Yuchai Electric Excavator Daily Maintenance & LFP Lithium Iron Phosphate Battery Care Guide

Against the backdrop of electrification in construction machinery, Yuchai electric excavators stand out as a reliable solution for urban infrastructure construction, indoor demolition, photovoltaic project construction and other working scenarios, featuring zero emissions, low noise and low operation & maintenance costs. Unlike conventional fuel-powered excavators, the core maintenance focus shifts from engine servicing to electrical system management and LFP lithium iron phosphate battery regulation. This manual compiles a a comprehensive set of maintenance procedures based on Yuchai equipment specifications and industrial standards, helping operators reduce breakdowns, extend equipment service life and cut overall operating costs.

Daily Maintenance: Mandatory Pre-Shift, Mid-Shift & Post-Shift Inspections for Safety Assurance

1. Pre-operation Full Machine Inspection (10 Minutes Before Work)

1.1 Exterior & Structural Inspection

- Walk around the entire machine to check for collision deformation on the main body, boom and stick; verify tightness of pin shaft bolts.

- Track sag shall be controlled within 20–30 mm; remove foreign objects jamming the track assembly.

- Inspect hydraulic pipelines and joints for oil leakage; confirm hydraulic oil level stays within marked scale ranges.

1.2 Critical Electrical & Battery Inspection

- Battery pack appearance: No bulging, deformation, liquid leakage or burn marks; terminal lugs are fastened securely without oxidation.

- BMS (Battery Management System) status: Dashboard SOC (State of Charge) reading ≥20%, no fault codes displayed; single cell voltage difference less than 0.05 V.

- High-voltage system: High-voltage cables free from damage and aging with intact insulation layers; charging port stays clean, dry and free of ablation marks.

1.3 Functional Test

- Power on without starting the machine, test joysticks and foot pedals for smooth operation without jamming.

- After startup, idle the machine for 3 minutes; listen for abnormal noises from drive motors and hydraulic pumps, confirm hydraulic oil temperature and motor operating temperature remain within normal ranges.

2. Real-Time Monitoring During Operation

- Constantly monitor dashboard data; shut down the machine immediately once any alarm is triggered.

- Avoid prolonged full-load operation, sudden acceleration or emergency stops to minimize high-current impact on the battery pack.

- Ambient temperature operating limits: The machine operates optimally at 0–45°C. Prolonged continuous operation is prohibited when ambient temperature exceeds 55°C or drops below -10°C.

3. Post-operation Standard Shutdown Procedures (15 Minutes After Work Completion)

- Cleaning: Clear mud and debris from the machine body and undercarriage; prioritize cleaning battery compartments, motor and hydraulic radiators to guarantee optimal heat dissipation efficiency.

- Retightening & Recheck: Reinspect oil leaks and loose bolts, with special attention to electrical connectors.

- Parking & Charging: Park the machine on flat, well-ventilated ground, engage parking brake and cut off the main power supply. Initiate charging promptly if SOC falls below 30%; charging ambient temperature must be maintained between 0–40°C.

- Periodic Scheduled Maintenance: Extend Equipment Lifespan by Following Hour-Based Cycles

Specialized LFP Lithium Iron Phosphate Battery Maintenance

1. Standard Charging Specifications

- Optimal SOC range for daily use: Maintain battery charge between 20%–90%; avoid deep discharge below 20%.

- Charging mode guidelines: Utilize slow charging for daily routine; fast charging is only for emergency energy top-up. Perform one full slow charge every week to calibrate the BMS battery management system.

- Temperature control during charging: Ambient charging temperature shall stay within 0–45°C. Preheat the battery pack before charging in winter when temperature drops below -10°C; never start charging immediately after the machine sits under intense summer sunlight.

- Operation notes: Only use genuine Yuchai battery chargers; wipe and clean the charging port thoroughly before plugging in.

2. Temperature Control Standards for LFP Batteries

- Optimal operating temperature window: 0–45°C; operation outside this range accelerates irreversible battery aging.

- Summer operation: Let the machine cool down naturally after finishing work; prohibit charging while battery temperature remains excessively high.

- Winter operation: Preheat the battery pack for 10–15 minutes before startup to boost lithium ion activity and retain full working range.

3. Battery Storage Maintenance for Long-Term Equipment Idling

- Short-term storage (less than 1 month): Charge battery to 40%–60% SOC; park in dry, ventilated premises and perform one supplementary charge per month.

- Long-term storage (1 month or longer): Charge battery to 80% SOC, disconnect the main power supply. Check battery charge level every 2–3 months; perform slow supplementary charging when SOC drops to 40%.

- Strict prohibitions: Never store the machine with fully charged or fully depleted batteries; avoid storage under high-temperature or humid conditions.

4. Troubleshooting for Common LFP Battery Abnormalities

5. Regular LFP Battery Calibration Maintenance

- Complete an automatic full charge at minimum every three days.

- For machines operating over 18 hours daily, conduct a full battery calibration maintenance cycle at least once per month.

- Do not disconnect the charging gun before the dashboard confirms charging completion.

- Immediately carry out battery calibration maintenance once the dashboard prompts a battery service reminder to restore normal battery system performance.

- Mandatory full battery calibration every three months to prevent permanent battery damage.

Step-by-Step Battery Calibration Operation Process

1. Adjust battery SOC to 25%–40%, park the machine on level ground and shut down working systems.

2. Turn the ignition key to OFF position, disconnect main power supply, then reconnect main power and switch ignition key to ON position; turn off air conditioning and all auxiliary electrical loads.

3. Keep the machine in this static powered-on state for 12–15 hours, then fully cut off vehicle power. Complete one full charge after finishing the calibration cycle.

Critical Note：Do not operate the machine or activate any electrical appliances during battery calibration; equipment usage will interrupt the entire calibration process.

Non-Negotiable High-Voltage Safety Protocols

- High-voltage maintenance safety: Cut power supply, perform voltage verification and post warning tags before any overhaul work; use certified insulated tools. Non-professional personnel are forbidden to disassemble any high-voltage components.

- Fire prevention regulations: Equip battery compartments with dry powder or CO₂ fire extinguishers. Never use water to put out electrical fires; keep flammable materials away from the machine, and welding or hot work near battery packs is strictly prohibited.

- Operator compliance requirements: All operators must complete proper professional training on the equipment and fully master equipment and lithium battery performance characteristics. Overloading and unauthorized improper operation are banned.

- Fault reporting rules: Shut down the machine right away upon detecting any abnormal conditions, record all displayed fault codes and contact Yuchai authorized after-sales support without delay.

（This maintenance guide serves as reference material only. All specific maintenance parameters shall be subject to the original product operation manual delivered with your Yuchai electric excavator.）