Yuchai YC20SR User manual

HYDRAULIC EXCAVATOR
YC20SR / YC18SR
U20 / U18
OPERATION MANUAL
GUANGXI YUCHAI HEAVY INDUSTRY COMPANY LIMITED

It is particularly important that the operator should read these instructions carefully in order to operate
and maintain the excavator safely and correctly. Otherwise accidents or damage may occur.
 Remember the safety procedures and proper use of the machine.
 Read and understand the instructions for the safe operation of the machine.
 Understand and be familiar with all safety signs on the machine.
 Make sure that nobody unrelated to the job is at the work site.
 Operators should have been trained in the safe operation of the machine before operating the
machine at the work site.
You are responsible for complying with relevant laws and regulations and following Yuchai Heavy
Industries' instructions on machine operation and maintenance.

CATALOGUE
1. Foreword ......................................................................................................................................................................... 1
1.1. To Users .................................................................................................................................................................. 1
1.2. Machine information ........................................................................................................................................... 2
1.3. Machine directions ............................................................................................................................................... 4
1.4. Machine components ........................................................................................................................................... 5
1.5. General Operation Information ......................................................................................................................... 6
1.5.1. Specified operations.................................................................................................................................... 6
1.5.2. Break-in ......................................................................................................................................................... 6
1.6. Safety-related information .................................................................................................................................. 6
1.7. Technical specifications ...................................................................................................................................... 8
1.7.1. Dimension paragauges ............................................................................................................................... 8
1.7.2. Working paragauges .................................................................................................................................. 9
1.7.3. Traveling mechanism .............................................................................................................................. 10
1.7.4. Hydraulic system ...................................................................................................................................... 10
1.7.5. Electric system .......................................................................................................................................... 10
1.7.6. Working condition ................................................................................................................................... 10
1.7.7. Interference ................................................................................................................................................ 11
2. Safety rules .................................................................................................................................................................. 12
2.1. General safety rules ........................................................................................................................................... 12
2.2. Safety labels and instructions ......................................................................................................................... 13
2.3. Safety equipment ............................................................................................................................................... 13
2.4. Security Signs ..................................................................................................................................................... 14
2.4.1. Classification of safety signs ................................................................................................................. 14
2.4.2. Location of safety Signs ......................................................................................................................... 15
2.4.3. Safety signs and descripton .................................................................................................................... 16
2.5. Workplace safety ............................................................................................................................................... 20
2.6. Safe Operations .................................................................................................................................................. 21
2.6.1. Start the engine ......................................................................................................................................... 21
2.6.2. Travel and Swinging ................................................................................................................................ 22

2.6.3. Safety rules when traveling .................................................................................................................... 23
2.6.4. Traveling or working on slopes ............................................................................................................ 23
2.6.5. Safe excavation operations ..................................................................................................................... 26
2.6.6. Tip and Skipping Prevention and Countermeasures ........................................................................ 30
2.6.7. Transportation and Handling ................................................................................................................. 31
2.6.8. Downtime maintenance .......................................................................................................................... 32
2.6.9. Fire, Explosion and Poisoning Prevention ......................................................................................... 33
2.6.10. Battery ......................................................................................................................................................... 35
2.6.11. Hydraulic system ...................................................................................................................................... 36
3. Introduction of Components .................................................................................................................................... 40
3.1. Control Consoles ............................................................................................................................................... 40
3.2. Safety locking components ............................................................................................................................. 41
3.3. Switch assembly ................................................................................................................................................ 42
3.4. Electronics Controls .......................................................................................................................................... 43
3.4.1. Key (start switch operation) ................................................................................................................... 43
3.4.2. Cigarette lighter ........................................................................................................................................ 44
3.5. Monitor ................................................................................................................................................................ 44
3.6. Work device s and Swing Controls ............................................................................................................... 45
3.7. Travel control ..................................................................................................................................................... 46
3.8. Throttle handle and stop handle ..................................................................................................................... 46
3.9. Driver's Seat ........................................................................................................................................................ 47
3.10. Seat belt ........................................................................................................................................................... 47
4. Operation Instructions ............................................................................................................................................... 49
4.1. Preparation before operating the machine ................................................................................................... 49
4.2. Engine Operation ............................................................................................................................................... 50
4.2.1. Check before starting the engine .......................................................................................................... 50
4.2.2. Starting the engine ................................................................................................................................... 51
4.2.3. After starting the engine ......................................................................................................................... 54
4.2.4. Shut down the engine .............................................................................................................................. 54
4.2.5. Check after turning off the engine ........................................................................................................ 55

4.3. Enter and exit the machine .............................................................................................................................. 55
4.4. Traveling .............................................................................................................................................................. 56
4.4.1. Safety principles for traveling ............................................................................................................... 56
4.4.2. Preparation for traveling ......................................................................................................................... 57
4.4.3. Travel forward........................................................................................................................................... 57
4.4.4. Travel backward ....................................................................................................................................... 58
4.4.5. Stop the machine ...................................................................................................................................... 58
4.5. Steering ................................................................................................................................................................ 59
4.5.1. Turning when the machine is stopped ................................................................................................. 59
4.6. Rotation ................................................................................................................................................................ 60
4.7. Working device Operations ............................................................................................................................. 60
4.7.1. Arm control ................................................................................................................................................ 60
4.7.2. Rotation control ........................................................................................................................................ 61
4.7.3. Boom control ............................................................................................................................................. 61
4.7.4. Bucket control ........................................................................................................................................... 61
4.7.5. Boom deflection control ......................................................................................................................... 61
4.7.6. Dozer blade control .................................................................................................................................. 61
4.8. Working on slope or water .............................................................................................................................. 62
4.8.1. Slope ............................................................................................................................................................ 62
4.9. Getting out of the Muddy Environment ....................................................................................................... 63
4.10. General Operations instruction .................................................................................................................. 64
4.10.1. Backhoe operation .................................................................................................................................... 64
4.10.2. Loading operation .................................................................................................................................... 64
4.10.3. Trenching operations ............................................................................................................................... 65
4.10.4. Backfilling or grading ............................................................................................................................. 65
4.10.5. Shake off the soil stuck in the bucket .................................................................................................. 65
4.10.6. Precautions for the use of related parts ............................................................................................... 65
4.11. Removal and installation of bucket .......................................................................................................... 66
4.12. Disassembly ................................................................................................................................................... 67
4.13. Parking............................................................................................................................................................. 68

4.14. After operation ............................................................................................................................................... 69
4.14.1. Check .......................................................................................................................................................... 69
4.14.2. Lock up ....................................................................................................................................................... 69
4.15. Loading and unloading and transportation .............................................................................................. 69
4.15.1. Safety rules ................................................................................................................................................ 69
4.15.2. Loading ....................................................................................................................................................... 70
4.15.3. Fixing the machine on the transport vehicle ...................................................................................... 72
4.15.4. Unloading from the transport vehicle .................................................................................................. 72
4.15.5. Lifting machine ......................................................................................................................................... 73
4.16. Operation in cold/hot climate ..................................................................................................................... 74
4.16.1. Operation in cold climate ....................................................................................................................... 74
4.16.2. Operating in hot weather ........................................................................................................................ 75
4.17. Storage of the machine ................................................................................................................................ 76
4.17.1. Preparation before storage ...................................................................................................................... 76
4.17.2. During storage ........................................................................................................................................... 77
4.17.3. Returning to work after storage ............................................................................................................ 77
4.18. Causes of technical failures and solutions .............................................................................................. 78
5. Maintenance ................................................................................................................................................................ 85
5.1. General knowledge of maintenance .............................................................................................................. 85
5.1.1. New machine break-in ............................................................................................................................ 85
5.1.2. Working in dusty sites ............................................................................................................................. 85
5.1.3. Oil and Filter ............................................................................................................................................. 85
5.1.4. Timer Readings ......................................................................................................................................... 86
5.1.5. Use genuine parts ..................................................................................................................................... 86
5.1.6. Waste disposal........................................................................................................................................... 86
5.1.7. Prevent objects from falling into the machine ................................................................................... 86
5.1.8. Periodic inspection and maintenance ................................................................................................... 87
5.1.9. Review after inspection and maintenance .......................................................................................... 87
5.2. Maintenance Summary ..................................................................................................................................... 88
5.2.1. Lubricant .................................................................................................................................................... 88

5.2.2. Fuel .............................................................................................................................................................. 88
5.2.3. Grease ......................................................................................................................................................... 88
5.2.4. Coolant ........................................................................................................................................................ 89
5.2.5. Filter element ............................................................................................................................................. 89
5.2.6. Hydraulic system ...................................................................................................................................... 89
5.2.7. Electrical System ...................................................................................................................................... 90
5.3. Wear and tear parts............................................................................................................................................ 90
5.4. Mandatory replacement parts.......................................................................................................................... 91
5.5. Oil selection table .............................................................................................................................................. 92
5.6. Tightening Torque ............................................................................................................................................. 93
5.6.1. Tightening torque for general parts ...................................................................................................... 93
5.6.2. Tightening torque for hydraulic Hoses ................................................................................................ 94
5.7. Periodic Inspection and Maintenance Table ............................................................................................... 96
5.8. General checking ............................................................................................................................................... 98
5.9. Engine Fuel System .......................................................................................................................................... 98
5.9.1. Oil level check and refueling ................................................................................................................. 98
5.9.2. Drain water and contaminants from the tank ..................................................................................... 99
5.9.3. Cleaning the fuel tank ............................................................................................................................. 99
5.9.4. Check the injection pressure .................................................................................................................. 99
5.9.5. Vent air from fuel circuit ...................................................................................................................... 100
5.9.6. Changing the fuel filter ......................................................................................................................... 100
5.9.7. Replace the fuel filter ............................................................................................................................ 101
5.10. Engine Cooling System ............................................................................................................................. 101
5.10.1. Check the coolant level ......................................................................................................................... 102
5.10.2. Check the condition of the rubber hoses and clamps ..................................................................... 102
5.10.3. Clean and inspect the radiator blades ................................................................................................ 103
5.10.4. Coolant replacement .............................................................................................................................. 103
5.10.5. Check the coolant concentration ......................................................................................................... 104
5.11. Engine Lubrication System ...................................................................................................................... 104
5.11.1. Oil level check ........................................................................................................................................ 105

5.11.2. Change the engine oil ............................................................................................................................ 105
5.11.3. Replace the engine oil filter element ................................................................................................. 106
5.11.4. Oil filter replacement ............................................................................................................................. 106
5.12. Engine air intake system ........................................................................................................................... 106
5.12.1. Cleaning of dust collection bin ........................................................................................................... 107
5.12.2. Clean the air filter element ................................................................................................................... 107
5.12.3. Replace the air filter element ............................................................................................................... 108
5.12.4. Check the air inlet pipe ......................................................................................................................... 108
5.13. Other engine maintenance......................................................................................................................... 108
5.14. Hydraulic system ........................................................................................................................................ 109
5.14.1. Check the oil level in the hydraulic oil tank .................................................................................... 110
5.14.2. Drain the water and dirt in the hydraulic oil tank ........................................................................... 111
5.14.3. Replace the hydraulic oil and clean the oil suction filter .............................................................. 111
5.14.4. Vent air from the hydraulic system .................................................................................................... 113
5.14.5. Replace the return oil filter element ................................................................................................... 115
5.14.6. Replace the pilot oil filter element ..................................................................................................... 116
5.15. Battery ........................................................................................................................................................... 117
5.15.1. Storage of battery ................................................................................................................................... 118
5.15.2. Charging of the battery ......................................................................................................................... 118
5.15.3. Installation of the battery ...................................................................................................................... 119
5.15.4. Battery maintenance .............................................................................................................................. 120
5.16. Speed Reducer ............................................................................................................................................. 120
5.16.1. Traveling reducer ................................................................................................................................... 121
5.16.2. Replace the lubricant (for each gearbox) .......................................................................................... 121
5.16.3. Check the tightening torque of the bolts connecting the travel reducer and the slewing
reducer 122
5.16.4. Check the solidity of the connecting bolts of the slewing reducer ............................................. 122
5.16.5. Tracks ........................................................................................................................................................ 122
5.17. Idler wheel and guide wheel ..................................................................................................................... 124
5.18. Lubrication ................................................................................................................................................... 124
5.19. Replacement of bucket teeth .................................................................................................................... 126

5.20. Flushing of the floor mat ........................................................................................................................... 127
6. Attachment Guide .................................................................................................................................................... 128
6.1. Safety issues ...................................................................................................................................................... 128
6.1.1. Safe operation of attachments ............................................................................................................. 129
6.2. Removing or installing attachments ............................................................................................................ 130
6.2.1. Attachment Installation/Removal Procedure ................................................................................... 130
6.3. Attachment Operation Guide ........................................................................................................................ 131
6.3.1. Hydraulic Hammer ................................................................................................................................. 132
6.4. Daily inspection of hydraulic hammer ....................................................................................................... 135
6.5. Quick coupler ................................................................................................................................................... 136
6.6. Grab Bucket ...................................................................................................................................................... 137
6.6.1. Installation of grab bucket .................................................................................................................... 137
6.6.2. Operation of the grab bucket ............................................................................................................... 138
6.6.3. Operation precasutions of the grapple ............................................................................................... 138
6.6.4. Maintenance of the grapple .................................................................................................................. 140
6.7. Drilling device .................................................................................................................................................. 140
6.7.1. Installation of drilling device ............................................................................................................... 140
6.7.2. Operation of the drilling unit ............................................................................................................... 141
6.7.3. Precautions for the operation of drilling device .............................................................................. 141
6.8. Backhoe bucket with scraper ........................................................................................................................ 142
6.8.1. Installation................................................................................................................................................ 142
6.8.2. Operation of the backhoe bucket ........................................................................................................ 143
6.8.3. Maintenance of the backhoe bucket ................................................................................................... 143

1
1. Foreword
1.1. To Users
Dear users.
Greetings!
Welcome to use Yuchai excavator and thank you for your great support to Yuchai business.
This manual is intended as a safety guide and for the proper use and maintenance of the
machine. Before starting and operating the machine for the first time and before servicing
the machine, please make sure to read and understand this manual carefully and fully
understand the safety procedures, operation and maintenance procedures.For easy access,
keep this manual in a safe place so it can be read regularly by qualified machine operators.
If this manual is lost, damaged or illegible, please order it immediately from our company
or dealer. When transferring the machine, please pass this manual along with it so the next
owner can use it properly.
Please entrust the overhaul and adjustment of the machine to Yuchai Heavy Industry's
dealer or service station, and use original parts and spare parts provided by our company. If
you use non- original parts or components, they may not have an obvious effect on the
machine at the time, but may cause problems later. Yuchai Heavy Industry will not
undertake the warranty service even if the machine breaks down during the warranty period
due to the use of non-original parts or components or the maintenance is done by
unauthorized organizations.
Based on the principle of "customer first", Yuchai Heavy Industry continuously improves
its products in order to provide the best possible products to customers, for which
improvements may be implemented at any time. For the products being sold at that time,
we do not replace the information and do not give any advance notice.
We sincerely hope that this machine will serve you better and create more value with your
proper use and careful care.