605-8839

Sep. 2019

Operation and
Maintenance
Manual
SEM 518/520/522 Compactor
S8Y/S8Z/S82 (Stage II)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic
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.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the
product and in this publication.
Caterpillar (Qingzhou) Ltd. cannot anticipate every possible circumstance that might 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
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the worksite. If a
tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar
(Qingzhou) Ltd. is used, you must satisfy yourself that it is safe for you and for others. You should also
ensure that you are authorized to perform this work, and that the product will not be damaged or become
unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.
The inf ormation, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service that is
given to the product. Obtain the complete and most current information before you start any job. Caterpillar
(Qingzhou) Ltd. dealer has 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.
Table of Contents Vibration Information ..................................... 25
Information Concerning Seat Vibration .......... 25
Foreword ........................................................ 4
Guidelines for Reducing Vibration Levels on
Safety Section ............................................. 6 Earthmoving Equipment ................................ 25
Description and location of the safety messages7 Product Information ................................. 27
General Precaution ....................................... 12 Summary ...................................................... 27
Safety Requirements..................................... 12 Month and Year of Manufacture..................... 30
Safety Devices.............................................. 13
Operation Section .................................... 33
Clothing and Personal Protective Equipment . 13
Control devices and monitoring system ......... 34
Pressurized Air and Water ............................. 13
Related Operation Information....................... 38
Trapped Pressure ......................................... 13
Storage Information ...................................... 44
Fluid Penetration ........................................... 13
Battery Use and Maintenance Considerations 50
Containing Fluid Spillage ............................... 14
Decommissioning and Disposal..................... 51
Dispose of Waste Properly ............................ 14
Crushing Prevention and Cutting Prevention .. 15 Maintenance Section ............................... 52
Burn Prevention ............................................ 15 Maintenance Considerations ......................... 56
Fire Prevention and Explosion Prevention...... 15 Key Safety Part Catalog and Change Interval 60
Battery and Battery Cables............................ 16 Important Maintenance Procedure................. 62
Lines, Tubes, and Hoses............................... 17 Maintenance for Cooling System ................... 62
Fire Extinguisher and First Aid Kit .................. 18 Maintenance of Engine Air Cleaner ............... 64
Fire Safety .................................................... 18 Engine Compartment – Cleaning................... 65
Fire Extinguisher Location ............................. 19 Replacement of Fuel Filter and Fuel Prefilter . 65
Tire Information............................................. 19 Maintenance of Engine Oil ............................ 66
Lightning Damage Prevention........................ 19 Replacement of engine oil filter ..................... 66
Before Starting Engine .................................. 19 Use and Maintenance of Diesel..................... 67
Visibility Information ...................................... 20 Brake system maintenance ........................... 73
Engine Starting ............................................. 20 Lubrication.................................................... 74
Before Operation........................................... 20 Welding Operation ........................................ 74
Operation...................................................... 20 Maintenance-free Battery Charging Regulations75
Fueling Machine............................................ 21 Clutch clearance regulation ........................... 75
Engine Stopping............................................ 21 Fluids specifications...................................... 77
Parking ......................................................... 21 Fault Reason and Troubleshooting................ 78
Slope Operation ............................................ 21 SEM 518/520/522Regular maintenance parts
list 83
Limiting Conditions and Criteria and Critical
Failures......................................................... 22
Sound Information ......................................... 25
Sound Level Information................................ 25

3
Foreword Maintenance
The maintenance section is a guide to the equipment
Literature Information care. The Maintenance Interval Schedule (PMM)
This manual contains safety information, operation lists the items to be maintained at a specific service
instructions, driving information, lubrication interval. Items without specific intervals are listed
inf ormation and maintenance information. under the “When Required” topic. The Maintenance
Interval Schedule also lists the page number for the
This operation manual details the important aspects step-by-step instructions required to accomplish the
of safety, operation, maintenance, inspection, etc., scheduled maintenance. Use the Maintenance
and should be kept available and read regularly. If Interval Schedule as an index or "one safe source
this manual is missing or dirty and not legible, you (spare parts, tools and fluids manuals)" for all
should re-purchase it at the dealer. When you sell maintenance procedures.
the machine, please ensure that the manual is also
f orwarded to the new user. Maintenance Intervals
The technical parameters, specifications and The maintenance section of this manual is a
illustrations in this manual are on the basis of guideline for routine maintenance of the machine
inf ormation that was available at the time that the and is organized by maintenance intervals. The
manual was written. Continuing modification of maintenance intervals listed in this manual are
product design may affect the maintenance and determined by using the service hour meter.
repair of the machine which are not included in this Calendar intervals shown (daily, weekly, monthly,
manual. Whenever a question arises regarding your etc.) can be used instead of service hour meter
machine, or this manual, please consult with the intervals if they provide more convenient servicing
manuf acturer or your dealer for the latest available schedules and approximate the indicated service
inf ormation. hour meter reading. Caterpillar (Qingzhou) Ltd.
recommends service should always be performed at
Safety the interval that occurs first. Under extremely severe,
Caterpillar (Qingzhou) Ltd. cannot anticipate every dusty or wet operating conditions, more frequent
working circumstance that might involve a hazard. lubrication than is specified in the scheduled
The warnings in this manual and on the product are, maintenance might be necessary. Perf orm service
theref ore, not all inclusive. If a tool, procedure, work on items at multiples of the original requirement. For
method or operating technique that is not specifically example, service those items listed under at Every
recommended by Caterpillar (Qingzhou) Ltd. is used, 500 Service Hours or 3 Months, also service those
you must satisfy yourself that it is safe for you and items listed under Every 250 Service Hours or 1
f or others. You should also ensure that the machine Month, Every 50 Service Hours Weekly and Every
will not be damaged or become unsafe by the 10 Service Hours or Daily.
operation, lubrication, maintenance or repair Engine Maintenance
procedures that you intend to use.
Proper maintenance and repair is essential to keep
Operation the engine and machine systems operating correctly.
The operation section is a reference for new As the heavy duty off-road diesel engine owner, you
operators and a ref resher for experienced ones. are responsible for the performance of the required
This section includes a discussion of gauges, maintenance listed in the Operation and
switches, machine controls, attachment controls, Maintenance Manual. It is prohibited for any person
transportation and towing information. engaged in the business of repairing, servicing,
selling, leasing, or trading engines or machines to
Photographs and illustrations guide the operator remove, alter, or render inoperative any emission
through correct procedures of checking, starting, related device or element of design installed on or in
operating and stopping the machine. an engine or machine that is in compliance with the
Operating techniques outlined in this publication are regulations. Certain elements of the machine and
basic. Skill and techniques develop as the operator engine such as the exhaust system, fuel system,
gains knowledge of the machine and the capabilities electrical system, intake air system and cooling
of the machine. system may be emission related and should not be
altered unless approved by Caterpillar (Qingzhou)Ltd.

4
Machine Capacity
Each compactor has its own design capability.
Additional attachments or modifications that
exceeding compactor design capacity can adversely
af f ect performance characteristics. These
perf ormance characteristics include operational
stability, brakes and steering gear. Please contact
your dealer for updated information. Each machine
has a product identification number as shown below:

SEM Product Identification Number

1. - World Manufacturing Code

2. - Machine Descriptor
3. - Check Character
4. - Machine Indicator

5
Safety Section

Please read and become familiar with all safety

instructions. Failure to do so could result in
serious injury or death.
This “Safety” Section also includes precautions
for optional attachments.

6
Description and location of the
safety messages
There are several specific safety messages on this
machine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiar with all safety
messages.
Make sure that all of the safety messages are legible.
Clean the saf ety messages or replace the safety
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 fall.
Replace any safety message that is damaged or
missing. If a saf ety message is attached to a part of
the machine that is replaced, install a safety
message on the replacement part. AnyCat dealer
can provide new safety messages.

7
8
9
1. Hydraulic Oil Sign
The message indicates the hydraulic oil and is 6. Keep Hands Away from Fan Sign
located next to the hydraulic oil tank. The message is located at the rear of the hood.

2. Fuel Tank Sign

This message is located by the fuel tank.

Please do not put your hands near the running

fan. Do not touch the machine in operation.

7. No Entry when Reversing Sign

3/4.Lift Point Indicator Sign
The message is located on the rear of the machine.
The message is located on the inside of the machine.

This message indicates the position of lifting the

whole machine. Do not get close to the machine until the engine
stops.
5. No Entry when Working Sign 8. Articulation Lock Sign
The message is located in the articulation position at The message is located in the articulation position at
the middle of the machine. the middle of the machine.

10
 12. Burn Prevention Warning Sign
9. Parking Brake Sign
The message is below the right side of the cab
The message is located inside the cab.

13. Fire Extinguisher Injury Warning Sign

This message is located on the right side of the cab
Engage the parking brake while the machine is
to indicate that the fire extinguisher is placed here,
parking. and should be used following the instruction.
10. Alternate Exit Sign
The message is located in the cab on the right post
by the window latch.

14. Machine Lubrication Oil Drain Sign

The message is located at articulation position of the
complete machine to indicate that the lubrication oil
If the primary exit becomes disabled, the window is drained here.
on the right side can be used as an alternate exit.
Pull the latch backward, then push the latch
outward and open the window to the partial open
position. Remove pin from the latch. Push the
window open and exit the machine through the
window.

11. Battery Warning Sign

This message is located near the battery to indicate
that the battery exists and electricity safety should be
noticed.

11
15. Hydraulic Oil Drain Sign
This message is located at the bottom of the
hydraulic tank to indicate that hydraulic oil is drained
here.

19. Lifting Instruction Poster

16. Adding Grease Sign

The message is located in the hood and indicates
that the grease is filled here.

20. Electric Shock Warning Sign

17. Anti-pinch Sign

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
machine.
• Do not operate the machine if you do not feel well,
18. Safety Lock Sign f eel dizzy after taking medication or after drinking.
In this case, it will lead to the wrong judgment and
potential accident.
• When working with another operator or traffic
commander on site, you must ensure that all
personnel understand the hand signals being used.
12
• Observe all rules concerning safety.
Safety Devices
• Make sure that all protective devices and hoods
are secured in the right place. Repair timely if they
are damaged.
• 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
Pressurized Air and Water
serious injury or death. Pressurized air can cause personal injury. When
Lock the safety devices when you exit pressurized air is used for cleaning, wear protective
masks, protective clothing and protective shoes. The
the operator seat. maximum air pressure for cleaning purposes must
• Engage the parking brake switch before you exit be below 205 kPa. The maximum water pressure for
the seat. If the control lever is accidentally touched, cleaning purposes must be below 275 kPa.
the work tools may suddenly move, causing • Avoid direct spraying of water on electrical
serious injury. connectors, connections, and components. When
• When you leave the compactor, turn off the using air for cleaning, allow the machine to cool to
working devices, turn parking break switch to park reduce the possibility of fine debris igniting when
position. , shut down the engine, lock all devices re-deposited on hot surfaces.
with the key, and take the key with you.
• If the right window is closed, make sure that the
Trapped Pressure
hooks are fully secured to prevent loosening. Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
• If the window is locked, be sure to tighten the lock
machine movement or attachment movement. Use
seat to prevent collision between the loose glass caution if you disconnect hydraulic lines or fittings.
and the lock seat. High-pressure oil that is released can cause a hose
to whip. High-pressure oil that is released can cause
Clothing and Personal oil to spray. Fluid penetration can cause serious
Protective Equipment injury and possible death.

• Do not wear loose clothing or jewelry. Do not keep Fluid Penetration

long hair. They may snap into or get caught in the
controls or moving parts, causing serious injury or Pressure can be trapped in the hydraulic circuit long
death. af ter the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
• Do not wear greasy clothing to prevent burning. escape rapidly if the pressure is not relieved
• When you operate or maintain the machine, wear correctly.
a hard hat, protective glasses, protective shoes, Do not remove any hydraulic components or parts
protective masks and gloves. Wear protective until pressure has been relieved or personal injury
goggles, hard hat, and heavy gloves when may occur. Do not disassemble any hydraulic
throwing metal chips and tiny debris, especially components or parts until pressure has been
when hammering pins and removing air filter relieved or personal injury may occur.
contaminants with compressed air. Also check to
make sure no one is near the machine.

13
 SEM equipment and replacement parts shipped from
Caterpillar (Qingzhou) Ltd. are asbestos free.
Caterpillar (Qingzhou) Ltd., recommends the use of
only genuine SEM replacement parts. Use the
f ollowing guidelines when you handle any
replacement parts that contain asbestos or when you
handle asbestos debris. Use caution. Avoid inhaling
dust that might be generated when you handle
components that contain asbestos fibers. Inhaling
this dust can be hazardous to your health. The
components that may contain asbestos fibers are
brake pads, brake bands, lining material, clutch
Always use a board or cardboard when you check plates, and some gaskets. The asbestos that is used
f or a leak. Leaking fluid that is under pressure can in these components is bound in a resin or sealed in
penetrate body tissue. Fluid penetration can cause some way. Normal handling is not hazardous unless
serious injury and possible death. A pin hole leak airborne dust that contains asbestos is generated.
can cause severe injury. If fluid is injected into your
skin, you must get treatment immediately. Seek If dust that may contain asbestos is present, there
treatment f rom a doctor that is familiar with this type are several guidelines that should be followed:
of injury. • Never use compressed air for cleaning.

Containing Fluid Spillage • Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.
Care must be taken in order to ensure that fluids are
contained during performance of inspection, • Use a wet method in order to clean up asbestos
maintenance, testing, adjusting, and repair of the materials.
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or • A vacuum cleaner that is equipped with a high
disassembling any component that contains fluids. ef f iciency particulate air filter (HEPA) can also be
used.
Ref er to Special Publication, the following items
inSEM Dealer Service Tools Catalog: Use exhaust ventilation on permanent machining jobs.

• Tools that are suitable for collecting fluids and • Wear an approved respirator if there is no other
equipment that is suitable for collecting fluids way to control the dust.

• Tools that are suitable for containing fluids and • Comply with applicable rules and regulations for
equipment that is suitable for containing fluids the work place.

Obey all local regulations for the disposal of liquids. Use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos” in
Inhalation addition to the requirements of the Industrial Safety
and Health Act.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.

Dispose of Waste Properly

Exhaust
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the machine in an
enclosed area, adequate ventilation is necessary.
Asbestos Information

14
Improperly disposing of waste can threaten the Any contact with hot coolant or with steam can cause
environment. Potentially harmful fluids should be severe burns. Allow cooling system components to
disposed of according to local regulations. cool before the cooling system is drained.
Always use leakproof containers when you drain Check the coolant level only after the engine has
f luids. Do not pour waste onto the ground, down a been stopped.
drain, or into any source of water.
Ensure that the f iller cap is cool before removing the
f iller cap. The f iller cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
Crushing Prevention and order to relieve the pressure.
Cutting Prevention Cooling system conditioner contains alkali. Alkali can
cause personal injury.
Support the equipment properly before you perform
any work or maintenance beneath that equipment. Do not allow the alkali to contact the skin, the eyes,
Do not depend on the hydraulic cylinders to hold up or the mouth.
the equipment. Unit can f all if a control is moved, or
if hydraulic lines break.
Oils
Hot oil and hot components can cause personal
Do not work beneath the cab of the machine unless
the cab is properly supported. injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while Remove the hydraulic tank filler cap only after the
engine has been stopped. The f iller cap must be cool
the engine is running.
enough to touch with a bare hand. Follow the
Never jump across the starter solenoid terminals in standard procedure in this manual in order to remove
order to start the engine. Unexpected machine the hydraulic tank filler cap.
movement could result.
Batteries
Whenever there are equipment control linkages the
clearance in the linkage area will change with the The liquid in a battery is an electrolyte. Electrolyte is
movement of the equipment or the machine. Stay an acid that can cause personal injury. Do not allow
clear of areas that may have a sudden change in electrolyte to contact the skin or the eyes.
clearance with machine movement or equipment Do not smoke while checking the battery electrolyte
movement.
levels. Batteries give off flammable fumes which can
Stay clear of all rotating and moving parts. explode.
If it is necessary to remove guards in order to
perf orm maintenance, always install the guards back
af ter the maintenance is completed. Keep objects Fire Prevention and Explosion
away f rom moving fan blades. The f an blade will
throw objects or cut objects.
Prevention

Burn Prevention
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
perf ormed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication
system, in the fuel system, or in the cooling system
bef ore any lines, fittings, or related items are All f uels, most lubricants, and some coolant mixtures
disconnected. are f lammable.
Coolant To minimize the risk of fire or explosion, Caterpillar
(Qingzhou) Ltd. recommends the following actions.
When the engine is at operating temperatures, the
engine coolant is hot and under pressure. The • Always perform a Walk-Around Inspection, which
radiator and all lines to the heaters or to the engine may help you identify a fire hazard. Do not operate
contain hot coolant. a machine when a fire hazard exists. Consult your
SEM dealer for details.

15
• Understand the use of the primary exit and
alternative exit on the machine. Refer to
“Alternative Exit” in the Operation and
Maintenance Manual.
• 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 surfaces or onto electrical components can
cause a f ire. A fire may cause personal injury or
death.
• Remove flammable material such as leaves, twigs,
papers, trash, and so on. These items may
accumulate in the engine compartment or around
other hot areas and hot parts on the machine. • Use caution when you are fueling a machine. Do
not smoke while you are fueling a machine. Do not
• Keep the access doors to major machine f uel a machine near open flames or sparks. Do not
compartments closed and access doors in working use cell phones or other electronic devices while
condition in order to permit the use of fire you are refueling. Always stop the engine before
suppression equipment, in case a fire should occur. ref ueling. Fill the fuel tank outdoors. Properly clean
Clean all accumulations of flammable materials areas of spillage.
such as fuel, oil, and debris from the machine.
• Avoid static electricity risk when fueling. Ultra low
Do not operate the machine near any flame. sulf ur diesel (ULSD) poses a greater static ignition
• Keep shields in place. Exhaust shields (if equipped) hazard than earlier diesel formulations with a
protect hot exhaust components from oil spray or higher sulfur content. Avoid death or serious injury
f uel spray in case of a break in a line, in a hose, or f rom fire or explosion. Consult with your fuel or
in a seal. Exhaust shields must be installed f uel system supplier to ensure that the delivery
correctly. Do not weld or flame cut on tanks or system is in compliance with fueling standards for
lines that contain flammable fluids or flammable proper grounding and bonding practices.
material. Empty and purge the lines and tanks. Never store f lammable fluids in the operator
Then clean the lines and tanks with a compartment of the machine.
nonf lammable solvent prior to welding or flame
cutting. Ensure that the components are properly Battery and Battery Cables
grounded in order to avoid unwanted arcs.
• Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
explosive. Repair such components in a well
ventilated area away from open flames or 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 fuel for fires.
Caterpillar (Qingzhou) Ltd. recommends the
• Store fuels and lubricants in properly marked f ollowing in order to minimize the risk of fire or an
containers away from unauthorized personnel. explosion related to the battery.
Store oily rags and flammable materials in
protective containers. Do not smoke in areas that Do not operate a machine if battery cables or related
are used for storing flammable materials. parts show signs of wear or damage. Consult your
SEM dealer for details.
Follow safe procedures for engine starting with jump-
start cables. Improper jumper cable connections can
cause an explosion that can result in injury. Refer to
“Engine Starting with Jump Start Cables” in the
Operation and Maintenance Manual for specific

16
instructions. • Fraying
Do not charge a frozen battery. This may cause an • Signs of abrasion or wear
explosion.
• Cracking
Gases f rom a battery can explode. Keep any open
f lames or sparks away from the top of a battery. Do • Discoloration
not smoke in battery charging areas. Do not use cell • Cuts on insulation
phones or other electronic devices in battery
charging areas. • Other damage
Never check the battery charge by placing a metal Make sure that all clamps, guards, clips, and straps
object across the terminal posts. Use a voltmeter in are reinstalled correctly. This will help to prevent
order to check the battery charge. vibration, rubbing against other parts, and excessive
heat during machine operation.
Daily inspect battery cables that are in areas that are
visible. Inspect cables, clips, straps, and other Attaching electrical wiring to hoses and tubes that
restraints for damage. Replace all damaged parts. contain flammable fluids or combustible fluids should
Check f or signs of the following, which can occur be avoided.
over time due to use and environmental factors: Consult your SEM dealer for repair or replacement
• Fraying parts. Keep wiring and electrical connections free of
debris.
• Abrasion
• Cracking
Lines, Tubes, and Hoses
• Discoloration Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
• Cuts on the insulation of the cable or damaged. Use the appropriate backup wrenches
• Fouling to tighten all connections to the recommended
torque.
• Corroded terminals, damaged terminals, and 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 surface. A battery cable
short produces heat from the battery current, which
may be a f ire hazard. Check lines, tubes, and hoses carefully. Wear
Personal Protection Equipment (PPE) to check for
An exposed wire on the ground cable between the leaks. Always use a board or cardboard when you
battery and the disconnect switch may cause the check f or a leak. Leaking fluid that is under pressure
disconnect switch to be bypassed if the exposed can penetrate body tissue. Fluid penetration can
area comes into contact with a grounded surface. cause serious injury and possible death. A pin hole
This may result in an unsafe condition for servicing leak can cause severe injury. If fluid is injected into
the machine. Repair components or replace your skin, you must get treatment immediately. Seek
components before servicing the machine. treatment f rom a doctor that is familiar with this type
of injury.
Replace the affected parts if any of the following
Fire on a machine can result in personal injury or conditions are present:
death. Exposed battery cables that come into • End f ittings are damaged or leaking.
contact with a grounded connection can result in
fires. • Outer coverings are chafed or cut.
Check electrical wires daily. If any of the following • Wires are exposed.
conditions exist, replace parts before you operate the • Outer coverings are swelling or ballooning.
machine.
17
• Flexible parts of the hoses are kinked. Fire Safety
• Outer covers have exposed embedded armoring.
Note:Locate the alternative exit and learn the usage
• End f ittings are displaced. of the alternative exit before you operate the
Make sure that all clamps, guards, and heat shields machine.
are installed correctly. During machine operation, Note: Locate the f ire extinguishers and learn how to
this will help to prevent vibration, rubbing against use a f ire extinguisher before you operate the
other parts, excessive heat, and failure of lines, machine.
tubes, and hoses.
If you f ind that you are involved in a machine fire,
Do not operate a machine when a f ire hazard exists. your safety and that of others on site is the top
Repair any lines that are corroded, loose, or priority. The f ollowing actions should only be
damaged. Leaks perf ormed if the actions do not present a danger or
may provide fuel for fires. Consult your SEM dealer risk to you and any nearby people. At all times you
should assess the risk of personal injury and move
f or repair or replacement parts. Use genuine SEM
parts or the equivalent, for capabilities of both the away to a saf e distance as soon as you feel unsafe.
pressure limit and temperature limit. Move the machine away from the combustibles such
as gas stations, buildings, garbage bins, covering,
Ether and lumber. Lower all implements as soon as
Ether (if equipped) is commonly used in cold- possible and turn off the engine. If you leave the
weather applications. Ether is flammable and engine running, the engine will continue to f eed a fire.
poisonous. Any damaged hoses that are connected to the
engine or pump can cause a f ire.
Only use approved ether cylinders for the ether
dispensing system fitted to your machine. Do not Turn the battery disconnect switch to the OFF
spray ether manually into an engine. Follow the position, if possible. Disconnecting the battery will
correct cold engine starting procedures. eliminate the ignition source in the event of a short
circuit. Disconnecting the battery will eliminate a
Use ether in ventilated areas. Do not smoke while second ignition source if electrical wiring is damaged
you are replacing an ether cylinder. Do not store by the f ire, resulting in a short circuit.
ether cylinders in living areas or in the operator
compartment of a machine. Do not store ether Notif y emergency personnel of the fire and your
cylinders in direct sunlight or in temperatures above location. If your machine is equipped with a fire
49°C (120.2°F). Keep ether cylinders away from suppression system, follow the manufacturer’s
open f lames or sparks. Dispose of used ether procedure to activate the system.
cylinders properly. Do not puncture an ether cylinder. Note: The f ire suppression systems need to be
Keep ether cylinders away from unauthorized regularly inspected by qualified personnel. You must
personnel. be trained to operate the fire suppression system.
Fire Extinguisher and First Aid Kit Use the on-board fire extinguisher and use the
f ollowing procedure:
In the event of injury or fire, take actions according to
the f ollowing precautions. 1. Pull the pin.

• Keep a f ire extinguisher on the machine. Read the 2. Aim the extinguisher or nozzle at the base of the
instructions carefully and make sure to know how f ire.
to use. 3. Squeeze the handle and release the
extinguishing agent.
• Always have a first aid kit at the work site. Check
regularly and, if necessary, supplement some 4. Sweep the extinguisher from side to side across
medicines. the base of the fire until the fire is put out.
• Know what to do in case of a fire or injury. Remember, if you are unable to do anything else,
shut off the machine before exiting. By shutting off
• Make available the phone numbers of some the machine, f uels will not continue to be pumped
people (such as doctors, emergency centers, fire into the f ire.
stations, etc.) to contact in case of emergency. Put
these contact numbers in the specified places and If the f ire grows out of control, be aware of the
make sure all people know the numbers and the f ollowing risks:
correct method of contact. • Tire poses a risk of explosion as tires burn. Hot
shrapnel and debris can be thrown great distances
18
 in an explosion.
• Tanks, accumulators, hoses, and fittings can
rupture in a fire, spraying fuels and shrapnel over a
large area.
• Remember that nearly all of the fluids on the
machine are flammable, including coolant and oils.
Additionally, plastics, rubbers, fabrics, and resins
in f iberglass panels are also flammable.
Unauthorized Modification (A) at least15 m
Any modifications not approved by Caterpillar (B) at least500 m
(Qingzhou) Ltd. may result in danger. Before
Don’t be near the hot tire. Keep the minimum
modifying the machine, consult your dealer
distance shown in the figure. Stay outside the
designated by Caterpillar (Qingzhou) Ltd. Caterpillar
shaded area shown above.
(Qingzhou) Ltd. assumes no liability for any
damages resulting from unauthorized modifications. When you inf late a tire, stand behind the tire and use
an auto-connected inflatable connector.
Servicing tires and rims can be dangerous. Only
Fire Extinguisher Location trained personnel that use proper tools and proper
procedures should perform this maintenance. If
Make sure that a f ire extinguisher is available on the correct procedures are not used for servicing tires
machine. Be familiar with the operation of the fire and rims, the assemblies could crack with explosive
extinguisher. Inspect the fire extinguisher and f orce. This type of explosion force will cause serious
service the fire extinguisher on a regular basis. injury or death. Caref ully obey the specific
Obey the recommendations on the instruction plate. instructions from your tire dealer.
Mount the f ire extinguisher in the cab.
Lightning Damage Prevention
Strap the mounting plate to a leg of the ROPS in
order to mount the fire extinguisher, as needed. If the When lightning is striking in the vicinity of the
weight of the fire extinguisher is more than 4.5 kg (10 machine, the operator should never attempt the
lb), mount the fire extinguisher as low as possible on f ollowing operations:
one leg. Do not mount the fire extinguisher at the
upper one-third area of the ROPS leg. • Mount the machine.

Note: Do not weld the fire extinguisher to the ROPS. • Dismount the machine.
Also, do not drill holes in the ROPS structure in order If you are in the operator’s station during an electrical
to mount the fire extinguisher on the ROPS. storm, stay in the operator’s station. If you are on
the ground during an electrical storm, stay away from
Tire Information the vicinity of the machine.
Explosions of pneumatic tires have resulted from
heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated Before Starting Engine
by welding, by heating rim components, by external
The steering frame lock must be in the unlocked
f ire, or by excessive use of brakes. position in order to steer the machine.
A tire explosion is much more violent than a blowout. Start the engine only from the operator compartment.
Explosion can keep the tire, rim component, and Never short across the starter terminals or across
shaf t component away from the machine500 mand
the batteries. Shorting could bypass the engine
more. Both the f orce of the explosion and the flying neutral start system. Shorting could also damage
debris can cause property damage, personal injury, the electrical system.
or death.
Inspect the condition of the seat belt and the
condition of the mounting hardware. Replace any
damaged parts or worn parts. Regardless of
appearance, replace the seat belt after three years of
use.
Do not use a seat belt extension on a retractable
19
seat belt. Adjust the seat so that full pedal travel can or to the controls, do not start the engine and do not
be achieved when the operator's back is against the move any controls.
back of the seat.
Move all hydraulic controls to the HOLD position
Make sure that the machine is equipped with a bef ore you start the engine.
lighting system that is adequate for the job conditions.
Move transmission control into the NEUTRAL
Make sure that all lights are working properly.
position. Engage the parking brake.
Bef ore you start the engine or before you move the
Diesel engine exhaust contains products of
machine, make sure that no one is on the machine,
combustion which can be harmful to your health.
underneath the machine, or around the machine.
Always operate the engine in a well ventilated area.
Ensure that there are no personnel in the area.
If you are in an enclosed area, vent the exhaust to
the outside.
Visibility Information Brief ly sound the horn before you start the engine.
Check f or the presence of personnel. Ensure that all
Bef ore you start the machine, perform a walk-around personnel are clear of the machine.
inspection in order to ensure that there are no
hazards around the machine. Before Operation
While the machine is in operation, constantly survey Ensure that there are no personnel on the machine
the area around the machine in order to identify or in the area around the machine.
potential hazards as hazards become visible around
the machine. Remove any debris that builds up in and around the
hoses and fittings to reduce damage or wear to the
Bef ore operating the machine, ensure that the visual hoses and fittings.
aids are in proper working condition and that the
visual aids are clean. Adjust the visual aids using Clear all obstacles from the path of the machine.
the procedures that are located in this Operation and Beware of hazards such as wires, ditches, etc.
Maintenance Manual. It may not be possible to
Ensure that all windows are clean. Secure the doors
provide direct visibility on large machines to all areas and the windows in the open position or in the shut
around the machine. Appropriate job site
position.
organization is required in order to minimize hazards
that are caused by restricted visibility. Job site Adjust the rear view mirrors (if equipped) for the best
organization is a collection of rules and procedures vision of the area near the machine.
that coordinates machines and people that work
Ensure that the horn, the backup alarm (if equipped),
together in the same area. Examples of job site
and all other warning devices are working properly.
organization include the following:
Fasten the seat belt securely.
• Saf ety instructions
• Controlled patterns of machine movement and Operation
vehicle movement
Machine Operating Temperature Range. The
• Workers that direct traffic to move when it is safe machine must work within the permissible
temperature range,The minimum requirement for the
• Restricted areas
machine to be able to work safely is:within the
• Operator training temperature of−20°Cto40°C, the relative humidity
is0-100%, there is an additional instruction in the
• Warning symbols or warning signs on machines or f unction specification except selling.
on vehicles
Only operate the machine while you are sitting in the
• Communication system operator seat. The seat belt must be fastened while
• Communication between workers and operators you operate the machine. Only operate the controls if
prior to approaching the machine the engine is running.

Modifications of the machine configuration by the While you operate the machine slowly in an open
user that result in a restriction of visibility shall be area, check f or proper operation of all controls and
evaluated. all protective devices.
Make sure that no personnel will be endangered
Engine Starting bef ore you move the machine.
If a warning tag is attached to the engine start switch Do not allow riders on the machine unless the

20
machine has the f ollowing equipment: personal protective equipment. Allow the cap to cool
bef ore fueling the machine.
• Additional seat
• Additional seat belt Engine Stopping
Note any needed repairs during machine operation. Do not stop the engine immediately after the
Report any needed repairs. machine has been operated under load. This can
If the machine begins to sideslip on a downgrade, cause overheating and accelerated wear of engine
immediately remove the load and turn the machine components.
downhill. Af ter the machine is parked and the parking brake is
Avoid any conditions that can lead to tipping the engaged, allow the engine to run for five minutes
machine. The machine can tip when you work on bef ore shutdown. This allows hot areas of the engine
hills, on banks and on slopes. Also, the machine can to cool gradually.
tip when you cross ditches, ridges or other
unexpected obstructions. Parking
Avoid operating the machine across the slope. Park the machine on a level surface. If you must
When possible, operate the machine up the slopes park the machine on a grade, block the tires. Please
and down the slopes. consider the following factors:
• Size of tire
Fueling Machine
• Weight of machine
• Condition of surface
Ultra Low Sulfur Diesel (ULSD) poses a greater Apply the service brake in order to stop the machine.
static ignition hazard than earlier diesel Move the transmission control device (lever) to the
formulations with a higher sulfur content, which NEUTRAL position. Move the throttle control device
may result in a fire or explosion. Consult with to the low idle position. Engage the parking brake.
your fuel or fuel system supplier for details on Lower all work tools to the ground. Activate any
proper grounding and bonding practices.
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 Always turn the battery disconnect switch to the OFF
while in an area that contains flammable liquids. position before leaving the machine. If the machine
will not be operated for a month or more, remove the
All f uels, most lubricants, and some coolants are battery disconnect switch key.
f lammable.
Keep all f uels and lubricants stored in properly
marked containers and away from unauthorized Slope Operation
persons.
The saf e operation of the machine in various
Fuel leaked or spilled onto hot surfaces or electrical application conditions depends on the following
components can cause a fire. conditions: machine type, configuration, machine
Store all oily rags or other flammable materials in a maintenance, machine operating speed, ground
protective container in a safe place. condition, liquid level and tire inflation pressure. The
most important criteria are the skill and judgment of
Remove all flammable materials such as fuel, oil, the operator.
and other debris before they accumulate on the
machine. A well trained operator that follows the instructions in
the Operation and Maintenance Manual has the
Do not expose the machine to flames, burning brush, greatest impact on stability. Operator training can
etc., if at all possible. provide the following abilities for the operator:
observe working conditions and ambient conditions,
Locate the fuel filler on the machine, and remove the
f iller cap. After fueling the machine, replace the filler understand machine performance, after identifying
cap and lock the filler cap into position. potential hazards and making the right decisions,
saf ely operate the machine.
The f iller cap may be hot. To avoid injury, use
When you work on side hills and when you work on
21
slopes, consider the following important points:
Limiting Conditions and
Speed of travel- At high speed, forces of inertia can
reduce the stability of the machine. Criteria and Critical Failures
Roughness of ground or surface– Uneven ground Limiting conditions are immediate issues with this
can reduce the stability of the machine. machine that must be addressed prior to continuing
operation. The Safety Section of this Operation and
Direction of travel– Avoid operating the machine Maintenance manual describes limiting condition
across the slope. When possible, operate the criteria f or replacing items such as safety messages,
machine up the slopes and down the slopes. Place seat belt and mounting hardware, lines, tubes, hoses,
the heaviest end of the machine uphill when you are battery cables and related parts, electrical wires, and
working on an incline. repairing any fluid leak.
Installed equipment– The f ollowing aspects may Maintenance Interval Schedule describes limiting
weaken the balance of the machine: the equipment condition criteria that require repair or replacement
which installed to the machine, machine f or items (if equipped) such as alarms, horns,
conf iguration, weight and counterweight. braking system, steering system, and rollover
Nature of surface– Ground that has been newly protective structures.
compacted may collapse from the weight of the
The Operation and Maintenance Manual, Monitoring
machine.
System (if equipped) provides information on limiting
Surface material– Rocks and moisture of the condition criteria, including a Warning Category 3
surf ace material may drastically affect the machine's that requires
traction and machine's stability. Rocky surfaces may immediate shutdown of the engine.
promote side slipping of the machine.
The f ollowing table provides summary information on
Slippage due to excessive loads– This may cause several limiting conditions found in this Operations
downhill tracks or downhill tires to be stuck in the and Maintenance Manual.
ground, which will increase the angle of the machine.
Width of tracks or tires – Narrow tracks or narrow The table provides criteria and required action for the
limiting conditions listed. Each System or
tires f urther increase the risk of being stuck in the Component in this table, together with the respective
ground, which causes the machine to be less stable. limiting condition, describes a potential critical failure
Implements attached to the drawbar– This may that must be addressed. Not addressing limiting
decrease the weight on the uphill tracks. This may conditions with required actions may, in conjunction
also decrease the weight on the uphill tires. The with other f actors or circumstances, result in a risk of
decreased weight will cause the machine to be less personal injury or death. If an accident occurs, notify
stable. emergency personnel and provide location and
description of accident.
Operated equipment– Be aware of performance
f eatures of the equipment in operation and the
ef f ects on machine stability.
Operating techniques – In order to achieve
optimum stability, Keep all attachments or traction
loads as low to the ground as possible.
Capabilities of 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
f luid level requirements and intended machine use.

22
 Limiting Conditions and Criteria and Critical Failures
System or
Component Limiting Condition Criteria for Action Required Action
Name
End f ittings are damaged or
leaking. Outer coverings are
chaf ed or cut. Wires are Immediately repair any
Visible corrosion,
exposed. Outer coverings lines, tubes, or hoses that
loose, or damaged
Line, tubes, and are swelling or ballooning. are corroded, loose, or
lines, tubes, or
hoses Flexible parts of the hoses damaged. Immediately
hoses. Visible fluid
are kinked. Outer covers repair any leaks as these
leaks.
have exposed embedded may provide fuel for fires.
armoring. End fittings are
displaced.
Signs of fraying, abrasion,
Visible damage to Immediately replace
Electrical Wiring cracking, discoloration, cuts
electrical wiring damaged wiring
on the insulation
Signs of fraying, abrasion,
cracking, discoloration, cuts
on the insulation of the cable, Visible damage to Immediately replace
Battery cable(s)
f ouling, corroded terminals, battery cable(s) damaged battery cables
damaged terminals, and
loose terminals
Do not operate machine
with damaged structure or
Visible damage to
Operator Structures that are bent, loose, missing, or damaged
structure. Loose,
Protective cracked, or loose. Loose, bolts. Contact your SEM
missing, or damaged
Structure missing, or damaged bolts. Dealer f or inspection and
bolts.
repair or replacement
options.
Worn or damaged seat belt Visible wear or Immediately replace parts
Seat Belt
or mounting hardware damage that are worn or damaged.
Replace seatbelt after three
Seat Belt Age of seatbelt Three years of use
years of use.

Damage to safety Replace the illustrations if

Saf ety Appearance of safety illegible.
messages making
Messages message
them illegible

Immediately repair or
Audible Warning Reduced or no
Sound level of audible replace audible warning
Device(s) (if audible warning
warning devices not working
equipped) present
properly.
Dirt or debris
Camera(s) (if Clean camera bef ore
Dirt or debris on camera lens obstructing camera
equipped) operating machine.
view

Dirt or debris
Cab Windows (if Dirt, debris, or cracked obstructing operator Clean windows before
equipped) windows visibility. Any cracked operating machine. Repair
windows. or replace cracked windows
bef ore operating machine.

Mirrors (if Dirt, debris, or cracked mirror Dirt or debris Clean mirrors before

23
 System or
Component Limiting Condition Criteria for Action Required Action
Name
equipped) obstructing operator operating machine. Repair
visibility. Any cracked or replace cracked mirrors
mirrors. bef ore operating machine.
System does not
Braking System Contact your SEM dealer to
Inadequate braking pass Braking System
inspect and, if necessary,
perf ormance -Test(s) included in
repair the brake system.
Maintenance Section

Stop the engine

immediately. Check the
coolant level and check the
radiator for debris. Refer to
Operation and Maintenance
Manual, “Cooling System
Cooling System Monitoring System
The coolant temperature is Coolant Level - Check”.
displays Warning
too high. Check the f an drive belts
Category 3
f or the water pump. Refer
to Operation and
Maintenance Manual,
“Belts - Inspect/Adjust/
Replace”. Make any
necessary repairs.

If the warning stays on

during low idle, stop the
Monitoring System
Engine Oil A problem has been detected engine and check the
displays Warning
System with the engine oil pressure. engine oil level. Perform
Category 3
any necessary repairs as
soon as possible.
Monitoring System Stop the engine
An engine f ault has been
Engine system displays Warning immediately. Contact your
detected
Category 3 SEM Dealer for service.
Stop the engine. Determine
Monitoring System
A problem has been detected the cause of the fault and
Fuel System displays Warning
with the f uel system. perf orm any necessary
Category 3
repairs.
Stop the engine
immediately. Check the
Monitoring System hydraulic oil level and
Hydraulic Oil The hydraulic oil temperature
displays Warning check the hydraulic oil
System is too high.
Category 3 cooler for debris. Perform
any necessary repairs as
soon as possible.

24
 organization, job site preparation, job site
Sound Information environment, job site weather, job site material,
Sound Level Information machine type, quality of the seat, quality of the
suspension system, attachments, and condition of
The sound values indicated below are f or specific the equipment.
operating conditions only. Machine and operator
sound levels will vary at different engine and/or Properly adjust machines. Properly maintain
cooling fan speeds. The cab was properly installed machines. Operate machines smoothly. Maintain the
and maintained. The tests were conducted with the conditions of the terrain. The f ollowing guidelines can
cab doors and the cab windows closed. Hearing help reduce the whole-body vibration level:
protection may be needed when the machine is 1. Use the right type and size of machine, equipment
operated with a cabin that is not properly maintained, and attachments.
or when the doors and/or windows are open for 2. Maintain machines according to the manufacturers
extended periods or in a noisy environment. recommendations: tire pressures and brake and
steering systems, controls, hydraulic system, and
The declared dynamic operator sound pressure level linkages.
f or a standard machine configuration, measured 3. Keep the terrain in good condition by performing
according to the procedures specified in the f ollowing items: remove any large rocks or
“ISO 6396:2008/GB/T25615-2010”, is 81/81/84 obstacles, fill any ditches and holes and provide
dB(A) with a cooling f an speedset at maximum value. machines and schedule time to maintain the
conditions of the terrain.
The declared dynamic machine sound power level 4. Keep the seat maintained and adjusted by doing
f or a standard machine configuration, measured the f ollowing: adjust the seat and suspension for the
according to the procedures specified in“ISO weight and the size of the operator and inspect and
6395:2008/GB/T25614-2010”, is 110 dB(A) with the maintain the seat suspension and adjustment
cooling fan speed set at maximum value. mechanisms.
5. Perf orm the following operations smoothly: steer,
Operators of the machines with brake, accelerate, and shift the gears.
sound pressure level at the 6. Move the attachments smoothly.
operator’s position in the 7. Adjust the machine speed and the route to
machine cab which exceeds minimize the vibration level by doing the following:
80db (see the table above) are recomended to use drive around obstacles and rough terrain and slow
personal protection equipement (hearing down when necessary to go over rough terrain.
protection equipement). 8. Minimize vibrations for a long work cycle or a long
Hearing protection may be also needed when the travel distance by doing the following: use machines
machine is operated with an open operator station that are equipped with suspension systems, if no ride
for extended periods or in a noisy environment. control system is available, reduce speed to prevent
Hearing protection may be also needed when the bounce and haul the machines between workplaces.
machine is operated with a cab that is not 9. Less operator comfort may be caused by other
properly maintained, or when the doors and risk f actors. The f ollowing guidelines can be effective
windows are open for extended periods or in a to provide better operator comfort: adjust the seat
noisy environment. and adjust the controls to achieve good posture,
adjust the mirrors to minimize twisted posture,
provide breaks to reduce long periods of sitting,
Vibration Information avoid jumping from the cab, minimize repeated
handling of loads and lifting of loads and minimize
Information Concerning Seat Vibration any shocks and impacts during sports and leisure
The suspension seat meets the criteria of "ISO 7096". activities.
This represents vertical vibration level under severe Consult your local SEM dealer for more
operating conditions. This seat is tested with the information about machine features that
input "spectral class EM3". The seat has a minimize vibration levels. Consult your local
transmissibility factor of “SEAT<1.0”. SEM dealer about safe machine operation

Guidelines for Reducing Vibration Levels Maintenance and Repair

on Earthmoving Equipment
Precautions
Vibration levels are influenced by many different
parameters, such as: operator training, operator 1. Cleaning: When the complete machine is shut
behaviour, operator mode and stress, job site down and flushed, turn the negative switch to

25
 OFF position, the user should avoid direct
injection to the sensor and harness connectors
with the high voltage water gun during the diesel
cleaning process, which could cause internal
short circuit, and burn out of sensor and ECU;
2. Solder mask: When using welding machines
such as electric welding and gas welding on the
whole vehicle, the user must disconnect the
connection between ECUand the power supply
or removeECU, to prevent excessive Current
f rom burningECUand sensor;
3. Check of connection: the user must
checkECUCheck the connection of terminals
such as sensor and harness to prevent foreign
matter f rom entering the terminals; To prevent
virtual connection, check whether the
connection between terminals is secure; To
prevent short circuit, avoid short circuit between
harness terminals, avoid short circuit between
harness terminal and ground. Ensure equipment
and personal safety;
4. anti-misoperation: When the diesel engine is
running, avoid sudden disconnection of the
battery, if it has a fault, you must stop engine to
check and disconnect the power to check;
5. The connector with electrification is forbidden to
plug in and pull out,when operating welding
repairmen, it is necessary to ensure that the
power supply of the while complete machine is
disconnected.

26
Product Information
Summary
Dual-f requency and dual-amplitude vibratory system,
is Caterpillar’s patented peapod-typed eccentric
mechanism, with higher reliability;
The vibratory pumps and motors is from
internationally renowned brands;
The vibratory wheel is thicker than the general
thickness of the same industry, which makes the
whole working steel wheel more thicker, achieving
the best compaction effect and greatly improving the
work ef ficiency;
The overall centrifugal chamber design makes
maintenance more convenient;
Digital engine speed, and vibratory frequency gauge
panelSBVDdesign;
Standard electrical distribution control gearbox,
make the complete machine operation more gentle;
Domestic famous brand’s drive axle, is equipped
with PTD Differential;
Advanced cooling module system, steering system
and drive system, these systems are partitioned
cooling, to achieve better effects;
With cross shaft hinge technology, maintenance is
more convenient;
The large spacious cab, offer a more wide visibility,
and the design of sliding window, is more
ergonomics;
Optimize the hydraulic line, which is more beautiful
and more reliable;
Improve and optimize repairable space;
The design of the centrifugal force and travel speed
is ahead of the competitor, the work efficiency has
been greatly improved.
Conf iguration available:
The tiltable cab is ergonomics, and maintenance and
repair is more convenient;
Install the compaction meter to monitor the
compaction effect in real time;
Air conditioning, heating, and cold start are designed
according to customer needs;
Being equipped with sunshade and wiper on the rear
window makes the driver more comfortable to drive;
The equipment of spiky roller is more reasonable.

27
Component names of the machine

1. Engine Hood 5. Front frame 9. Drive Train

2. Engine 6. Hydraulic system 10. Counterweight iron
3. Cab 7. Rear frame
4. Vibratory wheel 8. Battery box

28
Diesel Engines
Driveline
This product518/520/522series uses a six-cylinder
f our strokes, water-cooled engine, and acquires the Main clutch: The main clutch is a constant-engaged
certif ication of the ChinaⅡ emissions for a non-road single dry friction clutch, mounted directly on the
engine f lywheel, used to cut off the power of the
diesel machine, country.III/National II standard
engine to make the engine idling for shifting and
Emissions certification, the engine has good cold
steering operations. The operating mechanism of the
start performance, altitude performance, low fuel
main clutch is pneumatic booster mechanism,
consumption, low noise, low pollution emissions,
making the operation easy and flexible.
high reliability and durability.
When the machine is working, the fuel supply pump Transmission: The transmission is fixed shaft and
transf ers the fuel in the fuel tank through the fuel straight teeth constant engaged power shift
f ilter to the fuel injection pump, the fuel pressure is transmission. It is located at the front of the rear
increased in the pump and supply the fuel to the f rame and is a three-gear electronic control select
injector according to different working conditions to transmission. The machine can be moved forward
complete the power stroke. Excessive fuel supplied and backward at different speeds by control the shift
by the high pressure fuel pump returns to the suction lever.
line through injector and fuel return lines of the fuel
pump. There is a manual fuel pump on the transfer Drive axle: The machine drive axle main driver uses
a single-stage spiral bevel gear retarder, which is
pumps, which can be used to drain the air in the fuel
lines. mainly used to increase the powertrain torque and
reduce the powertrain speed, The differential uses a
Hydraulic system limited slip differential. The power output from the
engine is transmitted to the transmission via the
The hydraulic system is divided into three parts: the main clutch, and then transmitted by the drive shaft
vibratory hydraulic system, the steering hydraulic to the rear drive axle to directly drive the rear wheel
system and the power train hydraulic system. to make the compactor travel.

The vibratory hydraulic system uses a closed Brake System

hydraulic system consisting of a variable-
displacement piston pump and a fixed-displacement The brake system is divided into three parts: service
motor, ensuring the various performance brake, parking brake and clutch control system. The
requirements of the vibration parameter. The parking brake is a drum brake, which is mounted on
eccentric mechanism in vibratory motor is rotated the power output end of the transmission, and stops
f orward and reverse by the vibratory motor which is the machine by operating the brake knob. The
driven by the vibratory pump during vibration, and service brake system is a pneumatic hydraulic
which produce vibratory force with two vibratory caliper disc brake, depressing the brake pedal, the
amplitudes. Vibration can be controlled by a vibratory compressed air coming from the air reservoir enters
switch. the accumulator via the brake valve to push the
brake f luid into the disc brake, which brakes the
The steering hydraulic system uses a full Hydraulic vehicle. The clutch control system, depressing the
steering mechanism. The pressure oil which from the clutch pedal to interrupt the input of power to
steering pump that by the engine, is supplied to the transmission, and to achieve shifting.
steering gear, the steering wheel turn the steering
gear, and control the steering cylinder that installed Electrical System
on the hinge structure, to achieve steering.
The electrical system on the machine is powered by
The drive hydraulic system, fluids of drive pump two 12V batteries in series, rated voltage is 24V. The
which is driven by the engine, pass into the drive oil system is divided into starting, power generation
f ilter, and the pressure oil coming from the oil filter, system, control system, lighting system, gauge and
limit its required work pressure of clutch by the signal system, etc.; The generator is functioned by
control pressure valve, and supply the overflowed oil the engine via the V-belt, under normal conditions,
to the cooler, and the oil coming from the cooler the generator can both supply the power to the
directly flow into transmission lubrication line, to power unit, and charge to the battery. Each control
provide sufficient cool lubricants for every lubrication switch controls individual appliance.
points.
The structural parts of the machine are divided into
Structural Parts three parts: the front frame, the rear f rame and the
vibratory wheel. The front unit is the front frame and
29
the vibratory wheel, which is the work unit of the
compactor; The rear unit, that is, the rear frame, is
Month and Year of
the main part of the compactor, equipped with the Manufacture
power travel drive, the rear wheel, the console and
the cab, etc., the front and rear units are connected Product dataplate contains machine weight,
by the hinge structure. maximum vehicle speed, engine model, engine
horsepower, machine size, month and year of
Cab Manufacture, manufacture information,product
identification number, etc.
Currently, compactor518/520/522 is equipped with
only one standard cab. 518/520/522The damping
system of compactor can greatly reduce the vibration
and noise levels of the cab via the modal analysis
and test verification, and improve the comfort of the
cab and the operator's work efficiency. In order to
give the operator a good view when operating the
machine, our designers equip the machine with glass
windows and doors that are optimized in design.
Based on the basic configuration, you can choose
the premium seat, luxury seat, rear wiper, radio, air
conditioner, heating and so on. The operator controls Model(A)____________________________
is ergonomically arranged for convenient and
comfortable operation. Centrif ugal Force(B)_________________
Vibration Frequency(C)________________
Sheets
Nominal Amplitude(D)_________________
Sheets are divided into five parts: hood, oil tank,
diesel tank, counterweight iron, and side floor. Dimension(E)________________________
Product Identification Number(F)_________
Engine Dataplate
Machine Mass(G)_____________________
This dataplate is located on the engine timing gear
Engine Speed(H)_____________________
housing.
Engine Power(I)______________________
The contents of the dataplate mainly include engine
ratings, rated speed, serial number, date of Compacting Width(J)__________________
production, and net weight , Manuf acture Date(K)__________________
manuf acturer name and address, etc. Local regulation may require documentation of the
Month and/or Year of manufacture in the Opeation
Transmission Dataplate and Maintenance Manual. Enter on line (K) above if
required.
The dataplate is located on the right side of the
transmission housing
The contents of the dataplate mainly include model,
rated input power, rated input speed, number, date,
and manuf acturer name.

Drive axle
The dataplate is located on the right side of the
connection between the drive axle housing main
reducer and differential.
The contents of the dataplate mainly include axle
model, axle assembly number, axle number, and
manuf acturer name.

30
Main Technical Parameters

With standard cab

Size A B C D E F G H β
SEM518 6250 3200 2310 2130 1600 3100 460 2160 33°
SEM520 6250 3200 2310 2130 1600 3100 460 2160 33°
SEM522 6250 3200 2310 2130 1600 3100 460 2160 33°

31
 SEM518/520/522 Series compactor technical
parameters
Model SEM518 SEM520 SEM522
Operating weight kg 18000 20000 22000
Compaction
Dual f requency double amplitude vibratory system Standard Standard Standard
Vibratory frequency high / lower Hz 30/28 30/28 30/28
Rated Amplitude high / lower mm 2/1 2/1 2/1
Centrif ugal force high/lower KN 327/188 360/208 374/215
Static Linear Load N/cm 415 461 507
Engine
Power kw 129 129 140
Speed r/min 2000 2000 2000
Fuel Tank Capacity L 262 262 262
Hydraulic Tank Capacity L 80 80 80
Drum size
Drum width mm 2130 2130 2130
Drum thickness mm 40 50 50
Drum diameter mm 1600 1600 1600
Maneuverability
I speed km/h 2.98 2.98 2.98
II speed km/h 5.88 5.88 5.88
III speed km/h 9.60 9.60 9.60
Turning circle mm 12700 12700 12700
Grade Ability % 34 34 34
Tire Size 20.5-25-16PR 20.5-25-16PR 20.5-25-16PR

Tire Inf lation Pressure MPa F/R 0.35 F/R 0.35 F/R 0.35

32
Operation Section

Notice
Before operating this machine, please read
carefully and understand the content of this
manual so that you can operate the machine
correctly. Correct operation is critical to ensure
safety, achieve high work efficiency, and
increase the service life of the machine.

33
Control devices and monitoring system
Layout of the In-Cab Control Devices and Monitoring System

Number Description Function

1 High Beam Lights This light illuminates when the high beam is turned on

A warning for oil pressure. Lamp illumination indicates

2 Drive Oil Pressure Warning Indicator Light
abnormal oil pressure

Brake Air Pressure Low Warning Indicator

3 This light illuminates when the brake air pressure is low
Light

4 Steering Left Indicates the machine is turning left

5 Steering Right Indicates the machine is turning right

6 Low Beam Lights When turn on the high beam/low beam, this light illuminates

Transmission Oil Temperature Warning This light illuminates when the transmission oil temperature is
7
Lamp abnormal

8 Preheat Indicator Preheating indicator before engine start

When the diesel engine is working, this light illuminates,

indicating that the generator does not generate the power, and
9 Charging Indicator
immediately stops and inspect; when the engine is not working,
illumination is normal.

Lamp turns on when the water temperature is higher than the

10 Coolant Temperature Warning Lamp
safe temperature or before it goes below the safe temperature
Alarm occurs when oil pressure is above normal value or below
11 Engine Oil Pressure Indicator
the normal value

When the filter element is obstructed so that the pressure

difference between the inlet and the outlet reaches the alarm
12 Hydraulic System Oil Filter Indicator
setting value, the warning lamp lights up, and the filter element
must be replaced at this time.

34
Number Description Function
Position: upper left transmission oil temperature Position:
upper right battery voltage
13 LCD Display Position: middle vibratory frequency
Position: low show total hours

The indicator light flashes when damage to the component

14 Level Two or Three Warning Lamp occurs, or certain operation needs to be stopped immediately,
or potential accident exists.

15 Silent mode This light illuminates when the silent mode is turned on.
When the filter element is obstructed so that the pressure
difference between the inlet and the outlet reaches the alarm
16 Transmission oil filter indicator setting value, the warning lamp lights up, and the filter element
must be replaced at this time.

35
1. Shifting lever 5. Hazard Light Switch 9. Front washer switch
2. Throttle knob 6. Instrument light switch 10. Vibration switch
3. Front work light switch 7. Turn light switch 11. Vibratory amplitude Select Switch
4. Rear work light switch 8. Front wiper switch 12. Parking brake lever

36
 Engine Start Switch
Shifting lever
Af ter depressing the clutch pedal, operate the shift
lever to achieve shifting. When the lever is in the
middle position, it is neutral; when it is in the left
position, it is forward;When it is in the right position, it
is reversed. There are three gears for forward and
reverse respectively.
Throttle knob
Turn the knob clockwise to increase the throttle. Turn
the knob counterclockwise to decrease the throttle. OFF (OFF) - When you insert and remove the
engine start switch key, the engine start switch must
Amplitude switch be in OFF (OFF) position. Turn the engine switch to
OFF (OFF) position, which can stop the engine and
High amplitude and low amplitude can be selected disconnect the electrical circuits in the cab.
by amplitude switch. The f ront position is the low
amplitude; the rear position is the high amplitude; the ON (ON) - When turn the key clockwise to ON (ON)
middle position is the stop state. position, connect the electrical circuits in the cab.
Vibration switch START (START) - When turn the Key clockwise to
START (START) position, you can start the engine.
Decide whether to use vibration by selecting this Release the Key and the engine start switch returns
switch. to ON (ON)position. After you start the engine,
release the key.
Headlight Switch
This switch needs to be turned on when using the Brake pedal
headlights. The service brake pedal is located in right front of the
operator's seat. When the service brake pedal is
Rear light Switch depressed, the frond and rear drive axle wheel
This switch needs to be turned on when using the brakes will engage to brake. The braking light switch
rear lights. will be turned on at the same time to illuminate the
braking light. Release the service brake pedal will
Instrument light switch disengage the service brakes.
Turn this switch on when you need to turn on the In case of braking system malfunction, the repair
instrument light. should be performed in a timely manner to ensure
Front wiper switch enough braking capability of the machine.

Turn this switch on when using the front wiper. Battery negative switch
The battery negative switch is installed in the battery
Front washer switch
box on the right side of the compactor, and it is
Turn on this switch when you need to use the front visible by opening the battery box cover.
washer to clean the front glass.
Warning light switch
Turn on this switch and the rotation warning light
illuminates.
Turn light switch
Turn the turn light switch on when turning. The f ront
position is the left turn; the rear position is the right
turn; the middle position is the closed state.
Parking brake
Press the grip when driving and pull the grip up when
parking.

37
OFF status of the negative switch: Downhill Operation
To cut off the power supply for the electrical system Maintain a ground speed that is slow enough for the
of the whole machine, it is necessary to turn the conditions. Before you operate down a hill, select the
negative switch handle counterclockwise to the OFF proper gear before you start down the grade. The
position. proper gear should allow the machine to maintain the
ON status of the negative switch: appropriate speed on the down grade. The throttle
control should not be at high idle and the engine
Bef ore starting the machine, the negative switch should not overspeed. In most situations, the same
handle must be turned clockwise to the ON position. speed gear will be used when up and down the
The negative switch is different from the starting same slope.
switch. Turning off the negative switch will turn off If the machine builds up excessive speed, the engine
the electrical system of the whole machine. However, can overspeed. This can result in damage to the
when the starting switch is turned off, the battery is engine and/or damage to the power train system.
still connected to the electrical system of the whole Use the service brake or the engine brake to slow
machine and some electrical components can still the machine until a lower gear can be selected.
f unction. Select the lower gear and proceed with the throttle
control at high idle.
Changing the Direction and Gear
When the complete machine is shut down and
during flushing of the machine, the negative It is not recommended to change the speed gear at
switch needs to be turned to the OFF position. f ull engine speed, or shift the machine forward gear
at f ull engine speed. In any case, if you want to
Do not turn off the battery negative switch when change the travel direction, stop the machine
the engine is still running. Otherwise, it will completely and depress the main clutch pedal; or if
damage the electrical system of the complete you want to change the speed gear, reduce the
machine!!! speed and depress the main clutch pedal.
Vibration
Related Operation Information When the machine is working, set the engine at
rated speed for optimum vibration, steering and
Follow these basic instructions whenever you are travel control. When climbing up a steep slope, you
operating the machine: must move slowly to avoid engine stalls and the
• To prevent injury, make sure that no one is machine will be loss of control.
working on the machine or near the machine. Set the throttle controller to the rated speed position.
Always maintain control of the machine. Bef ore starting the vibratory system, choose a
• Bef ore you disengage the parking brake, depress reasonable travel speed. In order to achieve
optimum compaction, low range should be used.
the service brake pedal in order to keep the
machine from moving. Stop the vibration system when you travel over
concrete or pavement that is hard.
• Drive the machine forward for best visibility and for
best control.
Before starting the engine
• Reduce the engine speed when you maneuver in
tight quarters and when you are going over a hill. Make sure the work site safety
Bef ore starting operation, check the area around the
machine caref ully for any abnormal conditions that
may cause danger.
Falling objects could cause personal injury or
death. Check the terrain and ground surface of the job site
and determine the best and safest operation method.
Remove all overhangs and be ware of falling
objects. If the work 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 "No Entry" sign to
protect the pedestrians and vehicles.

38
For sites with buried facilities underneath, such as Check all of the oil levels, all of the coolant levels,
water pipe, gas pipe, high voltage cable pipe, the and all of the fuel levels.
relevant authority should be contacted to locate the
Remove any trash buildup and debris. Make all
buried f acilities. And attentions should be paid not to
necessary repairs before you operate the machine.
damage these facilities during the operation.
Make sure that all covers and guards are securely
Mounting and Dismounting attached.
Adjust the mirrors for the correct rear view of the
machine.
Make sure the engine air f ilter service indicator is not
in the red zone.
Grease all of the fittings that need to be serviced on
a daily basis.
Daily, perform the procedures that are applicable to
your machine:
Mount the machine and dismount the machine only
at locations that have steps and/or handholds. • Cooling system level - Check
Bef ore you mount the machine, clean the steps and • Engine Air Filter Service Indicator - Check
the handholds. Inspect the steps and handholds.
Make all necessary repairs. • Engine Oil Level- Check
Face the machine whenever you get on the machine • Hydraulic system oil level- Check
and whenever you get off the machine. Maintain a
• Indicators and Gauges - Test
three-point contact with the step and with handholds.
Note: Three-point contact can be two feet and one • Transmission oil level--Check
hand. Three-point contact can also be one foot and When you start the engine
two hands.
Bef ore mounting the machine, perform another walk-
Do not mount a moving machine. Do not dismount a around inspection of your machine and check for any
moving machine. Never jump off the machine. Do personnel or objects on, below or near the machine.
not carry tools or supplies when mounting or Check if there is any person in the working area.
dismounting the machine. Use a hand line to pull
equipment onto the platform. If a "Do Not Operate"warning message is attached to
the control lever, the engine must not be started.
Do not use any controls as handholds when you
enter the operator compartment or when you exit the Sound the horn when starting the engine to give an
operator compartment. alert.

Daily checks The engine can only be started and operated with
the operator sitting in the operator seat.
For maximum service life of the machine, perform a
thorough walk-around inspection before you mount No person other than the operator should stay in the
the machine and before you start the engine. cab. No one is allowed to sit on the machine body.

Inspect the area around the machine and under the The engine can only be started within the cab. Never
machine. Look for loose bolts, trash buildup, oil, start the engine by short-circuit the starting motor,
coolant leakage, broken parts, or worn parts. which will lead to damage to the electrical system of
the machine by starting the system with bypass
Note: Watch closely for leaks. If you observe a circuit. In addition, this operation is very dangerous.
leak, find the source of the leak and correct the
leak. If you suspect a leak or you observe a leak, Make sure the backup alarm, if equipped, functions
check the fluid levels more frequently. Inspect properly.
the condition of the equipment and of the Notice
hydraulic components. One starting attempt should not be longer than
Check the condition of the tires. Adjust the inflation 15 seconds (the continuous time of starting
pressure, if necessary. motor should not exceed 15 seconds). If the
starter does not start at that time, the starting
For liquid filled tire, check for Liquid leakage. switch should be released immediately. Wait at
least 30 seconds before attempt to start again.

39
This is jointly determined by the features of the • When starting traveling, sound the horn to give an
starting motor and the battery. If the engine fails alert.
to start after three consecutive attempts, it
should be checked. After the malfunction is • The machine can only be operated with the
corrected, and at least three minutes later, the operator sitting in the operator's seat.
engine can be started again. • Seat belt must be fastened. (If equipped)
• The engine should run at idle speed to warm-up • No person other than the operator should stay in
af ter starting(at least 5 minutes recommended) the cab. No one is allowed to sit on the machine
body.
• Listen to check if the engine operates properly
while it is running at low speed, and check the • Check the backup alarm, if equipped, for normal
transmission of abnormal noise. operation.
• Check all the instrumentation for proper operation, Precautions during traveling
and check the lighting devices, indicators, horn,
wipers, braking lights for proper operation. • The key in the starting switch must not be turned to
the OFF position while the machine is traveling. It
Notice is very dangerous if the engine is shut down during
Special attention should be paid to the instrument traveling, because the steering will be heavy. If the
panel for engine malfunction indicator lamps. engine dies, the brakes should be applied
immediately to stop the machine.
• Check the service brake and parking brake system
f or proper operation. • When operating, it is dangerous to look left and
right, the operator must concentrate on the work
• If there is no obstacles around the machine, turn during operation.
the steering wheel slowly to see if the machine
turns accordingly. • Driving too fast, sudden braking, sudden stopping,
sharp turns or zigzagging are all dangerous.
• If any abnormality (noise, vibration, smell, incorrect
direction before removing the key. display of instrumentation, air leak, oil leak etc.) is
After starting the engine f ound during the operation, the machine should be
moved to a safe place and find the causes.
Failure to perform the appropriate checks after
starting the engine will delay the discovery of the • Do not operate the steering wheel suddenly. If
abnormal phenomena. And this can result in serious doing so, the work tool may touch the ground
injury or machine damage. surf ace and the machine may lose balance, or
damage to the machines or structures around may
When conducting the checks, it should be performed occur.
in an open area without obstacles. No one should
get close to the machine. • When traveling on the uneven surface, keep the
speed low and avoid sudden steering.
• Check the operation of the instrument and
equipment. Check the operation of braking system, • Try to avoid driving over obstacles. A distance
drive system and steering system. should be kept from other machines or structures
during traveling or operating to avoid collision.
• Check the machine for unusual noise, vibration,
heating, smell or instrumentation operation. Check • If working in water, the allowed water depth must
f or hydraulic oil, lubricating oil, air or fuel leaks. not be exceeded. The water depth must not
exceed the bottom of the axle housing.
• If any abnormality is found, repair immediately. If
the machine is operated under unsuitable • When driving on bridges or structures on private
conditions, serious injury or machine damage may properties, first check the strength to see if it is
occur. enough to support the weight of the machine.
When driving on public roads, the rules of the
• Bef ore traveling or starting the work, the lockout appropriate authorities must be met and
lever should be locked in the ”RELEASE ”position appropriate regulations must be followed.
securely.
• Traf f ic rules should be followed when driving on
When starting traveling public roads. The driving speed of the machine is
• Bef ore starting traveling, check around the lower than the normal speed of automobiles. Drive
machine again to make sure there is no personnel on the side of the road to leave the center of the
and obstacles. road to other vehicles.

40
• If the machine runs at a high speed continuously precautions of machine operation;
f or a long period of time, the tires will overheat and
--- Protective measures should be taken in
the internal pressure will become extremely high. accordance with the construction safety
This may lead to the blowout of the tire. If the tire
regulations: overalls, hard hat, ear protectors,
blows out, extreme destructive force will be masks, safety glasses, reflective clothing, etc.;
generated, which may result in severe injury or
accident. • Bef ore starting the engine, all controls must be in
the “neutral” position.
• If you plan to drive the machine continuously,
please consult the authorized dealer of Caterpillar • When the machine operates after parking for a
(Qingzhou) Ltd. long time, check if the hydraulic oil and the
lubricant in each component have deteriorated,
and replace with the new oil if necessary.
Checks when changing the direction
• Be f amiliar with the workplace environment,
To avoid injury or death, the following rules must be operating conditions, and objects.
f ollowed before moving the machine or the work tool,
even if the machine is equipped with backup alarm The personnel should wear various protective
and mirrors: equipment
• It is f orbidden to drink alcohol and take stimulants
• Sound the horn to alert the personnel on the site.
or other drugs before operating the compactor or
• Check around the machine. There should be no compacting the ground.
person. Check especially the area behind the
• Find where the fire extinguisher, first-aid
machine as it is not visible from the operator's seat.
equipment, and alarm phone is located.
• Where there is a danger or the visibility is poor,
• Check if the mirrors provide the operator with a
one person should be specified to direct the traffic.
good view.
• Persons without approval must not enter areas in
• Check if all signs, symbols and figures in the cab
the turning direction or traveling direction.
are clear.
• The traveling direction must not be changed when
• Bef ore starting, the operator must ensure that
the machine is at high speed.
there are no personnel or obstacles near or under
Forbidden operation the compactor.
• The load of the machine must be kept within the • When the diesel engine is running, the operator
specified maximum load to avoid fall-over of the cannot exit the compactor at will.
machine and damage to the working device due to
overloading. Caterpillar (Qingzhou) Ltd. will not be • The cab door must be closed when the machine is
responsible for any injury, accident or damage to traveling or working.
the machine resulting from overloading of the
machine.
Starting the machine
Machine starting steps:
Traveling on slope
• Traveling on slope may cause the machine to fall • Check the battery master switch at ”ON”position
over or slide to one side. Be especially cautious. • Check the hand brake to ensure that it is in the
brake state
Operating Tips • Check and ensure that the speed control lever is in
the neutral position.
• Operator preparations:
• Check that the vibration switch is in the OFF
--- Should be trained to be qualified for each
position.
operation; don’t drink or use stimulants;
• Insert the start-up key and rotate it clockwise to a
--- Should be familiar with the workplace
environment, working conditions and job position,
objects; the f uel and current gauges indicate normal,
--- Should be familiar with the rules and continue to rotate to other position, engine should be
precautions of the workplace; immediately started.

--- Should read and understand the operation • Let the engine run at low speed to preheat for 5-10
manual and be f amiliar with various rules and Minutes, the driver should observe the gauge
41
 readings and engine operation. • The compactor is on the slope, if it is necessary to
shif t or turn, it must be carried out after parking
• Sound the horn to warn once.
brake, never disengage and coast during the
Running the machine downhill.

• Turn the throttle knob to make the engine reach • Shif t after the clutch pedal is depressed. Never
shif t gears without depress the clutch pedal.
the rated speed.
Vibration work
When the compactor is running, firstly select the
vibratory amplitude switch according to the
construction needs, and then press the vibration
switch. Pressing the vibratory amplitude switch
f orward is the low amplitude, pressing backwards is
high amplitude, and the middle position is to stop
vibration. Large amplitude compacts initial base layer,
small amplitude compacts sub-base layer.

• Check that the steering mechanism is working

properly by turning the steering wheel. Make sure
there are no personnel around the compactor.
• Depress the main clutch pedal and cut the power.
Place the shift lever to the desired gear and travel
orientation. Release the hand brake and slowly
release the main clutch pedal. The compactor 1 Vibration Switch 2 Amplitude Switch
starts. Depress the foot brake pedal and check if
the service brake system is normal. Vibration switch and amplitude switch diagram

• Backup High Amplitude

Put the shif t lever in the required gear and confirm In order to increase the height of the drum
that there is no person or obstacle on the road, then movement, place the vibratory system in high
reverse, at this time, the backup buzzer should have amplitude.
a tone.(If configured). High amplitude is used in the following situations:
• Steering • The job site requires higher compacting force in
Turn on the turn signal light firstly, after making sure order to meet the required density.
that there is no person or obstacle, the machine can • In order to compact material with a depth of 250
be steered. mmor more, use high amplitude.
• Service brake Note: Once you have achieved the desired density
Press the brake pedal and the compactor will stop. of the material, continued operation at high
Under normal circumstances, on a flat and straight amplitude can crush the aggregate.
road, when the compactor shift lever is in the neutral Note: The amplitude required for every job site is
position, the brake pedal is not required to be dif ferent due to the various conditions of the soil.
depressed, and the compactor can also stop. Moisture content and the type of material vary from
• Emergency brake job site to job site. In order to determine the
amplitude that is needed, establishing a test location
Under Hazardous conditions, when emergency at each job site is recommended.
brake is required, you must firstly depress the main
clutch pedal to cut the power, and then depress the 1. Turn the amplitude selection switch to high
f oot brake pedal, compactor will stop. amplitude,
• A special attention to be paid to the slope road 2. Press the vibration switch forward, start vibratory
surface, and only allow to go up and down a grade. system,start high-amplitude vibration work.
Turn to the first gear when approaching the slope. 3. Turn of f the vibration switch and stop the
• Never allow the engine is shut down when vibration.
operating on the slope to prevent the hydraulic Low Amplitude
steering system from malfunctioning.
42
In order to decrease the amplitude value of the drum Parking precautions
movement, place the vibratory system in low
• Park the machine on a flat, hard ground, and make
amplitude.
sure that it does not cause traffic jams.
Low amplitude is used in the following situations:
• If you need to park on a slope, be sure to block the
• When operating the machine in high amplitude and vibratory wheel and rear wheel with stones or
the drum separates from the soil, use low similar wedges.
amplitude to reach the desired soil density.
• The thickness of the material is less than 250 mm .
• Objects such as sewer systems or water systems
may be damaged due to high amplitude.
1. Set the amplitude selection switch to the low
amplitude.
2. Press the vibration switch forward to activate the
vibratory system. Start the low amplitude Fire safety procedures
vibration operation.
Fire prevention during equipment use, maintenance
3. Turn of f the vibration switch and stop the and storage
vibration.
--- Fire prevention during refueling process;
Caution: When changing the amplitude, you must
--- Fire prevention during welding or cutting
f irst turn the amplitude switch to the middle position.
Af ter the compactor stops vibrating, press the repair;
amplitude switch to select high/low amplitude. --- Muf fler, exhausts, etc. shall not be close to
withered grass, and flammable materials;
！ WARNING Cannot perform vibration on --- Fire prevention during equipment placement
hard roads
and storage;
Do not start the vibration in
！ WARNING place to avoid damage to the --- Fire prevention of battery;
machine and ground --- Fire prevention when working in explosive
When the compactor needs to conditions
！ WARNING change the travel direction, Measures to be taken in case of fire;
stop the vibration firstly.
--- Move the machine away from dangerous
！ WARNING When vibrating, always check if areas;
the gauge display is normal.
--- Stop the engine, and turn the ignition to "OFF”
When the filter alert indicator in position;
the instrument panel
！ WARNING illuminates, should stop the --- Exit the cab;
engine and replace the filter Do not get close to high-voltage cables
element immediately.
Do not allow the machine to touch the overhead
Operation steps of shutdown cables. Even just getting close to the cable can
cause electric shock. The safe distance as specified
• Move the amplitude switch to the middle position in the f ollowing table should be kept between the
to stop the compactor and then turn off the machine and the cable.
vibration switch.
VoltageV Minimum safe distance
• Depress the main clutch pedal and place the shift 100-200 2m 7ft
lever in the neutral position. Low Voltage
6,600 2m 7ft
• Rotate the throttle knob to the NEUTRAL position
22,000 3m 10 ft
f or3-5minutes.
66,000 4m 14 ft
Turn the start key to the “OFF”position.
High Voltage 154,000 5m 17ft
• Pull up the hand brake grip to place it in the brake 187,000 6m 20ft
position.
275,000 7m 23ft

43
 500,000 11 m 36ft circumstances, special cautions must be used
during driving.
• To prevent accidents from occurring, please do
• The road shoulder and roadside items will be
the following work well:
covered and become unclear after heavy snow.
1. If there is a potential risk of the machine touching Theref ore the snow must be cleaned carefully.
power cables on the working site, consult with
• When driving on snow-covered roads, antiskit tire
the power company before starting the operation,
and check and determine the feasibility of the chain should be used.
operation according to the current relevant • When driving on snow-covered slopes, never
regulations. apply the brake suddenly. To decelerate, depress
2. Wear rubber boots and rubber gloves. Place a the braking pedal intermittently for several times.
rubber pad on the operator's seat, and pay • The traction of the ground varies greatly with the
attention not to allow any exposed part of the inf luence of the snow. Therefore the load needs to
body contact the metal chassis. be adjusted accordingly to avoid skidding of the
3. Specify a signalman who will give warning machine during traveling.
signals when the machine gets too close to the
power cable. Storage Information
4. If the work tool makes contact with the cable, the Provide the precautions and tools information for
operator must not leave the cab. operators, who will do the long-term and short-term
machine storage operation.
5. When working in the vicinity of high-voltage
cables, do not allow any person to get close to Note: Short-term storage is the storage within 2
the machine.
months; long-term storage is the storage of 3 to
6. Consult the power company for the voltage of the
12 months.
cable before starting operation.
Pay attention to the following aspects to ensure good Short-Term Storage:
visibility:
• Clear away dirt and dust from the machine. Pay
1. When working in dark places, turn on the
attention to the cleanliness of the engine,
working light and the headlights, and install
lighting device at the working site if necessary. generator, start motor, injection pump, injector,
hydraulic pump and motor, hydraulic lines, and
2. Do not work in a foggy, hazy, snowy, heavy rainy surf aces. Clean them with a dry, soft cloth.
day or other circumstances with poor visibility.
Wait until it is clear and bright and there is • Drain the coolant in the radiator.
enough visibility before starting the work. • Clean the surface of each component and the
Using method of the brakes grease holes with kerosene and fill the holes with
wax once.
• Do not put your foot on the braking pedal unless
really necessary. • Maintain the machine to be able to start at any
time in the short-term storage.
• Do not depress the pedal repeatedly unless really
necessary. Long Term Storage

• When driving downhill, use the engine as a brake Storage Space

and never shift gears or put the transmission in the
neutral position. Store the machine in a dry and ventilated warehouse.
If placing the machine in open air, park the machine
Use caution in snowy days
on concrete ground with good drainage, cover the
• When working on roads with snow or ice, even a machine and store the machine in a place that is free
small slope can cause the machine to slide away. f rom natural disaster and from corrosive substance
Theref ore, the speed must be kept low and sudden and gas.
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
soft as the temperature rises and the traveling
conditions will become unstable. Under such
44
 Spread protective liquid Peel off the protective
on the surf ace paper. Blow it with hot
dry air or rinse it with
soda soap solution.

Spread oil or paint on Clean with hot water or

Cover the Compactor surf aces detergent. Or wipe with

organic solvent first and
Storage then clean with hot
• Place the machine horizontally on the platform in water or detergent.
order to prevent machine distortion and tire
def ormation. Ensure that the distance between each
Spread protective Cut the membrane at
wheel and the support surface is not less than 8cm.
polymer on surfaces the proper location and
• Disconnect batteries. When the machine is stored
over one month, remove the batteries from the peel it off
machine and store them in a specific place.
• Start the machine once per month and run the Spread lightproof Clean with detergent.
machine f or half an hour at low speed in order to
compound on rubber
grease all systems and in the meantime, fill all
grease f ittings. surf aces
• Conduct regular inspection of appearance,
protected surfaces, etc. Specified Storage Period
• Intervals to inspect long-term storage machine The specified storage period of this machine is 1
year. Af ter this specified storage period has expired,
• Inspect the machine once every six months in consult your SEM Dealer for inspect, repair, rebuild,
warm climate. Inspect the machine once every three install remanufactured, install new components, and
months in the tropical zone, in the cold temperature disposal options and to establish a new specified
in the warm temperature zone, cold zone and coastal storage period. If a decision is made to remove this
areas. machine f rom service, see the Decommissioning and
After Long-Term Storage Disposal section of this Operations and Maintenance
Manual.
• Remove the cover. Shipping of the machine
• Clear away the exposed protective liquid. Investigate the travel route for overpass height, width
• Charge the batteries. Install and connect the and the allowable load before shipping. The total
batteries. height, width and weight etc. with the machine
loaded on a shipping vehicle must not exceed the
• Drain and clean engine crankshaft, final reducer relevant regulations. In case of over-height or over-
and drive axle. Replace oil as required. width, please consult Caterpillar (Qingzhou) Ltd. or
• Replace the lubricant in the vibratory drum. its dealers for solution.
• Drain impurity and water from the hydraulic tank To prevent the safety accident of the machine
and f uel tank. slipping in transit, remove ice, snow, or other slippery
material f rom the loading dock and from the truck
• Grease all hitch joint area. bed before shipping.
• Ref er to the Operation Section for the inspection
Notice
bef ore operation.
Obey all local and national laws and regulations
Recommended Approaches to Clear Away that govern the height, width, length and weight
Protections: of a load while shipping.

Protection Approach Steering frame is locked

Make sure that there is no one in this when the
45
machine turns. Crush may occur and result in Note: Obey all laws that govern the
serious injury or death. characteristics of a load (height, weight, width,
and length). Observe all regulations that govern
Install the steering frame lock pin between the front
wide loads.
f rame and the rear f rame before you lift the machine
and bef ore you transport the machine on another When you move the machine to a colder climate,
vehicle. Also install the steering frame lock pin make sure that the cooling system has the proper
bef ore you perform maintenance near the center of antif reeze.
the machine.
In order to install the steering frame lock pin, the
machine must be in the straight ahead position.
1. Move the machine into position.
2. Engage the parking brake.
3. Turn engine start switch key to
OFF(OFF)position. Remove the key.
4. Remove the retaining pin from storage position.
Bef ore you load the machine, chock the trailer
wheels or the rail car wheels, as shown.
1. Rotate the antenna to the lower position.
2. Move the machine into position.
3. Engage the parking brake for the machine.
4. Turn engine start switch key to
OFF(OFF)position. Remove the key.
5. Install the steering frame lock pin. The pin will
f irmly secure the front frame and the rear frame.
6. Chock the machine, and tie down the machine.
For more detailed information, please refer to the
Operation and Maintenance Manual,” Lifting and
Tying down the Machine”.
7. Lock the doors and the access covers. Attach
5. Align the central lines of the hole1and the any vandalism protection. Install the cover on the
hole2f rom top to bottom, and insert the steering console. Cover the operator seat.
f rame lock pin in the3 into the hole1 and the
hole2, the pin could firmly secure the front and Notice
rear steering frame. When inspecting, maintaining, testing, adjusting,
and repairing the engine, please ensure that the
Note: When you disengage the steering lock, you
liquid that is flowing out is received. Be prepared
must put the steering lock pin in the storage
to collect the fluid with suitable containers
position. The steering frame lock pin is secured
before opening any compartment or
in the storage position by a retaining pin. When
you install the retaining pin, make sure that the disassembling any component containing fluids.
retaining pin is fully installed. Dispose of all fluids according to local laws and
regulations.
Shipping of Machine
8. To protect the cooling systems, mix solution of
Investigate the travel route for overpass clearances.
antif reeze and water. The solution should
Make sure that there is adequate clearance for the provide protection to the expected lowest outside
machine that is being transported.
temperature. Drain the excess coolant into a
Remove ice, snow, or other slippery material from suitable container.
the loading dock and from the truck bed before you
9. Perf orm a walk-around inspection and measure
load the machine onto the transport machine. the f luid levels in the various compartments.
Removing ice, snow, or other slippery material will
help to prevent the machine from slipping in transit.

46
The machine on the road 3. Lif t the machine. Move the machine to the
desired position.
For the short-distance transportation of compactor,
according to the road conditions, you can choose 4. Place the blocks in the front of vibratory wheels
second or third gear. Before starting off, you need to when the machine is positioned. When the
do the f ollowing preparations: machine is positioned, place the blocks behind
the tires.
Inf late the tire pressure to the specified value;
5. For more information, please refer to the
Check the f luid levels in the various compartments. Operation and Maintenance Manual,chapter on
“Shipping of Machines”.
Obtain the driving documents of the relevant roads;
Install any required marks, signals, or signal lights. Towing the machine
Drive at medium speed and follow various speed
limits.
Improper hookup and towing are dangerous and
Lifting and Tying Down the could result in injury or death to yourself or
Machine others.
Notice The towing connection must be secure, and the
Improper lifting or tie-down can cause the load to towing must be done by two machines of the same
shift and lead to the personal injury and damage. size or larger than the towed machine. If two
machines are used for towing, connect each
machine to the towed machine.
If only one machine is used for towing, this machine
must be larger than the machine being towed.
The machine being towed to the workshop must be
repaired or adjusted properly before returning to
service.
These towing instructions are for moving a disabled
machine f or a short distance at low speed. Move the
machine at a speed of 2 km/h or less to a convenient
location for repair. These instructions are only for
emergencies. Always haul the machine if long
For the basic specifications of the machine, refer to distance moving is required.
the Operation and Maintenance Manual,
Shielding must be provided on both machines. This
"Specifications". will protect the operator if the tow line or the tow bar
Lif ting Point - In order to lift the machine, attach the breaks.
lif ting devices to the lifting points. Do not allow an operator to be on the machine that is
being towed unless the operator can control the
Tie Down Point - In order to tie down the machine, steering and/or the braking.
attach the tie-downs to the tie down points.
Bef ore towing, make sure that the tow line or the tow
Use properly rated cables and properly rated slings bar is in good condition. Make sure that the tow line
in order to lift the machine. or the tow bar has enough strength for the towing
Position the crane or the lifting device in order to lift procedure that is involved. The strength of the towing
the machine in a level position. line or of the tow bar should be at least 1.5 times of
the gross weight of the towing vehicle. This is true for
The width of the spreader bar must be sufficient to a disabled machine that is stuck in the mud and for
prevent the lifting cables or the lifting straps from towing on a grade.
contacting the machine.
Keep the tow line angle to a minimum. Do not
1. Install the steering frame lock pin to maintain the exceed a 30 degree angle from the straight ahead
hinge rigidity. position.
2. Connect the four lifting cables to a spreader bar. Quick machine movement could overload the tow
The spreader bar must be centered over the line or the tow bar. This could cause the tow line or
machine.

47
the tow bar to break. Gradual, steady machine Af ter the compaction meter is turned on, the
movement will be more effective. interf ace is displayed as (Figure -2).
Normally, the towing machine should be as large as
the disabled machine. Make sure that the towing
machine has enough brake capacity, enough weight,
and enough power. The towing machine must be
able to control both machines for the grade that is
involved and for the distance that is involved.
You must provide sufficient control and sufficient
braking when you are moving a disabled machine
downhill. This may require a larger towing machine
or additional machines that are connected to the rear. Figure-2
This will prevent the machine from rolling away out of
control. The initialization interface shows
approximately3seconds, and instrument enters the
All situation requirements cannot be listed. Minimal normal working interface (Figure-3), this interface is
towing machine capacity is required on smooth, level called the main interface.
surf aces. On inclines in poor condition or on surfaces
in poor condition, maximum towing machine capacity
is required. Attach the towing device and the
machine before you release the brakes.

Compaction Meter Operation

Instructions

Figure-3

Use of function keys:

①Af ter pressing the “Function” button, the interface
switches to (Figure-4) interface, you can operate
according to the red text prompts.

The compaction meter is located on the front right

side of the driver
The compaction meter of compactor is used to Figure-4
measure the compacted ground level density. The
main technical parameters are as follows: ② When the cursor points to the “calibration” option
Applicable voltage range:DC 24 V±8 V (Figure-4), press the “OK” button, the interface
switches to (Figure-5) interface, you can operate
Instrumentation power consumption: ≤5 W according to the red text prompts.
Compaction accuracy: ±1%(sand-pouring method, Voltage value: Indicates the voltage value sampled
ring cutting method) at the time of entering the calibration interface.
Frequency accuracy: ±1 Hz Density: just press “→/ segment number”, “↑”, and
“↓” keys to complete the calibration. (The calibration
display:4.3inch color liquid crystal display,480 X value is the density data of the position measured by
272resolution the sand-pouring method or the ring cutting method).
Operating temperature :-10 ºC~75 ºC Qualif ied value: The value of the qualified density
Protection level: controllerIP 65sensorIP 68 required f or the subgrade. (Example: the soil density
on the construction road is required to be more
Operation Instructions: than95%, this value is called the qualified value. )
The calibration method is the same as above.
48
Calibration number: calibrate the number of different Width of compactor

soil f oundations, the default is0. Section number a-1

Caution: The density value and the qualified value

must be set together. You cannot calibrate twice.
Af ter completing the calibration, press ”→ / segment
number” key will prompt “Do you want to save?”
(Figure-6). Press the ”OK” key to save the calibration Section number a

value and return to the main interface; press

the ”Exit” key to abandon the calibration value and Forward direction of
compactor

return to the main interface. Back direction of compactor

End of section 2

End of section 1 and

beginning of section 2
Beginning of section 1

Lane a Lane 3 Lane 2 Lane 1

Figure-8

Data storage instructions:

① Af terU disc is inserted,

a red circle will blink on the upper right corner of the
Figure-5 display interface (Figure-9).

Figure-9
Figure-6
② “→/ segment number" key is the road section
③ When the cursor points to the ”View history
number selection key; ”storage/ Stop” key is a
calibration” option (Figure-4), press the ”OK” key to selection key for data storage or storage end.
switch to (Figure-7) interface, and operate according
First select the road section number and
to the red text prompts. press ”Save/Stop” key, the upper right corner of the
interf ace appears ”Start”,The data of a certain road
section number begins to be stored (Figure-10),
when the compactor is crushed to the end of the
road, when press ”storage/Stop”key again, “End”
appears in the upper right corner of the interface,
indicating that the storage is over. When the last
crushing of a certain section is completed, press
“→/segment number” key to select a new road
section number (Figure-11).
Figure-7

Data storage function

The roadbed density data is stored, and the data can
be import into a computer to analyze the crushed
road section.
In the process of compacting, the road needs to be
divided into several sections, each section is a
section number, and each section number is divided
into several paths. For example: (Figure-8). Figure-11

49
 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 first. When removing the battery,
disconnect the negative (-) terminal (ground wire
side) first.
• When installing or removing the battery, check
Figure-11 which one is positive (+) terminal or negative (-)
terminal first and then tighten the nut securely.
③ The data in the U disc can be displayed the
• Use a cloth when cleaning the top surface of the
analysis of the road section density on the computer
battery. Never use gasoline, solvent or any other
with the relative developed software.(Figure-12).
organic solvent or detergent. Tighten the battery
top cover securely.
• If the battery electrolyte is frozen, do not charge
the battery or use other power supply to start the
engine. This is dangerous, because it can set the
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
Figure-12
charging.
Start with Booster Cable
Battery Use and Maintenance If there is anything wrong with the connection of
Considerations booster cable, a fire can result. Therefore, the
f ollowing method must be taken.
Precautions • The starting operation requires two technicians to
The machine uses maintenance free batteries, complete (one sitting on the operator chair).
without the need to add electrolyte.
• Those two machines are not allowed to make
• Battery electrolyte contains sulfuric acid and the contact with each other when starting the other
battery can generate hydrogen. Therefore, machine.
improper handling of the batteries can lead to • When connecting the booster cable, turn OFF both
heavy injury or fire. For this reason, the following
the START switches of the functional machine and
considerations must be followed. Never put a
malf unctioned machine.
lighted cigarette or flame near the battery.
• When installing the booster cable, always connect
• If the work requires making contact with the battery,
the positive (+) cable first. When removing the
always wear safety glasses and rubber gloves.
booster cable, always disconnect the ground wire
• If the electrolyte inside the battery splashes on the or negative (-) cable first.
clothes or skin, flush with plenty of clean water • Finally connect the ground wire to the engine
immediately.
cylinder block of the malfunctioned machine. But,
• Battery electrolyte splashing into the eyes can this will cause spark, so keep away from the
result in blindness. If the electrolyte splashes into battery as far as possible during connecting.
the eyes, flush with plenty of clean water and see a • When removing the booster cable, be careful not
doctor immediately.
to let the clips of the booster cable touch each
If drinking the electrolyte accidentally, drink plenty of other or touch the machine.
water, milk, raw eggs or vegetable oil and see a
doctor or call the emergency center immediately. Charging Battery
• Shut down the engine before performing any work Improper handling of the battery can lead to battery
related to the engine. explosion when charging the battery. Therefore,
perf orm the charging in accordance with the battery
• Avoid accidental contact with metal objects (e.g. handling regulations and charging regulations in the
50
instructions, and obey 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.

• Connect the positive (+) clip to the positive (+)

terminal of the battery and negative (-) clip to
negative (-) terminal of the battery. Make sure to
tighten both the terminals tightly.
• If the charging rate of the battery is lower than 1 /
10, perform high-speed charging and set the hash
value below the battery rated capacity. If the
charging current is excessive, electrolyte can leak
or evaporate, which can lead to burning or
explosion.

Decommissioning and
Disposal
When the product is removed from service, local
regulations for the product decommissioning will vary.
Disposal of the product will vary with local
regulations.
Improperly disposing of waste can threaten the
environment. Obey all local regulations for the
decommissioning and disposal of materials.Utilize
appropriate personal protective equipment when
decommissioning and disposing product.
Consult the nearest SEM dealer for additional
inf ormation. Including information for component
remanuf acturing and recycling options.

51
Maintenance Section

Notice
During the use of this machine, maintain the
machine according to the maintenance intervals
and procedures specified in this manual. Good
maintenance of the machine is very important to
the extended machine service life and job safety.

52
SEM 518/520/522Regular During the maintenance, the daily routine
maintenance and first-time maintenance of the
maintenance corresponding parts should be strictly followed, and
• When servicing and repairing the machine, the then different regular maintenance plans should be
corresponding record should be made and executed according to the specific working hours.
archived. Regular maintenance is the implementation basis of
• It is important for compactor to correctly and executing the maintenance plan by the working
hours, or by the standard of /2000 working hours
properly maintain to ensure its normal function.
The machine should be kept clean to detect any every year. The corresponding periodic maintenance
f aults such as leakage, loose bolts or loose plan is: 250-PM1,500-PM2,750-PM1,1000-
PM3,1250-PM1,1500-PM2,1750-PM1,2000-PM4.
connections.
• Attention to environment protection! Do not
contaminate the environment with oil, fuel and
other substances that do harm to the environment.
• This chapter covers the related regulations for
regular inspection and maintenance. The
compactor driver should follow the regulations.
• To ensure that the compactor has a good working
perf ormance for a long time, correct and periodic
maintenance is very important. The instructions
described here should be carefully followed.
• Remove dirt from the surface of the work area
bef ore adding Liquid, checking the oil level, and
perf orming lubrication.

Only personnel who have trained

！ WARNING and passed the examination can
maintain and repair the machine.

Read the relevant contents of this

instruction carefully before
！ Notice proceeding with any maintenance
operation.

If the engine is running indoors,

！ Notice ensure good ventilation
conditions.

The maintenance intervals listed in this manual are

determined by using the service hour meter or the
calendar (day, month etc.). Caterpillar (Qingzhou)
Ltd. requires the service should always be performed
at the interval that occurs first among the above two
interval determination methods. Under extremely
severe, dusty or wet operating conditions, more
f requent lubrication than is specified in the scheduled
maintenance might be necessary.
In addition to routine maintenance, we identified four
regular maintenance points:PM1: 250H;PM2:
500H;PM3: 1000H;PM4: 2000H.

53
The specific maintenance plans can be found in the attached chart
Daily
Maintenance Items PM1 PM2 PM3 PM4
Maintenance
Check the engine oil level √ √ √ √ √

Check the coolant level √ √ √ √ √

Check hydraulic oil fluid level √ √ √ √ √

Check fuel level, drain the water and contaminants 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 √ √ √ √ √

Walk around the machine to visually check all systems for abnormal √ √ √ √ √
condition or leaks.

Visually check engine fans and drive belts √ √ √ √ √

Tighten all drive shaft bolts √ √ √ √ √

Check the ventilation plug √ √ √ √ √

Check/adjust/replace the scraper √ √ √ √ √

Check the air filter service indicators √ √ √ √ √

Clean the air conditioner inner filter element √ √ √ √ √

Perform the lubrication maintenance for every50 h

Check the clearance between brake shoes and brake drum of parking
√ √ √ √
brake at the first 50 working hours and adjust if not appropriate
Check clutch clearance at the first50working hours √ √ √ √

Check the torque of hub retaining bolts Initial Check √ √ √ √

Initial change of the engine oil and oil filter (the first 50working hours)

Initial change of transmission and drive system filter(the first100working

hours)
Initial change of the drive axle oil(the first100working hours)

Initial change of the return filter element of the hydraulic tank (the
first250working hours)

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 √ √ √ √

Battery or Battery Cable inspection/ replacement √ √ √ √

Clean the fuel tank fill screen √ √ √ √

Clean the oil tank fill screen √ √ √ √

Cleaning the ventilation plug √ √ √ √

Check the torque of the transmission and engine mounting bolts √ √ √ √

54
 Daily
Maintenance Items PM1 PM2 PM3 PM4
Maintenance
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 √ √ √ √

Check the tension of engine drive belts and air conditioner compressor
√ √ √ √
belts and for damage

Check the capability of service brake and park brake √ √ √ √

Replace the engine oil and oil filter √ √ √ √

Check engine shock pad/cab shock pad/cooling package shock pad √ √ √ √

Replace the fuel prefilter √ √ √ √

Replace the engine water processor √ √ √ √

Replace the vibratory system filter element √ √ √

Check the retaining bolts of frame articulation pin for looseness √ √ √

Tighten the bolts connecting the rear axles and the frames √ √ √

Clean the screen inside the air booster pump breather √ √ √

Replace the fuel filter √ √ √ √

Replace 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 √ √

Clean the fuel tank √ √

Clean the transmission breather √ √

Changing the Transmission Oil √ √

Replace the drive system filter. √ √

Replace the return filter element of the hydraulic tank √ √

Replace the axle oil √ √

Check the engine vibration damper √

Check the operation of service brake system lines and park brake
system and remove to check the friction shim for wear and replace the √
brake lines as necessary

Check the flexibility of the steering system and replace the steering
√
lines as necessary.
Check the alternator and starting motor; clean and check the
√
turbocharger

Clean and check the brake booster seal and spring, replace the brake
fluid and check the flexibility of the brake √

Replace the oil tank breather (fill screen) √

Replace the fuel tank breather (fill screen) √

Replace the coolant and coolant filter; clean the cooling system Replace
the coolant at least every year if the working hours do not meet the √
change interval

Replace the hydraulic oil, clean the oil tank and check the suction line √

55
Important Notice!!! Keep the work site clean and organized
Do not use maintenance parts that are not • Do not leave any service or maintenance tool
approved by Caterpillar (Qingzhou) Ltd. or around the work site. Thoroughly wipe off any
designated dealers of Caterpillar (Qingzhou) Ltd. grease, oil and other items that can make people
The use of unauthorized maintenance parts may slip. Always keep the work site clean and
create safety problems that are detrimental to the organized so that the job can be safely done.
normal operation of the machine and affect the
service life. • If the work site is not clean or organized, people
can trip, slip or tumble and get injured.
Maintenance Considerations Designate a responsible person when co-
working with other people
1 Before Maintenance • Designate a responsible person who will be
Malfunction notice listened to by everybody while repairing the
machine or installing/removing the work tool.
If the maintenance being performed is not specified
in the Operation and Maintenance Manual, • Mutual misunderstanding can cause serious
unexpected malfunctions can occur. accidents when co-working with other people.
Contact the designated dealers of Caterpillar Shut down the engine before accessing or
(Qingzhou) Ltd. for repair. maintaining the machine
• If another person starts the engine or operates the • Place the machine on a level ground where there
lever while the operator is maintaining the machine should be free of rock fall or landslide when
or adding oil, the operator can be severely injured accessing or maintaining the machine. If the terrain
or killed. is low, there should be free of flood risk, either.
• Post a warning label on the lever in the cab to alert Shut the engine OFF.
the other people that you are accessing the Suitable Tools
machine. Post a warning label around the machine
too, if necessary. Use only the tools suitable for the task. Using
damaged, poor quality, failed or temporary tools can
Access and Cleaning Before Maintenance cause personal injury.
• Clean the machine before access and Lighting Use
maintenance. This can ensure that dirt will not
• Use a lighting device with anti-explosion feature
enter the machine and maintenance job can be
when checking the fuel, lubricating oil, battery
saf ely done.
electrolyte or window glass detergent. If not,
• If the machine is still dirty when accessing and explosion can occur.
maintaining, it can be difficult to locate the problem
• If performing the job at a dark place without lighting,
and dirt or silt can spill into the eyes, and people
people can get injured, therefore, proper lighting
can slip and get injured.
device should be installed.
• The f ollowing needs to be noticed when cleaning
• Never use a lighter or flame for lighting even in a
the machine:
dark place. It could cause a fire and when the
1. Wear anti-skid shoes to avoid slipping on a wet gases exiting from the battery encounters a fire,
surf ace. explosion could happen.
2. Wear protective clothes when flushing the • When using the machine for lighting supply, obey
machine with high-pressure water. This can the instructions in the Operation and Maintenance
protect you from the impact from the high- Manual.
pressure water and prevent the dirt and silt from
spilling into your eyes. Fire Prevention

3. Do not spray water directly onto the electrical Fuel or gases exiting from the battery could cause a
system elements (e.g. sensor, wire connector). If f ire during the maintenance, therefore the following
water enters the electrical system, it can be considerations must be obeyed while accessing or
f ailed. maintaining.
• The f uel, lubricating oil and other flammable
materials must be stored away from the flame.
• Use nonflammable material as part detergent. Do

56
 not use diesel or gasoline which could cause a fire. Working on the Top of the Machine
• Do not smoke while accessing or maintaining. • When working on the top of the machine, make
Smoke at the designated place. sure that the foothold is clean and free of
restrictions and the following considerations must
• Use a lighting device with anti-explosion feature
be obeyed to avoid falling.
when checking the fuel, lubricating oil, battery
electrolyte. Never use a lighter or flame for lighting. 1. There should not be spilled lubricating oil or
grease.
• Move all flammable material to a safe place before
grinding or welding on the flame. 2. No tools around.
• There must be a fire extinguisher in the job site 3. Watch out for the step while walking.
where accessing or maintenance will be performed. • Never jump from the machine. When getting on/off
2 When Performing Maintenance the machine, always use the ladder and armrest
and keep three-point (two feet and one hand or
WHO two hands and one foot) contact any time.
• Maintenance and service of the machine should • Use protective devices if necessary.
only be carried out by qualified technicians. Keep
• The top of the engine hood is slippery and
anyone not involved in the maintenance and
service away from the area. Designate a person to dangerous so standing on it is forbidden.
attend the area if necessary. • The top of the tire is slippery and dangerous so
• Pay particular attention when grinding, welding or standing on it is forbidden.
using a sledge hammer. • Stand on the fender of the front frame when
attaching parts cleaning the front window glass of the cab.

• Designate a responsible person before starting the Do not drop foreign material into the machine
removal or installation of the accessory. • Take care not to drop any foreign material (e.g. nut,
• Do not allow anyone who is not involved in the job bolt, cotton yarn or tool )into the machine when
opening the access window or oil fill of the tank. If
to stand near the machine or accessory.
such kind of material is dropped into the machine,
• Put the accessory removed from the machine in a machine damage, failed operation and other
saf e place and make sure it does not fall. Install malf unction can occur.
rails around the accessory with a "No Entry" mark
• If any foreign material is dropped into the machine,
on the rail to prevent the unauthorized person from
it must be taken out of the machine.
getting close.
• While accessing, do now carry any unnecessary
Working under the Machine
tool or part in the pocket.
• Park the machine at the stable and flat ground,
Maintenance During Engine Operation
stop all of work before performing maintenance or
repair under the machine. Do not perform maintenance during engine operation
to avoid injury. If it is necessary to perform
• Block the tires with wedges.
maintenance during engine operation, the following
• If the machine is only supported by the work tools considerations must be taken:
with the tires above the ground, it is very • Ask a technician to sit on the operator seat and
dangerous to work under the machine. Never work
turn off the engine at any time. All technicians must
under a poorly-supported machine.
be in touch with other person.
Performing Maintenance with Frame Raised
• Use extreme care when the task point is near the
• Bef ore performing the job with work tool or frame rotating parts because there is the risk of getting
raised, lock the front and rear frames with locking caught in rotating parts.
lever. Place the lever at ” NEUTRAL ” position.
• Never allow any tool or any part of the body to
Block the work tools and frames with wedges.
touch the fan blade or fan belt. Serious injury can
• Bef ore raising, block the wheel with a wedge at the be caused.
opposite side. After raising, put wedges under the
machine.

57
 When Found It Abnormal
• If any abnormal condition is found during
accessing, repair it. Especially when a problem is
f ound in the brake system , steering system or
work tool system, serious accidents could occur.
• Prevent the work tool from moving when cleaning • Depending on the fault type, contact the
the interior of the radiator. Also pull the park brake designated dealers of Caterpillar (Qingzhou) Ltd.
switch to apply the park brake. f or repair.
• Do not touch any lever. If operating the lever is Regulations on Adding fuel or Lubricating Oil
necessary, signal the other technicians to alert
Fuel, lubricating oil, hydraulic oil, antifreeze, brake
them to walk into a safe place.
f luid and window glass detergent can be lit by a
Hammer Use Considerations f lame. The f ollowing regulations must be obeyed:
• Always wear safety glasses, helmet and other • Turn off the engine when adding fuel or lubricating
protective clothes when using a hammer and put a oil.
copper stick between the hammer and the object
being hit on. • No smoking.

• There could be a risk of debris flying into the eyes • Wipe off any spilled fuel, lubricating oil, hydraulic
causing injury if using a hammer to hit a hard part, oil, antifreeze, brake fluid or window glass
detergent.
For example a pin or bearing.
• Securely tighten all top covers of the containers for
Welding Repair
f uel, lubricating oil, hydraulic oil, antifreeze, brake
The welding must be performed by a qualified f luid or window glass detergent.
technician and in a place equipped with appropriate
equipment. Welding can generate gases and there • The place where the fuel, lubricating oil, hydraulic
exists the risk of fire and electric shock, therefore oil, antifreeze, brake fluid or window glass
never allow the unqualified technician to perform the detergent is added or stored must be well-
welding. The qualified technician must follow the ventilated.
f ollowing the considerations. High-pressure Hose Handling
• Disconnect the terminals of the battery to avoid • If the high-pressure hose leaks, failed operation
battery explosion. Remove the paint from the could occur which will cause personal injury or
position to be welded to prevent the generation of equipment damage. If damaged hose or loosened
hazardous gas. bolt is found, stop operation and contact the
• Welding on the hydraulic device or lines or places designated dealers of Caterpillar (Qingzhou)Ltd.
very near to it can generate flammable vapor and f or repair.
spark which can cause a fire, therefore, avoid to • Sophisticated technique is required when replacing
weld on such place. the high-pressure hose and installing torque is
• If the spark generated during the welding directly determined by the type and size of the hose,
falls on the rubber hose, wire or pressurized piping, theref ore, do not repair by yourself. Contact the
they can rupture and the insulation of the wire can designated dealers of Caterpillar (Qingzhou) Ltd.
be damaged, therefore, cover them with an anti- f or repair.
f ire baffle. High-Pressure Oil Considerations
• Wear protective clothes during welding. When accessing or replacing the hydraulic system
• Make sure the site where the welding is performed lines, check if the system pressure has been
released. If there is still pressure in the lines, serious
is well-ventilated.
injury or damage can occur. Theref ore, perform as
• Clear all f lammable materials and make sure there f ollows:
is a f ire extinguisher at the job site.
Battery Considerations
When repairing the electrical system or performing
welding on the machine, remove the negative (-) of
the battery or turn off the main power switch to
prevent current flow.

58
 regulations.
Inspection After Access and Maintenance
If the comprehensive access and maintenance is not
perf ormed and the function of each maintenance
position is not checked, unexpected problems can
occur which could cause personal injury or machine
damage. Therefore, always consider the following
questions.
• Inspection After Engine Shutdown
1. Have all access and maintenance positions been
checked?
• For details of releasing pressure, see "Turn off the 2. Have all access and maintenance items been
engine before check and maintenance" in perf ormed correctly?
the ”Maintenance Considerations”. Never access 3. Is there a tooling or part that dropped into the
or replace before the pressure is released machine? It is especially dangerous if it is stuck
completely.
on the linkage of the lever.
• Wear the safety and leather gloves. 4. Are the water leakage and the oil leakage
• If there is oil leak in the line, the line and the repaired??Are the bolts tightened?
surrounding area will be wet, therefore, check the • Inspection During Engine Operation
tube or hose for cracks and hose for bulge. If it is
difficult to locate the leak, contact the designated For the detail of the inspection during engine
dealers of Caterpillar (Qingzhou) Ltd. for repair. operation, see the ”Maintenance During Engine
Operation” section of ”Maintenance Considerations”.
• Use a plate or cardboard to check the leak instead Consider the following questions while ensuring
of bare hands. saf ety:
• If shot by the spilled high-pressure oil, see a doctor 1. Is the operation of the access and maintenance
immediately. positions normal.
Precautions for accessing at high temperature or 2. Does the hydraulic system leak oil when the
high pressure engine speed accelerates and high load is
• The coolant and oil at various positions is under applied.
high temperature and high pressure just after the
operation is stopped. Opening the engine hood,
draining the oil or coolant, or replacing the filter at
this point can cause burns or other injuries. Wait
f or it to cool down and access according to the
procedure in the Operation and Maintenance
Manual.
• For other inspection items, see the“ Regular
Maintenance ”and the related content in the
Operation and Maintenance Manual.
Scrap
To prevent pollution, especially in the area where
humans or animals live, the following procedures
must be followed.
• Never dump the used fuel or oil into the drains,
rivers, etc.
• Collect the drained oil into a container and never
drain the oil directly to the ground.
• Dispose of the hazardous material such as
lubricating oil, fuel, coolant, solvent, filter and
battery in accordance with the related laws and
59
Key Safety Part Catalog and
Change Interval
• To ensure the safety of the compactor during use,
the user must perform regular maintenance. In
addition, to ensure further safety, the user should
also change the parts outlined in the chart
periodically. These parts area essential to the
saf ety and fire 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.
Theref ore, no matter what their condition is, they
must be changed periodically to ensure their
perf ormance.
• If the change interval is not reached but their
abnormal operation is found, repair or replace
them immediately.
• If there is any damage (for example, deformation
or cracks) to the clip securing the hose, replace it
with the hose.
• The O ring, gasket or other similar parts must be
replaced together while replace the hose.
• Contact the designated dealers of Caterpillar
(Qingzhou) Ltd. for the replacement of key safety
key parts.

60
Regular Change Chart of Key Safety Part

Number Key safety part needed to be changed periodically Quantity Change Interval
Every 6 months or 1,000 hours,
1 Hydraulic oil return filter 1
whichever occurs first
2 Fan Belt 1
3 Fuel line (f uel tank - f uel) 1
4 Fuel line (high-pressure fuel pump - fuel tank) 1
5 Steering cylinder seal 2
Steering hose (rear steering cylinder connector -
6 2
pressure test connector)
7 Steering hose (pressure test connector - steering gear) 2
8 Steering hose (cooling package - steering gear) 1
9 Steering hose (steering pump - steering gear) 1
10 Steering hose (steering pump - hydraulic tank) 1
Every 2 years or 4000 working
11 Steering hose (cooling package - hydraulic tank) 1
hours, whichever occurs first.
12 Brake hose ( clutch main pump - clutch booster) 1
13 Brake hose (Parking Brake - Hand Brake Joystick) 2
14 Brake hose (clutch pedal - oil pot) 2
15 Brake hose ( clutch booster - air reservoir) 2
16 Brake hose (air brake valve - air reservoir) 1
17 Brake hose (air brake valve - air booster pump) 1
18 Brake hose (air booster pump - oil pot) 1
19 Brake hose (air booster pump - brake calipers) 1
Brake hose (air reservoir - fuel-water separator
20 1
combination valve)
Every 3 years or 6000 hours,
21 Air reservoir 1
whichever occurs first.

61
 replace it if damaged.
Important Maintenance
4. Tighten the radiator water fill cap.
Procedure 5. If the coolant needs to be added daily, check for
leaks in the engine cooling system. If a leak is
Maintenance for Cooling present, correct it and add antifreeze to an
appropriate level.
System
Add Coolant
Proper maintenance of engine cooling system is
extremely important. Overheat, overcooling, pitting, Bef ore adding coolant to a new machine or an
engine with a cleaned cooling system, determine the
cavitation, cylinder head cracks, piston sticking and
radiator clogged are common faults in the cooling concentration of the antifreeze in the coolant based
system, which not only reduce the engine's work on the local record low ambient temperature (it is
better to be lower10C than the lowest ambient
ef f iciency but also cause severe engine damage.。
temperature), and calculate the desired antifreeze
Anti-freeze amount based on the total capacity of the engine
cooling system.
The main purpose of the antifreeze is to reduce the
condensation point and raise the boiling point of the Notice
coolant. Use antifreeze even at a common ambient Never use water alone for coolant. Damage from
temperature, because it can raise the boiling point of corrosion can be the result of using water alone
the coolant and the additives in the antifreeze can for coolant. We will not provide the warranty of
reduce the possibility of corrosion and cracks on the cooling system components if using water
machine body. alone for coolant.
The perf ormance of the antifreeze brands The steps of adding coolant is as follows:
recommended by Caterpillar (Qingzhou)Ltd. is as
f ollows: 1. Connect the power negative switch; Insert key
into start switch and turn it clockwise to first gear,
Minimum Ambient
Antifreeze Model
connect the machine power; put the toggle
Temperature for Use ( C) switch of the air conditioner system at HEAT
－50 YF-3 position.
－45 YF-2A 2. Turn the hand valve of the engine water inlet line
to the ON position (the valve handle is in the
－40 YF-2B same direction of the line route at ON position).
－35 YF-2
3. Open the radiator water fill cap to add coolant
－25 YF-1 slowly until the level reaches the high mark on
the secondary water tank and keeps stable in 10
minutes.
Change the antif reeze with a good-quality one and
ref ill according to the instructions. Notice
While adding coolant, the air must be purged
Notice from the tube of the engine cooling system.
The antifreeze is flammable. Do not leave it close
to a flame. 1. 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
Coolant Level Check Method to make the coolant temperature above 85C.
The radiator is located at the tail of the machine. 2. Check the coolant level again and continue to
add coolant if necessary until the level reaches
1. It must wait until the engine coolant temperature
the high mark on the secondary water tank.
drops below 50C, loosen the radiator water fill
cap slowly to release the pressure. to prevent the 3. Check the seal of the radiator water fill cap and
burns caused by hot vapor or hot spilled coolant. replace it if damaged.
2. Check if the coolant level is between the high Notice
mark and low mark on the secondary water tank Do not add cold coolant to a hot engine,
as shown. Add coolant to the high mark if it is otherwise, the engine body can be damaged.
below the low mark. Wait until the engine temperature is below 50C.
3. Check the seal of the radiator water fill cap and
62
 Notice
Notice While adding the cleaning solution to the cooling
Caterpillar (Qingzhou)Ltd. will not be responsible system, the air must be purged from the tube of
for the loss caused by coolant leaks and the drop engine cooling system.
of antifreeze concentration due to the user's
During the whole cleaning process of the cooling
misuse.
system, the engine is running with the radiator
water filler cap removed.
Coolant Change or System Cleaning 1. Start the engine with the radiator water fill cap
Completely change the coolant in the cooling system removed, and run the engine for another 5
and clean the cooling system at every 2000 hours or minutes af ter the coolant temperature is above
1year, (whichever occurs first). 80C.

Bef ore this interval, if the coolant is contaminated, 2. Turn of f the engine and drain the cleaning
the engine is overheated, or there is bubbles in the solution.
radiator, clean the cooling system right now. 3. Fill the engine cooling system with clean water to
The steps of cleaning the cooling system are as normal operating level and keep it stable within
f ollows: 10 minutes. Start the engine with the radiator
water f ill cap removed, and run the engine for
1. Connect the power negative switch; Insert key another 5 minutes after the coolant temperature
into start switch and turn it clockwise to first gear, is above 80C.
connect the machine power; put the toggle
switch of the air conditioner system at HEAT 4. Turn of f the engine and drain the water in the
position. cooling system. If the water being drained is still
dirty, the system must be flushed again until the
2. Turn the hand valve of the engine water inlet line water comes out clean.
to the ON position (the valve handle is in the
same direction of the line route at ON position).
3. Start the engine and shut it down after idling it for
5 minutes. Turn the START switch to position 1 Engine coolant is toxic and undrinkable. Dispose
to energize the machine power, and put the of it according to the local laws and regulations.
toggle switch of the air conditioner system at
HEAT position to open the magnetic water valve Cleaning Radiator Fins
of the air conditioner.
If there is dirt sticking to the radiator, clean in the
4. Af ter the coolant temperature drops below 50C, f ollowing method.
loosen the radiator water f ill cap slowly to release
the pressure 1. Remove the bolts and remove the rear grid form
the rear of the machine. Meanwhile remove the
5. Open the water drain valve at the bottom of the connector of rear work light.
radiator and the drain valve of the engine oil
cooler to drain the engine coolant and collect it 2. Remove the dirt and leaves, etc. on the radiator
with a container. f ins with compressed air, vapor or water.

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
solution consisting of water and sodium
carbonate, and the mixing ratio is 0.5 liter of
sodium carbonate in every 23 liters of water. The 3. Also check the rubber hose. If cracks on the
level should reach engine operating level and hose or deterioration or hardening is found,
keep stable within 10 minutes. replace the hose with a new one. Also tighten the
loosened pipe clamp.

63
 seen.
3. Catch the clamps of external element rear cover
Maintenance of Engine and pull the external element out of the air
System cleaner cavity.
4. Maintain the external element according to the
Maintenance of Engine Air Cleaner maintenance instructions of air filter.
Notice 5. Bef ore installing back the external element, clean
Turn off the engine when maintaining the air the inside of the cleaner and remove the dust
cleaner to prevent damage. accumulating on the internal threads with a
bristle brush or a rag to make sure that the
Maintenance and Replacement of Engine Air
thread is smooth, and prevent dust from entering
Filter Element
the inside of the element.
The air f ilter is in the engine hood.
6. Install back all parts in the opposite order of
When the alarm appears red, use compressed air of removal and make sure that they are installed
less than 205 kPa, along the direction of the pleats, correctly to ensure a correct sealing. Do not omit
to clean the f ilter element from inside out. Do not use any part.
other tools to knock the filter element when removing
the f ilter element. Clean the inner wall of the filter Notice
outlet pipe and the sealing surface. Replace the filter Caterpillar (Qingzhou) Ltd. recommends to use a
element af ter 6 times of blowing or 250 (high dust) - certified air cleaner and cleaning service
500 (low dust) working hours. Check the connections provided by an authorized Caterpillar (Qingzhou)
to ensure that the filter cap matches the engine Ltd. dealer.
intake and is airtight. The cleaning process of Caterpillar (Qingzhou) Ltd.
employs proven procedures that ensure consistent
quality and long cleaner life. Observe the following
guidelines if you attempt to clean the filter element:

The air filter can only be serviced when the Do not tap or strike the filter element in order to
remove the dust.
engine is shut down. Otherwise, the engine may
be damaged as a result. Do not wash the filter element. Use the low pressure
compressed air to remove the dust from the filter
Service the air cleaner filter element when the element. The air pressure must not exceed 205 kPa.
blue plunger on the engine air filter service Direct the air f low up the pleats and down the pleats
indicator enters the red zone. f rom the inside of the filter element. Take extreme
Cleaning the air filter primary element care in order to avoid damage to the pleats.
Compressed air
Pressurized air will not remove deposits of carbon
and oil. Use filtered, dry air with a maximum
pressure of 207 kPa.

1. Loosen clips that connecting the rear cover and

the housing, then remove the rear cover and
clean the dust on the rear cover. Caution: When
parking check, the dust can be removed by the Note: When the f ilter elements are cleaned, always
dust valve, if damaged and lost, should be begin with the clean side (inside) in order to flush dirt
replaced in a timely manner.
particles toward the dirty side (outside).
2. Counterclockwise rotate the seal cover and
remove, and then the external element can be
64
Aim the hose so that the air flows inside the element • Number of cleanings
along the length of the filter in order to prevent
damage to the pleats. Do not aim the stream of air Store the box in a dry location.
directly at the primary air cleaner element. Dirt could Replacement of Safety Element
be f orced further into the pleats.
1. Open the engine hood.
Inspection of the Filter Elements
2. Remove the air cleaner cover from the air
cleaner housing. Remove the primary filter
element f rom the air cleaner housing.
3. Remove the secondary filter element.

Check if the filter element is clean and dry. Use a 60

watt blue light in a dark room or in a similar f acility.
Place the watt blue light in the filter element. Turn
the f ilter element. Inspect the filter element for tears
and/or holes. Inspect the filter element for light that 4. Cover the air inlet opening. Clean the inside of
may show through the filter material. To confirm the the air cleaner housing.
result, the element must be compared with a new
f ilter element with the same part number. 5. Remove the cover from the air inlet opening.
Do not use a primary air filter element that has any 6. Install the new secondary filter element.
tears and/or holes in the filter material. Do not use an 7. Install the primary filter element.
air cleaner element with damaged pleats, gaskets or
seals. Discard damaged air cleaner elements. 8. Install the air cleaner cover and tighten it.
Storage of the Filter Element 9. Close the engine hood.
If an element that passes the inspection will not be Notice
used, it can be stored for f uture use. Always replace the secondary element. Never
attempt to reuse the secondary filter element by
cleaning the element. When the secondary filter
element is replaced, the primary filter element
should also be replaced. The secondary filter
element should also be replaced if the exhaust
smoke is still black.

Engine Compartment – Cleaning

Notice
The engine should be shut off and cooled down
before spraying the high pressure water against
Do not use paints, waterproof covers, or plastics as the engine compartment. Do not spray the water
protective packaging when storing to prevent air directly to the hot fuel injection pump, otherwise
circulation from being blocked. To protect against dirt damage may occur.
and damage, wrap the filter elements in volatile Use a commercially available engine degreaser to
corrosion inhibited (VCI) paper. clean the engine compartment. Take care to keep
Place the f ilter element into a box for storage. For the water around the bearings and electrical
identification, mark the outside of the box and mark connections as little as possible.
the air f ilter element. Include the following
inf ormation: Replacement of Fuel Filter and
Fuel Prefilter
• Date of cleaning
65
Drain water and contaminants from the fuel filter Changing Engine Oil
Change the engine oil when the specified oil change
Place a suitable container under the fuel filter to
interval is met. Position the machine on a level
open the drain valve 1at the bottom of the fuel
surf ace and start the engine until the water
primary f ilter, and drain water and contaminants.
temperature reaches 60C. Then shut down the
Af ter draining, close the drain valve.
engine. Pull the park brake button. Remove the oil
Replace diesel filter, and diesel prefilter drain plug at the bottom of the oil pan to drain the oil
and collect it with a container. Replace the oil filter.
1. Clean the surrounding area of the filter and the
f ilter head first. Tighten the oil drain plug and fill with clean oil
through the engine oil filler to the “H” mark on the
2. Remove the filter from the head with a strap
dipstick. Operate the engine at idle speed to inspect
wrench.
f or leaks at the oil filter and the drain plug.
3. Remove the gasket from the threaded connector
Wait f or approximately10minutes after shutting down
of the head. Clean the sealing surface of the
the engine to allow the engine oil to flow back to the
head with a lint-f ree cloth.
oil pan and check the engine oil level again. If the oil
is not sufficient, add oil to the “H” mark on the
dipstick.
Notice
There should be a reading present on the engine oil
pressure gauge during15 seconds after starting the
engine. If there is no reading, shut down the engine
immediately to avoid damage and inspect for correct
oil level.

Replacement of engine oil filter

4. Install a new gasket onto the threaded connector
of the pre-filter mounting base; apply a coat of 1. Clean the area near the oil f ilter head.
engine oil to the sealing side of the filter; fill the
f ilter with clean diesel. 2. Remove the oil filter with a strap wrench.

5. Tighten the f ilter to the filter mounting base with

hand and tighten another 1/2~3/4 of a turn af ter
the f ilter gasket just contacts the head. Do not
overtighten with mechanical method or else the
f ilter can be damaged.

Maintenance of Engine Oil

Check the engine oil level
1. Drive the machine to a level ground, turn off the
engine and pull the park brake button.
2. Wait 10 minutes af ter the engine is off to allow
3. Clean the gasket surface on the head with a
the engine oil to flow back to the oil pan. clean cloth. If the old O-ring seal sticking to the
3. Open the engine hood, pull out of the dipstick, mounting base, remove it.
clean up the dipstick with a clean cloth, insert it
back into the engine oil filler to the end, and pull
it out again to check if the level is between the
“L” mark and the “H” mark on the dipstick.
4. If the oil level is below “L”mark, please add oil; if
the oil level is above “H” mark, loosen the oil
drain plug on the bottom of the oil pan and drain
some oil.
Notice
Too much or too little oil can cause damage to the
engine. 4. Install a newO-ring seal.
5. Install the oil filter to the filter head and tighten it
66
 until the oil f ilter gasket surface touches the head else the engine will die and there will be large
with hand and then tighten it to the requirement amount of water and contaminants at the bottom of
with a strap wrench. the f uel tank which will prevent the normal engine
operation.
Notice
Excessive mechanical tightening may damage Diesel Sulfur
thread or the seal of the oil filter element. The diesel sulfur percentage can affect the choice
of engine oil and oil change interval. The sulfur can
convert into sulfuric acid and sulfurous acid during
Use and Maintenance of Diesel burning which will corrode the metal surface.
Theref ore, use the diesel fuel with low sulfur content.
Diesel tank Some additives in the oil contain alkaline compound
which can neutralize the acid. Theref ore, the oil
The diesel fuel tank breather should be change interval should be adjusted based on the
maintained as the following procedure: diesel sulfur:
Generally, change the breather onceannually, but if it 1. If the diesel sulfur is below 0.5%, change fuel
is badly contaminated, it is recommended to change according to the interval specified in the “Regular
it onceevery 1,000 hours3 months . When slow Maintenance” in this manual.
ref illing speed is felt, remove the breather and
continue to refill. Blow out the dust etc. clogging the 2. If the diesel sulfur is 0.5%~1.5%, change fuel at
screen with high-pressure air when maintaining the 1/2 of the interval specified in the “Regular
breather weekly. Maintenance” in this manual.
The f uel f iller screen and the fuel tank should be 3. If the diesel sulfur is above 1.5%, change fuel at
cleaned periodically. The f uel tank can be cleaned 1/4 of the interval specified in the “Regular
with the f ollowing method: Maintenance” in this manual.
Remove the flange disc at the front end of the fuel
tank and f lush the inner surface of the tank. Loosen
the drain plug at the bottom of the diesel tank to Maintenance of Air
drain the f uel. Flush repeatedly until the drained fuel Conditioning Heater System
is clean.
Clean the internal and external element every 50
hours
Removing Water and Contaminants in the Diesel If the environment is poor, tap the element with hand
Fuel pump and injection pump are very precise or clean it with dry compressed air. Replace it in
devices. If there is water or contaminants in the advance if obvious insufficient air flow is felt or
diesel, the fuel pump and injection pump will not broken.
operate properly and will be prematurely worn.
Measure should be taken to remove the water and Ask the SEM dealer to check the air conditioner
contaminants in the diesel. The method is as follows: every year.
1. The diesel should be settled for 24 hours before
being added to the fuel tank if possible.
2. Bef ore refilling, open the drain plug at the bottom
of the fuel tank every week to drain the water
and contaminants.
3. Add diesel to FULL after the daily work to drain
the moisture in the fuel tank.
4. Wait f or5 to 10 minutes before starting the
engine af ter the fuel tank is filled to FULL, to
make the water and contaminants settle to the
bottom of the tank.
5. Af ter the daily work, loosen the water drain plug
at the bottom of the fuel prefilter and primary fuel
f ilter to drain the water and contaminants.
Do not wait to add fuel until the fuel tank is empty, or

67
 The transmission oil is not only the working medium
Maintenance of Transmission of transmission hydraulic system, it is also used to
cool and lubricate the transmission components,
Check the transmission oil level theref ore, the transmission oil grade should meet the
The transmission oil filler is at the rear top of the left requirements, and change the transmission oil
f loor. Check the transmission oil level at the specified according to the specified change interval, otherwise,
interval to ensure oil amount. (The transmission oil the service life of transmission will be shortened.
level should be in the middle of the oil mark when the Change the transmission oil as follows:
machine is running).
1. Start the engine to operate the machine for
Check the transmission oil level as follows:
several hours to make the contaminants, metal
1. Park the vehicle in a f lat place; debris and sediments suspend in the oil.
2. The transmission shift lever is placed in the 2. Position the machine on a level surface, put the
neutral “N” position; variable speed joystick to the neutral position,
pull the park brake button and install the frame
3. The operating temperature of the transmission is locking lever to prevent the machine from moving
within the normal range; and rotating.
4. The engine is at idle speed and the speed is 3. Turn of f the engine and loosen the oil drain plug
about1000 r/min; under the transmission and collect it with a
container.
4. Loosen the oil drain plug 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.

5. Use a magnet to remove the iron scurf sticking to

the oil drain plug and remove the iron scurf on
Transmission oil dipstick the inner wall of transmission.
5. In counterclockwise direction unscrew the oil 6. Install the oil drain plugs under the transmission
dipstick, remove and wipe it off; and the related seals.
6. Insert the oil dipstick into the oil fill tube and 7. Install the oil drain plug and the related seals.
tighten it, then loosen it and take it out when it is
8. Open the transmission oil filler cap and add
in place; clean transmission oil through the filler tube. The
7. Step5and6Should perform at leasttwice to transmission oil level should be at the highest
ensure the accuracy of the test; level that the oil level allows.

8. At 40℃,the oil level should be between the low 9. Start the engine and run it about 5 minutes.
Inspect if the transmission oil level is near the
scale “COLD” and the middle scale; At 60℃,the middle position of the dipstick. If the oil level is
oil level should be between the upper scale high, drain some transmission oil by loosening
“HOT” and the middle scale the oil drain plug at the bottom of the
Notice transmission. If the oil level is low, add some
Over high or low level can cause damage to the transmission oil.
transmission. Maintain the transmission oil level
10. Tighten the oil filler cap clockwise.
at a correct position.
While checking the transmission oil level and
changing transmission oil, unique care must be
taken not to allow the contaminants to enter the
transmission system which can cause damage to
the transmission.
Changing the Transmission Oil

68
Replacing the transmission oil pan suction Replacing Drive Axle Oil
element
1. Drive the machine for a period of time to allow all
1. Drain the oil in the same way of changing sediments in the axle housing to suspend. Then
transmission oil. drive the machine to a flat surface and slowly
move the machine to set the oil drain plug at the
2. Loosen the transmission oil pan suction bolts
drive axle curb end face at the lowest position.
and remove the oil pan. Take out the
The f ront and rear drive axle oil needs to be
transmission suction screen and clean or replace
drained several times because the oil drain plugs
it.
at the lef t and right and front and rear drive axle
3. Clean the transmission bottom. Install a new curb end f ace can not be at the lowest position
suction screen and tighten the oil pan bolts. simultaneously.
4. Add oil in the same way of changing 2. Turn of f the engine, put the variable speed
transmission oil. joystick to the neutral position and pull the park
brake button to prevent the machine f rom moving.
3. Remove the oil drain plugs at the drive axle curb
Notice
end f aces and the middle of the axle housing to
Before changing transmission oil, cover the park
drain oil and collect with a container.
brake so that the friction plate of the park brake
will not be contaminated by oil which can cause
reduction of braking performance.
The drive axle oil may be still hot at this point,
therefore wear protective devices and use care to
Maintenance of Drive Axle avoid personal injury.
4. Install all the oil drain plugs at the drive axle.
Check the oil level and replace the drive axle oil on
time according to the requirements in the “Regular 5. Slowly move the machine to make the arrow on
Maintenance”. the either side of the curb end cover point
vertically downward.
Check the drive axle oil:
6. Add clean drive axle oil through the oil level plug
There are respectively three oil drain plugs and oil fill
plugs for front and rear drive axles, located at the or oil drain plug at the axle curb end face until
middle of axle housing and both sides of curb. The the oil level reaches the lower edge of the oil
level plug of the front axle curb end face.
oil f ill plug can also be used to observe the oil level.
Observe for about 5 minutes after adding oil until
Checking the drive axle oil the oil level is stable (see the Operation and
Maintenance manual for the amount of refilling).
1. Drive the machine to a flat surface and slowly
move the machine to make the arrow on the front 7. Install the plugs at the drive axle curb ends.
drive axle curb end cover point vertically
8. Change the other drive axle oil in the same
downward. Pull the park brake button to prevent
the machine f rom moving and stop for 15 manner above.
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
Maintenance of the hydraulic
sides of drive axle curb and remove the oil level system
plug to check if the oil level in the drive axle is 8
mm f rom the lower edge of the oil drain. Small Check the oil level and replace the hydraulic oil on
amount of spillage is allowable. If the oil level is time according to the requirements in the “Regular
much lower than the lower edge of the oil drain, Maintenance”.
add drive axle oil. Observe for about 5 minutes Check the hydraulic oil level
af ter adding oil until the oil level is stable (check
the oil level by using any oil plug). The hydraulic oil tank is at the rear of the cab and
there is an oil level gauge at the f ront end of the tank.
3. Tighten the oil level plug.
To check the hydraulic oil level, position the machine
4. Check the rear drive axle oil level by using the on a f lat surface and put the bucket on the ground
same steps above. horizontally. Meantime, the front and rear f rame
should be straightened, leaving no angle between
the f ront and rear f rame. Now the hydraulic oil level
69
should be at 2/3 of the oil level gauge. air vent plug to release a small amount of
hydraulic oil. To change with new hydraulic oil,
Replacing the hydraulic oil tank drain element
open the air vent plug before adding the new oil.
1. Apply the park brake and turn off the engine. The level af ter added should be at the top of the
dipstick. Tighten the air vent plug after filling.
2. Remove the mounting bolts on the oil filter cover Af ter running the machine at idle for5minutes,
at the side of the tank and remove the cover. The activate the vibration mode to run f or 5-
cover can bounce due to the force of spring, so 10minutes, make the cylinder and oil tube fill of
press the cover while removing the bolts. hydraulic oil,
3. Remove the spring and element. 8. Turn of f the engine, open the oil filler cap of the
4. Install new element, spring and cover. hydraulic oil tank, and add clean hydraulic oil to
the center-upper position of the oil level gauge in
5. Press the cover while installing the bolts and hydraulic oil tank.
tighten the bolts evenly.
NOTE:
6. Check the oil level and add oil to the specified
level. 1. To repair the hydraulic system, such as pump,
hydraulic oil line, etc., the air vent plug must
7. Check the assembly joint at the oil filter cover for be opened to reduce the hydraulic oil drain
oil leaks. flow in the hydraulic oil tank, or else, the
hydraulic oil in the tank will be completely
Regular Replacement of Hydraulic Oil drained.
Replace the hydraulic oil once every 2000 service 2. The air vent plug must be opened to add
hours or every year. The method is as follows: hydraulic oil. The level should be at the top of
the dipstick after filling. The air vent plug
1. Park the machine on flat and open site, put the must be closed after filling and before
shif t joystick to the neutral position and pull the starting the machine, or else air will be drawn
park brake button and install the frame locking into the hydraulic system, causing serious
lever. Start the engine and run the engine at idle damage to the machine.
f or ten minutes. Finally, the engine is shut down.
2. Clean the opening of the oil drain tube under the
hydraulic oil tank and remove the oil drain plug to Check the Vibration Package Oil Level
drain the hydraulic oil and collect with a container.
Meantime, open the oil filler cap to accelerate the
oil draining.
3. Remove the oil inlet tube of the hydraulic oil
cooler to completely drain the oil residue in the
radiator.
4. Remove the oil drain element from the hydraulic
oil tank and replace with a new one. Open the oil
f iller cap and remove the oil filler screen for
cleaning.
5. Remove the tank clean-out flange disc under the
oil f iller and flush the bottom and walls of the
hydraulic oil tank and wipe with a clean cloth. 2 1
6. Install the oil drain plug of the hydraulic oil tank,
oil drain f ilter and top cover, oil filler screen, tank 1. Drain/refill plug
clean-out flange mouth and the oil inlet tube of 2. Oil level plug
the hydraulic oil cooler. When the oil level plug is just above it, loosen the
7. Add clean hydraulic oil through the oil filler of ref ill/drain plug and oil level plug, the oil flows out
hydraulic oil tank. The hydraulic oil can only f rom the oil level plug, indicating that the oil level in
enter f rom the underside of the barrel structure the vibration package is normal; otherwise, the oil is
due to suction port built in the barrel structure, supplied from the refill plug until the oil is discharged
and there is an air vent plug at the middle of the f rom the oil drain plug.
f lange at the top of the barrel. When releasing
hydraulic oil is required during repair, open the

70
Replacing the drive oil filter element inf lated with nitrogen can reduce the possibility of
explosion because nitrogen is nonflammable.
Remove the drive oil filter. Clean the oil filter base.
Nitrogen can also prevent oxidation, deterioration
Apply a coat of clean oil to the new seal and replace
of rubber and corrosion to the rim components.
f ilter element with a new one. Fix the filter by hand
and turn it 3/4 rotation when the gasket touches the Flat tire or rim damage is due to improper inflating
base of the filter, and tighten the filter. equipment or improper use, therefore, to avoid over
inf lation, make sure that proper equipment is used
Maintenance of Tire and the tire is inf lated by trained person.

Tire Handling
Wrong handling of the tire or rim can result in a blew
or ruptured tire and the hub can be damaged and
scattered which could cause serious injury or death.
The f ollowing considerations must be obeyed for
maintenance safety. Tire Storage Considerations
• The maintenance, removal, repair and installation • As a guideline, the tires must be stored in the
of the tire and rim require special equipment and warehouse where unauthorized person can enter.
techniques, therefore ask a tire repair shop to do If it is necessary to store the tires outside, set
the job. f ences around the tires and put a “NO ENTRY”
• Only use the specified tires and inflate them to the sign.
specified pressure. For the specified tire and
pressure, see Usage and Main Technical Features
and Parameters.
• Do not let anybody walk into the job site while
inf lating the tires. It is necessary to stand at the
side of the tire, use self-clamping collets and check
the tire pressure now and then to make sure that
the pressure will not be too high.
• If the rim is installed incorrectly, the rim can be
damaged or scattered after the tire is inflated.
Theref ore, put protective plates around the tire and Block
do not work at the side of the rim.
• The abnormal decrease of the inflation pressure
and the abnormal fit of the rim indicate that there is
a malf unction in the tire or rim. In this case, ask a • Put the tires uptight on a level surface and hold
tire repair shop to repair the tire. them with wedges so that they will not fall even if
• Do not adjust the inflation pressure after high- touched by unauthorized person. If the tire is
placed on its side, it will be crushed and the quality
speed traveling or high duty operation.
will reduce.
• The f ully inflated tire can explode because the air
• If the tire is going to fall, stand aside as soon as
inside the tire is heated and burnt. The heating is
caused by heating or welding the rim, external possible. The industrial tire is very heavy. Trying to
hold it can cause serious injury.
f lame, or air heat expansion or burn due to
f requent braking. Compactor Tire Charge Guide
• Tire explosion is much more forceful than • (compactor518tire does not need to be charged,
discharging the tire. Explosion can force the tires, only compactor 520/522 tire needs to be charged)
rims and final drive parts away from the machine
more than 500mand the explosion force and debris First, Tool Instruction
can cause personal injury or death and property Too Name: The special charging tools of
damage. compactor tire are as shown below
• 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
71
 The method of refilling the liquid after leaking the
solution (calcium chloride) that caused by damage of
tire
1. Hold the vehicle against the wedge and use the
jack to lift the damaged tire away from the
ground;
2. Remove the tire and drain the liquid and air in
Tire valve adapter: it is connected to the tire valve the tire as much as possible;
through the thread that matched with the valve;
3. Check the cause of the tire failure and complete
Ball valve: It can control the opening and closing of the repair;
the component1 tube inner cavity by the switch;
4. Install the repaired tire rim assembly to the
Booster device quick coupler: one end is connected machine;
to component2via thread, the other end is
connected to the liquid booster device line(for 5. Keep the repaired tire in an upright position and
devices with thread connectors) always ensure that the position of valve is at the
uppermost of the tire;
Valve core wrench: for removal/installation of the
valve core; 6. Formulation of the filling solution: In the suitable
container blend and stir the water and the
Second, Required tool that provided by yourself solution of calcium chloride in the proportion of
1. jack (loading capacity needs to be greater 3:1, to f ormulate the homogeneous solution of
than6Tons) calcium chloride with density of 1.2-1.4g/cm3,
(Give an priority to recommend to use calcium
2. and wedge chloride, if it is difficult to prepare, you can also
use sodium chloride instead);
3. Liquid booster equipment (such as, pressure
upper limit of the electric water pump for washing 7. Filling amount: ensure that the filling amount of
car needs to be less than0.5 Mpa) each tire calcium chloride solution is 345 L, after
completing filling, the total weight of a single
tire+the rim+ calcium chloride solution is
about765 KG. (It is recommended to use a
container with a scale to contain the solution or
mark the scale on other containers)
8. Remove the valve pin: Use the special filling tool
to remove the lower valve pin. As shown in the
4. Inf latable tooling and inflatable equipment f igure, connect the connector tooling to the valve
by the thread, and turn the ball valve on the
tooling to the open position. Use the matching
valve pin: insert the removal tool from the middle
of the tube, after connecting valve pin,
counterclockwise turn and remove the valve pin,
and take it out with removal tool of the valve pin
together.

5. Liquid container (determine the volume

according to the actual situation)

72
 The method of refilling the liquid after the
solution leakage of the tire
1. Check the tire and the cause of the leak to
ensure that the tire is not damaged. If the tire
tube is damaged, it needs to be disposal
according to the previous procedure:
2. f ormulate sufficient amount of calcium chloride
solution;
3. Position the tire valve at the uppermost of the tire,
and use the removal tool of the valve pin to
unscrew the valve pin and relieve the air
pressure inside the tire;
4. According to the step 6 above, connect the line
and f ill the liquid, Move the tire to position the
valve at the uppermost of the tire. According to
the leakage, evaluate the liquid volume and start
to f ill, when the leakage amount is expected to
reach, remove the liquid filling tool and observe
the tire spills: if it is liquid, it is not recommended
9. Use one end of the liquid-filled connector to to ref ill;
connect valve and the other end to connect the 5. Complete the filling and screw on the valve
liquid pump outlet. protection cap.
10. Ref ill Liquid
Tire Inflation Inspection
Put the Liquid pump inlet into the container
containing the calcium chloride solution, and Use the tire pressure gauge to detect the pressure of
af ter checking that the connections are correct, the lef t and right tires to ensure that the tire pressure
open the ball valve and activate the electric is 0.30-0.35 MPa.
pump. When refill the liquid to345 L, turn off the
electric pump. Turn off the ball valve and remove Check the tightening of the rim bolt
the electric pump line.
11. Install the valve pin: Place the valve pin on the Use wrench with the torque of700 N·mto detect the
removal tool of valve pin, insert the connector tightness of the left and right rim bolts. If this value is
tooling as shown in the figure, at the moment of not reached, tighten them. Tighten the wheel nut to
inserting, you need to synchronize to open the the torque of700-800 N·m. When a set of rim nuts
ball valve (there will be a small amount of Liquid are tightened, it must be performed
f lowing out), and quickly install the valve pin on symmetrically and evenly. In normal use, always
the tire.
check if the nut is loose and tighten in time.
12. Remove the connector tooling after installation If you replace the tire, you must ensure that the two
13. Inf lating: Inf late the tire with an inflatable device, tires have the same rolling radius. This is a
and the pressure is 0.35 Mpa necessary condition to ensure that the rear axle does
not slip at all.
When the air pressure is insufficient, inject air into
the tire through the valve (the valve is turned to the
top because there is calcium chloride solution in the
tire tube).

Brake system maintenance

Checking park brake performance

1. The park brake performance should be checked

f requently to ensure park safety and the braking
Remove the jack and tighten the bolt of the tire rim to capability in case of emergency barking.
torque of 700-800 N.m.
73
2. Regulate the tire pressure to the specified value Follow-up of Grease Fill
and confirm that the machine has good service
Remove the excessive grease at the grease nozzle
braking performance.
af ter f ill so that the grease will not adsorb
3. Start the engine and make the machine face a contaminants during operation clogging the nozzle or
20%-grade slope which should be flat and dry. allowing the contaminants to enter the grease
passage at next fill.
4. Depress the service brake pedal to stop the
machine. Put the variable speed joystick to the Safety Precautions and Preventative Measures
neutral position and turn off the engine.
• Accurately count working hours to determine the
5. Pull the park brake button and slowly release the lubrication time;
service brake pedal to check if the machine is
still at the original position. • Stop engine when lubricating oil is added; if it is
not parked according to the requirement of manual,
Replace brake fluid it cannot perform lubrication work;
• Fire protection measures when lubricating;
Unscrew the black cap of the reservoir and apply
brake f luid from the oil fill tube to the reservoir to • Prevent hot oil and harmful substances from
one-half of the entire volume. harming operators;
• Avoid mixing of different grades of lubrication oil;
Checking park brake friction plate
• Bef ore filling, the lubricated parts, vents etc. should
The 3 longitudinal gutters on the caliper friction plate be cleaned. After filling, the sealing effect of the
are marks for grinding amount, it needs to replace original ring seal should be retained;
with new plate if the gutters on it are smooth. • Regularly clean and replace the filter, after draining
the engine oil, should make the mark. Do not start
Lubrication without oil.
To reduce the difficulty in adding grease, improve the • Remove spilled lubricants.
maintenance for the entire machine, and improve the
service life and reliability of the machine, we Welding Operation
recommend all users to operate according to the
f ollowing instructions. When welding on the machine, perform as specified
below, to avoid machine damage or accidents.
Lubrication frequency
1. Read and understand the related safety
Lubrication of the machine in strict regulations on welding on the machine before
accordance with the specified cycle is welding.
Notice!
essential for the normal operation of
the machine. 2. The engine start switch must be turned off and
the power negative switch must be disconnected
bef ore welding.
Lubricate the hinge bracket, steering cylinder hinge
point, walking bearings, etc. every50h 3. The dashboard connectors must be removed
bef ore welding to avoid dashboard damage. Or
Grease Gun Use Considerations disconnect the cab harness (at the lower right of
Clean the grease nozzle before filling to make sure cab and near the f rame articulation;) from the
that no contaminants obstructs the grease nozzle or machine harness.
passage. 4. Do not use voltage greater than 200Vconstantly.
Check that the equipment is in good condition, 5. Weld area is within 1m meter from the ground
especially the connections of the soft (hard) adapter cable.
and the grease joint are tightly f astened before using;
bef ore adding the grease, first drain the air inside the 6. The ring seal and bearing should be not located
grease gun to ensure that the pressure of filling is between the weld area and ground cable.
reached. 7. Never weld or cut any pipe or container filled with
Connect one end of the hose/tube to the grease f uel, oil and hydraulic oil.
nozzle and adding grease by operating the handle. 8. Never weld or cut any sealed or poorly-ventilated
Increasing restriction will be felt during filling and container.
stop filling when the grease spills from the pin shaft
grease passage.
74
 3. It is recommended to use a charger rated at
Maintenance-free Battery constant voltage 16.0volts (The maximum
Charging Regulations voltage cannot exceed 16.2volts, otherwise, the
water will be electrolyzed, causing level drop and
This machine uses maintenance-free battery. The battery failure),the charger with current limit 25
f ollowing regulations must be obeyed during use. amperes charges the battery until the indicator is
Reason for Battery Discharge green. Turning green means the electricity is
suf ficient.
1. Abnormal use, for example, the electric
appliances on the vehicle are on for an extended 4. For the battery with a battery voltage less than
period of time before the vehicle is started. 11.0volts, the battery may not be able to charge
the electricity at initial phase. The reason is that
2. Long time of vehicle stopping, excessive current the sulf ur ratio in a badly discharged battery is
leakage, or installation of additional appliances. close to pure water. The battery inner resistance
3. Frequent start of the vehicle. is very high. This can be resolved by reducing
the charging current or changing for an alternator
4. Malf unctioning charging system (for example, with a larger power. As the charging is going on,
f ailed alternator and electronic elements, over the sulf ur ratio in the battery increases and the
low charging voltage setting of the alternator charging current will restore to a normal level
governor, loose engine drive belts) made the gradually.
battery charged improperly, causing battery
5. If a large amount of acid spills from the vent hole
discharge. The electrolyte indicator is black, and
the machine even can not be started. of the battery while charging, stop charging
immediately and find the reason.
5. The unused battery is stored for more than 6
6. When the battery temperature is above 45
months.
degrees centigrade while charging, stop charging.
The discharged battery due to the reasons above When the battery temperature drops to the room
can be corrected by charging timely and properly. temperature, cut the charging current in half and
continue charging.
Check the battery appearance before charging
1. The battery with a broken case or acid leakage Clutch clearance regulation
can not be charged. Replace the battery after
identifying the reason. Clutch master cylinder stroke regulation
2. The battery with a broken post can not be The ef f ective stroke of the clutch master cylinder is
charged. Replace the battery after identifying the approximately3-5 mm, when installing the clutch
reason. master cylinder, make sure that the clutch master
pedal is in a f ree state. The clutch master cylinder
3. Clean the post and remove the oxide coating on has a f ree stroke of4~5 mm, then tighten the nut. At
the surf ace before charging. this time, the pedal has a free stroke of about20~30
Charging Precautions mm

1. Wear saf ety glasses.

2. Keep the area well-ventilated while charging and
charge at normal temperature.
3. Never smoke while charging.
4. When connecting after charging, first connect the
positive connection; when disconnecting before
charging, first disconnect the negative
connection.
Battery Charging Regulations
1. Conf irm that the battery post is clean and the
charging return circuit is well connected.
2. The charger positive connects the battery 1. Booster pushrod
positive and the charger negative connects the 2. Adjusting nut
battery negative. Never charge the battery in
series (24 v).

75
Clutch pedal free stroke
Clutch Release Finger Regulation
Regulate the clutch booster cylinder: loosen the
locknut on the pushrod, rotate the pushrod end until
it touches the release finger, then rotate the pushrod
back1.75turns and tighten the locknut. At this time，
the clearance of the release bearing and release
f inger should be 3-5 mm.

76
Fluids specifications
Use the specifications and types specified in the
table below when adding or changing various oils in
this machine, to ensure normal machine operation.
Use Position Ambient Temperature Lubricating oil specification Remarks

-20℃-40℃ API CH-4 SAE15W-40

-25°C-40°C API CH-4 SAE10W-40

Engine
-30°C-40°C API CH-4 SAE5W-40

-35°C-40°C API CH-4 SAE0W-40

-20℃-40℃ SAE15W-40

-25°C-40°C SAE10W-40
Transmission
-30°C-40°C SAE5W-40

-35°C-40°C SAE0W-40

-15°C～49°C GL-5 85W-90

Drive axle -25°C～49°C GL-5 80W-90 Recommended oils:

Contact the local office dealer to use
-45°C～10°C GL-5 75W-90 designated oils by Caterpillar
(Qingzhou) Ltd.
-5°C-40°C L-HM 46

Hydraulic system -26°C-40°C L-HV 46

-35°C-40°C SAE0W-40

DOT4 or DOT3 brake oil that meets

Air booter pump
SAEJ703 standard

Generic grease NGLI2

Anti-freeze YF-2 or YF-2A

Above 4°C 0#
Fuel tank Above -14°C -20#

Above -29°C -35#

Note: The replacement of transmission oil should

not be lower than API CD grade.

CAUTION STATEMENT
1. Do not mix the oils with the same
specifications but from different brands. If
the oil from another brand must be used for
some reason, flush the system clean first.
2. If the machine operates at a frigid zone for a
long period of time, the hydraulic oil should
be HV46 or HS46 low temperature anti-wear
hydraulic oil.
3. Various oils should be changed timely even
the oil is still clean.The oil can also
deteriorate if stored for an excessive period
of time.
4. The fuel should be chosen based on the local
record low air temperature.

77
Fault Reason and Troubleshooting

78
The follow section describes the common fault reasons and troubleshooting methods for this machine for
the user's reference.
During the use of the compactor, due to natural wear, improper use or maintenance, or poor manufacturing and
assembly, various malfunctions may occur. Fault inspection and diagnosis can be performed according to the
contents of this chapter. The common faults and troubleshooting of the compactor listed in this chapter are f or
ref erence only.
Ref er to the attached engine user's manual for engine failure analysis and troubleshooting.
Transmission

Fault Type Probable Causes Troubleshooting Method

Difficult to engage the 1. Improper clutch adjustment, incomplete disengagement Adjust

gear 2. Improper adjustment of controls Check Adjustment
1. Dirty Lube Replace
2. Insufficient lubrication or lubrication oil does not meet
Abnormal damage to the the quality requirements Check and replace
bearing
3. The cleanliness of boxes and the parts are not good Cleaning before assembling

4. Use low-quality bearings Replace

1. Oil seal is worn, hardened or lost the elasticity Replace the oil seal
2. Transmission journal that matches with oil seal is worn Weld the gearbox shaft

Transmission leakage 3. Transmission case has cracks Change the transmission housing
4. Damaged bushings or defective seams Replace the gasket
5. Oil level is too high Drain the excess oil

Brake System
Fault Probable Causes Troubleshooting Method
1. The brake disc is oily, the friction plates are excessively Check the oil leakage and
worn so that the rivets are exposed. troubleshooting it, then re-rivet the friction
plate
2. Lack of brake fluid Add the brake fluid to required position
Bad braking
3. Air booster cylinder is not returned Replace the driving cylinder elements or
performance
groups
4. The air is mixed in the brake circuit The air should be purged from the brake
system
5. Brake disc clearance is too large Adjust the brake disc gap
1. The brake disc of one side is oily Clean the brake disc

One-sided braking 2. The brake hose or connector of one side is blocked Clean brake hoses and fittings
3. The brake friction plate is excessive worn Replace friction plate

79
Hydraulics vibratory system

Fault Probable Causes Troubleshooting Method

1. Vibration switch fails Check circuit, and replace vibration
switch
2. Solenoid valve is not energized or damaged Check circuit, and replace solenoid valve
3. Hydraulic fluid oil level is too low Add hydraulic fluid to the specified oil
level
Compactor does not
vibrate 4. Refilling pressure is too low Adjust the refilling pressure ≥1.2 Mpa
5. Motor coupling is damaged Replace the coupling
6. The hydraulic pump is damaged Access the hydraulic pump

7. Hydraulics motor is damaged Access the hydraulic motor

8. Vibration bearings is stuck Access vibration bearings
1. Corresponding vibration switch or electromagnetic coil Check circuit, and replace it
fails
Only one amplitude
2. Corresponding high pressure relief valve fails Access or replace the relief valve

3. Solenoid valve and shuttle valve are stuck Access the solenoid valve
One-sided vibration Spline shaft is damaged Replace the spline shaft
1. Vibration package leaks oil Replace the seal and access the
Vibration package vibration device
temperature is too
2. Vibration bearing lubrication oil level is too low or too high Correctly adjust lubrication oil level
high or noisy
3. Vibration bearings are damaged or stuck Replace vibration bearings
1. Engine speed is too low Maneuver the throttle grip and increase
the throttle to bring the engine to Rated
speed
2. The displacement of pump is not suitable Service staff adjust the displacement of
pump

3. Hydraulic system has a serious leakage Check the reason and replace the seal
4. Vibration bearings are damaged or stuck Replace bearings
Vibratory frequency is
too low
5. The filter is blocked Clean or replace the filter
6. The hydraulic oil level is too low Add hydraulic fluid to the specified oil
level
7. The relief valve adjustment is not suitable or damaged Adjust or replace the relief valve

8. The internal leakage is in hydraulic pump Access the hyd raulic pump
9. The internal leakage is in hydraulic motor Access the hydraulic motor

Steering Hydraulic System

Fault Probable Causes Troubleshooting Method

1. Filter plugging Clean or replace the filter
2. Insufficient oil supply from hydraulic pump Check and repair the hydraulic pump

3. Air is in the steering system Discharge the air in the system and
Hard steering
check the suction line for leaks
4. Steering valve and check valve fail Check and repair the steering valve
5. Hydraulic oil viscosity is too high Use oil with recommended viscosity

80
 6. Tank oil level is too low Refill to the specified oil level
The relief valve in the steering valve block has a pressure Adjust the relief valve pressure or wash
lower than the operating pressure , or blocked, or the spring the relief valve. Replace the spring or
is faulty and the seal is damaged seal

Clutch
Fault Probable Causes Troubleshooting Method
1. The free stroke of clutch pedal is too large Adjust the free stroke of clutch pedal

2. The height of the release lever inner ends is not in the Adjust the release lever in ner ends to the
Clutch is not same plane and the adjustment of the release lever is too same height plane and have a certain
disengaged low height
completely
3. Clutch Steel Sheet is deformed Replace the clutch Steel Sheet
4. Friction disc is too thick Replace or repair the friction disc

Drive axle

Fault Probable Causes Troubleshooting Method

1. Excessive wear or damage of gears, bearings, etc. of Replace gear or bearing
parts
2. Poor engagement of drive and driven bevel gears Adjust the gearing clearance of the bevel
gear pair
Abnormal sound
3. Improper clearance adjustment of drive and driv en bevel Adjust the bearing clearance of the
gear bearing driving and driven bevel gear
4. Broken teeth or damaged bearings Replace gear or bearing
5. Lack of lubricant Add lubricating oil to standard level

Air conditioning system is not refrigerating

Condensing fan not Compressor Check if the fan connector is disconnected, if the
Evaporation fan

running working grounding is good, and if the fan is damaged.

running

Condensing fan running Compressor not Check whether the temperature control switch is
working damaged, whether the relay is closed, and whether the
relay terminal is loose.
Not refrigerating

Condensing fan running, Check if the speed control switch is malfunctioning, if the fan wire is
fan stopped
Evaporation

compressor working disconnected, and if the fan ground wire is good.

The condenser fan not Check if the fuse is blown, check if the relay is normal and no wires are loose.
running and the
compressor not working

Excessive R-134a is filled into the system. Check if the pressure is within the
The compressor

specified value by using the high and low pressure gauge.

is normal

Both steam fan and R-134a leaks in the system after long time of not working. Check with high
condenser fan working and low pressure meters to determine whether there is R-134a.

Both steam fan and The inlet and outlet of the reservoir are reversed.
compre
capacit

Insuffic
cooling

normal
ssor is

The

condenser fan work Check the expansion valve for ice or dirt obstruction and replace the reservoir.
ient
y

properly. Evaporator and Replace R-134a.

condenser are normal

81
 The fan is working Check if the condenser surface is blocked by fouling.
properly, other things are
normal

Other troubleshooting methods

Number Symptom Cause Troubleshooting Method

In initial time system refrigeration is good, after a
Often run on bad roads, Use a leak detector to find the
period of use, the cool air is not enough; observe
1 resulting in loose connections leakage point and carefully
the air bubble inside the orifice; the readings of
and leaks due to vibration tighten the loose part
high and low pressure meter are all low
The system is not refrigerating. The air coming out Improper use. The
of the outlet is hot. No temperature difference temperature sensing block of
Replace the expansion valve
2 between the inlet and outlet of the expansion valve the expansion valve is worn
and refill R-134a
can be felt by hand. The reading of the low and leaks, making the valve
pressure meter is very low. hole closed
Turn on the air-conditioning
system intermittently, which can
The wind at the air outlet is not cold, the Impurities are trapped in the
eliminate the instantaneous
temperature of the compressor rises, the pointer of system, the expansion valve
blockage if the blockage is not
3 the low pressure gauge drops rapidly to near the screen is blocked, and a thin
severe. Or remove the
value of 0, and the high pressure meter reading is frost or "sweat" at the
expansion valve and clean it
high expansion valve occurs.
with alcohol, drain the system
and refill R-134a
The cooling volume is insufficient, and the Drain the system, replace the
Throttle orifice in the
4 evaporator frosts; high and low pressure readings expansion valve, and refill R-
expansion valve not working
are all low 134a
After the system is running for a period of time, the The desiccant in the reservoir
cooling capacity gradually decreases, the high is saturated, and the Drain the system, replace the
5
pressure meter reading is high, and the low expansion valve orifice is reservoir, and refill R-134a
pressure reading is low. blocked by ice.
Poor connection of Check the temperature control
After the air-conditioning system is turned on, there
temperature control switch or switch for damage with
6 is only the wind but no cold air. The readings of
damage to the compressor multimeter; replace compressor
high and low pressure meters not changing.
solenoid clutch wire harness solenoid valve clutch

The temperature control

Frequent action of the compressor solenoid val ve
switch opening is too small, Check the temperature control
clutch and the engagement time is short. It is not
7 automatically forcing the switch and turn it to the coldest
cold in the cab. The high and low pressure meter
compressor to stop, resulting position
readings are normal
in insufficient cooling

82
SEM 518/520/522Regular
maintenance parts list
1. Maintenance Interval Schedule
A. Fluids (with different applicable temperatures, the
customer should choose oil based on the local
condition)
This list contains SEM5XXspecial oils used for
regular maintenance. For detailed change operation,
see the Operation and Maintenance Manual

Demand First
Interval
Where used Item Description User Instructions Volume Maintenance
(h)
(L) (h)
-20°C-40°C API CH-4 SAE15W-40

-25°C-40°C API CH-4 SAE10W-40

Engine 16 50 250
-30°C-40°C API CH-4 SAE5W-40

-35°C-40°C API CH-4 SAE0W-40

-20°C-40°C SAE15W-40

-25°C-40°C SAE10W-40
Transmission 18 100 1000
-30°C-40°C SAE5W-40

-35°C-40°C SAE0W-40
-15°C-49°C GL-5 85W-90
26
Drive axle -25°C-49°C GL-5 80W-90 (Curb 5.5, Main 100 1000
reduction15)
-45°C-10°C GL-5 75W-90

-5°C-40°C L-HM 46

Oil tank -26°C-40°C L-HV 46 80 2000

-40°C-40°C SAE5W-40

-15°C-49°C GL-5 85W-90

Vibration package -25°C-49°C GL-5 80W-90 8.5*2 2000

-45°C-10°C GL-5 75W-90

Note: The fuel amount is only for reference, and the final fuel amount is subject to the oil standard.
B. Saf ety

Interval (h) Item Description Demand (L) Where used Remarks

According to actual needs Brake oil DOT3 3 Air booter pump

According to actual needs Brake discs 2pieces per caliper Calipers

83
C. Filters
This list contains SEM5XX genuine elements used
f or regular maintenance. For detailed replacement
operation, see the Operation and Maintenance
Manual.
Note: The air f ilter needs to be cleaned when the air
f ilter element indicator alerts, and needs to be
replaced after 6consecutive cleanings. For all other
f ilters, if the filter alarms indicate that they need to be
replaced, replace them immediately (filter elements).

Stage II engine
First
Where used Item Description Quantity Maintenance Interval (h)
(h)
Engine Oil filter element 1 50 250

Air filter element 1

Engine Diesel primary filter 1 250

Diesel secondary filter 2

Drive hydraulic Element 1 100 1000

Oil tank Drain Element 1 250 1000

Vibratory hydraulic
Filter Element 1 500
system

Oil tank Oil filler filter 1

2000
Diesel tank Oil filler filter 1

2. Material list required for the maintenance within 2000 hours (one year) (Stage II)

Demand Volume
Replacement time Filter
Item Description Where used
(h) Oil (L) element
(piece)
Oils 16 Engine
First 50 h
Oil filter 1 Engine
Transmission lubrication oil 18 Transmission
Drive axle lubrication oil 26 Drive axle
First 100
Power Train Hydraulic
Drive oil filter element 1
System

First 250 Oil drain filter 1 Hydraulic Oil Tank

Oils 16 Engine
Oil filter element 1 Engine

Fuel primary filter 1 Engine

250
Fuel secondary filter 2 Engine
Air filter element 1 Engine

Diesel engine oil 16 Engine

500
Oil filter element 1 Engine

84
 Demand Volume
Replacement time Filter
Item Description Where used
(h) Oil (L) element
(piece)
Air filter element 1 Engine

Diesel secondary element 2 Engine

Diesel primary element 1 Engine
Element 1 Vibratory hydraulic system

Oils 16 Engine
Oil filter element 1 Engine
750 Fuel primary filter 1 Engine

Fuel secondary filter 2 Engine

Air filter element 1 Engine
Diesel engine oil 21 Engine

Oil filter element 1 Engine

Air filter element 1 Engine
Diesel secondary element 2 Engine

Diesel primary element 1 Engine

1000 Element 1 Vibratory hydraulic system

Transmission lubrication oil 18 Transmission

Drive axle lubrication oil 26 Drive axle

Power Train Hydraulic
Drive oil filter element 1
System
Oil drain filter 1 Hydraulic Oil Tank

Oils 16 Engine
Oil filter element 1 Engine
1250 Fuel primary filter 1 Engine

Fuel secondary filter 2 Engine

Air filter element 1 Engine
Diesel engine oil 16 Engine

Oil filter element 1 Engine

Air filter element 1 Engine
1500
Diesel secondary element 2 Engine

Diesel primary element 1 Engine

Element 1 Vibratory hydraulic system
Oils 16 Engine

Oil filter element 1 Engine

1750 Fuel primary filter 1 Engine
Fuel secondary filter 2 Engine
Air filter element 1 Engine

85
 Demand Volume
Replacement time Filter
Item Description Where used
(h) Oil (L) element
(piece)
Number 46 anti-wear hydraulic oil 80 Oil tank

Oil filler filter 1 Oil tank

Oil filler filter 1 Diesel tank
Transmission lubrication oil 18 Transmission

Gear Oil 26 Drive axle

Diesel engine oil 16 Engine
Oil filter element 1 Engine
2000 Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine

Element 1 Vibratory hydraulic system

Gear Oil 8.5*2 Vibration package
Power Train Hydraulic
Drive oil filter element 1
System
Oil drain filter 1 Hydraulic Oil Tank

86