Yuchai YC135 Operation And Maintenance Manual Download Page 36

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POSSIBILITY OF OBJECT FALLING DOWN

RUSHING 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.

Summary of Contents for YC135

Page 1: ...YU U UC C CH H HA A AI I I E E EN N NG G GI I IN N NE E EE E ER R RI I IN N NG G G M M MA A AC C CH H HI I IN N NE E ER R RY Y Y C C CO O O L L LT T TD D D I I Is s ss s su u ue e e 2 2 20 0 00 0 05...

Page 2: ......

Page 3: ...ve 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...

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Page 5: ...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 Leve...

Page 6: ...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...

Page 7: ...teristics 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 t...

Page 8: ...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 l...

Page 9: ...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...

Page 10: ...on 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 rea...

Page 11: ...SE 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...

Page 12: ...cify model kind and serial number of you machine The plate where is written the machine registration number is installed on front side MACHINE KIND AND REGISTRATION NUMBER KIND MODEL REGISTRATION No E...

Page 13: ...xi 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 export yuchai excavator com Web site www yu...

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Page 15: ...over 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 l...

Page 16: ...ine 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 whe...

Page 17: ...tion 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 sea...

Page 18: ...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 ho...

Page 19: ...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...

Page 20: ...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...

Page 21: ...iage 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 boa...

Page 22: ...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 work...

Page 23: ...e 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 an...

Page 24: ...gine 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...

Page 25: ...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...

Page 26: ...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 y...

Page 27: ...he 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 do...

Page 28: ...rea 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...

Page 29: ...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 gr...

Page 30: ...re is a danger of falling rocks 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 gr...

Page 31: ...dden 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 inj...

Page 32: ...afety 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...

Page 33: ...TE 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 sh...

Page 34: ...hine 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...

Page 35: ...n 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...

Page 36: ...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...

Page 37: ...od 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...

Page 38: ...n 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 Batter...

Page 39: ...tive 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...

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Page 41: ...cal 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 mach...

Page 42: ...th 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 INSPECT...

Page 43: ...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 c...

Page 44: ...ATORS 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...

Page 45: ...rical 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 PRECAU...

Page 46: ...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 inv...

Page 47: ...se 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...

Page 48: ...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 u...

Page 49: ...R MAIN PARTS DESCRIPTION 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 Sproc...

Page 50: ...um 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 v...

Page 51: ...51 5 2 1 Transport blocked All dimensions are in mm they may change without notice...

Page 52: ...rk 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 peopl...

Page 53: ...ency 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 du...

Page 54: ...54 5 4 IDENTIFICATION PLATE MODEL YEAR Yuchai Engineering Machinery Co Ltd 168 Tianqiao Road Yulin Guangxi P R 537005 China POWER kW WEIGHT kg SERIAL No...

Page 55: ...6 1 OPERATORS SEAT DESCRIPTION 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...

Page 56: ...r 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 u...

Page 57: ...r 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...

Page 58: ...ING 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 tu...

Page 59: ...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 Sw...

Page 60: ...60 6 2 INSTRUMENT PANEL AND SWITCHES 6 2 1 Instrument and Switches 11 13 12 14 18 19 20 21 17 16 15 22 23 24 25 26 27 2 28 29...

Page 61: ...uge 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 s...

Page 62: ...T 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...

Page 63: ...ter 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...

Page 64: ...lock 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 Failur...

Page 65: ...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 po...

Page 66: ...CH 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...

Page 67: ...llow 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 possi...

Page 68: ...e 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...

Page 69: ...t 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 position FRON...

Page 70: ...nlock 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 Emergenc...

Page 71: ...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 th...

Page 72: ...n 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 slo...

Page 73: ...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 t...

Page 74: ...f 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...

Page 75: ...able 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 Instru...

Page 76: ...e must be leant against the backrest Fast the seat belt 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...

Page 77: ...imum 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 o...

Page 78: ...on then check that moving levers or pedal no action will result in any hydraulic parts neither the machine can travel 7 3 4 Noise and exhaust check 1 Put the safety lock lever in unlock position then...

Page 79: ...zer 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 u...

Page 80: ...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 c...

Page 81: ...CHANGING DIRECTION STEERING PRECAUTION BEFORE MACHINE OPERATING Be careful when travel backwards there are blind spots to the rear of the machine Before act travel levers check the dozer blade positi...

Page 82: ...ht 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 lef...

Page 83: ...ng 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 an...

Page 84: ...put some pieces of wood under crawlers then thrust the bucket under ground 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 neutr...

Page 85: ...f 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 S...

Page 86: ...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 FORBIDDEN OP...

Page 87: ...nd this will reduce the life of the machine To prevent this always leave a small safety margin when operating the cylinder FORBIDDEN OPERATIONS USING DROPPING FORCE OF BUCKET Do not using the dropping...

Page 88: ...g 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 AVOID HITTING BLADE Be careful not to...

Page 89: ...ravel over the obstacle at the centre f the tracks As far as possible remove such obstacle or avoid travelling over them PERMISSIBLE WATER DEPTH When driving the machine out of water if the angle of t...

Page 90: ...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...

Page 91: ...eed 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...

Page 92: ...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 B...

Page 93: ...e 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 confine...

Page 94: ...t 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...

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Page 96: ...ep 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 indepen...

Page 97: ...ature 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...

Page 98: ...t 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...

Page 99: ...r 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...

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Page 101: ...ndle 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 shoe...

Page 102: ...ove 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 carr...

Page 103: ...lowing condition Even when the tension is correct be extremely careful when carrying out these operations When travelling over curbs rocks or places where there is a big difference in level approx 20...

Page 104: ...rubber shoe In this condition the rubber shoe may come off if the machine travels further in reverse a gap is formed among the track roller idler and the rubber shoe If the machine travels in reverse...

Page 105: ...ding 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 machin...

Page 106: ...ch 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 possibl...

Page 107: ...ct 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...

Page 108: ...108...

Page 109: ...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 pu...

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Page 111: ...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 s...

Page 112: ...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 improv...

Page 113: ...eful 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 ac...

Page 114: ...114 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 Disconnect Connect...

Page 115: ...as 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 t...

Page 116: ...f 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 the problem machine connect one clip of jump start cable 4 to the...

Page 117: ...ive 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 extr...

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Page 119: ...ed 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...

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Page 121: ...nd 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 Remov...

Page 122: ...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 dam...

Page 123: ...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 t...

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Page 125: ...en 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 in...

Page 126: ...ution 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 spr...

Page 127: ...s 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 val...

Page 128: ...ng cartridge fuel filter Check the rubber hoses and clamps Check coolant level Clean radiator fins Cooling circuit Replace coolant U Check the hydraulic oil level Check the hydraulic oil clean the suc...

Page 129: ...rols check Levers check Throttle lever check Controls and levers Pedal check Ordinary maintenance operation U First maintenance in breaking in period 18 3 MAINTENANCE DURING BREAKING IN PERIOD Breakin...

Page 130: ...NKS FLUID 10 0 10 20 30 SAE 30 SAE 10W SAE 10W 30 Engine oil pan Engine oil SAE 15W 40 Swing machinery case Travel device Oil SAE 80W 90 SAE 10W SAE 10W 30 Hydraulic work equipment Hydraulic oil SAE 1...

Page 131: ...y 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 W...

Page 132: ...ul 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 th...

Page 133: ...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...

Page 134: ...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 MACHINER...

Page 135: ...ntenance 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...

Page 136: ...e kg m Thread diameter of bolt mm a Width across flat mm b Nominal value Admissible value M6 M8 M10 M12 M14 10 13 17 19 22 1 35 3 2 6 7 11 5 18 0 1 2 1 5 2 8 3 5 6 0 7 5 10 0 12 5 16 0 20 0 M16 M18 M2...

Page 137: ...y 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...

Page 138: ...g 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 outsi...

Page 139: ...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...

Page 140: ...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 t...

Page 141: ...o 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...

Page 142: ...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...

Page 143: ...he track tension has been achieved REPLACE RUBBER SHOES MACHINE LIFTING Two operators must carry out these operations One must travel the machine according to signal from the other The track tension c...

Page 144: ...rain 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 th...

Page 145: ...on the idler 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 tha...

Page 146: ...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 1 Park the machine on a level and soli...

Page 147: ...ubricator 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 Tra...

Page 148: ...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...

Page 149: ...ONS 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 e...

Page 150: ...eck 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 o...

Page 151: ...xagonal 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...

Page 152: ...nator fixed Put the piece of wood between the metal bar and the alternator to prevent the latest may be damaged 2 Loose bolt 1 and nuts 2 3 Move the alternator 3 so that the fan belt deflect is in 10...

Page 153: ...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...

Page 154: ...f the filter holder then tighten it up o 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 1...

Page 155: ...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 t...

Page 156: ...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 separ...

Page 157: ...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 filt...

Page 158: ...r 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 valve...

Page 159: ...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 1 Open the engine hood 2 Use compresse...

Page 160: ...rk the machine on a level and solid ground 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...

Page 161: ...ound 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 3 Let the engine r...

Page 162: ...IR 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 Unscr...

Page 163: ...temperature so wait for temperature cool down What prepare a pan to collect the drained oil 1 Park the machine on a level and solid ground 2 Unfasten the bolt 1 and the drain plug 2 for each idler 3 U...

Page 164: ...the radiator cap or drain plugs slowly Clean the cooling system replace the coolant and anti corrosive fluid s is showed in table below Coolant System cleaning and fluid replacing schedule Add anticor...

Page 165: ...er 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 clos...

Page 166: ...cool down When drain the hydraulic oil be careful to prevent drop on yourself What prepare a pan to collect the drained oil 1 Park the machine on a level and solid ground 2 Start the engine and keep...

Page 167: ...ver 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 th...

Page 168: ...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 a hexagonal wrench a pan to collect drained oil 1 Put a co...

Page 169: ...169 20 HYDRAULIC SCHEME...

Page 170: ...cumulator 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 moto...

Page 171: ...171 21 ELECTRICAL SCHEME...

Page 172: ...urning 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 Star...

Page 173: ...he fuel system Exhaust and clean fuel circuit Oil filter is plugged injecting nib is dirty or trouble Contact assistant service Accelerator joining can t be adjusted Replace the high pressure oil tube...

Page 174: ...sensor Air filter is plugged Clean the core filter Fan belt is loosen or damaged Tighten or replace Cooling system dirty Clean the cooling system Radiator s fins are blocked or damaged Clean or repair...

Page 175: ...mp Check and tighten pipe connection There is water in hydraulic oil Replace oil Hydraulic oil is emulsified or there is foams in the oil Oil level is too low Refill Safety valve is broken Contact ass...

Page 176: ...lling Front idler tension unit or lower roller is trouble Contact assistant service Capability of oil pump lowered Contact assistant service Slewing motor is damaged Contact assistant service Slewing...

Page 177: ...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...

Page 178: ...heck 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 PRECAU...

Page 179: ...179 24 NOTICE...

Page 180: ...180...

Page 181: ...ck 78 Introduction and general information 9 L Left lever 59 Lever and pedal 56 Load precaution 107 Loading work 93 Long term storage 111 Lubricants coolant fuel characteristics 130 Lubricating 149 M...

Page 182: ...old weather 77 Start key 65 Starting 76 Starting machine 71 Starting machine with jump start cables 113 Swinging 85 T The bucket 121 Throttle lever 57 Transport precaution 37 Transportation 105 Travel...

Page 183: ...port Department Office 36 Cuizhu Road Guilin Guangxi 541002 P R China Tel 0086 773 5588521 5588522 5588523 Fax 0086 773 5588530 E mail export yuchai excavator com Web site www yuchai excavator com YUC...

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Yuchai YC135, Operation And Maintenance Manual

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