Yuchai YC135 User manual

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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 Maintenance every 200 hours...........................................................................153
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 Maintenance every 400 hours...........................................................................158
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 Maintenance every 800 hours...........................................................................164
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.
The plate where is written the machine registration number is installed on
front side.
MACHINE KIND AND REGISTRATION NUMBER
KIND/MODEL:
REGISTRATION No.:
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: [phone] 5588522 5588523
Fax: [phone]
E-mail: [email protected]
Web-site: www.yuchai-excavator.com
YUCHAI EUROPE:
Address: V. Del Fonditore, 14 40138 Bologna, Italy
Tel:0039
Fax:0039
E-mail: [email protected]

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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.

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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.
A
lso
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.
Unlock
Lock

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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.

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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.

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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.