site: www.yuchai-excavator.com
YUCHAI EUROPE:
Address: V. Del Fonditore, 14 40138 Bologna, Italy
Tel:0039
Fax:0039
183

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YYUUCCHHAAII EENNGGIINNEEEERRIINNGG MMAACCHHIINNEERRYY CCOO.. LLTTDD..

Duplication, total or partial, with any device of this manual is

1. INTRODUCTION AND GENERAL INFORMATION ............................... 9

This manual provide regulations and orientations which

If you sell the machine, deliver the manual to new owner.

Machine project improvement could cause changing on the machine without

The YUCHAI ENGINEERING MACHINERY CO. LTD. deny liability for

MACHINE RUNNING IN PERIOD:

During the running in period:

MACHINE KIND AND REGISTRATION NUMBER

The plate where is written the machine registration number is installed on

ENGINE KIND AND REGISTRATION NUMBER

HYDRAULIC MOTORS KIND AND REGISTRATION NUMBER

YUCHAI ENGINEERING MACHINERY CO. LTD.

Export Department Office:

Tel: 0086-773-5588521 5588522 5588523

FOLLOWS THE SAFETY REGULATIONS

NON ALLOWED MODIFICATION

• Each modify made without YUCHAI ENGINEERING MACHINERY CO.

SET THE SAFETY LOCK LEVER BEFORE LEAVING THE SEAT

• NEVER jump on or off the machine.

PREVENT ASBESTOS INHALATION HAZARD

Asbestos inhalation may cause lungs cancer.

• To avoid hot water splash out:

• To avoid hot oil splash out:

FIRE EXTINGUISHER AND FIRST AID KIT

PAY ATTENTION DO NOT CRASH THE CABIN GLASS

If the cabin glass is damaged, it is dangerous use the machine. Always

3.1 PRECAUTIONS BEFORE ENGINE START

WORKING AREA SAFETY

• Remove wood splinter, leaves, paper and any flammable materials

INSIDE THE CABIN

• If it necessary turn on the engine inside a room, provide to adequate

LIGHT AND WINDOWS PRECAUTION

WHEN TURN OF THE ENGINE

CHECK THE POSITION OF THE TRACKS BEFORE TRAVELLING

• In dangerous zone o where there is incomplete view, put always a signal.

Downhill Uphill WRONG CORRECT

• Never undercut a high bank. Be particularly alert for the possibility of a

• Is forbidden to use the excavator lake a load’s lifter.

DO NOT PASS WITH THE BUCKET OVER PEOPLE

Voltage Safe clearance

ENSURE GOOD VIEW

OPERATE ON SNOW OR ICE WITH EXTRA CARE

• When travelling on snow or frozen surface, keep the machine travel

OPERATE ON RAMBLING SURFACE

• When operate on slope surface, there is a risk of machine lose stability

• If is not possible avoid place with falling down object YUCHAI

LOAD AND UNLOAD

3.4 PRECAUTION WHEN OPERATE WITH BATTERY

BATTERY RISK PREVENTION

• Batteries contain sulphuric acid which will damage eyes or skin on

3.5 PULLING PRECAUTION

WHEN PULL THE MACHINE CONNECT THE CABLE ON THE FRAME

4.1 PRECAUTIONS BEFORE STARING MAINTENANCE

• Before make any maintenance operation, regulation or reparation on

PERIODICAL SAFETY PART SUBSTITUTION

STOP ENGINE BEFORE MAKE INSPECTION AND MAINTENANCE

RADIATOR WATER LEVEL

4.2 PRECAUTION DURING MAINTENANCE