j j

m m
2 2
8 8
s s
605-8850
2020-07
z z

Operation and
Maintenance
J
Manual J
M M
2 2
8
SEM655D Wheel Loader 8
_ _
S55 (655D Stage II Emission)
j j
m m
2 2
8 8
s s
z z
 j j
m m
2 2
8 8
s Important Safety Information s
Most accidents that z involve product operation, maintenance and repair are caused by failure to observe basicz
saf ety rules or precautions.An accident can often be avoided by recognizing potentially hazardous situations
bef ore an accident occurs.A person must be alert to potential hazards, including human factors that can affect
saf ety.This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify that you
are authorized to perform this work, and have read and understood the operation, lubrication,
maintenance and repair information.
Saf ety precautions and warnings are provided in this manual and on the product.If these hazard warnings are not
heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”,
“WARNING” or “CAUTION”.The Saf ety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
J J
The message that appears under the warning explains the hazard and can be either written or pictorially
M presented. M
2 A non-exhaustive list of operations that may cause product damage are identified by2
“NOTICE” labels on the
product and in this publication.
8 Caterpillar (Qingzhou) Ltd.. cannot anticipate every possible circumstance that might 8 involve a potential
_
hazard.The _
warnings in this publication and on the product are, therefore, not all inclusive.You must not
use this product in any manner different from that considered by this manual without first satisfying
j that you have considered all safety rules and precautions applicable to the operation
yourself j of the
product in the location of use, including site-specific rules and precautions applicable to the worksite.If a
tool, m
procedure, work method or operating technique that is not specifically recommended m by Caterpillar
(Qingzhou)2 Ltd. is used, you must satisfy yourself that it is safe for you and for others.You should
2 also
ensure that you are authorized to perform this work, and that the product will not be damaged or become
unsafe by the8 operation, lubrication, maintenance or repair procedures that you intend to use. 8
The inf ormation,
sspecifications, and illustrations in this publication are on the basis of information that wass
available at the time that the publication was written.The specifications, torques, pressures, measurements,
z
adjustments, illustrations, and other items can change at any time.These changes can affect the service thatzis
given to the product.Obtain the complete and most current information before you start any job.SEM dealers have
the most current information available.

When replacement parts are required for this

product, Caterpillar (Qingzhou) Ltd. recommends
using SEM replacement parts.
Failure to follow this warning may lead to
premature failures, product damage, personal
injury or death.
 j j
m m
2 2
8 8
s
Table of Contents s 20
Fueling Machine ...........................................
z
PREFACE ....................................................... 5 z 20
Engine Stopping ...........................................

Parking ......................................................... 20
Safety Section 7
Slope Operation ............................................ 20
Description and location of the safety messages7
Work Tools.................................................... 21
General Precaution ....................................... 11
Equipment Lowering with Engine Stopped ..... 22
Safety Requirements..................................... 11
Sound Level Information ............................... 22
Safety Devices.............................................. 11
Vibration Information ..................................... 22
Clothing and Personal Protective Equipment . 11
Information Concerning Seat Vibration .......... 22
Pressurized Air and Water ............................. 11
Cab .............................................................. 23
Trapped Pressure ......................................... 11

Fluid Penetration ........................................... 12 Product Information 23

Containing Fluid Spillage ............................... 12 General Information ...................................... 23

J J
Usage and main technical parameters........... 26
M Dispose of Waste Properly ............................ 13 M
2 Crushing Prevention and Cutting Prevention .. 13 2
Operation Section 31
8 Burn Prevention ............................................ 13 8
Control devices and monitoring system ......... 32
_
Batteries ....................................................... 13
_
Driver seat adjustment .................................. 38
j j
Fire Prevention and Explosion Prevention...... 14 Operating Precautions .................................. 41
m m
Batteries and battery cables .......................... 14 1 Before starting the engine .......................... 41
2 2
Lines, Tubes, and Hoses ............................... 15 2 When starting the engine............................ 42
8 8
Fire Extinguishers and First Aid Kit .................. 16 s 43
3 After starting the engine .............................

z
Fire Safety .................................................... 16 z 46
4 Storage of the machine ..............................

Fire Extinguisher Location ............................. 17 5 Shipping of the machine ............................. 47

Tire Information ............................................. 17 6. Battery Use and Maintenance Considerations50
Lightning Damage Prevention........................ 18 7. Towing ...................................................... 51

Before Starting Engine .................................. 18 Decommissioning and Disposal..................... 51

Visibility Information ...................................... 18 Machine Operation........................................ 53

Restricted Visibility ........................................ 19 Maintenance Section 57
Engine Starting ............................................. 19 Maintenance Considerations ......................... 60
Before Operation........................................... 19 Key Safety Part Catalog and Change Interval 65
Operation...................................................... 19 Important Maintenance Procedure................. 67
3
 j j
m m
2 2
8 8
s Maintenance......................... 67
Engine Coolant s
z
Maintenance of Engine Air Cleaner ................ 69 z
Cleaning the air filter primary element ............ 69

Replacement of Safety Element..................... 69

Use and Maintenance of Diesel ..................... 70

Maintenance of Engine Oil............................. 71

Maintenance of Air Conditioning Heater System72

Maintenance of Transmission ........................ 72

Maintenance of Drive Axle ............................. 73

Maintenance of Hydraulic System.................. 74

Knowledge of Tire Maintenance and Inflation . 76

Bucket Kickout Adjustment ............................ 76

J J
Checking park brake performance ................. 76
M M
Checking service brake performance ............. 77
2 2
8 Checking park brake friction plate .................. 77 8
_
Grease fill process for main drive shaft: ......... 78 _
j Reason and Troubleshooting ................ 81
Fault j
m Regular Maintenance Parts List .... 86
SEM655D m
2 2
8 8
s s
z z

4
 j j
m m
2 2
8 8
PREFACEs
z The maintenance section is a guide to the equipmentz
Literature Information
This manual contains safety information, operation
instructions, driving information, lubrication
inf ormation and maintenance information.
This operation manual details the important aspects
of safety, operation, maintenance, inspection, etc.,
and should be kept available and read regularly.If this
manual is missing or dirty and not legible, you should
re-purchase it at the dealer.When you sell the
machine, please ensure that the manual is also
f orwarded to the new user.
The technical parameters, specifications and
illustrations in this manual are on the basis of
inf ormation that was available at the time that the
manual was written.Continuing modification of
product design may affect the maintenance and
repair of the machine which are not included in this
manual.Whenever a question arises regarding your
J machine, or this manual, please consult with the
manuf acturer or your dealer for the latest available
M inf ormation.
2 SECURITY
8 Caterpillar (Qingzhou) Ltd. cannot anticipate every
working circumstance that might involve a hazard.
_ warnings in this manual and on the product are,
The
theref ore, not all inclusive.If a tool, procedure, work
j
method or operating technique that is not specifically
m
recommended by Caterpillar (Qingzhou) Ltd. is used,
you must satisfy yourself that it is safe for you and for
others.You2 should also ensure that the machine will
not be damaged or become unsafe by the operation,
8
lubrication, maintenance or repair procedures that
you intend to use.
s the engine and machine systems operating s
Operation z
The operation section is a reference for new
operators and a ref resher for experienced ones.This
section includes a discussion of gauges, switches,
machine controls, attachment controls, transportation
and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic.Skill and techniques develop as the operator
gains knowledge of the machine and the capabilities
of the machine.
Maintenance s
care.The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval.Items without specific intervals are listed
under the “When Required” service interval.The
Maintenance Interval Schedule also lists the page
number f or the step-by-step instructions required to
accomplish the scheduled maintenance.Use the
Maintenance Interval Schedule as an index or "one
saf e source (spare parts, tools and fluids manuals)"
f or all maintenance procedures.
Maintenance Intervals
The maintenance section of this manual is a
guideline for routine maintenance of the machine and
is organized by maintenance intervals.The
maintenance intervals listed in this manual are
determined by using the service hour meter.Calendar
intervals shown (daily, weekly, monthly, etc.) can be
used instead of service hour meter intervals if they
provide more convenient servicing schedules and
approximate theJindicated service hour meter
reading.Caterpillar M (Qingzhou) Ltd. recommends
service should always be performed at the interval
2
that occurs f irst.Under extremely severe, dusty or wet
operating conditions, more frequent lubrication than
is specified in the scheduled8 maintenance might be
necessary.Perform service on items at multiples of
_
the original requirement.For example, at every 500
service hours or 3 months, also jservice those items
listed under every 250 service hours or monthly,
every 50 service hours or weekly andm every 10
service hours or daily.
2
Engine Maintenance
8
Proper maintenance and repair is essential to keep
correctly.As the heavy duty off-road diesel engine
owner, you are responsible for the performancez of the
required maintenance listed in the Operation and
Maintenance Manual.It is prohibited for any person
engaged in the business of repairing, servicing,
selling, leasing, or trading engines or machines to
remove, alter, or render inoperative any emission
related device or element of design installed on or in
an engine or machine that is in compliance with the
regulations.Certain elements of the machine and
engine such as the exhaust system, fuel system,
electrical system, intake air system and cooling
system may be emission related and should not be
altered unless approved by Caterpillar (Qingzhou)
Ltd.
5
 j j
m m
2 2
8 8
s
Machine Capacity s
Each loader has its zown design capability. Additional z
attachments or modifications may exceed loader
design capacity which can adversely affect
perf ormance characteristics. Included would be
operational stability, brakes and steering.Please
contact your dealer for updated information.

SEM Product Identification Number

The product iIdentification number is on the machine
product dataplate.

① -SEM World Manufacturing Code

② -Machine’s Model Number
J J
③ -Check Character
M ④ -Pref ix Code of Engineering Model
M
2 ⑤ -Machine’s Serial Number (S/N)
2
8 8
_ _
j j
m m
2 2
8 8
s s
z z

6
 j j
m m
2 2
8 8
s
Safety Section s
z z

J J
M M
2 2
8 8
_ _
j j
m Description and location m of the
2 safety messages 2
Please read8and become familiar with all safety 8 on this
There are several specific safety messages
instructions. Failure to do so could result in machine.The exact location of the hazards and the
serious injury s
or death. s
description of the hazards are reviewed in this
section.Please become familiar with all safety
z also includes precautions for
This Safety Section messages.
z
optional attachments.
Make sure that all of the safety messages are
legible.Clean the safety messages or replace the
saf ety messages if you cannot read the
words.Replace the illustrations if the illustrations are
not legible.When you clean the safety messages,
use a cloth, water and soap.Do not use solvent,
gasoline, or other harsh chemicals to clean the safety
messages.Solvents, gasoline, or harsh chemicals
could loosen the adhesive that secures the warning
sign.Loose adhesive will allow the warning sign to
f all.
Replace any safety message that is damaged or
missing.If a safety message is attached to a part of
the machine that is replaced, install a saf ety message
on the replacement part.Any SEM dealer can provide
new saf ety messages.
7
 j j
m m
2 2
8 8
s s
z z

J J
M M
2 2
8 8
_ _
j j
m m
2 2
8 8
s s
z z

8
 j j
m m
2 2
8 8
s
Do Not Operate s
No Entry when Reversing message
z is located in the cab.
This saf ety message z
The message is located on the rear of the machine.

Do not operate this machine unless you have Do not get close to the machine until the engine
J read and understand the instructions and stops. J
M warnings in the Operation and Maintenance
Manual.Failure to do so may result in personal
M
2 injury or death.Contact any Caterpillar dealer for Message for No2Standing Under
replacement manuals.Proper care is your
8 responsibility. the Boom 8
_ _ outside of the boom.
The message is located on the

Warn
j labels for Hands Hurt by Fan j
m
The message is located at the rear of the hood. m
2 2
8 8
s s
z z

Please do not put your hands near the running

fan. Do not touch the machine in operation.
 j j
m m
2 2
8 8
s
Lift Point Indicator s the
window open and exit the machine through
window.
z on the inside of the machine.
The message is located z
Parking Brake sign
The message is located inside the cab.

This message indicates the position of lifting the

whole machine.

Articulation Lock sign

The message is located in the articulation position at
the middle of the machine.

J J
M M
2 2 while the machine is
Engage the parking brake
parking.
8 8
_ Hydraulic Oil _
j j oil and is
The message indicates the hydraulic
m located next to the hydraulic oil tank.
m
2 2
Alternate8Exits 8
s
The message is located in the cab on the right post
s
z
by the window latch. z

Fuel Tank sign

This message is located by the fuel tank.

If the primary exit becomes blocked, the window

on the right side can be used as an alternate
exit.Pull the latch backward, then push it outward
to open the window to the partial open
position.Remove pin from the latch.Push the

10
 j j
m m
2 2
8 8
s switch, shut off the engine, lock all devicesswith the
key, and take the key with you.
z • If the right window is closed, make sure that the
z
hooks are f ully secured to prevent loosening.
• If the window is locked, be sure to tighten the lock
seat to prevent collision between the loose glass
and the lock seat.

Clothing and Personal

General Precaution
Safety Requirements
• Only trained and appropriately qualified personnel
could operate and maintain the machine.
• Observe all safety rules, precautions and
instructions when operating and maintaining the
J machine.
M • Do not operate the machine if you do not feel well,
2 feel dizzy after taking medication or after drinking.In
this case, it will lead to the wrong judgment and
8 potential accident.
•_When working with another operator or traffic
commander on site, you must ensure that all
j
personnel understand the hand signals being used.
m all rules concerning safety.
• Observe
Safety2 Devices
8
• Make sure that all protective devices and hoods are
secured in thesright place. Repair timely if they are
damaged.
z Pressurized Air and Water z
• Use saf ety devices properly, such as lever locking
devices and safety belts.
• Never remove the safety device. Always keep it in
good working condition.
• Improper use of safety devices can result in serious
injury or death.
Lock the safety devices when you
exit the operator seat.
• Engage the parking brake switch before you exit
the seat.If the control lever is accidentally touched,
the work tools may suddenly move, causing serious
injury.
• When you leave the loader, lower the work tool
completely to the ground, engage the parking brake
Protective Equipment
• Do not wear loose clothing or jewelry. Do not keep
long hair.They may snap into or get caught in the
controls or moving parts, causing serious injury or
death.
• Do not wear greasy clothing to prevent burning.
• When you operate or maintain the machine, wear a
hard hat, protective glasses, protective shoes,
protective masks and gloves.Wear protective
goggles, hard hat, and heavy gloves when throwing
J tiny debris, especially when
metal chips and
M removing air filter
hammering pins and
contaminants with compressed air.Also check to
make sure no one is 2 near the machine.
8
_
j
m
2
8
s
Pressurized air can cause personal injury.When
pressurized air is used for cleaning, wear protective
masks, protective clothing and protective shoes.The
maximum air pressure for cleaning purposes must be
below 205 kPa.The maximum water pressure for
cleaning purposes must be below 275 kPa.
• Avoid direct spraying of water on electrical
connectors, connections, and components.When
using air f or cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when
re-deposited on hot surfaces.
Trapped Pressure
Pressure can be trapped in a hydraulic
system.Releasing trapped pressure can cause
sudden machine movement or attachment
11
 j j
m m
2 2
8 8
movement.Usescaution if you disconnect hydraulic Inhalation s
lines or f ittings.High-pressure oil that is released can
z
cause a hose to whip.High-pressure oil that is z
released can cause oil to spray.Fluid penetration can
cause serious injury and possible death.

Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
af ter the engine has been stopped.The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur.Do not disassemble any hydraulic
Exhaust
components or parts until pressure has been relieved Use caution.Exhaust fumes can be hazardous to
or personal injury may occur. your health.If you operate the machine in an
enclosed area, adequate ventilation is necessary.

Asbestos Materials
SEM equipment and replacement parts shipped from
J J Ltd. are asbestos
Caterpillar (Qingzhou)
f ree.Caterpillar (Qingzhou) Ltd.recommends the use
M of only genuine SEM Mreplacement parts.Use the
2 f ollowing guidelines when
2 you handle any
replacement parts that contain asbestos or when you
8 handle asbestos debris.Use 8 caution.Avoid inhaling
dust that might be generated when you handle
_ _ fibers.Inhaling this
components that contain asbestos
dust can be hazardous to your health.The
j use a board or cardboard when you check for
Always j
components that may contain asbestos fibers are
a leak.Leaking fluid that is under pressure can
m body tissue.Fluid penetration can cause
penetrate brake pads, brake bands, lining material,
m clutch
serious injury and possible death.A pin hole leak can plates, and some gaskets.The asbestos that is used
2 injury.If fluid is injected into your skin,
cause severe 2 or sealed in
in these components is bound in a resin
you must get8treatment immediately.Seek treatment some way.Normal handling is not hazardous unless
f rom a doctor that is familiar with this type of injury.
8
airborne dust that contains asbestos is generated.
s If dust that may contain asbestos is present,sthere
Containing Fluid Spillage are several guidelines that should be followed:
z z
Care must be taken in order to ensure that fluids are • Never use compressed air for cleaning.
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the • Avoid brushing materials that contain asbestos.
equipment.Prepare to collect the fluid with suitable • Avoid grinding materials that contain asbestos.
containers before opening any compartment or
disassembling any component that contains fluids. • Use a wet method in order to clean up asbestos
materials.
Ref er to Special Publication SEM Dealer Service
Tools Catalog for the following items: • A vacuum cleaner that is equipped with a high
• Tools that are suitable for collecting fluids and ef f iciency particulate air filter (HEPA) can also be
used.
equipment that is suitable for collecting fluids
Obey all local regulations for the disposal of liquids. • Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for

12
 j j
m m
2 2
8 8
s
the work place. If it is necessary to remove guards in order tosperform
maintenance, always install the guards after the
Use the requirements found in the “Ordinance on
z
Prevention of Health Impairment due to Asbestos” in
maintenance is performed.Keep objects away from z
moving fan blades.The fan blade will throw objects or
addition to the requirements of the Industrial Safety
cut objects.
and Health Act.
• Obey environmental regulations for the disposal of Burn Prevention
asbestos.
Do not touch any part of an operating engine.Allow
• Stay away f rom areas that might have asbestos the engine to be cool before any maintenance is
particles in the air. perf ormed on the engine.Relieve all pressure in the
air system, in the oil system, in the lubrication system,
Dispose of Waste Properly in the f uel system, or in the cooling system before
any lines, f ittings, or related items are disconnected.

J J
M M only after the engine has
Improperly disposing of waste can threaten the
2 environment.Potentially harmful fluids should be
disposed of according to local regulations.
8 8 be cool enough to touch
Always use leakproof containers when you drain
f_
luids. Do not pour waste onto the ground, down a
drain, or into any source of water.
j j alkali.Alkali can
Crushing
m Prevention and
Cutting 2 Prevention
Support the equipment properly before you perform
8
any work or maintenance beneath that equipment.Do
s hydraulic cylinders to hold up the
not depend on the
equipment.Unit can fall if a control is moved, or if
z
hydraulic lines break.
Do not work beneath the cab of the machine unless
the cab is properly supported.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while the
engine is running.
Coolant
When the engine is at operating temperature, the
engine coolant is hot and under pressure.The
radiator and all lines to the heaters or to the engine
contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns.Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level
been stopped.
2
Ensure that the f iller cap is cool before removing the
f iller cap.The f iller cap must
with a bare hand.Remove the f iller cap slowly in order
to relieve the pressure. _
Cooling system conditioner contains
cause personal injury.
m
Do not allow alkali to contact the skin, the eyes, or
the mouth. 2
Oil 8
Hot oil and hot components can cause personal s
injury.Do not allow hot oil to contact the skin.Also, do
not allow hot components to contact the skin. z
Remove the hydraulic tank filler cap only after the
engine has been stopped.The filler cap must be cool
enough to touch with a bare hand.Follow the
standard procedure in this manual in order to remove
the hydraulic tank filler cap.

Never jump across the starter solenoid terminals in Batteries

order to start the engine.Unexpected machine
movement could result.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine.Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.
Stay clear of all rotating and moving parts.
The liquid in a battery is an electrolyte.Electrolyte is
an acid that can cause personal injury.Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels.Batteries give off flammable fumes which can
explode.

13
 j j
m m
2 2
8 8
s
Fire Prevention and Explosion
Preventionz
All f uels, most lubricants, and some coolant mixtures
are f lammable.
To minimize the risk of fire or explosion, Caterpillar
(Qingzhou) Ltd. recommends the following actions.
• Always perform a Walk-Around Inspection, which
may help you identify a f ire hazard.Do not operate
a machine when a f ire hazard exists.Consult your
J SEM dealer for details..
• Understand the use of the primary exit and
M alternative exit on the machine.Refer to Operation
2 and Maintenance Manual, “Alternative Exit”.
8 • Do not operate a machine with a fluid leak.Repair
leaks and clean up fluids before resuming machine
_operation.Fluids that are leaking or spilled onto hot
surf aces or onto electrical components can cause a
j fire may cause personal injury or death.
f ire.A
m flammable material such as leaves, twigs,
• Remove
papers, trash, and so on.These items may
2
accumulate in the engine compartment or around
8 and hot parts on the machine.
other hot areas
• Keep the access
s doors to major machine
compartments closed and access doors in working
z to permit the use of fire
condition in order
suppression equipment, in case a fire should
occur.Clean all accumulations of flammable
materials such as fuel, oil, and debris from the
machine.
Do not operate the machine near any flame.
Keep shields in place.Exhaust shields (if equipped)
protect hot exhaust components f rom oil spray or fuel
spray in case of a break in a line, in a hose, or in a
seal.Exhaust shields must be installed correctly.Do
not weld or flame cut on tanks or lines that contain
f lammable fluids or flammable material.Empty and
purge the lines and tanks.Then clean the lines and
tanks with a nonflammable solvent prior to welding or
f lame cutting.Ensure that the components are
properly grounded in order to avoid unwanted arcs.
• Dust that is generated from repairing nonmetallic
14
s
hoods or f enders may be flammable and/or
explosive.Repair such components in a well
ventilated area away from open flames or z
sparks.Use suitable Personal Protection
Equipment (PPE).
• Inspect all lines and hoses for wear or
deterioration.Replace damaged lines and
hoses.The lines and the hoses should have
adequate support and secure clamps.Tighten all
connections to the recommended torque.Damage
to the protective cover or insulation may provide
f uel f or fires.
• Store f uels and lubricants in properly marked
containers away from unauthorized
personnel.Store oily rags and flammable materials
in protective containers.Do not smoke in areas that
are used f or storing flammable materials.
J
M
2
8
_
j
m
2
Use caution when you are fueling a machine.Do not
8
smoke while you are f ueling a machine.Do not fuel a
machine near open flames or sparks.Do notsuse cell
phones or other electronic devices while you are
z
ref ueling.Always stop the engine before refueling.Fill
the f uel tank outdoors.Properly clean areas of
spillage.
• Avoid static electricity risk when fueling.Ultra low
sulf ur diesel (ULSD) poses a greater static ignition
hazard than earlier diesel formulations with a
higher sulf ur content.Avoid death or serious injury
f rom fire or explosion.Consult with your fuel or fuel
system supplier to ensure that the delivery system
is in compliance with fueling standards for proper
grounding and bonding practices.
Never store f lammable fluids in the operator
compartment of the machine.
Batteries and battery cables
 j j
m m
2 2
8 8
s • Corroded terminals, damaged terminals, and
z z
Caterpillar (Qingzhou) Ltd.recommends the following
in order to minimize the risk of fire or an explosion
related to the battery.
Do not operate a machine if battery cables or related
parts show signs of wear or damage.Consult your
J SEM dealer for details.
Follow safe procedures for engine starting with
M jump-start cables.Improper jumper cable connections
2 can cause an explosion that can result in injury.Refer
to Operation and Maintenance Manual, “Engine
8 Starting with Jump Start Cables” for specific
instructions.
_ conditions exist, replace parts_before you operate the
Do not charge a frozen battery.This may cause an
j
explosion.
Gases mf rom a battery can explode.Keep any open
f lames or sparks away from the top of a battery.Do
not smoke 2in battery charging areas.Do not use cell
phones or other electronic devices in battery
8
charging areas.
Never check thesbattery charge by placing a metal
object across the terminal posts.Use a voltmeter in
order to check thezbattery charge.
Daily inspect battery cables that are in areas that are
visible.Inspect cables, clips, straps, and other
restraints for damage.Replace all damaged
parts.Check for signs of the following, which can
occur over time due to use and environmental
f actors:
• Fraying
• Abrasion
• Cracking
• Discoloration
• Cuts on the insulation of the cable
• Fouling
s loose
terminals
Replace damaged battery cables and replace any
related parts.Eliminate any fouling, which may have
caused insulation failure or related component
damage or wear.Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surf ace.A battery cable short
produces heat f rom the battery current, which may be
a f ire hazard.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes into contact with a grounded surf ace.This may
result in an unsaf e condition for servicing the
machine.Repair components or replace components
bef ore servicing the machine.
J
Fire on a machine could result in personal injury
or death.ExposedM battery cables that come into
contact with a grounded connection could result
in fires.
2
8
Check electrical wires daily.If any of the following
machine.
j
• Fraying
m
• Signs of abrasion or wear
2
• Cracking
• Discoloration
8
• Cuts on insulation
s
• Other damage
z
Make sure that all clamps, guards, clips, and straps
are reinstalled correctly.This will help to prevent
vibration, rubbing against other parts, and excessive
heat during machine operation.
Attaching electrical wiring to hoses and tubes that
contain flammable fluids or combustible fluids should
be avoided.
Consult your SEM dealer for repair or replacement
parts.Keep wiring and electrical connections free of
debris.
Lines, Tubes, and Hoses
Do not bend high-pressure lines.Do not strike
high-pressure lines.Do not install any lines that are
bent or damaged.Use the appropriate backup
15
 j j
m m
2 2
8 8
s all connections to the
wrenches to tighten
recommended torque.
z Use ether in ventilated areas.Do not smoke while you
Check lines, tubes, and hoses carefully.Wear
Personal Protection Equipment (PPE) to check for
leaks.Always use a board or cardboard when you
check f or a leak.Leaking fluid that is under pressure
can penetrate body tissue.Fluid penetration can
cause serious injury and possible death.Even a
pinhole size leak can also lead to serious personal
injury.If fluid is injected into your skin, you must get
J treatment immediately.Seek treatment from a doctor
that is f amiliar with this type of injury.
M medicines.
Replace the affected parts if any of the following
2 conditions are present:
8 • End f ittings are damaged or leaking.
•_Outer coverings are chafed or cut.
• Wires
j are exposed.
• Outer
mcoverings are swelling or ballooning.
• Flexible2parts of the hoses are kinked.
• Outer covers8 have exposed embedded armoring.
• End f ittings are
s displaced.
Make sure that all clamps, guards, and heat shields
z
are installed correctly.During machine operation, this
will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes, and
hoses.
Do not operate a machine when a f ire hazard
exists.Repair any lines that are corroded, loose, or
damaged.Leaks
may provide fuel for fires.Consult your SEM dealer
f or repair or replacement parts.Use genuine SEM
parts or the equivalent, for capabilities of both the
pressure limit and temperature limit.
Ether
Ether (if equipped) is commonly used in cold -weather
applications.Ether is flammable and poisonous.
Only use approved ether cylinders for the ether
dispensing system fitted to your machine. Do not
16
spray ether manually into an engine. Follows
the
correct cold engine starting procedures.
z
are replacing an ether cylinder.Do not store ether
cylinders in living areas or in the operator
compartment of a machine.Do not store ether
cylinders in direct sunlight or in temperatures above
49°C (120.2°F).Keep ether cylinders away from open
f lames or sparks.Dispose of used ether cylinders
properly.Do not puncture an ether cylinder.Keep
ether cylinders away from unauthorized personnel.
Fire Extinguisher and First Aid
Kit
In the event of injury or fire, take actions according to
the f ollowing precautions.
• Keep a f ire extinguisher on the machine. Read the
instructions carefully and make sure to know how
to use.
• Always have a f irst aid kit at the work site.Check
regularly and, J
if necessary, supplement some
M
• Know what to do in case
2 of a f ire or injury.
• Make available the phone
8 numbers of some people
(such as doctors, emergency centers, fire stations,
_
etc.) to contact in case of emergency.Put these
contact numbers in the specified places and make
j and the correct
sure all people know the numbers
method of contact.
m
Fire Safety 2
Note: Locate secondary exits and how to8use the
secondary exits before you operate the machine.
s
Note: Locate f ire extinguishers and how to use a f ire
extinguisher before you operate the machine. z
If you f ind that you are involved in a machine fire,
your safety and that of others on site is the top
priority.The following actions should only be
perf ormed if the actions do not present a danger or
risk to you and any nearby people. At all times you
should assess the risk of personal injury and move
away to a saf e distance as soon as you feel unsafe.
Move the machine away from flammables, such as
gas stations, buildings, garbage dumps, coverings
and wood.Lower any implements and turn off the
engine as soon as possible.If you leave the engine
running, the engine will continue to feed a f ire. Any
damaged hoses that are connected to the engine or
pump can cause a fire.
Turn the battery disconnect switch to the OFF
position, if possible.Disconnecting the battery will
eliminate the ignition source in the event of a short
 j j
m m
2 2
8 8
s the battery will eliminate a
circuit.Disconnecting Strap the mounting plate to a leg of the ROPSs in
second ignition source if electrical wiring is damaged order to mount the fire extinguisher, as needed.If the
z in a short circuit.
by the f ire, resulting weight of the fire extinguisher is more than 4.5 z
kg (10
lb), mount the fire extinguisher as low as possible on
Notif y emergency personnel of the fire and your
one leg.Do not mount the fire extinguisher at the
location.If your machine is equipped with a fire
upper one-third area of the ROPS leg.
suppression system, follow the manufacturer’s
procedure to activate the system. Note: Do not weld the ROPS structure in order to
install the f ire extinguisher.Also, do not drill holes in
Note: Fire suppression systems need to be regularly
the ROPS structure in order to mount the fire
inspected by qualified personnel.You must be trained
extinguisher on the ROPS.
to operate the fire suppression system.
Use the on-board fire extinguisher and use the Tire Information
f ollowing procedure:
Explosions of pneumatic tires have resulted from
1. Pull the pin. heat-induced gas combustion inside the
2. Aim the extinguisher or nozzle at the base of the tires.Explosions can be caused by heat that is
f ire. generated by welding, by heating rim components, by
external f ire, or by excessive use of brakes.
3. Squeeze the handle and release the
extinguishing agent. A tire explosion is much more violent than a
blowout.The explosion can propel the tire, the rim
4. Sweep the extinguisher from side to side across components, and the axle components from the
the base of the fire until the fire is put out. machine.Stay outside the area with f lying
J Remember, if you are unable to do anything else, objects.Both theJforce of the explosion and the flying
shut off the machine before exiting.By shutting off the debris can cause property damage, personal injury,
M machine, f uels will not continue to be pumped into or death. M
2 the f ire. Typical example of tire 2
is shown below.
8 Iff ollowing
the f ire grows out of control, be aware of the
risks:
8
_
• Tires on wheeled machines pose a risk of explosion
_
asj tires burn. Hot shrapnel and debris can be j
thrown great distances in an explosion.
m m
• Tanks, accumulators, hoses, and fittings can
rupture 2
in a f ire, spraying fuels and shrapnel over a 2
large area.
8 8
• Remember that nearly all of the fluids on the
machine are fs lammable, including coolant and oils. s
Additionally, plastics,
z rubbers, fabrics, and resins in z
Do not approach a warm or an apparently damaged
f iberglass panels are also flammable. tire.
Unauthorized Modification Caterpillar (Qingzhou) Ltd.recommends against
using water or calcium as a ballast for the tires except
Any modifications not approved by Caterpillar in machines designed for this additional mass.For
(Qingzhou) Ltd. may result in danger.Before those applicable machines, the maintenance section
modifying the machine, consult your dealer will contain instructions on the correct tire inflation
designated by Caterpillar (Qingzhou) Ltd.Caterpillar and f illing procedures.Ballast, such as fluid in the
(Qingzhou) Ltd.. assumes no liability for any tires, increases overall machine weight and may
damages resulting from unauthorized modifications. af f ect braking, steering, power train components, or
the certification of the protective structure such as the
Fire Extinguisher Location ROPS.The use of tire/rim rust preventatives or other
liquid additives is not required.
Make sure that a f ire extinguisher is available on the
machine.Be familiar with the operation of the fire
extinguisher.Inspect the fire extinguisher and service
the f ire extinguisher on a regular basis. Obey the
recommendations on the instruction plate.
Mount the f ire extinguisher in the cab.
17
 j j
m m
2 2
8 8
s Before Starting Engine s
z z
The steering frame lock must be in the unlocked
To avoid overinflation, proper nitrogen inflation
equipment and training in the usage of the position in order to steer the machine.
equipment are necessary.A tire blowout or a rim Start the engine only from the operator
failure can result from improper equipment or compartment.Never short across the starter terminals
from misused equipment, which could result in or across the batteries.Shorting could bypass the
personal injury or death.Due to the high pressure engine neutral start system.Shorting could also
of approximately 15,000 kPa (2,200 psi) in the damage the electrical system.
nitrogen tank when fully filled, improper use of
the inflation equipment can result in tire blowout Inspect the condition of the seat belt and the
and/or rim failure. condition of the mounting hardware.Replace any
damaged parts or worn parts.Regardless of
Dry nitrogen gas is recommended for inflation of appearance, replace the seat belt after three years of
tires.If the tires were originally inflated with air, use.
nitrogen is still preferred for adjusting the Do not use a seat belt extension on a retractable seat
pressure.Nitrogen mixes properly with air. belt.Adjust the seat so that full pedal travel can be
Nitrogen inflated tires reduce the potential of a tire achieved when the operator's back is against the
explosion because nitrogen does not aid back of the seat.
combustion.Nitrogen helps to prevent oxidation of the Make sure that the machine is equipped with a
rubber, deterioration of rubber, and corrosion of rim lighting system that is adequate for the job
components. conditions.Make sure that all lights are working
J properly.
J
To avoid overinflation, proper nitrogen inflation
M equipment and training in the usage of the equipment Bef ore you start theMengine or before you move the
are necessary.A tire blowout or a rim failure can result machine, make sure that
2 f rom improper equipment or from misused 2 no one is on the machine,
underneath the machine, or around the
8 equipment. machine.Ensure that there8are no personnel in the
When you inf late a tire, stand behind the tread and area.
_
use a self -attaching chuck.
_
j Visibility Information
j
Servicing tires and rims can be dangerous.Only
trained personnel that use proper tools and proper Bef ore you start the machine, perform a walk-around
m
procedures should perform this maintenance.
m
inspection in order to ensure that there are no
If correct 2 2
hazards around the machine.
procedures are not used for servicing tires
and rims, the assemblies could burst with explosive While the machine is in operation, constantly survey
8
f orce.This explosive force can cause serious
8
the area around the machine in order to identify
personal injury s
or death.Carefully obey the specific potential hazards as hazards become visiblesaround
instructions from your tire dealer. the machine.
z Bef ore operating the machine, ensure that the visual
z
Lightning Damage Prevention aids are in proper working condition and that the
When lightning is striking in the vicinity of the visual aids are clean.Adjust the visual aids using the
machine, the operator should never attempt the procedures that are located in this Operation and
f ollowing procedures: Maintenance Manual.It may not be possible to
provide direct visibility on large machines to all areas
• Mount the machine. around the machine.Appropriate job site organization
is required in order to minimize hazards that are
• Dismount the machine. caused by restricted visibility.Job site organization is
If you are in the operator’s station during an electrical a collection of rules and procedures that coordinates
storm, stay in the operator’s station.If you are on the machines and people that work together in the same
ground during an electrical storm, stay away from the area.Examples of job site organization include the
vicinity of the machine. f ollowing:
• Saf ety instructions
• Controlled patterns of machine movement and
vehicle movement

18
 j j
m m
2 2
8 8
• Workers that s
direct traffic to move when it is safe s
Move transmission control into the NEUTRAL
position.Engage the parking brake.
• Restricted areasz z
Diesel engine exhaust contains products of
• Operator training combustion which can be harmful to your
health.Always operate the engine in a well ventilated
• Warning symbols or warning signs on machines or area.If you are in an enclosed area, vent the exhaust
on vehicles to the outside.
• A system of communication Brief ly sound the horn before you start the
engine.Check for the presence of personnel.Ensure
• Communication between workers and operators
that all personnel are clear of the machine.
prior to approaching the machine
Modifications of the machine configuration by the Before Operation
user that result in a restriction of visibility shall be
evaluated. Ensure that there are no personnel on the machine or
in the area around the machine.
Restricted Visibility Remove any debris that builds up in and around the
hoses and fittings to reduce damage or wear to the
The size and the configuration of this machine may hoses and fittings.
result in areas that cannot be seen when the operator
is seated.The illustration provides an approximate Clear all obstacles from the path of the
visual indication of areas of significant restricted machine.Beware of hazards such as wires, ditches,
visibility.The illustration indicates restricted visibility etc.
J areas at ground level inside a radius of 12 m (40 ft) J
Ensure that all windows are clean.Secure the doors
f rom the operator on a machine without the use of
M optional visual aids.This illustration does not provide
and the windows inM the open position or in the shut
position.
2 areas of restricted visibility for distances outside a 2
radius of 12 m (40 f t). Adjust the rear view mirrors (if equipped) for the best
8 vision of the area near the8machine.

_ _ alarm (if equipped),

Ensure that the horn, the backup
and all other warning devices are working properly.
j Fasten the seat belt securely.
j
m m
Operation
2 2
Only operate the machine while you are sitting in the
8 8 while
operator seat.The seat belt must be fastened
you operate the machine.Only operate the controls if
s the engine is running. s
z While you operate the machine slowly in an open z
area, check for proper operation of all controls and all
protective devices.
Bef ore you move the machine, make sure that no
one will be endangered.Do not allow riders on the
machine unless the machine has an additional seat
with a seat belt.The rider must be seated and the
Note: The shaded areas indicate the approximate seat belt must be fastened.
location of areas with significant restricted
visibility. Never use the work tool for a work platform.Note any
needed repairs during machine operation.Report any
Engine Starting needed repairs.
Carry work tools at approximately 40 cm above
If a warning tag is attached to the engine start switch
ground level.
or to the controls, do not start the engine and do not
move any controls. Do not go close to the edge of a cliff, an excavation,
or an overhang.
Move all hydraulic controls to the HOLD position
bef ore you start the engine. Avoid operating the machine across the slope.When

19
 j j
m m
2 2
8 8
s the machine up the slopes and
possible, operate
Engine Stopping s
down the slopes.If the machine begins to sideslip on
z
a downgrade, immediately remove the load and turn z
Do not stop the engine immediately after the machine
the machine downhill. has been operated under load.This can cause
Avoid any conditions that can lead to tipping the overheating and accelerated wear of engine
machine.The machine can tip when you work on hills, components.
on banks and on slopes.Also, the machine can tip Af ter the machine is parked and the parking brake is
when you cross ditches, ridges, or other unexpected engaged, allow the engine to run for five minutes
obstructions.Maintain control of the machine.Do not bef ore shutdown.This allows hot areas of the engine
overload the machine beyond the machine capacity. to cool gradually.
Never straddle a wire cable.Never allow other
personnel to straddle a wire cable. Parking
Know the maximum dimensions of your machine. Park the machine on a level surface.If you must park
the machine on a grade, block the tires.Please
Fueling Machine consider the following factors:
• Size of tire
• Weight of machine
Ultra Low Sulfur Diesel (ULSD) poses a greater
static ignition hazard than earlier diesel • Condition of surface
formulations with a higher sulfur content, which Apply the service brake in order to stop the
J may result in a fire or explosion.Consult with machine.Move the J transmission control device (lever)
your fuel or fuel system supplier for details on to the NEUTRAL position.Move the throttle control to
M proper grounding and bonding practices. M
the low idle position.Engage the parking brake.
2 Lower all work tools to 2
the ground.Activate any
8 8
control locks.Stop the engine.
Turn the engine start switch to the OFF position and
_ _
remove the engine start switch key.
To avoid possible injury or death, do not smoke
j in an area that contains flammable liquids.
while j switch to the OFF
Always turn the battery disconnect
position before leaving the machine.If the machine
m most lubricants, and some coolants are
All f uels, m
will not be operated for a month or more, remove the
f lammable.
2 battery disconnect switch key. 2
Keep all f uels and lubricants stored in properly
8 and away from unauthorized
marked containers Slope Operation 8
persons. s s
The saf e machine operation in various applications
Fuel leaked or spilled onto hot surfaces or electrical depends on the following conditions:the machine
z a fire.
components can cause model, configuration, machine maintenance, z
operating speed of the machine, conditions of the
Store all oily rags or other flammable materials in a
terrain, f luid levels, and tire inflation pressures.The
protective container in a safe place.
most important criteria are the skill and judgment of
Remove all flammable materials such as fuel, oil, and the operator.
other debris before they accumulate on the machine.
A well trained operator that follows the instructions in
Do not expose the machine to flames, burning brush, the Operation and Maintenance Manual has the
etc., if at all possible. greatest impact on stability.Operator training provides
a person with the following abilities:observation of
Locate the fuel filler on the machine, and remove the
working and environmental conditions, feel for the
f iller cap.After fueling the machine, replace the filler
machine, identification of potential hazards, and
cap and lock the filler cap into position.
operating the machine safely by making appropriate
The f iller cap may be hot.To avoid injury, use decisions.
personal protective equipment.Allow the cap to cool
When you work on side hills and when you work on
bef ore fueling the machine.
slopes, consider the following important points:
Speed of Travel - At higher speeds, forces of inertia
tend to make the machine less stable.

20
 j j
m m
2 2
8 8
Roughness of s terrain or surface – The machine
may be less stable with uneven terrain.
z
Direction of travel – Avoid operating the machine
across the slope.When possible, operate the
machine up the slopes and down the slopes.Place
the heaviest end of the machine uphill when you are
working on an incline.
Mounted equipment – Balance of the machine may
be impeded by the following components:equipment
that is mounted on the machine, machine
conf iguration, weights, and counterweights.
Nature of surface – Ground that has been newly
f illed with earth may collapse from the weight of the
machine.
Surface material – Rocks and moisture of the
surf ace material may drastically affect the machine's
traction and machine's stability.Rocky surfaces may
promote side slipping of the machine.
Slippage due to excessive loads – This may cause
downhill tracks or downhill tires to dig into the ground,
J which will increase the angle of the machine.
Width of tracks or tires – Narrower tracks or
M narrower tires f urther increase the digging into the
2 ground which causes the machine to be less stable.
8 Implements attached to the drawbar – This may
decrease the weight on the uphill tracks.This may
_ decrease the weight on the uphill tires.The
also
decreased weight will cause the machine to be less
j
stable.
Heightmof the working load of the machine – When
the working loads are in higher positions, the stability
2 is reduced.
of the machine
8
Operated equipment – Be aware of performance
features of the equipment in operation and the effects
s
on machine stability.
z – Keep all attachments or
Operating techniques
pulled loads low to the ground for optimum stability.
Machine systems have limitations on slopes –
Slopes can affect the proper function and operation
of the various machine systems.These machine
systems are needed for machine control.
Note: Saf e operation on steep slopes may require
special machine maintenance.Excellent skill of the
operator and proper equipment for specific
applications are also required. Consult the Operation
and Maintenance Manual sections for the proper fluid
level requirements and intended machine use.
s
Work Tools
Only work tools recommended by Caterpillar z
(Qingzhou) Ltd. may be used on SEM machines.Any
use of work tools including buckets that are not
recommended by Caterpillar (Qingzhou) Ltd. or
whose weight, size, flow rate, pressure, etc. exceed
the specified specifications may result in diminished
perf ormance of the machine, including but not limited
to, reduced production, stability, reliability, and
component durability.Caterpillar (Qingzhou)
Ltd.recommends appropriate work tools for our
machines to maximize the value our customers
receive f rom our products.Caterpillar (Qingzhou) Ltd.
understands that customers may use work tools that
exceed our specifications under special
circumstances.In these cases, customers must be
aware that such choices can reduce the machine
perf ormance and can affect their warranty claims
when they detect premature failures on the machine.
Make sure to use work tools and work tool control
systems that are compatible with SEM machine for
J
saf e machine operation and/or reliable machine
operation.Consult your SEM dealer with any
M the compatibility of a
questions that concern
particular work tool with your machine.Make sure that
2
all protective guards are secured in place on the
machine and on the work 8 tools.
Secure all windows and doors _of the machine in the
shut position.A polycarbonate guard needs to be
installed when the machine is notj equipped with
windows and when a work tool that creates flying
objects is used.Do not exceed them maximum
operating weight as specified.If your machine is
2 the driver
equipped with an extendable stick, install
pin when you are using the following work 8
tools:When you are working with the hydraulic
hammers, augers and compactors, you should s
always wear the goggles.Always wear the protective
equipment that is recommended in the operation z
manual f or the work tool.Wear other protective
equipment that is required for working condition.To
avoid injury caused by flying objects, ensure that all
personnel are out of the work area.While you are
perf orming any maintenance, any testing, or any
adjustments to the work tool, stay clear of the
f ollowing areas:cutting edges, pinching surfaces, and
crushing surfaces.Never use the work tool for a work
platf orm
21
 j j
m m
2 2
8 8
s s
EquipmentzLowering with
Engine Stopped
Bef ore lowering any equipment with the engine
stopped, clear the area around the equipment of all
personnel.The procedure to use will vary with the
type of equipment to be lowered.Keep in mind that
most systems use a high pressure fluid or air to raise
or lower the equipment.The procedure will cause
high pressure air, hydraulic, or some other media to
be released in order to lower
the equipment.Wear appropriate personal protective
equipment and follow the established procedure in
the Operation and Maintenance Manual, “Equipment
Lowering with Engine Stopped” in the Operation
Section of the manual.
Sound Level Information
Ref er to the machine Operation and Maintenance
J Manual for the specific sound levels for your machine.
“ISO 6396:2008” is used to measure the value for an
M enclosed cab. The measurement was conducted at
the maximum engine cooling fan speed. The declared
2 dynamic operator sound pressure level is 83
8 dB(A).The sound level may vary at different engine
cooling fan speeds. The measurement was
_
conducted with the cab doors and the cab windows
closed.
j j system, and
Ref er to the machine Operation and Maintenance
mf or the specific sound levels for your
Manual
machine.2 The value is measured according to the
dynamic test procedures and the conditions that are
8
specified in “ISO 6395:2008”. The measurement was
conducted at thesmaximum engine cooling fan speed.
The declared exterior sound power level is 112
z may vary at different engine
dB(A).The sound level
cooling fan speeds.
When sound levels are specified using either
“ISO6395:2008” or “ISO 6396:2008”, the declared
level is a maximum sound level. The maximum sound
level includes both measurement uncertainty and
uncertainty due to production variation.
Hearing protection may be also needed when the
machine is operated with an open operator station
for extended periods or in a noisy environment.
Hearing protection may be also needed when the
machine is operated with a cab that is not properly
maintained, or when the doors and windows are
open for extended periods or in a noisy
environment.
22
Vibration Information z
Information Concerning Seat Vibration
The suspension seat meets the criteria of "ISO 7096".
This represents vertical vibration level under severe
operating conditions. This seat is tested with the input
"spectral class EM3". The seat has a transmissibility
f actor of “SEAT<1.0”.
Guidelines for Reducing Vibration Levels
on Earthmoving Equipment
Vibration levels are influenced by many different
parameters, such as: operator training, operator
behaviour, operator mode and stress, job site
organization, job site preparation, job site
environment, job site weather, job site material,
machine type, quality of the seat, quality of the
suspension system, attachments, and condition of
the equipment.
J
Properly adjust machines. Properly maintain
machines. OperateM machines smoothly. Maintain the
conditions of the terrain. The f ollowing guidelines can
help reduce the whole-body2 vibration level:
1. Use the right type and size
8 of machine, equipment
and attachments.
2. Maintain machines according _ to the manufacturers
recommendations: tire pressures and brake and
steering systems, controls, hydraulic
linkages.
3. Keep the terrain in good conditionm by performing
the f ollowing items: remove any large 2 rocks or
obstacles, fill any ditches and holes and provide
machines and schedule time to maintain 8 the
conditions of the terrain.
4. Keep the seat maintained and adjusted bysdoing
the f ollowing: adjust the seat and suspension for the
weight and the size of the operator and inspectzand
maintain the seat suspension and adjustment
mechanisms.
5. Perf orm the following operations smoothly: steer,
brake, accelerate, and shift the gears.
6. Move the attachments smoothly.
7. Adjust the machine speed and the route to
minimize the vibration level by doing the following:
drive around obstacles and rough terrain and slow
down when necessary to go over rough terrain.
8. Minimize vibrations for a long work cycle or a long
travel distance by doing the following: use machines
that are equipped with suspension systems, if no ride
control system is available, reduce speed to prevent
bounce and haul the machines between workplaces.
9. Less operator comfort may be caused by other risk
f actors. The f ollowing guidelines can be effective to
provide better operator comfort: adjust the seat and
adjust the controls to achieve good posture,
 j j
m m
2 2
8 8
s to minimize twisted posture,
adjust the mirrors
Product Information s
provide breaks to reduce long periods of sitting, avoid
z minimize repeated handling of
jumping from the cab, z
loads and lifting of loads and minimize any shocks
and impacts during sports and leisure activities.
General Information
Consult your local SEM dealer for more information The main mechanisms on SEM655D machine are
about machine features that minimize vibration levels. equipped with the following features and advanced
Consult your local SEM dealer about safe machine technologies:
operation.
• Equipped with reputable local brand engine that
Cab meets off-road Stage II emissions standards. The
optimized engine has a more reasonable match
Any modifications to the inside of the operator station with the drive train and a better efficiency.
should not project into the operator space or into the
space for the companion seat (if equipped).The • An articulated vehicle frame is used to achieve a
def ined operator and companion seat space (if small turning radius, mobility and flexibility. Easy to
equipped) will be maintained.if the addition of a radio, operate in narrow areas.
f ire extinguisher, and other equipment must be
installed.Any item that is brought into the cab should • The hydraulic mechanical transmission can
not project into the defined operator space or the automatically change the speed continuously
space for the companion seat (if equipped).Loose according to the external resistance, making full
items must be secured.Objects must not pose an use of the engine power, improving the mobility of
impact hazard in rough terrain or in the event of a the whole machine, simplifying the operation of the
loader, while protecting the engine and driveline
J rollover.
components. J
M • Load-sensing fullM
hydraulic steering, working and
2 steering combination2 for better energy-saving.
Fixed shaft power shifting transmission with
8 optimized technology by8Cat, and reliable working
device pilot hydraulic control make the operation of
_ _ the movement
the machine easy and flexible,
stable and reliable.
j j
• Equipped with service braking system, emergency
m m safe and
and parking braking system to provide
2 reliable braking performance, fully meeting
2 the
requirements of GB/T21152.
8 8
s s
z z

23
 j j
m m
2 2
8 8
s names of the machine
Component s
z z

J J
M M
2 2
8 8
_ _
j j
m m
2 2
8 8
s s
z z

24
 j j
m m
2 2
8 8
s
Diesel Engines standard, and the rollover protection cab is s
optional.The ROPS and FOPS can effectively protect
z
This machine is equipped with the six-cylinder, the operator's safety in the event of rollover andz
f our-stroke, water-cooled, turbocharged, ATAAC f alling objects.Modal analysis and test verification
engine. This engine provides the good cold start show that the cab with the damping system can
perf ormance, high altitude performance, low fuel greatly reduce the vibration and noise levels inside
consumption, low noise, reduced pollution emissions, the cab, and improve the comfort of the cab and the
high reliability and durability. operator's work efficiency.In order to give the
operator a good view when operating the machine,
Hydraulic System our designers equip the machine with glass windows
The hydraulic system is composed of pilot hydraulic and doors that are optimized in design.
system, implement hydraulic system, steering Sheets
hydraulics and drive train hydraulics.
Sheet metal components include engine hood,
The implement hydraulic system and steering
hydraulic system employ the double pump lubricating oil tank, diesel tank, hand rail etc.
combination technology, and steering hydraulic
system employs the variable system.The steering Electrical Systems
pump oil gives priority to the steering demand and
the remaining oil is supplied to the implement The electrical system of the machine is powered by
hydraulic system;When not steering, all the hydraulic two 12 v batteries in series, rated at 24 v.It contains
oil f rom both the steering pump and implement pump power supply system, starting system, control system,
is supplied to the implement hydraulic system. lighting system, instrument and indicator system,
J etc.Each controlJswitch controls individual appliance.
Driveline
M M Dataplate
Machine Product
The drive train includes the torque conveter, drive
2 shaf t, transmission and drive axle. 2 machine weight,
Product dataplate contains
maximum vehicle speed, engine model, engine
8 The transmission is a fixed shaft type, with four horsepower, machine size,8month and year of
f orward gears and four reverse gears.
_
The SO28 drive axle is equipped as the standard. It
_
Manuf acture, manufacture information,product
identification number, etc.
hasjone-stage gear reducer and one-stage planetary j
gear reducer.
m m
Cooling System
2 2
Three-module radiator is used for independent
8 coolant, hydraulic oil and drive oil
cooling of engine 8
respectively.
s s
Ensure an optimized heat balance between water
z and an optimized working
and oil temperature z
temperature for each component. Maintain the fluid
Brand(A)____________________________
quality within the lifecycle of the components.
Machine Mass(B)_____________________
Brake System
Engine Model(C)_____________________
The braking system consists of the service brake and
parking brake.The service braking system is a Dimension(D)________________________
double-circuit caliper disc type. When the braking Product Identification Number(E)_________
pedal is depressed, the compressed air from the air
cylinder enters the air booster pump through the Model(F)____________________________
braking valve, and the braking oil enters the brake to Max Nominal Speed(G)________________
stop the machine;The parking brake is a drum type
brake installed on the transmission output shaft Engine Power(H)_____________________
f lange. The parking brake is engaged by the Manuf acture Date(I)___________________
operation of the manual brake lever.
Local regulation may require documentation of the
Cab Month and/or Year of manufacture in the Opeation
and Maintenance Manual. Enter on line (I) above if
The cab with f resh air system is equipped as a required.
25
 j j
m m
2 2
8 8
s main technical
Usage and s
parametersz z

J J
M M
2 2
8 8
_ _
j j
m m
2 Attention 2
This section8is of great significance for the correct use, maintenance and repair of the machine8
s s
z z

26
 j j
m m
2 2
8 8
Purpose s s
z construction machine mainly used for handling of bulk material.Mainly used for:digging,z
This loader is a large
levelling, bulldozing, loading and dumping, towing operation.

Working environment requirements

1 Altitude:≤3000m
2 Ambient Temperature: Ambient Temperature: Standard Configuration -15℃~43℃ ( If not equipped with high
ambient radiator or pre-heater.)
3 Fording Depth:≤650mm

This loader is a general construction machine and is not applicable to flammable, explosive, high dust or toxic gas
environment.
Restricted Operation
1 Use with overload.
2 Lif t heavy objects with lifting sling hanging directly on the bucket tip.
3 Lif t the bucket and excavate over the machine.

Attention
The precautions regarding the operation, maintenance and safety regulations provided in this manual are
J only applicable to the machine used for specified purposes.Caterpillar J(Qingzhou) Ltd.. will not take any
M safety liabilities if the user uses this machine outside the scope of use speci
M fied in this manual. The use
will take the safety liabilities in such operations.Under no circumstances, the operations forbidden in this
2 manual shall be taken. 2
8 Main specifications 8
_ SEM655D Loader Technical Parameters _
Mainj Parameters j
Rated mload kg 5000 m
Operating 2weight kg 16,800 2
Standard Bucket Capacity m3 2.7
8 8
Full load bucket capacity (110% fill factor) m3 2.97
Max gradability
s ° 27
s
Dimensions
z z
Machine Length mm 8,085
Bucket Width mm 2,963
Machine Height mm 3,463

Operational Parameters
Maximum Breakout Force kN 177
Maximum Dumping Height mm 3,072
Dump Reach mm 1,462

Maximum Height of B Pin mm 4162

Steering Angle ° 38±1
Minimum turning radius (over tire) mm 3,225

Minimum Turning Radius (over bucket) mm 6,732

27
 j j
m m
2 2
8 8
Depth of Cut s mm 32 s
Overall Dimensions z z
Wheelbase mm 3,200
Overall Height (Maximum lift of bucket with no mm 5,315
load)
Overall Height Cab mm 3,463
Overall Height Muffler mm 3,245

Overall Height Engine Hood mm 2485

Minimum Ground Clearance mm 468

Engine
Emission Stage II
Diesel Ratings kw 162

Net Power kw 147

Rated diesel engine speed r/min 2000
Bore x Stroke mm 126×130
J Displacement L
J 9.726
M Maximum diesel engine torque @ rpm N.m/rpm M 975/1200-1400
2 Fuel consumption rate under standard d iesel g/kw.hr 2 210
engine conditions
8 Diesel engine fan diameter (blower) mm
8 780
_ _
j
Transmission j
m Type
Transmission m
Fixed shaft power shifting

2 gears
Transmission F4/R4 2
Transmission oil p ump (gear pump) operating Mpa 1.6+0.2
pressure 8 8
Torque converters type Single-stage three element centripetal s
z
Torque converter conversion factor 3.2±0.05 z
Cooling of torque converter Air cooling with pressure circulation
Manufacturer and model TR200

Operating Speed
Forward gear I speed km/h 7.9
Forward gear II speed km/h 15
Forward gear III speed km/h 23

Forward gear IV speed km/h 39

Reverse I speed km/h 7.9
Reverse II speed km/h 15

Reverse III speed km/h 23

Reverse gear IV speed km/h 39

28
 j j
m m
2 2
8 8
s
Working Hydraulic System s
Implement pump model z W273400000 z
Implement distribution valve model Dual valve stem type
Number of boom cylinders-inside diameter X mm 2-Φ170×721
stroke
Number of bucket tilt cylinders-inside diameter X mm 1-Φ190×563
stroke
Implement model Z-type linkage

Hydraulic Cycle Times

Boom raise time s 5.13
Dump s 1.07

Lower s 3.32
Sum of three implement actions s 9.5
Implement pump

Implement pump displacement ml/r 100

Operating pressure of the implement system Mpa 17
J J
M Brake System M
Service brake type
2 2Disk/Caliper
Parking brake type Shoe/drum
8 Diameter of brake drum mm
8 328
_ _
j System
Steering j
mHydraulic System type
Steering msteering
Co-axial flow-amplified

Number of2 steering cylinders-inside diameter X mm 2-Φ90×324 2

stroke
Steering pump8type 8
Variable Displacement Piston Pumps
s of the steering hydraulic
Operating pressure Mpa 16 s
system
z z
Steering Angle ° 38±1

Drive axle
Main drive type Single stage spiral deceleration
Hub reducer type Single stage planetary reducer
Gear Ratio 22.85
Main drive reduction ratio 4.63

Hub Reduction Ratio 4.94

Oscillation Angle ° ±11

Tires
Tire Model 23.5-25

29
 j j
m m
2 2
8 8
Tire Model s Bias s
Ply z 16 z
Tread pattern L3/E3
Tire Air Pressure Mpa F:0.45 R:0.3

Fuel refill capacity L 253

Hydraulic oil refill capacity L 165
Coolant L 48
Crankcase refill capacity L 21

Transmission system refill capacity L 53

Differential and final drive
Front axle refill capacity L 36

Rear axle refill capacity L 36

Electrical System Voltage v 24

J Battery model J 6-QW-120B

Bulb voltage v 24
M M
Diesel engine starting type Electric Start
2 Working medium of air conditioning system
2 R134a
8 Heating capacity of air conditioning system kilowatt
8 5
_ capacity of air conditioning system
Cooling kilowatt _
4.5

j of air conditioning system

Voltage v 24 j
m m
2 2
8 8
s s
z z

30
 j j
m m
2 2
8 8
s Section
Operation s
z z

J J
M M
2 2
8 8
_ Attention
_
j
Before operating this machine, please read
j
m and understand the content of this
carefully m
manual so that you can operate the machine
2
correctly.Correct operation is critical to ensure 2
safety, achieve high work efficiency, and increase
8 of the machine.
the service life 8
s s
z z

31
 j j
m m
2 2
8 8
s
Control devices and monitoring system s
z z
Layout of the in-cab control devices and monitoring system of SEM655D

J J
M M
2 2
8 Symbol Description Function
8
_ _
Coolant Temperature Warning Engine coolant temperatures in the green area are normal and
j Lamp those in the red area are high. j
m Transmission Oil Temperature
m
Turns on when the transmission oil temperature is too high.
2 Warning Lamp 2
8 8
s LED Display Display working time
s
z z

Engine RPM/Fuel Gauge Display RPM/ Fuel Level

Steering Left Indicates the machine is turning left

Steering Right Indicates the machine is turning right

Braking Air Pressure Indicator Illuminate when braking air pressure is too low.

32
 j j
m m
2 2
8 8
Symbol s Description Function s
z The indicator light illuminates when the diesel engine is running
to indicate that the alternator is not supplying power and the
z
Charging Indicator engine needs to be stopped and checked immediately; It is
normal for the lamp to be illuminated when the engine is not
running

Engine Oil Pressure Indicator Alarm when oil pressure is above or below normal value

Drive train oil pressure Illuminate when oil pressure is abnormal

Low Beam Lights Low beam lights are on

Parking Brake Indicator Lamp turns on when the hand brake is engaged

Preheat Indicator Preheating indicator before engine start

J High Beam Lights High beam lights are on

J
M M
2 Water in oil warning light
2
Indicates the primary filter needs to be drained
8 8
_ _
The indicator light flashes when damage to the component
Level Two or Three Warning Lamp occurs, or certain operation needs to be stopped immediately, or
j potential accident exists. j
m m
The light turns on when the engine fails Need to stop and check
2 Engine Fault Indicator
immediately 2
8 8
s Economy Mode The power switch is in economic mode s
z z
Heavy Duty Mode The power switch is in heavy duty mode

33
 j j
m m
2 2
8 8
s s
z z

J J
M M
2 2
8 1. Front Work Lights
6. Rear wiper
2. Rear Work Lights
7. Rear washer 8. Alert Lamp
3. Emergency Light 4. Front 8wiper 5. Front washer

_ _
j j
m m
2 2
8 8
s s
z z

1. Steering Wheel 2. Shifting control lever 3. Horn switch 4. accelerator pedal 5. Start Switch 6.
Parking Brake button 7.Pilot handle 8. Switch valve 9.Shut-down control lever 10. High/low speed control
lever;

34
 j j
m m
2 2
8 8
Shut-downscontrol lever s
Attention
z lever is located on the control
The shut-down control z
console. The engine will shut down 3-6 seconds after The switch key can only be inserted or removed
the lever is pulled up. in this OFF position.

Parking Brake Knob
The parking brake button is located on the control
console.When the button is pulled up, the parking
brake is engaged and braking is applied;When it is
pushed down, the parking brake is released and the
braking is removed.
The parking brake also serves as the emergency
brake.In case of emergency during the operation of
the machine, manually pull up the parking brake
button to apply emergency brake.
If there is a malf unction in the service brake system,
and the air pressure in the service brake circuit is less
than 0.4Mpa, the parking brake will engage
automatically.The loader will take emergency stop to
ensure saf e operation.
J Start switch
3. ON -- The f irst position the starting switch key
reaches when it is turned clockwise after it is
inserted into the switch.In this position, the
electrical system of the whole machine is
powered on and functions normally.
4. START -- The second position the starting switch
key reaches when it is turned clockwise after it is
inserted into the switch.Start the machine with
this position. The starting motor is powered on
and starts the engine. Please release the starting
switch key immediately after the engine is started
successfully. As this position can not be held
automatically, the starting switch key will turn
back to the ON position of the starting switch after
it is released.
J Attention

M The starting switch (also called electric lock) is

Please make sure Mthe negative switch is in the ON
position and the speed control lever is in the
2 located on the control console. The switch has four 2 starting the engine.
neutral position before
positions, which, in clockwise order, are as follow.
8 8
_ _
If the engine fails to start, the starting switch
j must be turned to the OFF j position before
starting the engine again. Otherwise damage to
m the starting switch may occur. m
2 2 than 15
Each starting attempt must not be longer
seconds. Wait at least 30 seconds between two
8 8
starting attempts, and the number of consecutive
s s
starting attempts must not exceed 3 times.After
three starting attempts, the starting motor and
z shut-down electromagnet should be allowed z to
cool down completely before starting again.
Otherwise the service life of the battery will be
shortened, and damage to the starting motor and
shut-down electromagnet can also occur.
1. Accessory -- Turn the key counterclockwise to When starting on a high slope, do not use the
this position after it is inserted into the starting power cut-off function to ensure safety.
switch. This position is self-restoring (returns
back to the OFF position automatically when
released).
Accelerator Pedal
2. OFF -- When the switch is in this position, the
power supply control circuit of the whole machine The acceleration pedal is located in front of the
is cut off, and only the roof light and horn still driver's seat, on the right side.When the pedal is in its
f unction normally. natural position, the engine will idle.When the
acceleration pedal is depressed, the fuel supply to
the diesel engine is increased for a bigger power
output of the diesel engine.

35
 j j
m m
2 2
8 8
Switching sValve During loading operation, make full use of the s boom
f loat device and bucket auto-levelling device to
z z
ef f ectively reduce the work load of controlling the
work tools and increase the comfortability of
operation.
Kick Out
Af ter dumping at the highest position, move the
handle to the tilt back position, and the joystick will be
locked. The handle will move to hold position
automatically when the bucket is kicked out. Then
move the handle to the lower position and place the
bucket on the ground. The kick out function improves
the working efficiency.

Before the operation of the boom and bucket, it

Located on the control console. During normal
operation, the switch valve button is in the ON
position, and the transmission power will be cut off
J during braking to avoid the slipping of the
transmission clutch and increase the service life of
M the transmission. During slope operation, the switch
2 valve button is in the OFF position, and the
transmission power will not be cut off during braking
8 to prevent the danger caused by sudden failure of the
service braking and ensure safe operation.
_ _
High/low speed control lever
j j under the
Push f orward to get high speed and pull backward to
mspeed. The middle position is neutral.
get low
2 can operate the machine in forward gear 2 I, gear
Pilot control handle
8 handle is installed on the control
The pilot control
console.It is used to control the working device. Move
s to raise the boom;move it
the handle backward
z boom;move left to rollback the
f orward to lower the
bucket;move right to dump the bucket.The natural
state of the handle is in the HOLD position, i.e. the
middle position.
Push the pilot control handle forward to the foremost
position to put the boom in the float state. Pull the
pilot control handle back to the middle position to
remove the boom float state.
must be confirmed that there is no obstacles or
personnel around, over and below the machine,
otherwise damage to the equipment or personal
injury may occur, whatever state the machine is
in!！！
J
M
Horn switch
2
The horn switch is in the middle of the steering wheel.
Push the horn switch and 8 the horn will sound.
Shifting control lever
The shif ting control lever is installed
steering wheel.Moving the lever forward or backward,
in combination with the high/low speedm control lever,
II ,gear III and gear IV;reverse gear I, gear II, gear III,
gear IV and neutral. 8
When the high/low speed lever is in the lows speed
position, push the shifting control lever f orward, the
z
f irst position is forward first gear, and the second
position is forward second gear; push the shifting
control lever backward, the first position is reverse
second gear, and the second position is reverse one
gear. When the high/low speed lever is pushed to the
high speed position, the machine gears can be set in
f orward third and fourth gears, backward third and
f ourth gears follow above operation.

When lowering the boom, the pilot control handle can
be pushed to the float position, and the boom will
drop under the action of gravity.At this time, the right
hand of the operator can perform other operations
(e.g. levelling the bucket) to increase work efficiency.
During scraping or loading operation, push the pilot
control handle to the float position to allow the bucket
to f ollow the ground contours and avoid damage to
the ground surface.
Steering Wheel
The machine uses articulated coaxial flow
amplification steering with the steering
wheel installed in the cab. The steering
wheel is connected with the coaxial flow
amplification steering gear.During normal operation,
turning the steering wheel clockwise will cause the
machine to turn right;turning the steering wheel
counterclockwise will cause the machine to turn left.

36
 j j
m m
2 2
8 8
The coaxial flow samplification steering has the
f ollowing features:
z
1. The angle the steering wheel turns is not equal to
the angle the machine turns. Turn the steering
wheel continuously will increase the turning angle
of the machine until it reaches the desired
steering position.
2. The f aster the turning speed of the steering wheel,
the f aster the machine turns.
3. The steering wheel will not restore to the original
position automatically after it is turned and the
machine will hold the turning angle.Therefore,
when the steering of the machine is completed,
the steering wheel should be turned in the
opposite direction so that the machine can drive
in a straight direction.
BRAKE PEDAL
The service brake pedal is located in front of the
operator's seat on the left.When the service brake
pedal is depressed, the frond and rear drive axle
J wheel brakes will engage to brake.The braking light
switch will be turned on at the same time to illuminate
M the braking light.Release the service brake pedal will
2 disengage the service brakes.
8 In case of braking system malfunction, the repair
should be performed in a timely manner to ensure
_
enough braking capability of the machine.
Battery
j negative switch
m negative switch in installed in the battery
The battery
case on the right side of the loader and can be seen
2
once the battery case cover is opened.
8 8 the
s and the rear combination lights include the rears small
z light.
OFF status of the negative switch:
To cut off the power supply for the electrical system of
the whole machine, it is necessary to turn the
negative switch handle counterclockwise to the OFF
position.
When the negative switch is in OFF status, the
s
handle of the switch points to the right bottom
direction of the negative switch mounting plate.
ON status of the negative switch:
z
Bef ore starting the machine, the negative switch
handle must be turned clockwise to the ON
position.When the negative switch is in ON status,
the handle of the switch points to the left bottom
direction of the negative switch mounting plate.
The negative switch is different from the starting
switch.Turning off the negative switch will turn off the
electrical system of the whole machine.However,
when the starting switch is turned off, the battery is
still connected to the electrical system of the whole
machine and some electrical components can still
f unction.
When the whole machine is shut down and
during flushing of the machine, the negative
switch needs to be put in the OFF position.
J
Do not turn off the battery negative switch when
the engine is stillM
running. Otherwise damage to
the electrical system of the whole machine can
occur!！！ 2
8
_
Lighting of the whole machine
The lighting of the whole machine j consists of the
f ront combination lights (one piece on each side),
rear combination lights (one piecem on each side),
indoor light, fog-proof light (one on each side), rear
working light (one on each side) and the2 beacon.
Of which, the front combination lights include
headlights, front small lights, and front turning lights,
lights, rear turning lights, braking light and backup
z
Air conditioning system switch
The air conditioning system of the machine has three
functions, including cooling, heating and natural wind.
Air conditioning control panel
The air conditioning control panel is located in the
bottom of the seat on the left of the evaporator.As
shown in the f igure below.
37
 j j
m m
2 2
8 8
s s due to
radiator plumbing can be f rozen and cracked
the low temperature.！！
z z
Backup automatic alarm system
The backup alarm is mounted on the rear sealing
plate. When the steering and shifting lever is
operated to reverse the machine, the backup alarm
will sound automatically.

Turn the air volume switch clockwise to increase the

air volume and counterclockwise to reduce the air
volume. There are three air volume positions, i.e.
high, medium and low. Turn the switch to the OFF
position to turn off the fan.
The selection switch has two positions, natural wind
(O position) and cooling (AC position).
The specific functions and operation instructions are
as f ollow:
Cooling:
J 1. Move the air volume switch to a suitable air
M volume position after starting the engine.
2 2. Turn the selection switch clockwise to the cooling
position.
8 The ref rigerating system will start to work and cold air
_ f low out of the air outlet.
will
Heating:
j j
1. Move the air volume switch to a suitable air
m position after the engine has been started
volume
f or a period
2 of time.
2. Turn the selection switch counterclockwise to the
8 position (O position). The heating
natural wind
system will start
s to work and hot air will f low out of
the air outlet continuously.
Natural wind:
z z
The air conditioning system of the machine is
equipped with internal and external circulation
devices. In cool seasons like spring and autumn,
when you only need the natural wind and use it to
adjust the air f low in the cab, turn the air volume
switch to a suitable position and turn the selection
switch to the natural wind position.
The backup alarm is close to the radiator. When
adjusting the sound volume of the backup alarm,
the engine must be shut down and protection
against high temperature must be used to avoid
burning.！！
Usage of Cat® Product Link
Communication Devices
Cat ® Product Link communication device
uses cellular andJsatellite positioning technology
to communicate the information to Caterpillar
M
(Qingzhou) Ltd., Caterpillar (Qingzhou) Ltd. dealers,
and Caterpillar (Qingzhou) Ltd. customers. The
2
inf ormation may include: device serial numbers,
device locations and work8 data, fault codes, etc.
which will be used to provide services to customers,
_ help maintain
detect the health of equipment,
equipment, and improve equipment efficiency.
m
For machines equipped with Cat®2Product Link
device, if electric detonators are used in the
blasting operation, the radio frequency 8 device
will interfere with the electric detonators, causing
serious injury and death. The communication s
device shall be deactivated within the distances
mandated by applicable national or regional
regulations. In the absence of regulatory
requirements, Caterpillar (Qingzhou) Ltd.
recommends that users to conduct their own risk
assessment to determine the safe operating
distance.

Since our device uses satellite positioning and

When the ambient temperature is below 0°C and the
engine is not working, if antifreeze is not added to the
engine coolant, the engine water tank should be
emptied, and the hot water valve and
electromagnetic water valve should be opened to
drain the coolant in the evaporator. Otherwise the
cellular technology for communication, our
communication device may not work properly in
areas or periods where or when there is no
communication signal, communication signal is
weak, communication signal is unstable, or is
susceptible to interference. Caterpillar (Qingzhou)
Ltd. does not bear any liability for problems
arising from this, including device not being able

38
 j j
m m
2 2
8 8
to function sproperly and receive remote s
commands (including shutdown or start
commands) or userz notices, and the resulting z
personal injury or property damage.

Driver seat adjustment

The operator seat on this machine can be adjusted in
terms of hardness and softness (i.e. stiffness),
f orward and backward position, backrest angle and
headrest height to accommodate the needs of Height adjustment
different operators and different working situations.
The seat height can be adjusted between three
positions. When the seat is at its lowest position, it is
in position 1. Lift the cushion with hand until a click is
heard, and the seat in position 2. Lift f urther up until a
click is heard and the seat in position 3. Lift further to
the highest point (neutral position) and release, the
seat will return to position 1 automatically.

J J
M M
2 2
8 8
_ _
2. Armrest adjustment
j j
Turn the adjustment wheel below the armrest
m clockwise to lower the armrest andm counterclockwise
to raise it. (Note: The armrest is used to support the
2 arms and must not be used to support2other heavy
objects. Breakage of the armrest can occur.
8 8
s s
z z

1. Weight adjustment
Turn the adjustment handle according to the weight
of the user. Turn the handle clockwise to increase the
weight adjustment scale and the other way to reduce, Mechanical handle seat adjustment
until you f eel comfortable. For weight adjustment, method
ref er to
1. Forward and backward Adjustment
damper stiffness adjustment reference table.
Pull up the forward and backward adjustment handle,
move the seat back and forth, and release the handle.
The seat will lock to a desired position automatically.

39
 j j
m m
2 2
8 8
s lockout mechanism locks securely. s
3. When the weight adjustment scale reaches the
z z
red warning line, it must not be adjusted further.
Use of the door lock
If the door lock is engaged, the key cylinder can not
be pushed down.At this time, insert the key and turn
180°in clockwise direction before removing the key.
Hold the door lock with the thumb pushing down the
key cylinder and pull the door outward to open the
Damper stiffness adjustment reference table door.To lock the door, first close the door, then insert
the key and turn 180°in the counterclockwise
direction before removing the key.
Use of the position lock
Open the door to the 90°position. The position lock
on the door will contact the buckle outside the cab
and lock the door to this position.Hold the inside door
handle with your hand with the thumb pushing down
the key cylinder.Pull the door outward at the same
time to open the door.

J J
M M
The doors and windows must be closed when the
2 driver is operating the2machine to ensure safety.

8 Mirror adjustment 8
_ There is one mirror in the top_ of the cab, and one on
each of the left and right side of the cab. Before
2. jBackrest Angle Adjustment operating the machine to perform j any work, the
Whilem mirrors must be adjusted to ensure the driver has a
seated in the seat with the back rested against
good rear view.
m
the backrest, pull up the backrest adjustment handle
2 and lean forward or backward until the
with lef t hand, 2
Loosen the bolt connecting the mirror bracket and the
backrest is in a comfortable position before releasing cab, and move the bracket to adjust the mirror
the handle. 8 8
position relative to the cab; Loosen the connecting
s bolt between the mirror and the bracket, andsmove
the mirror to adjust the angle of the mirror.Tighten the
z bolts after the adjustment is complete. z
Run-in of new machine
The run-in of new machine is of great importance for
increasing the service life of the machine, eliminating
potential failure trouble, and avoiding severe
f ailures.After buying the machine, the user must
perf orm the operation and maintenance of the
machine according to the new machine run-in
Caution Statement procedures specified in this manual before normal
1. During the forward and backward adjustment and use of the machine.
the backrest angle adjustment of the seat, the
adjustment handle should be pulled to the correct
Run-in requirements of the new machine
position to make sure the lockout teeth is 1. The run-in period of the new machine is 10 hours.
disengaged completely before performing the
adjustment. 2. Idle the machine f or 5 minutes after starting.

2. Af ter the adjustment, the handle should be 3. During the run-in period, each of the forward I, II,
returned to the correct position to make sure the III, IV and reverse I, II, III, IV gears should be

40
 j j
m m
2 2
8 8
used evenlysfor run-in.
4. The machine should start with low speed and
z
small throttle, and accelerate gradually.Sudden
starting, accelerating, turning and braking should
be avoided unless in case of emergency.
5. During the run-in period, it is preferably to load
some loose material and the operation must not
be too hard and too quick.During the run-in
period, the loading weight must not exceed 70%
of the rated load and the travelling speed must
not exceed 70% of the rated maximum machine
speed.
6. Pay attention to the lubrication of the machine.
Replace or add lubricating oil or grease as per
the specified time interval.
7. Frequent attentions must be paid to the
temperatures of the transmission, torque
converter, front and rear axle, wheel hub, parking
brake, central supporting shaft, hydraulic oil,
engine coolant and engine lubricating oil. If
overheating is found, identify the cause and
J repair as necessary.
M 8. Check the bolts and nuts of all components for
tightness
2 appropriate operation2 specifications should be
Perform the following after eight hours of run-in
8 of the new machine:
_ Completely check the bolts and nuts of all
1.
components for tightness, especially the diesel
jengine cylinder head bolts, exhaust pipe bolts,
f ront and rear axle mounting bolts, rim nuts,
m shaft connecting bolts, diesel engine
driving
mounting
2 bolts, transmission mounting bolts,
f ront and rear f rame articulation bolts etc. should
be checked8 completely once.
s
2. Check the tension of the fan belt, engine belt and
air conditioning compressor belt.
z
3. Check the oil level of transmission oil, drive axle
oil and diesel engine oil.
4. Check the hydraulic system and braking system
f or leak tightness.
5. Check all the control levers and acceleration
lever f or secure connection.
6. Check the temperature and connection of
components in the electrical system, check the
power supply of the alternator, and check the
lamps and turning signal lights etc. for normal
operation.
over: s
1. Completely check the bolts and nuts of all
components for tightness, especially the diesel
z
engine cylinder head bolts, exhaust pipe bolts,
f ront and rear axle mounting bolts, rim nuts,
driving shaft connecting bolts, diesel engine
mounting bolts, transmission mounting bolts,
f ront and rear f rame articulation bolts etc. should
be checked completely once.
2. Check the tension of the fan belt, engine belt and
air conditioning compressor belt.
3. Check the hydraulic system and braking system
f or leak tightness.
4. Change the transmission oil and drive axle
lubricating oil.
5. Replace the f ilter elements of the transmission oil
f ilter, diesel engine oil filter and diesel fuel filter.
6. Clean the oil drain f ilter element of the hydraulic
oil tank.
J Attention
M transmission oil, drive axle
When changing the
lubricating oil and diesel engine oil, the
followed.
8
_
Operating Precautions
j
1 Before starting themengine
2
Job Site Safety
8 around
• Bef ore starting operation, check the area
the machine carefully for any abnormal conditions
that may cause danger. s
z site
• Check the terrain and ground surf ace of the job
and determine the best and safest operation
method.
• Bef ore starting operation, prepare the ground
surf ace as solid and level as possible.If there is
heavy dust at the job site, water should be sprayed
bef ore starting operation.
• If the job is to be completed on the street, there
must be a special person to direct the traffic, or a
f ence should be set up with the "Do not enter" sign
to protect the pedestrians and vehicles.

Attention
When checking the oil levels, the appropriate
operation specifications should be followed.
Perform the following after the run-in period is
41
 j j
m m
2 2
8 8
• For sites withsburied facilities underneath, such as • Adjust the operator seat to a position where
s easy
water pipe, gas pipe, high voltage cable pipe, the operation can be performed. Check the seat belt
relevant authority z should be contacted to locate the and the mounting hardware for damage.The z seat
buried facilities.And attentions should be paid not to belt must be replaced after three years of use.
damage these facilities during the operation.
• Check all the instrumentation for normal operation.
• When working in water or passing sand bank, Check if the control levers are in the correct
check the surface condition, water depth and water position.
f low velocity first.The allowed fording depth must
not be exceeded.When working in puddle or • Remove all the dirt on the window glass and lights
swamp site, the water depth must not exceed the to ensure good visibility.
bottom of the axle housing.Clean and check the • Adjust the position of the mirrors so that best views
lubrication check points after the operation is can be achieved from the operator seat.Clean the
complete. surf ace of the mirrors.Replace the glass of the
mirror with new one if damaged.
• Check the headlights and working lights for proper
illumination.Repair if any abnormal results are
f ound.
• A f ire extinguisher must be available and its use
method must be mastered.
• Do not place the machine close to open fire.
J J
M 2 When starting M the engine
2 • Bef ore mounting the 2 machine, perform another
walk-around inspection of your machine and check
8 8 on, below or near the
f or any personnel or objects
machine. Check if there is any person in the
_ working area.
_
Checks before starting the engine
j
Perf orm the following checks everyday before
j
• If a "Do not operate" warning message is attached
mthe engine.Failure to perform these checks
starting m
to the control lever, the engine must not be started.
may lead to serious injury or damage. • Sound the horn when starting the engine
2 2 to give an
• Check the area around the engine and battery for alert.
buildup of 8
flammable material, check for fuel, 8
• The engine can only be started and operated with
lubricating oil and hydraulic oil for leaks, and check
s rails and steps for contamination
the mirrors, hand
the operator sitting in the operator seat. s
by f uel. z • No person other than the operator should stay z in
the cab.No one is allowed to sit on the machine
• Do not leave parts and tools around the operator body.
seat.Due to the vibration during travelling and
operating, these objects may fall down and cause • The engine can only be started within the cab.
damage to the control levers or switches, or cause Never start the engine by short-circuit the starting
the control levers to move to start the work tools, motor, which will lead to damage to the electrical
which will result in accidents. system of the machine by starting the system with
bypass circuit.In addition, this operation is very
• Bef ore mounting the machine, remove the dirt and dangerous.
f ine sands attached to the shoes, as they will
accumulate at the supporting points of the
acceleration pedal and braking pedal, preventing
the pedals returning to the original positions.If there
is dirt and sand accumulation at these points, it
should be removed immediately.
• Check the coolant level, fuel level and the oil level
in the engine oil pan. Check the air filter for
plugging and the wiring for damage.

42
 j j
m m
2 2
8 8
• Make sure thesbackup alarm, if equipped, functions
properly.
z z
Attention
One starting attempt should not be longer than 15
seconds (the time that the starting motor works
continuously should not exceed 15 seconds). If
the starter does not start the engine after 15
seconds, the starting switch should be released
immediately. Wait at least 30 seconds before
another starting attempt.This is jointly
determined by the features of the starting motor
and the battery. If the engine fails to start after
three consecutive attempts, it should be checked.
After the malfunction is corrected, and at least
three minutes later, the engine can be started
again.
• The engine should run at idle speed to warm-up
af ter starting(at least 5 minutes recommended)
• Listen to check if the engine operates properly
while it is running at low speed, and check the
J transmission of abnormal noise.
M • Check all the instrumentation for proper operation,
and check the lighting devices, indicators, horn,
2 wipers, braking lights for proper operation.
8 Attention
_ the cab.No one is allowed to
Special attention should be paid to the
instrumentation panel for engine malfunction
j
indicator lamps.
m
• In f reezing seasons, preheating of the hydraulic oil
should 2
be performed.Pull back the pilot valve
bucket control lever and hold it in position for 4-5
8
minutes. Meantime, increase the throttle to keep
the stop block of the bucket against the boom and
s oil to overflow, which will
make the hydraulic
increase the hydraulic
z oil temperature rapidly.
• Check the service brake and parking brake system
f or proper operation.
• If there is no obstacles around the machine, turn
the steering wheel slowly to see if the machine
turns accordingly.
3 After starting the engine
Checks after starting the engine
Failure to perform the appropriate checks after
starting the engine will delay the discovery of the
abnormal phenomena.And this can result in serious
injury or machine damage.
When conducting the checks, it should be performed
in an open area without obstacles.No one should get
close to the machine.
• Check the operation of the instrumentationsand
equipment. Check the operation of the bucket,
boom, braking system, driving system and steering
system.
• Check the machine for unusual noise, vibration,
heating, smell or instrumentation operation. Check
f or hydraulic oil, lubricating oil, air or fuel leaks.
• If any abnormality is found, repair immediately.If the
machine is operated under unsuitable conditions,
serious injury or machine damage may occur.
• Bef ore travelling or starting operation, the lockout
lever should be locked in the RELEASE position
securely.
When starting travelling
• Bef ore starting travelling, check around the
machine again to make sure there is no personnel
and obstacles.
• When starting travelling, sound the horn to give an
alert.
J
• The machine can only be operated with the
operator sitting inM
the operator's seat.
2
• Seat belt must be fastened.(If equipped)
• No person other than the8operator should stay in
_ sit on the machine
body.
j
• Check the backup alarm, if equipped, for normal
operation. m
Precautions during travelling 2
• The key in the starting switch must not8
be turned to
the OFF position while the machine is travelling.An
s is
engine shutdown when the machine is travelling
dangerous.As the steering can become heavy.If the
engine dies, the brakes should be applied z
immediately to stop the machine.
• It is dangerous to gaze around during
operation.Stay fully concentrated to the work.
• Driving too fast, sudden braking, sudden stopping,
sharp turns or zigzaging are all dangerous.
• If any abnormality (noise, vibration, smell, incorrect
display of instrumentation, air leak, oil leak etc.) is
f ound during the operation, the machine should be
moved to a safe place and find the causes.
• Adjust the height of the working device to the
position where the lowest point of the bucket is
300-400 mm above the ground, and travel on a f lat
surf ace.
43
 j j
m m
2 2
8 8
s even if the machine is equipped with backupsalarm
and mirrors:
z z
• Sound the horn to alert the personnel on the site.
• Check around the machine. There should be no
person.Check especially the area behind the
machine as it is not visible f rom the operator's seat.
• Where there is a danger or the visibility is poor, one
• Do not operate the pilot control lever of the working person should be specified to direct the traffic.
device during travelling.If the operation of the pilot
control lever of the work tool is required, the • Persons without approval must not enter areas in
machine should be stopped first before the the turning direction or travelling direction.
operation of the pilot control lever. • The travelling direction must not be changed when
• Do not operate the steering wheel suddenly.If doing the machine is at high speed.
so, the work tool may touch the ground surf ace and Forbidden operation
the machine may lose balance, or damage to the
machines or structures around may occur. • The load of the machine must be kept within the
specified maximum load to avoid fall-over of the
• When travelling on the uneven surface, keep the machine and damage to the working device due to
speed low and avoid sudden steering.
overloading.The specified capacity of the machine
• Try to avoid driving over obstacles.If it is necessary must not be exceeded during operation.
J f or the machine to drive over an obstacle, try to J
• Caterpillar (Qingzhou) Ltd.. will not be responsible
keep the bucket close to the ground surface.
M M or damage to the machine
f or any injury, accident
• A distance should be kept from other machines or resulting from overloading of the machine.
2 structures during travelling or operating to avoid 2
Travelling on slope
8 collision. 8
• Travelling on slope may cause the machine to fall
•_If working in water, the allowed water depth must _especially cautious.
over or slide to one side. Be
not be exceeded.The water depth must not exceed
j bottom of the axle housing.
the j lowest position of
• When travelling on the slope, the
the bucket should be kept 200-300 mm over the
• When
mdriving on bridges or structures on private m lower the
surf ace ground.In case of emergency,
properties, first check the strength to see if it is
bucket to the ground quickly to help2
stop the
enough2to support the weight of the machine.When
machine.
driving on public roads, the rules of the appropriate
authorities8
must be met and appropriate regulations 8
• Do not turn or travel transversely on a slope.Drive
must be followed.
s s
the machine down to a level surface to complete
these operation.
• Traf f ic rules should
z be followed when driving on z
public roads.The driving speed of the machine is
lower than the normal speed of automobiles. Drive
on the side of the road to leave the center of the
road to other vehicles.
• If the machine runs at a high speed continuously for
a long period of time, the tires will overheat and the
internal pressure will become extremely high.This
may lead to the blowout of the tire.If the tire blows • When travelling downhill, never shift gears or put
out, extreme destructive force will be generated, the transmission in the neutral position.Put the
which may result in severe injury or accident. transmission in the low speed gear before starting
• If you plan to drive the machine continuously, driving downhill.
please consult the authorized dealer of Caterpillar • Keep the speed low when driving downhill.If
(Qingzhou) Ltd. necessary, use the braking pedal to control the
Checks when changing the direction driving speed.

To avoid injury or death, the following rules must be • Do not drive at high speed on grassland, fallen
f ollowed before moving the machine or the work tool, leaves or wet steel plate.If operating this way, even

44
 j j
m m
2 2
8 8
s can cause the machine to slide
a very small slope s
cable, the operator must not leave the cab.
to one side, and the driving speed, therefore,
5. When working in the vicinity of high-voltage
z
should be kept low.When driving on a slope, drive z
cables, do not allow any person to get close to
straight upward and downward.
the machine.
• When travelling on a slope, if the engine dies, the 6. Consult the power company for the voltage of the
braking pedal should be depressed fully cable before starting operation.
immediately to apply the brake and the bucket
should be lowered to the ground before applying Operating Precautions
the parking brake to secure the machine in position.
• If the bucket is loaded when driving up or down a
slope, the bucket should always point to the uphill
direction (i.e., facing front when going up, and
f acing back when going down).When driving on a
slope with a loaded bucket, keep the bucket toward
the downhill direction will cause the danger of
machine f all-over.
• Do not get too close to the edge of a cliff.During
Do not get close to high-voltage cables dike-building or earth-filling, or dumping into a cliff,
• Do not allow the machine to touch the overhead pile the earth into a dump, and push the dump
through another dump.
cables.Even just getting close to the cable can
cause electric shock.The safe distance as specif ied • When pushing the earth down a cliff or to the top of
J in the f ollowing table should be kept between the J of the machine can become light
a slope, the load
machine and the cable. suddenly.In such cases, it can be dangerous as the
M driving speed willM
increase suddenly. Therefore, the
Voltage(V) Minimum safe distance
2 2
speed must be kept low.
Low 100-200 2m 7f t • When the bucket is fully8loaded, the machine must
8 Voltage not start, turn or stop suddenly.
6,600 2m 7f t
_
High 22,000 3m 10 f t
_
• When moving unstable load, e.g. round or
j
Voltage
66,000 4m 14 f t
j raising the working
cylindrical object, layered sheet,
device can cause the danger of the load falling on
m 154,000 5m 17f t m injury or
the top of the cab, resulting in serious
damage.When moving unstable load, pay attention
2 187,000 6m 20f t not to raise the work tool too high or2tilt the bucket
8 275,000 7m 23f t backward too much. 8
s500,000 11 m 36f t s
z
• To prevent accidents from occurring, please do the
z
f ollowing work well:
1. If there is a potential risk of the machine touching
power cables on the working site, consult with the
power company before starting the operation,
and check and determine the feasibility of the
operation according to the current relevant
regulations.
2. Wear rubber boots and rubber gloves.Place a
rubber pad on the operator's seat, and pay • If the working device falls or stops suddenly, the
attention not to allow any exposed part of the reacting force can cause the machine to fall
body contact the metal chassis. over.Especially when the machine is loaded,
extreme attention must be paid to the operation of
3. Specify a signalman who will give warning signals the work tool.
when the machine gets too close to the power
cable. • Do not use the bucket or boom for lifting purpose.
4. If the working device makes contact with the • The machine can only undertake specified work.
45
 j j
m m
2 2
8 8
s beyond the scope of use of the
Other operation
machine can damage the machine.See "Usage and
z
main technical capacity and parameters" for
specified work.
• Pay attention to the following aspects to ensure
good visibility:
1. When working in dark places, turn on the working
light and the headlights, and install lighting device
at the working site if necessary.
2. Do not work in a foggy, hazy, snowy, heavy rainy
day or other circumstances with poor
visibility.Wait until it is clear and bright and there
is enough visibility before starting the work.
• Pay attention to the following to prevent the
working device from collide with other objects:
1. When working in the tunnel, under the bridge,
under the cable or in other places where the
height is limited, special attention should be paid
not to allow the bucket hit any objects.
J 2. When loading a dump truck, check to make sure
there is no person around the machine. Pay
M attention not to allow the bucket to touch the cab
of the dump truck.
2 3. To avoid accidents resulting from collision with
8 other objects, the machine should work at a
speed of safe operation, especially in limited
_ space, indoor or places with other vehicles.
j method of the brakes
Using
• Do m
not put your foot on the braking pedal unless
really necessary.
2 • If there is a danger of falling stone or2rollover at the
• Do not depress the pedal repeatedly unless really
necessary.8
• When drivingsdownhill, use the engine as a brake
and never shif t gears
z or put the transmission in the
neutral position.
Use caution in snowy days
• When working on roads with snow or ice, even a
small slope can cause the machine to slide away.
Theref ore, the speed must be kept low and sudden
start, stop or turn must be avoided.There will be a
danger of slippery, especially when going up or
down a slope.
• On f rozen roads, the ground surface will become
sof t as the temperature rises and the travelling
conditions will become unstable.Under such
circumstances, special cautions must be used
during driving.
• The road shoulder and roadside items will be
covered and become unclear after heavy snow.
Theref ore the snow must be cleaned carefully.
46
• When driving on snow-covered roads, antiskit
s tire
chain should be used.
z
• When driving on snow-covered slopes, never apply
the brake suddenly.To decelerate, depress the
braking pedal intermittently for several times.If
necessary, lower the bucket onto the ground to stop
the machine.
• The traction of the ground varies greatly with the
inf luence of the snow. Theref ore the load needs to
be adjusted accordingly to avoid skidding of the
machine during travelling.
Do not work on soft and loose ground
• Do not operate the machine on soft and loose
ground.As the machine tends to get stuck on such
ground and it can be difficult to get out.
• Do not let the machine get too close to the edge of
a clif f, or the suspended part and deep trench.If
these places collapse due to the weight or vibration
of the machine, the machine can drop or fall over,
J injury or death.Remember, the
resulting in serious
ground will become soft after heavy rain, explosion
or earthquake. M
2
• Piles of earth on the ground and near the trench
are soft and loose.It can collapse due to the weight
8 causing the machine to
or vibration of the machine,
f all over.
_
• If there is a danger of falling stone at the working
j
site, the f alling object protective structure (FOPS)
should be installed. m
working site, the rollover protective structure
(ROPS) should be installed and the seat 8 belt
should be fastened.
s
4 Storage of the machine z
• Park the machine on a level surface and lower the
working device to the ground.The location should
be f ree of falling stone or landslip.If in low-lying
area, there also should be free of the danger of
f lood.
• If it is necessary to park the machine on a slope,
chock the wheels to prevent the machine from
moving.Then lower the work tool to the ground.
• When parking on the roads, a fence, signal, flag or
warning light should be set up and other necessary
signals should be placed to make sure the machine
can be clearly seen by the passing vehicles.In
addition, the machine, fence, or flag must not
hamper the traffic.
• When leaving the machine, lower the bucket
completely to the ground, and lock the control
 j j
m m
2 2
8 8
slocking device to hold it in the
levers with the
braking position.Lock all equipment with the
key.Remove thezkey and take it with you.
Perf orm the following required operation if the
machine needs to be stored for a long period:
1. Bef ore Storage
• Clean each part of the vehicle and dry in the air.
Store the machine in a dry warehouse.If the
machine can only be stored outdoors, it should be
parked on a concrete surf ace that drains easily and
covered by canvas.
• Bef ore storage, fill up the fuel tank, grease each
moving pin shafts and drive shafts, and change the
hydraulic oil.
• Move the joystick to the NEUTRAL position.
• Pull the park brake button to apply the park brake.
• Level the bucket on the ground and put the pilot
control lever in the neutral position.
J • Put all switches in neutral or OFF position.Lock all
doors.
M M
2 • Apply a thin film of grease on the exposed part of
the hydraulic oil cylinders.
8 • Remove the battery from the vehicle and store
_separately.
• If jthe ambient temperature can possibly goes below
0C, add antif reeze in the engine and make sure the
antifm
reeze reaches the engine body and the
evaporator of the air conditioning system.Or drain
2 system completely. Also drain the air
the cooling
conditioning system.
8 8
• Secure the f ront and rear vehicle frames with the
f rame lockoutslever.
2. During storagez
• Start the machine once every month. Run each
system and grease each moving pin shafts and
drive shafts so that the moving components get
lubricated and the battery gets charged.
• Bef ore starting the vehicle, wipe off the grease on
the piston rod of the hydraulic oil cylinders.Apply a
thin f ilm of grease again after the operation is
complete.
• Apply anti-rust oil to rust-prone areas.
Attention
If anti-rust oil is used indoors, open the doors
and windows for ventilation to remove the toxic
gases.
3. Af ter Storage s
Perf orm the following operations when the long
z
period storage of the machine is over:
• Change the engine, transmission and drive axle
lubricating oil, as well as hydraulic oil and
antif reeze.
• Grease all the moving pin shafts and drive shafts.
• Bef ore starting the vehicle, wipe off the grease on
the piston rod of the hydraulic oil cylinders.
Precautions for cold areas
• Af ter completion of the work, remove all the water,
snow or sludge attached to the wiring, wiring
connectors, switches or sensors as well as the
covering parts of these parts.If these are not
removed, the water contained in them will freeze
and cause the machine to fail during the next usage,
and may result in unexpected malfunctions.
J clot of the working device and
Remove the frozen
driving system before starting.
• Warm up completely.If the machine is not warmed
up completely before2operating the control levers,
the response of the machine can be slow, which
can lead to unexpected 8
accidents.
_
j
m 650
2
s
Specified Storage Period z
The specified storage period of this machine is 1 year.
Af ter this specified storage period has expired,
consult your SEM Dealer for inspect, repair, rebuild,
install remanufactured, install new components, and
disposal options and to establish a new specified
storage period. If a decision is made to remove this
machine f rom service, see the Decommissioning and
Disposal section of this Operations and Maintenance
Manual.
5 Shipping of the machine
Investigate the travel route for overpass height, width
and the allowable load before shipping. The total
height, width and weight etc. with the machine loaded
on a shipping vehicle must not exceed the relevant
regulations. In case of over-height or over-width,
47
 j j
m m
2 2
8 8
s
please consult Caterpillar (Qingzhou) Ltd. or its Shipping Considerations s
dealers f or solution.
z
To prevent the safety accident of the machine Loading and Unloading Machine z
slipping in transit, remove ice, snow, or other slippery
material from the loading dock and f rom the truck bed
bef ore shipping. • Improper lifting and improper tie-downs can
Attention allow the load to shift or fail and cause injury or
damage. Use only properly rated cables and
Obey all local and national laws and regulations slings with lift and tie down points provided.
that govern the height, width, length and weight
of a load while shipping. • Follow the instructions in Operation and
Maintenance Manual, "Lifting and Tying Down
Follow the following procedure in shipping: the Machine" for the proper technique for
1. Bef ore loading the machine, chock the trailer securing the machine. Refer to Operation and
wheels or the truck wheels. Maintenance Manual, "Specifications" for
specific weight information
2. When the machine is driven onto the trailer or
truck, steering operation is not allowed midway. If • If lif ting is required for loading and unloading the
the steering operation is required, the machine machine, please hoist according to the lifting
should return to the level ground before the diagram.
steering operation can be performed.
3. Secure the f ront and rear vehicle frames with the
J f rame lockout lever after the machine is parked. J
M 4. Level the bucket on the transport vehicle and put M
the speed control lever to the neutral position.
2 2
8 8
_
Incorrect lifting can cause the machine to drift, _
resulting in personal injury and damage.
j j
m towing, all personnel should stay away
5. During m
f rom both
2 sides of the tow rope to avoid injury NOTICE 2
caused by the breakage of the rope.
• Improper lifting or tie-downs can allow
8 the shift
6. Typically,8the tractor should be the same size of and cause injure or damage .Install the steering
the machinesbeing towed.The tractor should have frame lock link before lifting. s
the suf ficient braking capacity, weight and power
z operation and traveling
to control the uphill • Ensure that the lift arms are in fully lowered
z
distance of both machines. position before lifting the machine.
7. While the machine being towed is going downhill, • Check all of the laws that govern the load
in order to obtain sufficient control and braking characteristics (height, weight, width, and
capacities, there should be a larger trailer or length).
another machine behind the machine being
towed, to prevent the machine from rolling down • Reference: For shipping instructions, refer to
when the control is lost. Operation and Maintenance Manual, "Shipping
the Machine".
8. If the direction of the machine being towed can be
controlled by the operator, the operator must • Lifting the Machine
steer in the direction of the wire cable. • Note: Do not use handles or steps in order to lift the
machine. Do not use the work tool for a lifting point.
• Note: The machine shipping weight that is listed is
the weight of the most common configuration of the
machine. If attachments have been installed on
your machine, the weight of your machine and the
center of gravity of your machine may vary.
48
 j j
m m
2 2
8 8
• Ref erence: Refer
s to Operation and Maintenance s
the rear axle to tie down the machine. Avoid
Manual, "Specifications" for the dimensions and using the front axle as a tie down location
z
weight of the machine z
whenever possible.
• The lifting points are identified by a label that shows
a hook.
There may be more than one way to tie down the
• Lif ting Point - In order to lift the machine, attach the machine. Local regulations should be used to
lif ting devices to the lifting points.
determine the best method. Obey all local and
• Use properly rated cables and properly rated slings regional governmental regulations.
to lif t the machine.
• Remove structures above the rear lifting points as Note: The machine shipping weight that is listed
necessary in order to route lifting cables to the
is the weight of the most common configuration
lif ting points.
of the machine. If attachments have been
• Position the crane or the lifting device in order to lift
installed on your machine, the weight of your
the machine in a level position.
machine and the center of gravity of your
• The width of the spreader bar must be sufficient to
prevent the lifting cables or the lifting straps from machine may vary.
contacting the machine.
• Do not allow any personnel in the area around the • Ref erence: Refer to Operation and Maintenance
J Manual, "Specifications"
J for the dimensions and
machine.
weight of the machine.
M Mspecified locations for tying
• Note: Use only the
1. Engage the parking brake before you sling
2 the machine and before you secure the
down the machine. Do 2 not use any other locations
in order to tie down the machine.
8 machine with tie-downs. 8
• Tie Down Point – In order to tie down the machine,
_ 2. Install the f rame lock pin prior to lifting the attach the tie-downs to the_
tie down points.
machine.
j3. Attach two lifting cables to the rear of the • Use properly rated cables andj shackles for tying
mmachine. There is one lifting eye on each down the machine. m
2 of the rear of the machine.
side • Secure the machine at the tie-down2positions. The
positions are identified on the machine by a label.
4. Attach two lifting cables to the front of the
8 8 are
• Use the f ront eyes and the rear eyes that
machine. There is one eye on each side of
s of the machine.
the f ront
provided on the lower frame of your machine.s Use
corner protection when necessary. Avoid routing
5. Connect thez four lifting cables to the cables over tires. Avoid contact with the work z
tool to
spreader bars. The spreader bars must be prevent f alse tension.
centered over the machine. • Install tie-downs at all four locations. Place wheel
6. If equipped, secure any attachments. chocks in front of the machine and behind the
machine.
7. Lif t the machine. Move the machine to the
desired position. • Consult your SEM dealer for shipping instructions
f or your machine.
8. When the machine is positioned, place the
blocks behind the tires.
Shipment
• If the machine is transported with a tractor, obey
Tying Down the Machine the national and local regulations on the weight,
height, width and length of heavy objects.Also obey
all related traffic regulations.
Note: Do not use handles or steps in order to tie
• Consider the weight, height, width and length of the
down the machine. Do not use the work tool to tie
machine when determining the shipping route.
down the machine. Do not wrap chains around
• When driving on bridges or structures on private
49
 j j
m m
2 2
8 8
s check the strength to see if it is
properties, first
enough to support the weight of the machine.When
z road, always meet and follow
traveling on the public
the related regulations of the local authority.
• The machine may be separated into several parts
during shipping.Therefore, contact the designated
dealers of Caterpillar (Qingzhou) Ltd. to perform
these work.
6. Battery Use and
Maintenance Considerations
Precautions
The machine uses maintenance free batteries,
without the need to add electrolyte.
• Battery electrolyte contains sulfuric acid and the
battery can generate hydrogen.Therefore, improper
handling of the batteries can lead to heavy injury or
f ire.For this reason, the following considerations
must be followed.Never put a lighted cigarette or
J f lame near the battery.
M • If the work requires making contact with the battery,
always wear saf ety glasses and rubber gloves.
2 • When installing the booster
• If the electrolyte inside the battery splashes on the
8 clothes or skin, flush with plenty of clean water
immediately.
_ _
• Battery electrolyte splashing into the eyes can
j in blindness.If the electrolyte splashes into
result
the eyes, f lush with plenty of clean water and see a
m immediately.
doctor
If drinking2the electrolyte accidentally, drink plenty of
water, milk, raw eggs or vegetable oil and see a
doctor or call8the emergency center immediately.
sengine before performing any work
• Shut down the
related to the engine.
z z
• Avoid accidental contact with metal objects (e.g.
tools) which can result in a short circuit between
positive (+) terminal and negative (-) terminal of the
battery.
• When installing the battery, connect the positive (+)
terminal f irst.When removing the battery,
disconnect the negative (-) terminal (ground wire
side) f irst.
• When installing or removing the battery, check
which one is positive (+) terminal or negative (-)
terminal f irst and then tighten the nut securely.
• Use a cloth when cleaning the top surface of the
battery.Never use gasoline, solvent or any other
organic solvent or detergent.Tighten the battery top
cover securely.
50
• If the battery electrolyte is f rozen, do not charge
s the
battery or use other power supply to start the
engine.This is dangerous, because it can setzthe
battery on fire.When charging the battery or using
other power supply to start the engine, melt the
battery electrolyte and check for leaks before
starting the engine.
• Remove the battery from the machine before
charging.
Start with Booster Cable
If there is anything wrong with the connection of
booster cable, a fire can result. Therefore, the
f ollowing method must be taken.
• The starting operation requires two technicians to
complete (one sitting on the operator chair).
• Those two machines are not allowed to make
contact with each other when starting the other
machine.
• When connecting the booster cable, turn OFF both
J of the functional machine and
the START switches
malf unctioned machine.
M
2 cable, always connect
the positive (+) cable first.When removing the
8
booster cable, always disconnect the ground wire
or negative (-) cable first.
• Finally connect the ground wire to the engine
j machine.But,
cylinder block of the malfunctioned
this will cause spark, so keep away f rom the battery
m
as f ar as possible during connecting.
2 careful not to
• When removing the booster cable, be
let the clips of the booster cable touch each other
or touch the machine.
8
Charging Battery s
Improper handling of the battery can lead to battery
explosion when charging the battery.Therefore,
perf orm the charging in accordance with the battery
handling regulations and charging regulations in the
instructions, and obey the the following
considerations.
• Charge the battery in a well-ventilated area with the
top cover removed.This can spread the hydrogen
and prevent the explosion.Gases from a battery
can explode.
• There should not be flame or spark above the
battery pack.Do not smoke during charging.
• Set the voltage of the charger to match that of the
battery being charged.If the voltage setting is
wrong, the charger can overheat and burn, and
even explode.
 j j
m m
2 2
8 8
s s
The wire cable used must not have broken wire
strands, kinked or reduced diameter.
z • Do not stand on the wire cable.
z
• While connecting to the machine to be towed,
never allow anybody to stand between the towing
machine and the towed machine.
• Keep the hook of the towed machine flush with the
trailing part and hold it in place.

Decommissioning and
• Connect the positive (+) clip to the positive (+) Disposal
terminal of the battery and negative (-) clip to
negative (-) terminal of the battery.Make sure to When the product is removed from service, local
J tighten both the terminals tightly.
J product decommissioning will vary.
regulations for the
M Disposal of the product
M will vary with local
• If the charging rate of the battery is lower than 1/10, regulations.
2 perf orm high-speed charging and set the value
Improperly disposing of2waste can threaten the
below the battery rated capacity.If the charging
8 current is excessive, electrolyte can leak or 8 regulations for the
environment. Obey all local
decommissioning and disposal of materials.Utilize
evaporate, which can lead to burning or explosion.
_ _ equipment when
appropriate personal protective
7. jTowing decommissioning and disposing product.
j
Consult the nearest SEM dealer for additional
When
mTowing inf ormation. Including information m
for component
If the disabled remanuf acturing and recycling options.
2 machine is towed in a wrong method,
or the selected wire cable is incorrect, injury or death
2
8 ore, the following considerations
can result. Theref Machine Traveling Operation 8
must be obeyed.
s s bucket
1. Operate the pilot valve joystick to turn the
• Operate according to the instructions on towing in to stop status and raise the boom to transport
z Maintenance Manual.
this Operation and position (i.e. the lowest point of the bucket z
is
about 300-400 mm away from the ground).
• Wear leather gloves while handling the wire cable.
• While preparing for the towing with other
technicians, determine the signals to be used
bef ore performing the work.
• If the engine of the malfunctioned machine can not
start or the braking system is malfunctioned,
contact the designated dealers of Caterpillar
(Qingzhou) Ltd. for repair.
2. Depress the service brake pedal and meantime
• It is dangerous to tow a machine on a slope, so do press the park brake button to release the park
it on a smooth surface.If this kind of place is brake.Release the service brake pedal slowly
unavailable, choose a place with minimum grade. and see if the machine is moving.

• If the malf unctioned machine is towed by another

machine, the wire cable used must be capable of
carrying the weight of the malfunctioned machine. If the machine is moving, depress the service

51
 j j
m m
2 2
8 8
s
brake pedal immediately and pull the park brake s
button to apply the park brake.Then check if the
z system of the machine is
variable speed control z
malfunctioned.If the machine is uphill, block the
wheels to prevent the machine from moving Never steer at a slope. Drive the machine down to
before checking the machine. the smooth ground to perform these work.

3. Push the variable speed control handle forward to

I position or push it backward to reverse position
while depressing the accelerator pedal suitably, in
order that the machine can travel forward or
backward.
4. Drive the machine to an open and smooth site. If
the steering performance check is not performed
during the previous operation due to narrow site,
turn the steering wheel at this point, to check if
the machine is able to counterrotate to the left or
right.
5. Check the performance of the service
brake.Drive the machine at forward shift position
1 or 2 in an open and smooth site. Release the
accelerator pedal f irst and then smoothly depress
J the service brake pedal. The machine should
decelerate obviously and stop.
M M
Attention
2 2
If obvious deceleration can not be felt after the
8 service brake pedal is depressed, pull the park
brake button immediately to apply emergency
_
brake.Meantime operate the pilot joystick to
j the boom to the lowest point and turn over
lower
the bucket forward to make the bucket teeth
insertminto or against the ground to force the
machine to stop for safety.
2 2
6. Check the engagement of each shift
8 the machine to an open and
position.Drive
smooth site. Engage each shift position
s
individually to check the shift response of the
machine. z 9. Close the left and right doors and climb down the
7. Machine Steering Operation
If turning the machine is required due to the curve
ahead, operate in accordance with the related local
traf fic laws and regulations.
Bef ore turning, push the turn light switch to the
appropriate direction (pushing left is to turn left,
pushing right is to turn right) and meanwhile the turn
lights on the left or right side at the front and rear of
the machine as well as the turn light on the
dashboard will illuminate to alert the adjacent
vehicles and pedestrians that the machine is going to
turn.Then turn the steering wheel in the desired
direction and the steering starts.
To steer at a higher traveling speed, the accelerator
pedal must be released and apply the service brake if
necessary to ensure travel safety.
52
8. Machine Braking Operation
To apply braking, release the accelerator pedal first
and then smoothly depress the service brake pedal.
While traveling at a higher speed, do not depress
the brake pedal to the ground rapidly unless
there is emergency to avoid accidents and
damage to the machine.
Parking the Machine
1. Drive the machine to a smooth area where there
should be free of falling stones, landslide and
f lood. J
2. Use the service brake to stop the machine.
3. Move the joystick to the NEUTRAL position.
4. Pull the park brake button to apply the park
brake. 8
_ to lower the boom
5. Operate the pilot valve joystick
and put the bucket evenly on the ground and then
j
slightly push down the bucket.
mto allow the parts
6. Let the engine idle for 5 minutes
to cool down evenly.
7. Turn the electric key counterclockwise to OFF
8 the
position to stop the engine and cut down
power of the machine and remove the key.
s
8. Move each switch to neutral or OFF position.
z
ladder according to the regulations.
10. If the machine is going to be stored for a long
period of time (for example, overnight), open the
right battery case cover to move the battery
negative switch to OFF position.
11. If there is no antifreeze in the machine,
immediately open all engine water drain valves
and drain all coolant in the evaporators of cooling
system and air conditioning system after the
machine stops in winter climate.
12. Lock all equipment and take the key with you.
Attention
Place the machine on the smooth ground. If
parking the machine on a slope is necessary,
 j j
m m
2 2
8 8
s to prevent the machine from
block the wheels the ground. s
moving.
Do not lower the boom until the machine is about one
z z
meter away f rom the pile, and allow the bucket to
Machine Operation touch the ground and shift from forward 2 to forward
1.
1. Preparation Before Operation
Bef ore doing the work, use this machine to level the Attention
site, including removing the protrusion, filling the When the bucket touches the ground, avoid
holes and removing the wet and slippery ground excessive pressure from the bucket to ground
surf ace.Remove large and sharp stones from the site which will cause unnecessary restriction and
to avoid tire scratches. teeth wear.Meantime, the front and rear frame
If using this machine to load or unload the truck or should be straightened, leaving no angle between
hopper, adjust the kickout height of the boom raise the front and rear frame.
kickout to allow the hopper of the loader to enter or Depress the accelerator pedal to allow the bucket to
exit f rom the truck or hopper safely and not to insert into the pile completely.When the machine can
damage the truck or hopper due to excessive
not move further, the operator toggles the pilot valve
unloading height. bucket joystick backward to rotate the bucket
backward and then push the joystick back to the
neutral position. Then the machine will continue to
insert into the pile. Repeat the insert and rotation
operation until the bucket is filled with material.
J J method
• Combined loading
M M is suitable for loading hard
Combined loading method
or sticky material.
2 2
The operation before inserting into the material is the
8 same with common loading 8 method.The operator
makes a push of the pilot valve boom joystick after
_ _
the bucket inserts into the pile and then push it back
j j bucket so that it
to the neutral position to raise the
can insert forward f urther. Then the operator makes a
m push of the pilot valve boom joystickm backward and
then push it back to the neutral position to rotate the
2 bucket backward so that the bucket can 2 continue to
insert f orward.Repeat the insert, raise, insert and
8 8
rotation operations until the bucket is filled with
s material. s
z • Exiting from the pile z
Af ter the bucket is filled with material, the operator
operates the pilot bucket joystick to turn the bucket
backward until the bucket kickout touches the boom,
and then move the bucket joystick to the neutral
position.Now maximum retract angle can be
obtained.
Raise the boom to certain height to allow the bucket
2. General Techniques to avoid the pile when the machine is moving
• Common loading method backward.The operator moves the joystick backward
to reverse position with left hand to reverse the
Common loading method is suitable for carrying machine while holding the steering wheel with right
loose materials. hand.
While the loader is approaching the loose material in Af ter exiting from the pile, the operator operates the
f orward shift 2 with the center of bucket targeting the boom control lever to lower the bucket to the position
pile, the operator holds the steering wheel with left where the lowest point of the bucket is 300-400 mm
hand and operate the pilot valve boom control lever above the ground.
with right hand to lower the boom to 300 mm above
53
 j j
m m
2 2
8 8
• Material Handling
s s
machine.Then move the pilot valve bucket joystick
f orward to tilt the bucket forward and to pour the
Self -handling can z
be used in the following conditions: material into the truck and hopper. At this point,zthe
1. The truck can not be used due to soft and drive should watch for the bucket movement in order
unleveled site. that the bucket will not touch the truck or hopper edge.
If the material is too sticky, push the bucket joystick
2. Handling distance is within 500 meters and it is back and forth repeatedly to allow the bucket kickout
not economic to use the truck. to hit the boom repeatedly to remove the material
During handling, keep the lowest point of the bucket sticking to the bucket.
at transport position (300-400 mm above the ground) If the body length of the truck is more than twice the
and turn the bucket backward to stop position (bucket width of the bucket, start dumping from the front of
kickout touches the boom) to make sure the handling the body.
operation is smooth and safe and not easily-spilling.
Attention
The machine speed during handling depends on the
handling distance and road condition. When the During dumping, the bucket kickout should not
machine travels over a hole or a bump, release the hit the boom excessively and the number of hit
accelerator pedal and slightly apply the service brake should be limited in order not to damage the
as necessary to slow down the machine and reduce machine.
the impact to the machine and the spilling when
passing over the restrictions.
Af ter dumping, the operator pushes the pilot bucket
joystick to the rearmost position until the bucket
J J and then move the bucket
kickout hits the boom
joystick back to neutral position.Then the operator
M moves the variableM speed joystick to reverse position
and release the brake pedal to move the machine
2 away f rom the truck or 2
hopper.When the machine is
leaving the truck or hopper, the operator should drive
8 8
the machine carefully and watch for the bucket
_ _ will not touch the
movement in order that the bucket
truck or hopper edge. When the bucket completely
j j
leaves the truck or hopper, the operator can lower the
boom while driving to prepare for the next cycle.
m m
Never handle material with the bucket raised to 2. Dump at low position
2
higher position which can cause machine
2
When handling material between sites, dumping at
rollover. 8 low position can be possible which means 8dumping
with the bucket close to the ground.In this case,
• Dump s rotate the bucket backward to the horizontalsposition
bef ore raising the boom.Otherwise, the boom may
z or hopper
1. Dump to the truck z
not be raised due to the interference of work tool
When the loader f illed with material is 15 meters linkage.
away f rom the truck or hopper, release the
accelerator pedal and slightly apply the service brake
if necessary to slow down the machine so that the • Pushing operation
machine can approach the truck or hopper at low Place the bucket against the ground horizontally and
speed.Meanwhile, the operator pushes the pilot valve variable speed joystick at shift position 1 and depress
joystick to the rearmost position and the joystick will the accelerator pedal to move the machine ahead. If
be caught up by the electromagnet. Now the operator restrictions are f ound during bulldozing, slightly raise
can release his hand and the joystick will not bounce the boom to continue. The pilot valve boom control
back to the neutral position.During this process, the lever should be operated between RAISE and
operator should drive the machine carefully to LOWER position instead of any RAISE or LOWER
observe the process in which the bucket is position, in order to ensure smooth bulldozing
approaching the truck or hopper and the operator can operation.
move the joystick back at any time to prevent the
bucket from touching the truck or hopper. • Blading operation
With the bucket over the truck or hopper, the operator Raise the boom and rotate the bucket forward until
depresses the brake pedal to slow down the the blade touches the ground and the angle between

54
 j j
m m
2 2
8 8
s should be kept at about 40
the blade and ground s
degrees. For hard surface road , put the pilot valve
boom control leverzat FLOAT position; for soft surf ace z
road, put it at neutral position. Move the joystick to
reverse shif t position and depress the accelerator
pedal to reverse the machine and blade the ground
with the blade.
• Towing operation
A 20-ton f latbed trailer can be configured to tow the
machine.The method is as follows: • Vertical loading
1. Securely connect to the tow pin of the machine. The loader f aces the pile and travels in a straight line
2. Equipped with brake system of good at reverse position after f illed with material.
perf ormance. Then drive a dump between the loader and pile.
3. Put the bucket at transport position. This method needs less loading time which reduces
4. Moderate action is required for start and stop and the duty cycle time efficiently.
braking should be applied when going down a
slope.
Attention

J When applying the brake, apply to the flatbed J

trailer first and then the machine.
M M
2 Operating method 2
8 8
_ _
j j
m m
Cold Weather Operation
2 2
Low Temperature Considerations
8 8
If the ambient temperature is too low, it is difficult for
s s
the engine to start and the radiator may freeze.
Theref ore, the following precautions must be taken:
z z
1. All parts use low-cohesive fuel, hydraulic oil and
• V-shaped method lubricant, and add coolant to the water.For
specific oil type, see the Fluids Specification in
As illustrated, the loader faces the pile and the angle the Operation and Maintenance Manual.
between the truck and the traveling direction of the
loader is 60 degrees. Stop moving when it is 12-15 2. Antif reeze Use ConsiderationsDo not mix
meters away f rom the pile and when the loader is antif reezes of different category.
f illed with material, reverse the loader to where there
is 12-15 meters away f rom the pile. Drive to the truck
Attention
while steering and raising the bucket. After dumping
the material, reverse to the original position for next The antifreeze must be away from the flame and
loading. smoking is forbidden when adding the antifreeze.

3. Battery Use Considerations

• When the ambient temperature reduces, the
battery capacity reduces too.If the charging rate of
the battery is low, the electrolyte may freeze,

55
 j j
m m
2 2
8 8
s maintain the charging rate at 100%
theref ore try to s
and keep it warm if possible so that the engine is
z next day.
easily to be started z
• In the extreme cold area, use batteries that can
overcome extreme cold.
Considerations After Daily Work
To prevent the silt, water or snow sticking to the
machine f rom affecting engine start the next day, the
f ollowing measures must be taken:
1. Thoroughly remove the silt, water or snow
sticking to the machine.Prevent the silt, water or
snow f rom entering the seals and freezing in
them which can damage the sealing capacity.
2. Park the vehicle on a dry and hard surface.If this
is not possible, park the machine on a
board.Using a board can prevent the machine
f rom freezing on the ground and makes the start
the next day easier.
3. At low temperature, battery capacity will reduce
J significantly as parking time grows. Cover the
battery or move it to a warmer place and install it
J
M back the next day. M
2 After Cold Weather 2
8 When the weather gets warm, the following work
needs to be done:
8
_
1. All components change to use semi-cohesive fuel,
_
jhydraulic oil and lubricant.For specific oil type, j
see the Fluids Specification in the Operation and
m
Maintenance Manual. m
2. If the 2
permanent antifreeze is not used, 2
completely drain and clean the cooling system
8 with new coolant.
and replace 8
s s
z z

56
 j j
m m
2 2
8 8
s
Maintenance Section s
z z

J J
Attention
M M
During the use of this machine, maintain the
2 machine according to the maintenance intervals 2
8 and procedures specified in this manual.Good
maintenance of the machine is very important to
8
_ extended machine service life and job safety.
the _
j j
SEM655D Regular Maintenance
m m
The maintenance intervals listed in this manual are
determined2 by using the service hour meter or the 2
calendar (day,8 month etc.).Caterpillar (Qingzhou) Ltd.. 8
requires the service should always be performed at
the interval thatsoccurs first among the above two s
interval determination methods.Under extremely
severe, dusty or wetz operating conditions, more z
f requent lubrication than is specified in the scheduled
maintenance might be necessary.
Besides the daily maintenance, we also specify four
maintenance points: PM1:250H; PM2:500H;
PM3:1000H; PM4:2000H.
During the maintenance, the daily routine
maintenance and first-time maintenance of the
corresponding parts should be strictly followed, and
then different regular maintenance plans should be
executed according to the specific working hours.
Regular maintenance is based on working hours,or
perf orm the maintenance every year/2,000 working
hours.The appropriate regular maintenance plans are:
250-PM1, 500-PM2, 750-PM1, 1000-PM3, 1250-PM1,
1500-PM2, 1750-PM1, 2000-PM4.

57
 j j
m m
2 2
8 8
The specific smaintenance plans can be found in the attached chart s
ANNEXES z z
Maintenance Items Daily PM1 PM2 PM3 PM4
Maintenance
Check the Engine Level √ √ √ √ √
Check the coolant level √ √ √ √ √
Check hydraulic oil fluid level √ √ √ √ √
Check fuel level, drain the fuel and debris in the fuel prefilter √ √ √ √ √
Check the operation of lights and gauges √ √ √ √ √
Check the tire pressure and for damage √ √ √ √ √
Check the reverse alarm operation √ √ √ √ √
Check the transmission oil level √ √ √ √ √
Check the lubrication of each greasing point and add grease to √ √ √ √ √
each greasing point as directed by machine maintenance chart
posted on the machine.
Check the brake booster oil level √ √ √ √ √
Check the variable speed control system and adjust as necessary √ √ √ √ √
Check and tighten steering wheel retaining nut √ √ √ √ √
J Walk around the machine to visually check all systems for √ J √ √ √ √
abnormal condition or leaks.
M M
Visually check engine fans and drive belts √ √ √ √ √
2 Add grease to each drive shaft as directed by machine √ √
2 √ √ √
8 maintenance chart posted on the machine. 8
Tighten all drive shaft bolts √ √ √ √ √
_
Check the clearance between brake shoes and brake drum of Initial Check √
_√ √ √
parkjbrake at the first 50 working hours and adjust as necessary. j
Check the torque of hub retaining bolts Initial Check √ √ √ √
m
Initial change of the engine oil and oil filter (the first 50 working Initial Check
m
hours) 2 2
Initial change of the oil in the transmission, torque converter, Initial
8 system filter
radiator and drive Change 8
s drain filter element of the hydraulic oil tank
Initial change of the
(upper element in the oil tank)
Initial
Change
s
z hydraulic system filter element
Initial change of the pilot Initial Wash z
Change
Keep the battery post clean and apply vaseline to it to avoid post √ √ √ √
corrosion by acid mist
Sweep the engine cylinder head √ √ √ √
Sweep the radiator set √ √ √ √
Clean the fuel tank fill screen √ √ √ √
Clean the oil tank fill screen √ √ √ √
Check the torque of the transmission and engine mounting bolts √ √ √ √
Check all the stressed welds and mounting bolts of the work tool √ √ √ √
and the front and rear frames for cracks and looseness
Check the oil level of front and rear axles √ √ √ √
Check the engine air intake system √ √ √ √
Continued Chart
Check the tension of engine drive belts and air conditioner √ √ √ √

58
 j j
m m
2 2
8 8
s
compressor belts and for damage s
√ √ √
Check the capability of service brake and park brake
z z√
Replace the engine oil and oil filter √ √ √ √
Clean the air conditioner inner filter element √ √ √ √ √
Replace the fuel prefilter √ √ √ √
Replace the engine water processor √ √ √ √
Check the retaining bolts of frame articulation pin for looseness √ √ √
Check the brake oil level. √ √ √
Tighten the bolts securing the front and rear axles to the frames √ √ √
Clean the screen inside the air booster pump breather √ √ √
Clean the fuel prefilter √ √ √
Change fuel filters √ √ √
Replace the oil tank breather element √ √ √
Replacing the Air Cleaner Element √ √ √
Adjust the engine valve lash √ √
Check the engine tensioner bearing and fan shaft housing √ √
Tighten all battery retaining bolts and clean the top of the battery √ √

J Clean the fuel tank J √ √

Clean the transmission and torque converter breather √ √
M Replace the oil in the transmission torque converter and radiator
M √ √
2 Replace the drive system filter. 2 √ √

8 Replace the drain filter element of the hydraulic oil tank (upper
element in the oil tank)
8 √ √

_ the axle oil

Replace _ √ √
j the pilot hydraulic system filter element
Replace j √ √
Replace the air dryer (If equipped) √ √
m m
Check the engine vibration damper √
Check the 2 operation of service brake system lines and park brake 2 √
system and remove to check the friction shim for wear and
8
replace the brake lines as necessary
8
s of the steering system and replace the
Check the flexibility s √
steering lines as necessary.
z
Check the alternator and starting motor; clean and check the
z√
turbocharger
Clean and check the brake booster seal and spring, repl ace the √
brake fluid and check the flexibility of the brake
Check the sealing capability of the distribution valve and √
operating cylinder by measuring the natural recess of the cylinder
Replace the oil tank breather (fill screen) √
Replace the fuel tank breather (fill screen ) √
Replace the coolant and coolant filter; clean the cooling √
systemReplace the coolant at least every two years if the working
hours do not meet the change interval
Replace the hydraulic oil, clean the oil tank and check the suction √
line

59
 j j
m m
2 2
8 8
s ！
Important Notice!！
z
Do not use maintenance parts that are not
approved by Caterpillar (Qingzhou) Ltd. or
designated dealers of Caterpillar (Qingzhou)
Ltd.The use of unauthorized maintenance parts
may create safety problems that are detrimental
to the normal operation of the machine and affect
the service life.
Maintenance Considerations
1 Before Maintenance
Malfunction notice
If the maintenance being performed is not specified in
the Operation and Maintenance Manual, unexpected
malf unctions can occur.
Contact the designated dealers of Caterpillar
(Qingzhou) Ltd. for repair.
• If another person starts the engine or operates the
lever while the operator is maintaining the machine
J or adding oil, the operator can be severely injured
M or killed.
2 • Post a warning label on the lever in the cab to alert
the other people that you are accessing the
8 machine.Post a warning label around the machine
too, if necessary.
_ _
Access and Cleaning Before
j
Maintenance
mthe machine before access and
• Clean
maintenance.This
2 can ensure that dirt will not enter
the machine and maintenance job can be safely
done. 8 the engine and wait for the engine and 8
• If the machinesis still dirty when accessing and
maintaining, it can be difficult to locate the problem
z spill into the eyes, and people
and dirt or silt can
can slip and get injured.
• The f ollowing needs to be noticed when cleaning
the machine:
1. Wear anti-skid shoes to avoid slipping on a wet
surf ace.
2. Wear protective clothes when f lushing the
machine with high-pressure water.This can
protect you from the impact from the
high-pressure water and prevent the dirt and silt
f rom spilling into your eyes.
3. Do not spray water directly onto the electrical
system elements (e.g. sensor, wire connector).If
water enters the electrical system, it can be
f ailed.
60
s
Keep the work site clean and organized
• Do not leave any service or maintenance toolz
around the work site.Thoroughly wipe off any
grease, oil and other items that can make people
slip.Always keep the work site clean and organized
so that the job can be safely done.
• If the work site is not clean or organized, people
can trip, slip or tumble and get injured.
Designate a responsible person when
co-working with other people
• Designate a responsible person who will be
listened to by everybody while repairing the
machine or installing/removing the work tool.
• Mutual misunderstanding can cause serious
accidents when co-working with other people.
Coolant Level in the Radiator
J
M
2
8
j
m
2
• To check the coolant level in the radiator, shut down
radiator to
cool down.Do not open the radiator top cover under
normal circumstances. s
z
• If there is no need to open the radiator top cover,
perf orm as follows:
1. Wait the radiator to cool down before checking
the coolant level.(To check if the water
temperature has reduced, put your hand close to
the engine or radiator to check air
temperature.Be careful not to touch the engine or
radiator for burn prevention).
2. When the water fill cap is cold enough that can be
touched with bare hands, slowly loosen the cap
to release the internal pressure.
• Wait f or the radiator to cool down and then release
the internal pressure so that the radiator top cover
can be opened.
 j j
m m
2 2
8 8
s engine before accessing
Shut down the • Never use a lighter or flame for lighting even
s in a
or maintaining the machine dark place.It could cause a f ire and when the gases
z z
exiting from the battery encounters a f ire, explosion
• Place the machine on a level ground where there could happen.
should be free of rock fall or landslide when
accessing or maintaining the machine.If the terrain • When using the machine for lighting supply, obey
is low, there should be free of flood risk, either.Shut the instructions in the Operation and Maintenance
the engine OFF. Manual.

• Lower the work tool to the ground after the engine
turns off.
Operate the work tool lever to RAISE, LOWER and
RETRACT several times to release the retaining
pressure inside the hydraulic oil lines.
Fire Prevention
Fuel or gases exiting from the battery could cause a
f ire during the maintenance, therefore the following
considerations must be obeyed while accessing or
maintaining.

• Pull the park brake switch to apply the brake and • The f uel, lubricating oil and other flammable
put a wedge under the tire. materials must be stored away from the flame.

• Lock the front and rear f rames with locking lever. • Use nonf lammable mat erial as part detergent.Do
not use diesel or gasoline which could cause a f ire.
• Take extreme care during maintenance not to be hit
or hooked by moving parts. • Do not smoke while accessing or
maintaining.Smoke at the designated place.
J • Use a lighting J
device with anti-explosion feature
when checking the fuel, lubricating oil, battery
M electrolyte.NeverM
use a lighter or flame for lighting.
2 2
• Move all flammable material to a safe place before
grinding or welding on the flame.
8 8
• There must be a f ire extinguisher in the job site
_ _ will be performed.
where accessing or maintenance
j j
2 When Performing Maintenance
m WHO
m
2 2 should
• Maintenance and service of the machine
8 8
only be carried out by qualified technicians.Keep
Support Work anyone not involved in the maintenance and
s Tool s to
service away from the area.Designate a person
• While raising thezbucket to perform inspection and attend the area if necessary.
z
maintenance, support the boom with a bracket to • Pay particular attention when grinding, welding or
prevent the work tool from falling.
using a sledge hammer.
• Place the lever at NEUTRAL position. Appendix
Suitable Tools • Designate a responsible person before starting the
Use only the tools suitable for the task.Using removal or installation of the accessory.
damaged, poor quality, failed or temporary tools can
cause personal injury. • Do not allow anyone who is not involved in the job
to stand near the machine or accessory.
Lighting Use
• Put the accessory removed from the machine in a
• Use a lighting device with anti-explosion feature saf e place and make sure it does not f all.Install rails
when checking the fuel, lubricating oil, battery around the accessory with a "NO Entry" tag on the
electrolyte or window glass detergent.If not, rail to prevent the unauthorized person f rom getting
explosion can occur. close.
• If performing the job at a dark place without lighting, Working under the Machine
people can get injured, therefore, proper lighting
device should be installed. • Park the machine at the hard and level ground.
61
 j j
m m
2 2
8 8
Lower all workstools to the ground before it must be taken out of the machine. s
perf orming maintenance or repair under the
machine. z • While accessing, do not carry any unnecessary
z tool
or part in the pocket.
• Block the tires with wedges.
Maintenance During Engine Operation
• If the machine is only supported by the work tools
Do not perform maintenance during engine operation
with the tires above the ground, it is very dangerous
to work under the machine.Never work under a to avoid injury.If it is necessary to perform
maintenance during engine operation, the following
poorly-supported machine.
considerations must be taken:
Performing Maintenance with Frame
• Ask a technician to sit on the operator seat and turn
Raised off the engine at any time.All technicians must be in
• Bef ore performing the job with work tool or frame touch with other person.
raised, lock the front and rear f rames with locking • Use extreme care when the task point is near the
lever.Place the lever at NEUTRAL position.Block rotating parts because there is the risk of getting
the work tools and frames with wedges. caught in rotating parts.
• Bef ore raising, block the wheel with a wedge at the • Never allow any tool or any part of the body to
opposite side.After raising, put wedges under the touch the f an blade or f an belt.Serious injury can be
machine. caused.
• Prevent the work tool from moving when cleaning
Working on the Top of the Machine
J J radiator.Also pull the park brake
the interior of the
• When working on the top of the machine, make switch to apply the park brake.
M sure that the f oothold is clean and free of
M
2 restrictions and the following considerations must 2
be obeyed to avoid falling.
8 1. There should not be spilled lubricating oil or 8
_ grease. _
2. jNo tools around. j
3. Watch out for the step while walking.
m m
• Never jump f rom the machine.When getting on/off
2 always use the ladder and armrest
the machine, 2 lever is
• Do not touch any lever.If operating the
and keep three-point (two f eet and one hand or two necessary, signal the other technicians to alert
8
hands and one foot) contact any time. them to walk into a safe place. 8
s
• Use protective devices if necessary. Hammer Use Considerations s
z hood is slippery and
• The top of the engine z
• Always wear safety glasses, helmet and other
dangerous so standing on it is forbidden. protective clothes when using a hammer and put a
copper stick between the hammer and the object
• The top of the tire is slippery and dangerous so being hit on.
standing on it is forbidden.
• There could be a risk of debris flying into the eyes
• Stand on the fender of the front frame when causing injury if using a hammer to hit a hard part,
cleaning the front window glass of the cab. For example a pin or bearing.
Do not drop foreign material into the Welding Repair
machine The welding must be performed by a qualified
• Take care not to drop any foreign material (e.g. nut, technician and in a place equipped with appropriate
bolt, cotton yarn or tool )into the machine when equipment.Welding can generate gases and there
opening the access window or oil fill of the tank.If exists the risk of fire and electric shock, therefore
such kind of material is dropped into the machine, never allow the unqualified technician to perform the
machine damage, failed operation and other welding.The qualified technician must follow the
malf unction can occur. f ollowing the considerations.

• If any f oreign material is dropped into the machine, • Disconnect the terminals of the battery to avoid
62
 j j
m m
2 2
8 8
s
battery explosion.Remove the paint from the High-pressure Hose Handling s
position to be welded to prevent the generation of
hazardous gas. z • If the high-pressure hose leaks, failed operation
z
could occur which will cause personal injury or
• Welding on the hydraulic device or lines or places equipment damage.If damaged hose or loosened
very near to it can generate flammable vapor and capscrew is found, stop operation and contact the
spark which can cause a f ire, therefore, avoid to designated dealers of Caterpillar (Qingzhou) Ltd.
weld on such place. f or repair.
• If the spark generated during the welding directly • Sophisticated technique is required when replacing
f alls on the rubber hose, wire or pressurized piping, the high-pressure hose and installing torque is
they can rupture and the insulation of the wire can determined by the type and size of the hose,
be damaged, therefore, cover them with an anti-fire theref ore, do not repair by yourself. Contact the
baf fle. designated dealers of Caterpillar (Qingzhou) Ltd.
f or repair.
• Wear protective clothes during welding.
• Make sure the site where the welding is performed High-Pressure Oil Considerations
is well-ventilated. When accessing or replacing the hydraulic system
lines, check if the system pressure has been
• Clear all f lammable materials and make sure there released.If there is still pressure in the lines, serious
is a f ire extinguisher at the job site. injury or damage can occur. Therefore, perform as
Battery Considerations f ollows:

J When repairing the electrical system or performing J

welding on the machine, remove the negative (-) of
M the battery or turn off the main power switch to M
prevent current flow.
2 2
When Found It Abnormal
8 8
• If any abnormal condition is found during accessing,
_repair it.Especially when a problem is found in the _
brake
j system , steering system or work tool system, j
serious accidents could occur.
m on the f ault type, contact the designated
• Depending m
dealers2 of Caterpillar (Qingzhou) Ltd. for repair. 2
Regulations 8 on Adding fuel or 8
Lubricating Oil • For details of releasing pressure, see "Turn
s s off the
engine before check and maintenance" in the
Fuel, lubricating oil, hydraulic oil, antifreeze, brake
z detergent can be lit by a
f luid and window glass Maintenance Considerations.Never access or z
f lame.The following regulations must be obeyed: replace before the pressure is released completely.
• Turn off the engine when adding fuel or lubricating • Wear the saf ety and leather gloves.
oil.
• If there is oil leak in the line, the line and the
• No smoking. surrounding area will be wet, therefore, check the
tube or hose for cracks and hose for bulge.If it is
• Wipe off any spilled fuel, lubricating oil, hydraulic oil, difficult to locate the leak, contact the designated
antif reeze, brake fluid or window glass detergent. dealers of Caterpillar (Qingzhou) Ltd. for repair.
• Securely tighten all top covers of the containers for • Use a plate or cardboard to check the leak instead
f uel, lubricating oil, hydraulic oil, antifreeze, brake of bare hands.
f luid or window glass detergent.
• If shot by the spilled high-pressure oil, see a doctor
• The place where the f uel, lubricating oil, hydraulic immediately.
oil, antifreeze, brake fluid or window glass
detergent is added or stored must be
well-ventilated.

63
 j j
m m
2 2
8 8
Precautions sfor accessing at high s
1. Is the operation of the access and maintenance
temperature or high pressure positions normal?
z 2. Does the hydraulic system leak oil when the
z
• The coolant and oil at various positions is under engine speed accelerates and high load is
high temperature and high pressure just after the applied?
operation is stopped.Opening the engine hood,
draining the oil or coolant, or replacing the filter at 3 Tires
this point can cause burns or other injuries.Wait for
it to cool down and access according to the Tire Handling
procedure in the Operation and Maintenance
Manual. Wrong handling of the tire or rim can result in a blew
or ruptured tire and the hub can be damaged and
• For other inspection items, see the Regular scattered which could cause serious injury or death.
Maintenance section and the related content in the The f ollowing considerations must be obeyed for
Operation and Maintenance Manual. maintenance safety.
Scrap • The maintenance, removal, repair and installation
To prevent pollution, especially in the area where of the tire and rim require special equipment and
humans or animals live, the following procedures techniques, therefore ask a tire repair shop to do
must be followed. the job.
• Never dump the used fuel or oil into the drains, • Only use the specified tires and inflate them to the
rivers, etc. specified pressure.For the specified tire and
J • Collect the drained oil into a container and never
pressure, seeJUsage and Main Technical Features
and Parameters.
M drain the oil directly to the ground. M
• Do not let anybody walk into the job site while
2 • Dispose of the hazardous material such as inf lating the tires.It is 2
necessary to stand at the side
lubricating oil, fuel, coolant, solvent, filter and of the tire, use self-clamping collets and check the
8 battery in accordance with the related laws and tire pressure now and then 8 to make sure that the
regulations. pressure will not be too high.
_ _
• If the rim is installed incorrectly, the rim can be
j
Inspection After Access and damaged or scattered after the j tire is
Maintenance
m inf lated.Therefore, put protectivemplates around the
tire and do not work at the side of the rim.
If the comprehensive access and maintenance is not
2
perf ormed and the function of each maintenance
2
• The abnormal decrease of the inflation pressure
8 checked, unexpected problems can
position is not and the abnormal fit of the rim indicate8 that there is
occur which could cause personal injury or machine a malf unction in the tire or rim.In this case, ask a
s always consider the following
damage. Therefore, tire repair shop to repair the tire. s
questions.
z • Do not adjust the inflation pressure after z
• Inspection After Engine Shutdown high-speed traveling or high duty operation.
1. Have all access and maintenance positions been • The f ully inflated tire can explode because the air
checked? inside the tire is heated and burnt.The heating is
2. Have all access and maintenance items been caused by heating or welding the rim, external
perf ormed correctly? flame, or air heat expansion or burn due to frequent
braking.
3. Is there any tool or part f alling into the machine?It
is especially dangerous if the tool or part sticks • Tire explosion is much more forceful than
into the linkage of the lever. discharging the tire. Explosion can force the tires,
rims and f inal drive parts away from the machine
4. Have the coolant leak and oil leak been more than 500 meters and the explosion force and
repaired?Have all the bolts been tightened? pieces can cause personal injury and property
• Inspection During Engine Operation damage.

See the Maintenance During Engine Operation
section of Maintenance Considerations.Consider the
f ollowing questions while ensuring safety:
64
• It is recommended to use dry nitrogen (N2) to
inf late the tire.If there is air remaining in the tire, it is
recommended to use nitrogen that can be mixed
with air to regulate the tire pressure.The tire inflated
 j j
m m
2 2
8 8
s reduce the possibility of explosion
with nitrogen can s
Key Safety Part Catalog and
because nitrogen is nonflammable.Nitrogen can
z deterioration of rubber and
also prevent oxidation, Change Interval z
corrosion to the rim components.
• To ensure the saf ety of the loader during use, the
• Flat tire or rim damage is due to improper inflating user must perform regular maintenance.In addition,
equipment or improper use, therefore, to avoid over to ensure f urther safety, the user should also
inf lation, make sure that proper equipment is used change the parts outlined in the chart
and the tire is inf lated by trained person. periodically.These parts area essential to the saf ety
and f ire prevention.
• The material of these parts can be deteriorated or
more easily to be worn or corroded over time.And it
is very difficult to judge the condition of these parts
only based on the regular maintenance.Therefore,
no matter what their condition is, they must be
changed periodically to ensure their performance.
Tire Storage Considerations • If the change interval is not reached but their
• As a guideline, the tires must be stored in the abnormal operation is found, repair or replace them
warehouse where unauthorized person can enter.If immediately.
it is necessary to store the tires outside, set fences • If there is any damage (for example, deformation or
around the tires and put a NO ENTRY sign on it. cracks) to the clip securing the hose, replace it with
J • Put the tires uptight on a level surface and hold the hose. J
M them with wedges so that they will not fall even if Mor other similar parts must be
• The O ring, gasket
touched by unauthorized person.If the tire is placed replaced with the hose.
2 on its side, it will be crushed and the quality will 2
reduce. • Contact the designated dealers of Caterpillar
8 8
(Qingzhou) Ltd. for the replacement of key safety
• If the tire is going to fall, stand aside as soon as
_possible.The industrial tire is very heavy. Trying to key parts. _
hold
j it can cause serious injury. j
m m
2 2
8 8
s s
z z

65
 j j
m m
2 2
8 8
No s part needed to be changed periodically Quantity
Key safety Change Interval s
1 z
Hydraulic oil tank filter element 1
Every 6 months or 1,000 hours, whichever z
occurs first
2 Fan Belt 1
3 Fuel line (fuel tank - fuel prefilter) 1

4 Fuel line (fuel prefilter - transfer pump) 1

5 Fuel line (transfer pump - diesel filter) 1
6 Fuel line (diesel filter - high-pressure pump) 1

7 fuel line (fuel drain line) 1

8 Steering cylinder seal 2
9 Steering hose (pump - priority valve) 1
10 Steering hose (priority valve - steering gear) 1

11 Steering hose (steering gear - tank connector) 1

12 Steering hose (steering gear - steering cylinder) 6
Every 2 years or 4000 hours, whichever
13 Brake hose (air reservoir - air brake valve) 1 occurs first.

14 Brake hose (air reservoir - hand control brake valve) 1

J 15 Brake hose (air brake valve - air booster pump) 2
J
M 16 Brake hose (air booster pump - front and rear T fitting) 2 M
2 17 Brake hose (air brake valve - switch valve) 1 2
8 18 Brake hose (switch valve - air control shutoff valve) 1 8
_19 Brake hose (air control shutoff valve - park brake air
chamber)
1 _
20j Brake hose (air control shutoff valve - variable speed valve) 1 j
21
mBrake hose (hand control brake valve - air control shutoff 1
m
valve T fitting)
22
2
Brake hose (hand control brake valve - barometer) 1
2
8 8
Every 3 years or 6000 hours, whichever
23 Air reservoir 1
s occurs first.
s
z z

66
 j j
m m
2 2
8 8
s Maintenance
Important s and
3. Check the seal of the radiator water fill cap
replace it if damaged.
z
Procedure 4. Tighten the radiator water fill cap.
z
5. If the coolant needs to be added daily, check for
Engine Coolant Maintenance leaks in the engine cooling system.If a leak is
present, correct it and add antifreeze to an
Proper maintenance of engine cooling system is appropriate level.
extremely important. Overheat, overcooling, pitting,
cavitation, cylinder head cracks, piston sticking and Add Coolant
radiator clogged are common faults in the cooling Before adding coolant to a new machine or an engine
system, which not only reduce the engine's work with a cleaned cooling system, determine the
ef f iciency but also cause severe engine damage. concentration of the antifreeze in the coolant based
Minimum Ambient Antifreeze
on the local record low ambient temperature (10C
Temperature for Use (C) Model below the record low ambient temperature is better)
and calculate the desired antifreeze amount based
－50 YF-3 on the total capacity of the engine cooling system.
－45 YF-2A

－40 YF-2B Attention

－35 YF-2 Never use water alone for coolant.Damage from

J －25 YF-1
M Anti-freeze
2 The main purpose of the antifreeze is to reduce the
8 condensation point and raise the boiling point of the
coolant.Use antifreeze even at a common ambient
_
temperature, because it can raise the boiling point of
the coolant and the additives in the antifreeze can
j the possibility of corrosion and cracks on
reduce
machine body.
m m
The perf ormance of the antifreeze brands
2 by Caterpillar (Qingzhou) Ltd. is as
recommended
f ollows:
8
Change the antif reeze with a good-quality one and
ref ill according s
to the instructions.
z secondary water tank and keeps stable in 10 z
Attention
The antifreeze is flammable. Do not leave it close
to a flame.
Coolant Level Check Method
The radiator is located at the tail of the machine.
1. After the engine coolant temperature drops below
50°C, loosen the radiator water fill cap slowly to
release the pressureto prevent the burns caused
by hot vapor or hot spilled coolant.
2. Check if the coolant level is between the high
mark and low mark on the secondary water tank
as shown. Add coolant to the high mark if it is
below the low mark.
corrosion can be the result of using water alone
for coolant.WeJwill not provide the warranty of
the cooling system components if using water
alone for coolant.M
2
The steps of adding coolant is as follows:
8
1. Turn on the negative switch of the power;Insert
_ and turn it to position
the key into the start switch
1 clockwise to energize the machine power;Push
j switch to HEAT
the air conditioner system toggle
position.
2. Turn the hand valve of the engine water inlet line
to the ON position (the valve handle2 is in the
same direction of the line route at ON8position).
3. Open the radiator water fill cap to add coolant
s on the
slowly until the level reaches the high mark
minutes.
Attention
While adding coolant, the air must be vented from
the engine coolant piping.
4. Start the engine with the radiator water fill cap
open and run it at low idle speed for 5 minutes
f irst and then run at high idle speed for 5 minutes
to make the coolant temperature above 85°C.
5. Check the coolant level again and continue to
add coolant if necessary until the level reaches
the high mark on the secondary water tank.
6. Check the seal of the radiator water fill cap and
replace it if damaged.

67
 j j
m m
2 2
8 8
s mixture of water and sodium carbonate ands the
Attention mixing ratio is 0.5 The level should reach engine
z operating level and keep stable within 10 z
Do not add cold coolant to a hot engine, or else, minutes.
the engine body can be damaged.Wait until the
engine temperature is below 50 °C. Attention
While adding the cleaning solution to the cooling
Attention system, the air must be vented from the engine
coolant piping.
Caterpillar (Qingzhou) Ltd.. will not be
responsible for the loss caused by coolant leaks During the whole cleaning process, the engine is
and the drop of antifreeze concentration due to running with the radiator water fill cap removed.
the user's misuse. 9. Start the engine with the radiator water fill cap
removed, and run the engine for another 5
minutes af ter the coolant temperature is above
Coolant Change or System Cleaning 80°C.
Completely change the coolant in the cooling system 10. Turn off the engine and drain the cleaning
and clean the cooling system every 10,000 hours or 5 solution.
years, whichever occurs first.
11. Fill the engine cooling system with clean water to
Before this interval, if the coolant is contaminated, the normal operating level and keep it stable within
engine is overheated, or there is bubbles in the 10 minutes.Start the engine with the radiator
radiator, clean the cooling system right now.
J water f ill capJremoved, and run the engine for
The steps of cleaning the cooling system are as another 5 minutes after the coolant temperature
M f ollows: is above 80°C.M
2 1. Turn on the negative switch of the power;Insert 12. Turn off the engine2and drain the water in the
the key into the start switch and turn it to position cooling system.If the water being drained is still
8 1 clockwise to energize the machine power;Push dirty, the system must8be flushed again until the
water comes out clean.
_ the air conditioner system toggle switch to HEAT
position.
_
2. jTurn the hand valve of the engine water inlet line j
to the ON position (the valve handle is in the
m
same direction of the line route at ON position).
m
Engine coolant is toxic and undrinkable. Dispose
of it according to the local laws and regulations.
2 engine and shut it down after idling it for
3. Start the 2
5 minutes.Turn
8 the START switch to position 1 to Cleaning Radiator Fins 8
energize the machine power, and put the toggle
If there is dirt sticking to the radiator, clean in the
sair conditioner system at HEAT
switch of the
f ollowing method. s
position to open the magnetic water valve of the
air conditioner.z 1. Remove the bolts and remove the rear gridzform
the rear of the machine.Meanwhile remove the
4. Af ter the coolant temperature drops below 50°C,
connector of rear work light.
loosen the radiator water f ill cap slowly to release
the pressure 2. Remove the dirt and leaves, etc. on the radiator
f ins with compressed air, vapor or water.
5. Open the water drain valve at the bottom of the
radiator and the drain valve of the engine oil
cooler to drain the engine coolant and collect it
with a container.
6. Af ter all coolant is drained, close the water drain
valve at the bottom of the radiator and the drain
valve of the engine oil cooler.
7. Check all the water pipes and clamps for damage
and replace if necessary.Check the radiator for
leaks, damage and dirt accumulation. Clean and
repair if necessary.
8. Fill the engine cooling system with a cleaning
3. Also check the rubber hose.If cracks on the hose
68
 j j
m m
2 2
8 8
s or hardening is found, replace the
or deterioration s
the machine to check, the dust can be removed
hose with a new one.Also tighten the loosened by dust valve in time. Replace the dust valve
pipe clamp. z immediately when it is damaged or missing.z
2. Counterclockwise rotate the seal cover and
Maintenance of Engine Air remove, and then the external element can be
Cleaner seen.
3. Catch the clamps of external element rear cover
Attention and pull the external element out of the air
Turn off the engine when maintaining the air cleaner cavity.
cleaner to prevent damage. 4. Maintain the external element according to the
maintenance instructions of air filter.
Maintenance and Replacement of Engine 5. Bef ore installing back the external element, clean
Air Filter Element the inside of the cleaner and remove the dust
accumulating on the internal threads with a bristle
brush or a rag to make sure that the thread is
The air f ilter is in the engine hood. smooth, and prevent dust f rom entering the inside
When the alarm appears red, use compressed air of of the element.
less than 205 kPa, along the direction of the pleats, to 6. Install back all parts in the opposite order of
clean the f ilter element from inside out.Do not use removal and make sure that they are installed
other tools to knock the filter element when removing correctly to ensure a correct sealing. Do not omit
the f ilter element.Clean the inner wall of the filter
J outlet pipe and the sealing surface.Replace the filter
any part. J

M element af ter 6 times of cleaning or 250 (high dust) - MAttention

500 (low dust) working hours.Check the connections
2 Caterpillar (Qingzhou)2Ltd.. recommends the use
to ensure that the filter cap matches the engine
of a certified air cleaner and cleaning service
intake and is airtight.
8 provided by an authorized 8 Caterpillar (Qingzhou)
Ltd. dealer.
_ _
The cleaning process of Caterpillar (Qingzhou) Ltd.
Thej air filter can only be serviced when the employs proven procedures thatj ensure consistent
engine is shut down.Otherwise, the engine may quality and long cleaner life.Observe the following
m
be damaged as a result. m filter element:
guidelines if you attempt to clean the
2 air cleaner filter element when the
Service the 2order to
Do not tap or strike the filter element in
blue plunger on the engine air filter service remove dust.
8 the red zone.
indicator enters 8
Do not wash the filter element.Use low pressure
s compressed air to remove the dust from thesfilter
Cleaning the air filter primary element.The air pressure must not exceed 205
z z
kPa.Direct the air flow up the pleats and down the
element pleats from the inside of the filter element.Take
extreme care in order to avoid damage to the pleats.

Replacement of Safety
Element
1. Open the engine hood.
2. Remove the air cleaner cover from the air cleaner
housing.Remove the primary filter element from
the air cleaner housing.

1. Loosen all clips connecting the rear cover to the

housing, remove the rear cover, and remove any
dust on the rear cover. Caution:When stopping
69
 j j
m m
2 2
8 8
s s in
Removing Water and Contaminants
the Diesel
z z
Fuel pump and injection pump are very precise
devices. If there is water or contaminants in the
diesel, the fuel pump and injection pump will not
operate properly and will be prematurely
worn.Measure should be taken to remove the water
and contaminants in the diesel.The method is as
f ollows:
1. The diesel should be settled for 24 hours before
added to the fuel tank if possible.
3. Remove the secondary filter element.
2. Bef ore refilling, open the drain plug at the bottom
4. Cover the air inlet opening.Clean the inside of the of the fuel tank every week to drain the water and
air cleaner housing. contaminants.
5. Remove the cover from the air inlet opening. 3. Add diesel to FULL after the daily work to drain
6. Inspect the operator compartment for a buildup of the moisture in the fuel tank.
trash. 4. Wait 5 to 10 minutes before starting the engine
7. Install the primary filter element. af ter the f uel tank is filled to FULL, to make the
water and contaminants settle to the bottom of
8. Install the air cleaner cover and tighten it. the tank.
J 9. Close the engine hood. J
5. Af ter the daily work, loosen the water drain plug
M Attention at the bottom ofM the fuel prefilter and primary fuel
f ilter to drain the water and contaminants.
2 Always replace the secondary element.Never 2
Do not wait to add fuel until the fuel tank is empty, or
8 attempt to reuse the secondary filter element by
cleaning the element.When the secondary filter
else the engine will die and8there will be large amount
of water and contaminants at the bottom of the fuel
_
element is replaced, the primary filter element
should also be replaced.The secondary filter
_ engine operation.
tank which will prevent the normal
j should also be replaced if the exhaust
element Diesel Sulfur j
smoke is still black.
m m the choice of
The diesel sulfur percentage can affect
engine oil and oil change interval.The sulfur can
2 2 acid during
convert into sulphuric acid and sulfurous
Use and Maintenance of Diesel burning which will corrode the metal
8 8
surf ace.Theref ore, use the diesel fuel with low sulfur
Diesel Fuel Tank
s content. s
The diesel f uel tank breather should be maintained Some additives in the oil contain alkaline compound
z
as the f ollowing procedure defined: z
which can neutralize the acid.Therefore, the oil
Typically change the breather annually, but if it is change interval should be adjusted based on the
badly contaminated, it is recommended to change it diesel sulfur:
every 1,000 hours or 3 months. When slow refilling 1. If the diesel sulfur is below 0.5%, change oil
speed is felt, remove the breather and continue to according to the interval specified in the Regular
ref ill. Blow out the dust etc. clogging the screen with Maintenance in this manual.
high-pressure air when maintaining the breather
daily. 2. If the diesel sulfur is between 0.5%~1.5%,
change oil at 1/2 of the interval specified in the
The f uel f iller screen and the fuel tank should be Regular Maintenance in this manual.
cleaned periodically. The f uel tank can be cleaned
with the f ollowing method: 3. If the diesel sulfur is above 1.5%, change oil at
1/4 of the interval specified in the Regular
Remove the flange disc at the front end of the fuel Maintenance in this manual.
tank and flush the inner surf ace of the tank with clean
diesel. Loosen the drain plug at the bottom of the
tank to drain the fuel.Flush repeatedly until the
drained f uel is clean.

70
 j j
m m
2 2
8 8
Replacements of Fuel Filter and Fuel s
Prefilter Changing Engine Oil
z z
1. Clean the surrounding area of the filter and the Change the engine oil when the specified oil change
f ilter head first. interval is met.Position the machine on a level
surf ace and start the engine until the water
2. Remove the filter from the head with a strap temperature reaches 60°C. Then turn off the
wrench. engine.Pull the park brake button.Remove the oil
3. Remove the gasket 1 from the threaded drain plug at the bottom of the oil pan to drain the oil
connector of the head.Clean the sealing surface and collect it with a container. Replace the oil filter.
of the head with a lint-free cloth. Install the oil drain plug and fill with clean oil through
the oil f iller to the H mark on the dipstick.Operate the
engine at idle speed to inspect for leaks at the oil filter
and the drain plug.
Wait 10 minutes after the engine is off to allow the
engine oil to flow back to the oil pan and check the
engine oil level again. If the oil is not sufficient, add oil
to the H mark on the dipstick.
Attention
There should be a reading present on the engine
oil pressure gauge after 15 seconds the engine is
J 4. Install a new gasket to the threaded connector of started.If thereJ is no reading, shut down the
the pref ilter head;Apply a film of engine oil to the engine immediately to avoid damage and inspect
M sealing surface of the filter;Fill the filter with clean M
for correct oil level.
diesel.
2 2
5. Tighten the f ilter to the filter head with hand and
8 tighten another 1/2-3/4 of a turn after the filter 8
Replace engine oil filter
_ gasket just touches the head.Do not overtighten
with mechanical method or else the filter can be
_f ilter head.
1. Clean the area near the oil
2. Remove the oil filter with a strap wrench.
jdamaged. j
m m
Maintenance
2 of Engine Oil 2
Check the8Engine level 8
s
1. Drive the machine to a level ground, turn off the
s
zthe park brake button.
engine and pull z
2. Wait 10 minutes after the engine is off to allow the
engine oil to flow back to the oil pan.
3. Open the engine hood, pull out of the dipstick,
wipe the dipstick clean, insert it back into the oil 3. Clean the gasket surface on the head with a
f iller to the end, and pull it out again to check if clean cloth.If the old O-ring seal sticking to the
the level is between the L mark and the H mark head, remove it.
on the dipstick.
4. If the oil level is below the L mark, add oil;If the oil
level is above the H mark, loosen the oil drain
plug at the bottom of the oil pan to drain partial
oil.

Attention
Too much or too little oil can cause damage to the
engine.

71
 j j
m m
2 2
8 8
4. Install a newsO-ring seal. 2. The oil level should be at the upper positions of the
dipstick before starting the engine is started
5. Install the oil filter to the filter head and tighten it
z
until the oil f ilter gasket surface touches the head
which means that the engine can be started.If z the
oil level is not at the upper position of the dipstick,
with hand and then tighten it to the requirement
add oil to the upper position so that the engine
with a strap wrench.
can be started.
Attention 3. Position the machine on a level surface, put the
Excessive mechanical tightening may damage variable speed joystick to the neutral position, pull
thread or the seal of the filter element. the park brake button and install the frame
locking lever to prevent the machine from moving
and rotating.Engine is at idle.

Maintenance of Air 4. Start the engine and run it about 5

minutes.Inspect if the transmission oil level is
Conditioning Heater System near the middle position of the dipstick.If the oil
level is high, drain some transmission oil by
Clean the internal and external element loosening the oil drain plug at the bottom of the
every 50 hours transmission. If the oil level is low, add some
transmission oil.
If the environment is poor, tap the element with hand
or clean it with dry compressed air. Replace it in
advance if obvious insufficient air flow is felt or
broken.
J Ask the SEM dealer to check the air conditioner J
every year.
M M
2 2
8 8
_ _
j j
m m
2 2
8 8
s Attention s
Over high or low level can cause damage to the
z z
transmission. Maintain the transmission oil level
Maintenance of Transmission at a correct position.
While checking the transmission oil level and
Checking the Transmission Oil Level changing transmission oil, unique care must be
The transmission oil filler is at the rear top of the left taken not to allow the contaminants to enter the
f loor. Check the transmission oil level at the specified transmission system which can cause damage to
interval to ensure oil amount.The level can be the transmission.
checked by observing the dipstick at the right of the
transmission body (transmission oil level should be in
the middle position during machine operation).
Changing the Transmission Oil
Check the transmission oil level as follows: The transmission oil is not only the working medium
of hydraulic torque converter - transmission hydraulic
1. Check the cold oil surface before the cold system, it is also used to cool down and lubricate the
machine is started;The purpose is to make sure torque converter - transmission parts, therefore, the
that there is sufficient oil when the machine is selection of transmission oil should meet the
started.It is especially important for a loader that requirements and change the transmission oil
is not used for quite a long time. according to the specified change interval, or else,
the service life of transmission will be shortened.
72
 j j
m m
2 2
8 8
s
Change the transmission oil as follows: oil. s
1. Start the engine to operate the machine for
z
several hours to make the contaminants, metal
z
Attention
debris and sediments suspend in the oil.
Before changing transmission oil, cover the park
2. Position the machine on a level surface, put the brake so that the friction plate of the park brake
variable speed joystick to the neutral position, pull will not be contaminated by oil which can cause
the park brake button and install the frame reduction of braking performance.
locking lever to prevent the machine from moving
and rotating. Replacing the drive oil filter element
3. Turn off the engine and loosen the oil drain plug 1. Clean the area near the drive oil filter head.
under the transmission and collect it with a
container. 2. Remove the drive oil filter housing with a strap
wrench and remove the element.
4. Loosen the oil drain plug under the torque
converter and collect it with a container.

The transmission oil is still hot at this point,

therefore wear protective devices and use care to
avoid personal injury.
J J
5. Use a magnet to remove the iron scurf sticking to
M the oil drain plug and remove the iron scurf on the
M
2 inner wall of transmission. 2
3. Clean the gasket surface on the head with a
8 6. Install the oil drain plugs under the transmission
and torque converter oil cooler and the related clean cloth and install 8
a new element.
_ seals. _
7. jInstall the oil drain plug under the torque j
converter and the related seals.
m the transmission oil f iller cap and add clean
8. Open m
transmission
2 oil through the filler tube. The 2
transmission oil level should be at the highest
level that8the oil level allows. 8
s and run it about 5
9. Start the engine
minutes.Inspect if the transmission oil level is
s
near the middle z position of the dipstick.If the oil 4. Install the drive oil filter housing. z
level is high, drain some transmission oil by
loosening the oil drain plug at the bottom of the Attention
transmission. If the oil level is low, add some
transmission oil. The drive oil filter is directional.During
installation, the direction of the arrow should face
10. Tighten the oil filler cap clockwise. away from the drive pump.
Replacing the transmission oil pan
suction element Maintenance of Drive Axle
1. Drain the oil in the same way of changing Check the oil level and replace the drive axle oil
transmission oil. according to the requirements in the Regular
Maintenance.
2. Loosen the transmission oil pan suction bolts and
remove the oil pan.Take out the transmission Check the drive axle oil:
suction screen and clean or replace it. There are respectively three oil drain plugs and oil fill
3. Clean the transmission bottom.Install a new plugs for front and rear drive axles, located at the
suction screen and tighten the oil pan bolts. middle of axle housing and both sides of curb.The oil
f ill plug can also be used to observe the oil level.
4. Add oil in the same way of changing transmission
73
 j j
m m
2 2
8 8
s axle oil
Checking the drive
1. Drive the machine to a flat surface and slowly
z
move the machine to make the arrow on the front
drive axle curb end cover point vertically
downward. Pull the park brake button to prevent
the machine f rom moving and stop for 15 minutes
(the f ront and rear drive axle oil level needs to be
checked twice).
2. Clean the area near the oil level plugs at both
sides of drive axle curb and remove the oil level
plug to check if the oil level in the drive axle is 8
mm below the lower edge of the oil drain. Small
amount of spillage is allowable.If the oil level is
much lower than the lower edge of the oil drain,
add drive axle oil.Observe for about 5 minutes
af ter adding oil until the oil level is stable (any oil
level plug can be used to check the oil level).
3. Tighten the oil level plug.
4. Check the rear drive axle oil level by using the
same steps above.
J Replacing Drive Axle Oil
M 1. Drive the machine for a period of time to allow all
sediments in the axle housing to suspend.Then
2 drive the machine to a flat surface and slowly
move the machine to set the oil drain plug at the
8 drive axle curb end face at the lowest
_ position.The front and rear drive axle oil needs to
be drained several times because the oil drain
jplugs at the left and right and front and rear drive
axle curb end face can not be at the lowest
m simultaneously.
position
2 the engine, put the variable speed
2. Turn off
joystick to the neutral position and pull the park
8 to prevent the machine from
brake button
moving.
s s
3. Remove the oil drain plugs at the drive axle curb
end f aces andzthe middle of the axle housing to
drain oil and collect with a container.
The drive axle oil may be still hot at this point,
therefore wear protective devices and use care to
avoid personal injury.
4. Install all the oil drain plugs at the drive axle.
5. Slowly move the machine to make the arrow on
the either side of the curb end cover point
vertically downward.
6. Add clean drive axle oil through the oil level plug
or oil drain plug at the axle curb end face until the
oil level reaches the lower edge of the oil level
plug of the front axle curb end face.Observe for
74
about 5 minutes after adding oil until thesoil level
is stable (see the Operation and Maintenance
manual f or the amount of oil added). z
7. Install the plugs at the drive axle curb ends.
8. Change the other drive axle oil in the same
manner above.
Maintenance of Hydraulic
System
Check the oil level and replace the hydraulic oil
according to the requirements in the Regular
Maintenance.
Check the hydraulic oil level
The hydraulic oil tank is on the right side of the cab
and there is an oil level gauge at the front end of the
tank.
To check the hydraulic oil level, position the machine
on a level surf ace and put the bucket on the ground
horizontally. Meantime, the front and rear f rame
J
should be straightened, leaving no angle between the
f ront and rear f rame.
M the hydraulic oil level
Now
should be at 2/3 of the oil level gauge.
2
Replacing the hydraulic oil tank drain
element 8
1. Raise the boom and put the _ bucket at retract
position. Support the boom with a bracket to
j
prevent the work tool from falling.Put the work
tool lever at neutral position.Apply the park brake
and turn off the engine. m
2. Remove the mounting bolts on the2oil filter cover
at the side of the tank and remove the cover.The
8
cover can bounce due to the force of spring, so
press the cover while removing the bolts.
3. Remove the spring and element.
z
4. Install new element, spring and cover.
5. Press the cover while installing the bolts and
tighten the bolts evenly.
6. Check the oil level and add oil to the specified
level.
7. Check the assembly joint at the oil filter cover for
leaks.
Regular Replacement of Hydraulic Oil
Change the hydraulic oil every 2000 service hours or
every year.The method is as follows:
1. Remove any debris in the bucket. put the variable
speed joystick to the neutral position and pull the
park brake button and install the frame locking
lever.Start the engine and idle it for 10 minutes
during which repeat the actions of lifting boom,
 j j
m m
2 2
8 8
s tilting bucket forward and tilting
lowering boom, s
the right side oil filler built in the barrel structure,
bucket backward several times. and there is an air vent plug at the middle of the
z
2. Finally, raise the boom the highest position, tilt
f lange at the top of the barrel.When releasing z
hydraulic oil is required during repair, open the air
the bucket to the maximum position and turn off
vent plug to release a small amount of hydraulic
the engine.
oil.To change with new hydraulic oil, open the air
3. Push the bucket joystick of the pilot valve forward vent plug before adding the new oil. The level
to allow the bucket to tilt forward through its own af ter added should be at the top of the dipstick.
weight to drain the fluid in the bucket Tighten the air vent plug after f illing.After idling fo r
cylinder;After the bucket tilts to the desired 5 minutes, operate the pilot valve joystick to raise
position, push the of the pilot valve boom lever and lower the boom, tilt the bucket forward and
f orward to allow the boom to descend through its backward and steer left and right to the largest
own weight to drain the fluid in the boom cylinder. angle f or 2-3 times, to fill the cylinder and lines
with hydraulic oil.
4. Clean the opening of the oil drain tube under the
hydraulic oil tank and remove the oil drain plug to 10. Turn off the engine, open the oil filler cap of the
drain the hydraulic oil and collect with a hydraulic oil tank, and add clean hydraulic oil to
container.Meantime, open the oil filler cap to the center-upper position of the oil level gauge in
accelerate the oil draining. hydraulic oil tank.
5. Remove the oil inlet tube of the hydraulic oil Note:
cooler to completely drain the oil residue in the
1. To repair the hydraulic system, such as pump,
radiator.
hydraulic oil line, etc., the air vent plug must be
J 6. Remove the oil drain element from the hydraulic J the hydraulic oil drain flow in
opened to reduce
oil tank and replace with a new one.Open the oil the hydraulic oil tank, or else, the hydraulic oil in
M f iller cap and remove the oil filler screen for the tank will beMcompletely drained.
cleaning.
2 2. The air vent plug must 2 be opened to add
7. Remove the tank clean-out flange disc under the hydraulic oil. The level should be at the top of the
8 oil f iller and flush the bottom and walls of the 8 air vent plug must be
dipstick after filling. The
hydraulic oil tank and wipe with a clean cloth. closed after f illing and before starting the
_ machine, or else air will be _ drawn into the
8. Install the oil drain plug of the hydraulic oil tank, hydraulic system, causing serious damage to the
joil drain f ilter and top cover, oil filler screen, tank machine.
j
clean-out flange mouth and the oil inlet tube of
mhydraulic oil cooler.
the Replacing pilot oil elementm
2 2 head.
1. Clean the area near the pilot oil filter
8 2. Open the pilot oil filter housing with a8
wrench and
remove the element.
s s
3. Clean the gasket surface on the head with a
z z
clean cloth (replace if the ring seal is damaged)
and install a new element.

4. Assemble pilot oil filter.

The structure of the hydraulic oil tank is as shown
9. Add clean hydraulic oil through the oil filler of
hydraulic oil tank. The hydraulic oil can only enter
f rom the underside of the barrel structure due to
Replacing the seriously contaminated
hydraulic oil
If the work environment is poor, or the hydraulic oil is

75
 j j
m m
2 2
8 8
sto serious contamination, such as
deteriorated due corrosion to the rim components. s
darkening color or bubbles, replace the hydraulic oil
Wait f or the tires to cool down sufficiently before
in time. z z
checking and adjusting the tire inflation pressure.The
1. Remove any debris in the bucket. put the variable tire inf lation pressure of using nitrogen is same with
speed joystick to the neutral position and pull the that of using with air.Caterpillar (Qingzhou) Ltd..
park brake button and install the frame locking recommends to choose the tire inflation pressure
lever.Start the engine and idle it for 10 minutes based on the operating condition of the machine.
during which repeat the actions of lifting boom,
Tire Size:23.5-25
lowering boom, tilting bucket forward and tilting
bucket backward several times. Tire inf lation pressure (kPa) Front wheels:400 Rear
wheels:350
2. Finally, raise the boom the highest position, tilt
the bucket to the maximum position and turn off Attention
the engine.
If the machine travels at high speed for an
3. Push the bucket joystick of the pilot valve forward extended period of time, stop the machine for 30
to allow the bucket to tilt forward through its own minutes every 45 km, to cool down the tires.
weight to drain the fluid in the bucket
cylinder;After the bucket tilts to the desired
position, push the of the pilot valve boom lever
Bucket Kickout Adjustment
f orward to allow the boom to descend through its This machine has a bucket self-leveling function.
own weight to drain the fluid in the boom cylinder. Rational use of this function during operation can
4. Clean the oil drain under the hydraulic oil tank improve the work efficiency significantly.
J and remove the oil drain plug to drain the J
Adjust the bucket self-leveling device
hydraulic oil and collect with a
M container.Meantime, open the oil filler cap to
M
1. Position the machine on a level surface and put
2 accelerate the oil draining. the variable speed 2joystick to the neutral
position.Operate the pilot valve joystick to level
8 5. Open one end of all the tubes to drain the oil
residue in the steering cylinder, hydraulic oil
8 pull the park brake
the bucket on the ground,
button, and turn off the engine;Install the frame
_ cooler and any tube. locking lever. _
6. jAf ter the oil draining finishes, install the oil drain
2. Loosen the arrow bolt on thej caliper, move the
plug under the hydraulic oil tank and all opened
arrow to the middle position of the tilting cylinder
m
tubes.
small chamber connector bodym and tighten the
7. Open2 the oil filler cap of hydraulic oil tank and arrow bolt. 2
add clean hydraulic oil to the lower mark of the oil
3. Af ter completion, remove the frame locking lever,
8
level gauge.
start the engine, and check for proper8
8. Perf orm oil s change one more time according to adjustment. s
the procedure in the Regular Replacement of
z
Hydraulic Oil, replace the oil drain element, and Checking park brake z
clean the f iller screen and hydraulic oil tank.
performance
Knowledge of Tire The park brake performance should be checked
Maintenance and Inflation f requently to ensure park safety and the braking
capability in case of emergency barking.
The maintenance, removal, repair and installation of
1. Adjust the tire pressure of the machine to the
the tire and rim require special equipment and
specified value and level the bucket about 300
techniques, therefore ask a tire repair shop or a
mm above the ground.Verify the machine has
specially trained person to do the job and obey all
good service brake performance.
related regulations.
2. Start the engine and make the machine face a
It is recommended to use dry nitrogen (N2) to inflate
20%-grade slope which should be flat and dry.
the tire.If there is air remaining in the tire, it is
recommended to use nitrogen that can be mixed with 3. Depress the service brake pedal to stop the
air to regulate the tire pressure. The tire inflated with machine.Put the variable speed joystick to the
nitrogen can reduce the possibility of explosion neutral position and turn off the engine.
because nitrogen is nonflammable.Nitrogen can also
4. Pull the park brake button and slowly release the
prevent oxidation, deterioration of rubber and
service brake pedal to check if the machine is still
76
 j j
m m
2 2
8 8
s position.
at the original Note: It is recommended to shorten the s
maintenance interval if the working conditions is
z
Checking service brake z
harsh.
performance
Replacement Procedure
Make sure that the park brake system is operational
bef ore checking the service brake performance to The air dryer and lower shell are connected by screw
apply the park brake at emergency. threads. When replacing the air dryer, first unscrew
the old one, then wipe the sealing ring between the
Drive the machine at 20 km/h on a flat, straight and air dryer and the lower shell and put it back, and
dry on a cement pavement and depress the service f inally screw on the new air dryer with a torque of
brake pedal. After the machine stops, push the 25NM.
variable speed joystick to the neutral position, pull the
park brake button, and then release the service brake
pedal.Check the machine's brake distance which
should not exceed 9 meters.
Drive the machine at 32 km/h and slightly apply the
service brake, the machine should be stopped
instantly without deflecting.

Checking park brake friction

plate
J J
The 3 longitudinal gutters on the caliper friction plate
M are marks for grinding, it needs to replace with new M
2 plate if the gutters on it are smooth. 2
8 Maintenance of the Air Dryer 8
_
Introduction _
j braking system of machine, the condensate in
In the
compressed air from the air compressor is the main
Note: please use SEM genuinej parts when
causem of pipeline corrosion and lubrication failure. replacing the air dryer. m
Especially when the ambient temperature is low, the
2 be frozen. This will decrease the
pipeline may Maintenance of Pin Shaft 2 and
reliability and service life of the braking system, and
8 Drive Shaft 8
even brake f ailure. The air dryer can effectively
s and oil in the compressed air.
remove the moisture s the
To reduce the difficulty in adding grease, improve
Maintenance Interval maintenance for the entire machine and the service
z z all
lif e and reliability of the machine, we recommend
The air dryer should be replaced every 1000 service users to operate according to the following
hours or 6 months. instructions.
Check whether there is water in the air tank regularly.
It is recommended to check every 250 service hours Reference point for articulation pin shaft grease
or once a month. When water is found in the air tank, fill position:
it means the dryer has failed and should be replaced
immediately.

There are 21 articulation pin shaft grease fill positions.

Please add grease according to the positions

77
 j j
m m
2 2
8 8
s below during each maintenance
outlined in the table 2. Grease f ill at transmission end s
event and make sure that each joint is properly
lubricated: z z
Fill position Quantity
Bucket and boom joint 2
Bucket and drawbar joint 1
Drawbar and rocker lever
1
joint

Rocker lever and boom joint 1

Raising cylinder and boom
2 3. Grease f ill at transmission end
joint
Tilting cylinder and rocker
1
lever joint

Boom and front frame joint 2

Tilting cylinder and front
1
frame joint
Raising cylinder and fro nt
2
frame joint
J Steering cylinder and front J
2
frame joint
M M
Steering cylinder and rear
2 frame joint
2 2
8 Swing frame and rear frame 2
Welding Operation
8
joint
_Front and rear frame joint 2
_
When welding on the machine, perform as specified
j j or accidents.
below, to avoid machine damage
Grease fill device: 1. Read and understand the related
m m safety
regulations on welding on the machine before
Use the shown grease gun supplied with the SEM
2 has been tested at site to meet the
machine that welding. 2
grease f ill requirements of the machine. 2. The engine start switch must be turned
8 8 off and
the power negative switch must be disconnected
Grease Gun Use Considerations
s
Clean the grease nozzle before filling to make sure
bef ore welding. s
that no contaminants z obstructs the grease nozzle or 3. The dashboard connectors must be removed
bef ore welding to avoid dashboard damage.Or
z
passage.
disconnect the cab harness (at the lower right of
Check the device for good condition, especially the cab and near the f rame articulation;) from the
connection between the hose/tube connector and machine harness.
grease nozzle f or tightness before it is used.Remove
the air inside the grease gun before adding grease to 4. Do not use voltage greater than 200 V constantly.
make sure that the filling pressure is achieved. 5. Weld area is within 1 meter from the ground
cable.
Grease fill process for main drive
shaft: 6. The ring seal and bearing should be not located
between the weld area and ground cable.
The main drive shafts on the currently produced 50
7. Never weld or cut any pipe or container filled with
and 60 loaders by Caterpillar (Qingzhou) Ltd. need to
f uel, oil and hydraulic oil.
be maintained every 500 hours or 3 months.
8. Never weld or cut any sealed or poorly-ventilated
Fill procedure: container.
1. The grease gun connector aligns with the grease Maintenance-free Battery Charging
nozzle and the grease can be added smoothly.

78
 j j
m m
2 2
8 8
s
Regulations (do not exceed 16.2 volts, or else the water swill be
electrolyzed and the level will drop, causing battery
z f ailure). The maximum current is 25 amperes. z
This machine uses maintenance-free battery. The Charge the battery with a charger until the electrolyte
f ollowing regulations must be obeyed during use. indicator is green.Turning green means the electricity
Reason for Battery Discharge is sufficient.

1. Abnormal use, for example, the electric For the battery with a battery voltage less than 11.0
volts, the battery may not be able to receive the
appliances on the vehicle are on for an extended
period of time before the vehicle is started. electricity at initial phase.The reason is that the sulfur
ratio in a badly discharged battery is close to pure
2. Long time of vehicle stopping, excessive current water. The battery inner resistance is very high.This
leakage, or installation of additional appliances. can be resolved by reducing the charging current or
changing for an alternator with a larger power. As the
3. Frequent start of the vehicle.
charging is going on, the sulfur ratio in the battery
4. Malf unctioning charging system (for example, increases and the charging current will restore to a
f ailed alternator and electronic elements, over normal level gradually.
low charging voltage setting of the alternator
If a large amount of acid spills from the vent hole of
governor, loose engine drive belts) made the
the battery while charging, stop charging immediately
battery charged improperly, causing battery
and f ind the reason.
discharge. The electrolyte indicator is black, and
the machine even can not be started. When the battery temperature is above 45 degrees
centigrade while charging, stop charging. When the
5. The unused battery is stored for more than 6
J months. J drops to the room temperature,
battery temperature
cut the charging current in half and continue
M The discharged battery due to the reasons above can charging. M
be corrected by charging timely and properly.
2 2
Check the battery appearance before charging
8 1. The battery with a broken case or acid leakage 8
_ can not be charged. Replace the battery after _
identifying the reason.
j
2. The battery with a broken post can not be
j
m Replace the battery after identifying the
charged. m
reason.
2
3. Clean the post and remove the oxide coating on
2
8 before charging.
the surf ace 8
s
Charging Precautions s
1. Wear saf ety glasses.
z z
2. Keep the area well-ventilated while charging and
charge at normal temperature.
3. Never smoke while charging.
4. Connect the positive cable first after
charging;Disconnect the negative cable before
charging.
Battery Charging Regulations
Conf irm that the battery post is clean and the
charging return circuit is well connected.
The charger positive connects the battery positive
and the charger negative connects the battery
negative.Never charge the battery in series (24 V).
It is recommended to use constant voltage16.0 volts

79
 j j
m m
2 2
8 8
s
Oil Use Regulations s
z and types specified in the table below when adding or changing various oils in this machine,
Use the specifications z
to ensure normal machine operation.

Use Position Ambient Temperature Lubricating oil specification Remarks

-20°C-40°C CH-4 SAE15W-40
-25°C-40°C CH-4 SAE10W-40
Engine
-30°C-40°C CH-4 SAE10W-40
-35°C-40°C CH-4 SAE0W-40
-25°C~40°C 8#Hydraulic drive oil
Transmission
-35°C～40°C SAE0W-40

-15°C～49°C GL-5 85W-90

Drive -25°C～49°C GL-5 80W-90
Recommended oils:
-45°C～10°C GL-5 75W-90 Contact SEM dealer to use
designated oils by Caterpillar
-5°C-40°C L-HM 46 (Qingzhou) Ltd.
Hydraulics -26°C-40°C L-HV 46
J -35°C-40°C SAE0W-40 J
M Air booster pump
DOT4 or DOT3 brake oil that meets M
SAEJ703 standard
2 Anti-freeze YF-2 or YF-2A
2
8 5°C 0# 8
_ Fuel tank -14°C -20# _
j -29°C -25# j
Caution Statement
m m
1. Do not mix the oils with the same specifications but f rom different brands. If the oil f rom another brand must be
used 2
f or some reason, flush the system clean first. 2
8 operates at a frigid zone a long period of time, the hydraulic oil should be HV46 or HS46
2. If the machine 8 low
temperature anti-wear hydraulic oil.
s
3. Various oils should be changed timely even the oil is still clean.The oil can also deteriorate if stored for an
s
z of time.
excessive period z
4. The f uel should be chosen based on the local record low air temperature.

80
 j j
m m
2 2
8 8
s
Fault Reason and Troubleshooting s
z z
Engine System
For the f ault reasons and troubleshooting methods for engine system, see the supplied engine instructions.
Driveline
1. Low speed change pressure at each shift position

Fault Reason and Characteristics Troubleshooting Method

1. Low transmission oil level 1. Fill to the specified oil level
2. Oil leak in gallery 2. Check and repair
3. Clogged transmission suction screen 3. Clean or replace the screen
4. Damaged speed change valve 4. Access or replace the speed change valve
5. Improper adjustment of pressure valve 5. Readjust as specified

2. Low speed change pressure at one shift position

1. The piston ring seal is damaged at this shift position 1. Replace the ring seal
2. Damaged ring seal in the oil circuit 2. Replace the ring seal
J J
3. Oil leak in the passage at this shift position 3. Check and repair
M M
2 3. High oil temperature in torque converter 2
8 1. Low transmission oil level 1. Fill to the specified level 8
2. High transmission oil level 2. Drain to the specified level
_ _
3. Clogged oil cooler 3. Clean or replace the cooler
4.
j Slipping clutch 4.
j
Access and correct the speed change pressure
5. m
Excessive time of constant high-duty work 5. Stop or idle the engine for cooling m
2
4. The machine can not travel after started
2
1.
8
Not into gear 1. Put into gear or adjust the shift lever into place
8
2. s
The speed change valve can not go back after shut off 2. Remove and check the speed change valve, and s
troubleshoot faults
z z
3. Low torque converter pressure 3. Adjust torque converter overflow method
4. Low speed change pressure 4. See 1 and 2
5. Insufficient drive power

1. Low speed change pressure 1. See 1 and 2

2. High oil temperature in torque converter 2. See 2
3. Damaged torque converter impeller 3. Remove and check the torque converter and replace
the impeller
4. Poor engine output power 4. Access the engine
5. Unreleased service brake or park brake 5. Access the brake system

Brake System
1. Poor service brake capability
1. Brake oil leak 1. Replace seal

81
 j j
m m
2 2
8 8
2. s
Air in the hydraulic brake lines 2. Vent air according to vent procedure s
3.
z
Low air pressure in the air line system 3. Check the air compressor
z
4. Worn cup of the air booster pump 4. Replace the cup
5. Oil on the friction plate 5. Identify the reason and correct it
6. Friction plate worn to the limit 6. Replace with a new plate

2. Unable to shift into gear after braking

1. Brake valve can not return to its original position 1. Remove, check and repair
2. Stuck speed change valve air valve lever 2. Remove, check and repair
3. Poor air pressure at the rear cavity of speed change 3. Access line system
shutoff valve lever

3. Brake unable to be released normally

1. Brake valve not in place, or stuck piston lever and failed 1. Check, adjust or replace damaged parts
return spring
2. Air booster pump piston can not return 2. Check, clean and correct
3. Caliper piston can not return freely 3. Clean or replace the rectangular ring seal
J J
4. Reservoir pressure dropping fast after parking
M M
1. Intake valve of brake valve stuck or damaged 1. Repeat braking several times, blow out the
2 2
contaminants or change the valve

8 2. Loose fitting or broken pipe 2. 8

Tighten the fitting or replace the pipe
3. Unsealed unloader 3. Identify the reason and replace if necessary
_ _
j
5. Pressure rising slowly after startup j
1. m
Air compressor not operating properly 1. Check the air compressor operation m
2.
2
Loose fittings 2. Tighten the fittings.
2
3. Unsealed brake valve or unlo ader 3. Access or replace
8
6. Deflection in braking
8
1.
s
Unequal brake torque for front and rear wheels 1. Check the air compressor operation
s
2. z
Unequal air pressure for front and rear wheel 2. Inflate at specified pressure z
7. Insufficient park brake capability

1. Excessive gap between brake drum and brake disc 1. Readjust as specified
2. Oil on the brake disc 2. Clean the brake disc

Work Tool and Hydraulic System

1. Lift arm rotates bucket slowly or does not move
1. Damaged cylinder seal 1. Replace the oil seal
2. Oil leak in pipeline system 2. Check and repair
3. Serious oil leak in working pump 3. Replace with a new pump
4. Improper adjustment of dump valve and low system 4. Adjust the system operating pressure to specified value
pressure
5. Air in the working pump suction tube or clogged oil filter 5. Clean the oil filter or replace the suction tube

82
 j j
m m
2 2
8 8
6. s
Excessive fit clearance at hydraulic control valve 6. Access or replace the hydraulic control valve s
z
2. Oil pump drawing oil or bubbles in oil
z
1. Low oil level 1. Fill to the specified level
2. Plugged oil filter 2. Clean the oil filter
3. Damaged oil pump 3. Access or replace with a new pump
4. Air leak in suction tube or damaged oil pump seal 4. Access or replace the damaged part
5. Poor oil or deteriorated oil 5. Change with new oil as specified

3. High oil temperature

1. Excessive time of operating at full load 1. Stop for cooling

2. System pressure adjusted too low 2. Adjust pressure as specified
3. Low oil level 3. Fill as specified
4. Damaged oil pump 4. Access or replace with a new pump
5. Plugged line or screen 5. Access, clean or replace
6. Small fan blast volume 6. Adjust belt tension as specified

J 4. Failed return J
M 1. Deformation of pilot valve return spring 1. Replace with new parts
M
2 2. Contaminants present between pilot valve press lever and 2. Parts washed 2
mating hole
8 3. Deformation of multi-way valve return spring 3. Replace with new parts
8
_
4. Contaminants present between multi-way valve levers 4. Parts washed _
j
5. Unreliable seating of pilot valve j
1. m
Insufficient magnetic draw 1. Replace with new parts m
2.
2
Contaminant on the mating face between magnet and 2.
spring seat
Parts washed
2
3. 8
Clearance between rocker and press lever not adjusted as 3. Adjust as specified 8
specified
s s
6. Poor control ofzpilot valve z
1. Stuck or unsmooth metering valve core 1. Check the cleanliness of fluid and clean valve core and
valve hole
2. Deformed metering valve 2. Replace the spring
3. Low pressure of flow control valve 3. Check for normal operation of pilot oil supply system
4. Unsmooth operation of main valve 4. Clean valve body and valve stem

Steering System
1. Hard Steering
A. Hard steering with fast or slow action

1. Insufficient oil supply from oil pump 1. Repair or replace the oil pump
2. Inflexible movement of priority valve core 2. Correct the cause of inflexible movement of priority
valve core, or replace the priority valve
3. Low control pressure of priority valve 3. Adjust the contro l pressure of priority valve

83
 j j
m m
2 2
8 8
4. s
Air in oil control circuit between priority valve and steering 4. Rotate the steering wheel. When the rotating wheel s
device reaches the limit position, continue to rotate the steering
z wheel to force the relief valve open in order to vent thez
air

B. Bubbles in the oil with irregular noise, oil cylinder not operating when rotating the steering wheel
Air in the steering system Check the oil level and add oil if necessary Check for air leak
in the suction line and troubleshootVent air in the system

C. Smooth under no load but heavy under load

1. Pressure setting of steering relief valve lower than 1. Readjust the steering relief valve pressure
operating pressure
2. Stuck steering relief valve 2. Remove the contaminants
3. High viscosity of fluid 3. Replace with proper fluid

D. Hard steering at small throttle but back to normal when throttle increases

1. Low volumetric efficiency of oil pump 1. Replace the fuel pump

2. Large clearance between priority valve core and body 2. Replace the priority valve
2. No Stop Limit
J J
When the rotating wheel reaches the limit position, rotating the steering wheel is still easy
M M
1. The pressure setting of the two -way snubber in the valve 1. Readjust the two -way snubber, with its opening
2 block mounted on the steering gear oil inlet surface lower 2
pressure not less than 1.25 times of steering relief valve
than the pressure setting of steering relief valve pressure setting
8 8
2. Serious wear between valve body,valve envelope and 2. Replace the damaged part or steering device
_ valve core, or between rotor and stator, causing large _
clearance
j j
m Failure
3. Steering m
A. Steering wheel not being able to return to neutral positronPressure runout increase at middle position
2 2
Broken spring disc Replace the damaged spring disc
8 8
s increasing significantly, rotating is impossible
B. Pressure runout s
z
Broken or deformed cotter or coupled axle opening Replace the cotter or coupled axle z

Ⅵ. Electrical System
1. Alternator Not Generating Power or with Low Voltage
1. Slippery drive belt 1. Adjust the drive belt
2. Oil-contaminated or worn commutator 2. Wipe with a clean cloth dip ped into gasoline or grind
with a fine grade of sandpaper
3. Poor connection between brush and commutator 3. Check and repair
4. Open circuit in excitation coil 4. Check the wiring of external magnetic field and check
the excitation return circuit
5. Disappearing remanence 5. Magnetize or replace the alternator

2. Battery Not Being Charged or with Low Current

1. Damaged voltage regulator 1. Access or replace

84
 j j
m m
2 2
8 8
2. s
Poorly connected wires or open circuit 2. Check the circuit between alternator and battery s
z
3. Big Spark Between Alternator Brush and Commutator
z
Seriously worn commutator Clean the commutator and remove the contaminants
between the cells

4. Overheated Alternator

1. High voltage regulation by voltage regulator 1. Adjust the regulator voltage

2. Bearing worn or insufficiently lubricated 2. Replace the bearing or add lubricating oil
3. Short circuit in commutator or armature coil 3. Repair or replace

5. Hard Engine Start

1. Low voltage or battery damage 1. Charge or replace with a battery

2. Damaged start switch 2. Access or replace
3. Poorly connected wires or open circuit 3. Check and repair
4. Air in engine oil inlet line 4. Vent air in the line

J Ⅶ. Air Conditioning System J

M 1. Inability to Blow Cool Air M
2 1. Loose or broken drive belt 1. 2
Tension or replace the belt

8 2. Burnt fuse link, disconnected o r broken wiring, damaged 2.

COOL switch, or failed blower motor
8
Replace the fuse link, repair the wirin g, switch and
blower motor
_
3. Compressor not rotating, belt slipping on the pulley 3. _
Remove the compressor for repair or replacement
4. j Compressor not operating, with little change of high and 4. j
Repair or replace the compressor valve disc
low pressure values while engine speed changing
5.
m
Broken refrigerant system lines, or refrigerant leaking to 5.
m
Repair the lines, check for system leaks, draw out
none, 2high and low pressure value bein g zero vacuum and add fluorine 2
6. Clogged reservoir dryer or expansion valve 6. Remove for repair or rep lacement
8 8
s Air
2. Insufficient Cool s
1. z
Air leak in air passage connection 1. z
Clean or replace th e air screen, remove the restriction in
air passage, reconnect the air passage
2. Abnormal operation of blower motor 2. Repair or replace the blower motor
3. Slipping compressor magnetic clutch 3. Repair or replace the magnetic clutch
4. Low efficiency of compressor 4. Repair or replace the compressor
5. Air in refrigerant system, too high reading on high pressure 5. Vent air, draw out vacuum and add fluorine
gauge, fog in sight glass
6. Insufficient refrigerant, air bubbles in sight glass, too high 6. Add refrigerant until the bubble is gone
reading on high pressure gauge
7. Insufficient air flow around the condenser, too high reading 7. Clean the condenser and engine water tank, or install
on high pressure gaug e an extra condensing fan
3. Intermittent Operation of Refrigerant System
1. Unadjustable idle controller and temperature controller 1. Readjust or repair
2. Slipping compressor magnetic clutch 2. Remove the brace or replace
3. Disengaged magnetic clutch or poor grounding 3. Remove for repair or replacement

85
 j j
m m
2 2
8 8
4. s
Water in refrigerant system causing intermittent clogging 4. Replace the reservoir dryer s
of expansion valve by water
z z
4. Louder Noise
1. Loose or overworn drive belt 1. Tension or replace th e belt
2. Loose compressor mounting brace 2. Tighten the brace mounting capscrew
3. Loose or worn blower motor 3. Repair or replace the motor
4. Slippery magnetic clutch causing noise 4. Remove for repair or replacement
5. Worn internal compressor parts 5. Repair or replace the compressor

SEM655D Regular Maintenance Parts List

I.Maintenance Interval Schedule
a.Oils (with different applicable temperatures, the customer should choose oil based on the local
condition)
This list contains SEM655D special oil used for regular maintenanceFor detailed change operation, see the
Operation and Maintenance Manual

J Demand J First
Interval
Where used Item Description User Instructions Volume Maintenance
(h)
M (L) M (h)

2 -20°C-40°C CH-4 SAE15W-40 2

-25°C-40°C CH-4 SAE10W-40
8 Engine 21 8 50 250
-30°C-40°C CH-4 SAE10W-40
_ -35°C-40°C CH-4 SAE0W-40
_
j Number 8 hydraulic drive j
-25°C-40°C
fluid
m
Transmission 53 100 m 1000
-35°C～40°C SAE0W-40
2 2
-15°C～49°C GL-5 85W-90
8 8
Axle -25°C～49°C GL-5 80W-90 36 * 2 250 1000
s -45°C～10°C GL-5 75W-90
s
z -5°C-40°C L-HM 46
z
Oil tank -26°C-40°C L-HV 46 165 2000 2000
-35°C-40°C SAE0W-40

B. Safety Class

Interval Demand Volume

Item Description Where used Remarks
(h) (L)
According to actual
Brake oil DOT3 3 Air booter pump
needs
According to actual
Brake discs 2 per caliper Calipers
needs
–35~50 Organic antifreeze - 35 5 years or 10,000
Engine Cooling
–45~50 Organic antifreeze - 45 service hours

86
 j j
m m
2 2
8 8
C.Elements s s
This list contains SEM655D genuine element used for regular maintenance. For detailed change operation, see the
z
Operation and Maintenance Manual
z
NOTE:The air filter needs to be cleaned when the air f ilter indicator gives a warning, and needs to be replaced after
6 consecutive cleanings.For all other filters, if the filter alarms indicate that they need to be replaced, replace them
immediately (filter elements).

First
Where used Item Description Quantity Maintenance Interval (h)
(h)
Engine Oil filter element 2 50 250
Air filter element 1 250

Engine Diesel secondary element 2 250 250

Diesel primary element 1 250
TRANSMISSION Drive oil drain element 1 100 1000
Transmission Screen group 1 100 1000

Pilot Element 1 250 1000

Oil tank Oil tank return element 1 250 1000

J Brake System(If equipped) Air dryer 1
J
1000 1000
M Oil tank Oil filler filter 1 M
2000 2000
2 Diesel tank Oil filler filter 1 2
8 8
II.Material list required for the maintenance within 2000 hours (one year)
_ _
Replacement Demand Volume
jtime: Item Description Fluid element
j Where used
(h)
m (L) Number of
m
Diesel engine oil 15W-40 CH 21 Engine
502 Oil filter element 2
2
Engine
8 Number 8 hydraulic drive fluid 53 8
Transmission
100 s Drive oil drain element 1 TRANSMISSIONs
zScreen assembly 50D 1 TRANSMISSION
z
80W-90 gear oil (summer) 36*2 Alex
Element YL-161-100 1 Pilot
Oil tank return filter 1 Oil tank
Diesel engine oil 15W-40 CH 21 Engine
250
Oil filter element 2 Engine
Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine
Diesel engine oil 15W-40 CH 21 Engine
Oil filter element 2 Engine
500 Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine

87
 j j
m m
2 2
8 8
Replacement s Demand Volume s
time: Item Description Where used
(h) z Fluid
(L)
element
Number of
z
Diesel engine oil 15W-40 CH 21 Engine
Oil filter element 2 Engine
750 Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine
Number 8 hydraulic drive fluid 53 Transmission
85W-90 gear oil 36*2 1 Drive
Drive oil drain element 1 Transmission
Screen assembly 50D 1 Transmission
Element YL-161-100 1 Pilot
Oil tank return filter 1 oil tank
1000
Air dryer 1 Brake System
Diesel engine oil 15W-40 CH 21 Engine
Oil filter element 2 Engine
J Air filter element J1 Engine

M Diesel secondary element 2 M Engine

Diesel primary element 1 Engine
2 Diesel engine oil 15W-40 CH 21
2 Engine
8 Oil filter element 2 8 Engine
_ 1500 Air filter element 1 _ Engine
Diesel secondary element 2 Engine
j j
Diesel primary element 1 Engine
m Diesel engine oil 15W-40 CH 21
mEngine
2 Oil filter element 2 2
Engine
1750 8 Air filter element 1 8
Engine

s Diesel secondary element 2 Engine

Diesel primary element
zHM46 anti-wear hydraulic oil
Oil filler filter
Oil filler filter
Number 8 hydraulic drive fluid
85W-90 gear oil
Drive oil drain element
Screen assembly 50D
2000
Element YL-161-100
Oil tank return filter
Air dryer
Diesel engine oil 15W-40 CH
Oil filter element
Air filter element
Diesel secondary element
s
1 Engine
165 Oil tank z
1 oil tank
1 Diesel tank
53 Transmission
36*2 Drive
1 Transmission
1 Transmission
1 Pilot
1 oil tank
1 Brake System
21 Engine
2 Engine
1 Engine
2 Engine

88
 j j
m m
2 2
8 8
Replacement s Demand Volume s
time: Item Description Where used
(h) z Fluid
(L)
element
Number of
z
Diesel primary element 1 Engine

J J
M M
2 2
8 8
_ _
j j
m m
2 2
8 8
s s
z z

89