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Operation and j
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Maintenance
Manual
SEM656D Wheel Loader
E S53(SEM656D CEV-Stage IV Engine) E
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4 Important Safety Information 4
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Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic
0 or precautions. An accident can often be avoided by recognizing potentially hazardous
saf ety rules 0 situations
bef ore an accident occurs. A person must be alert to potential hazards, including human factors that can affect
saf ety. Thisjperson should also have the necessary training, skills and tools to perform these jfunctions properly.
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Improper operation, lubrication, maintenance or repair of this product can be dangerousp
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.
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A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the
C product and in this publication. C
_ 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
c use this product in any manner different from that considered by this manual c without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
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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
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(Qingzhou) Ltd. is used, you must satisfy yourself that it is safe for you and for4others. You should also
ensure6 that you are authorized to perform this work, and that the product will not6 be damaged or become
unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.
0
The inf ormation, 0 that was
specifications, and illustrations in this publication are on the basis of information
available at jthe time that the publication was written. The specifications, torques, pressures, measurements,
j
adjustments, illustrations, and other items can change at any time. These changes can affect the service that is
p Obtain the complete and most current information before you start any job.pSEM dealers have
given to the product.
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.

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Table of Contents 4
Cab ................................................................25

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Product Information ................................. 26
Forward ........................................................ 5
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General Information ...................................... 26
Safety Section
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Component Names of the Machine................ 27
p Location of the Saf ety Messages ... 8
Description and p
Usage and Main Technical Parameters ......... 29
General Precaution.......................................... 14
Pressurized Air and Water ................................ 14 Operation Section .................................... 32
Trapped Pressure............................................ 14 Before Operation..............................................33
Fluid Penetration ............................................. 15 Control Devices and Monitoring System...............34
Containing Fluid Spillage .................................. 15 Operator Seat Adjustment .................................41
Inhalation ....................................................... 15 Seat Belt .........................................................42
Asbestos Information........................................ 15 Run-in of New Machine .....................................44
Dispose of Waste Properly ................................ 16 Operating Precautions.......................................45
Crushing Prevention and Cutting Prevention........ 16 Storage of the Machine .....................................50
Burn Prevention .............................................. 16 Shipping of the Machine ....................................51
Battery ........................................................... 17 Tying Down the Machine ...................................53
Fire Prevention and Explosion Prevention ........... 17 Battery Use and Maintenance Considerations.......54
E Battery and Battery Cables................................ 18
E
Trailing ...........................................................55
C Lines, Tubes, and Hoses .................................. 19 C
Machine Operation ...........................................57
_ Ether ............................................................. 19 _
Maintenance Section ............................... 61
c Fire Extinguisher and First Aid Kit....................... 19 c
r Saf ety...................................................... 20
Fire r
SEM656D Periodic Maintenance ........................62
Unauthorized Modification................................. 20 Maintenance Considerations ..............................65
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Fire Extinguisher Location................................. 20 Key Saf ety Part Catalog and Change Interval .......71
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Tire Information............................................... 21 Engine Coolant Maintenance .............................73
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Lightning Damage Prevention............................ 21
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Maintenance of Engine Air Cleaner .....................75
j Engine ..................................... 21
Before Starting j
Diesel Tank .....................................................75
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Visibility Information p
Maintenance of Engine Oil .................................77
Restricted Visibility........................................... 22 Maintenance of Engine After-treatment System.....78
Engine Starting................................................ 22 Maintenance of Air Conditioning System ..............80
Before Operation ............................................. 23 Maintenance of Transmission.............................81
Operation ....................................................... 23 Maintenance of Drive Axle .................................83
Fueling Machine.............................................. 23 Maintenance of Hydraulic System .......................84
Engine Stopping .............................................. 23 Knowledge of Tire Maintenance and Inflation........85
Slope Operation .............................................. 24 Bucket Kickout Adjustment ................................86
Work Tools ..................................................... 25 Brake System Check ........................................86
Equipment Lowering with Engine Stopped ........... 25 Maintenance of Pin Shaft and Drive Shaft ............88
Sound Information and Vibration Information........ 25 Welding Operation ........................................ 89
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Maintenance-free Battery Charging Regulations89 4
6 or Battery Cable- Inspect/ Replace .... 90
Battery 6
Recycling
0 of Battery ...................................... 91 0
Fluids Specifications...................................... 92
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Fault Reason and Troubleshooting ................ 93
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SEM656D Regular Maintenance Parts List .. 108

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Forward Maintenance 4
6 The maintenance section 6 is a guide to the equipment
Literature Information care. The Maintenance Interval Schedule (PMM) lists
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This manual contains safety information, operation
the items to be maintained at0a specific service
interval. Items without specific intervals are listed
instructions,j driving information, lubrication under the “When Required” service j interval. The
inf ormation and maintenance information. Maintenance Interval Schedule, for the step-by-step
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instructions required to accomplish the scheduled
This operation manual details the important aspects
of safety, operation, maintenance, inspection, etc., maintenance.
and should be kept available and read regularly. If Maintenance Intervals
this manual is missing or dirty and not legible, you
should re-purchase it from SEM dealer. When you The maintenance section of this manual is a
sell the machine, please ensure that the manual is guideline for routine maintenance of the machine and
also f orwarded to the new user. is organized by maintenance intervals. The
maintenance intervals listed in this manual are
The technical parameters, specifications and
illustrations in this manual are on the basis of determined by using the service hour meter.
Calendar intervals shown (daily, weekly, monthly,
inf ormation that was available at the time that the
etc.) can be used instead of service hour meter
manual was written. Continuing modification of
intervals if they provide more convenient servicing
product design may affect the maintenance and
schedules and approximate the indicated service
repair of the machine which are not included in this
manual. Whenever a question arises regarding your hour meter reading. Caterpillar (Qingzhou) Ltd.
recommends service should always be performed at
machine, or this manual, please consult with the
the interval that occurs first. Under extremely severe,
manuf acturer or SEM dealer for the latest available
inf ormation. dusty or wet operating conditions, more frequent
lubrication than is specified in the scheduled
E Safety maintenance
E might be necessary. Perform service on
items at multiples of the original requirement. For
C Caterpillar (Qingzhou) Ltd. cannot anticipate C those items listed under at Every
example, service
every working circumstance that might involve a 500 Service Hours or 3 Months, also service those
_ hazard. The warnings in this manual and on the _ Every 250 Service Hours or 1
items listed under
product are, therefore, not all inclusive. If a tool, Month, Every 50 Service Hours Weekly and Every 10
c procedure, work method or operating technique that c
Service Hours or Daily.
is not specifically recommended by Caterpillar
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(Qingzhou) Ltd. is used, you must satisfy yourself r
Engine Maintenance
that4it is safe for you and for others. You should also 4 repair are essential to keep
Proper maintenance and
ensure that the machine will not be damaged or
the engine and machine systems operating correctly.
become 6 unsafe by the operation, lubrication, 6
As the heavy-duty off-road diesel engine owner, you
maintenance or repair procedures that you intend to
use. 0 0
are responsible for the performance of the required
maintenance listed in the Operation and Maintenance
Operationj j engaged in the
Manual. It is prohibited for any person
business of repairing, servicing, selling, leasing, or
The operationpsection is a reference for new p alter, or
trading engines or machines to remove,
operators and a ref resher for experienced ones. This render inoperative any emission related device or
section includes a discussion of gauges, switches, element of design installed on or in an engine or
machine controls, attachment controls, transportation machine that is in compliance with the regulations.
and towing information. Certain elements of the machine and engine such as
Photographs and illustrations guide the operator the exhaust system, fuel system, electrical system,
through correct procedures of checking, starting, intake air system and cooling system may be
operating and stopping the machine. emission related and should not be altered unless
approved by Caterpillar (Qingzhou) Ltd.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and the capabilities
of the machine.

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Machine Capacity 4
Each 6 loader has its own design capability. Additional 6
attachments or modifications may exceed loader
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design capacity which can adversely affect 0
perf ormance characteristics. Included would be
operational jstability, brakes and steering. Please j
contact your SEM dealer for updated information.
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SEM Product Identification Code
The product identification code is located on the
machine dataplate.

① — SEM World Manufacturer Code

② — Machine Model
③ — Check Character
④ — Model Design Code
E ⑤ — Machine Factory Number (S/N) E
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Safety Section 4
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c Please read and become familiar with all safety
instructions. Failure to do so could result in c
serious
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This
4 “Safety Section” also includes precautions 4
for optional attachments.
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Description and Location of 4
the 6Safety Messages 6
There are0several specific safety messages on this 0
machine. The exact location of the hazards and the
j the hazards are reviewed in this
description of j
p become familiar with all safety
section. Please p
messages.
Make sure that all 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 off
machine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the machine that is replaced, install a saf ety message
on the replacement part. Any SEM dealer can
provide new safety messages.
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Do4Not Operate Keep Hands Away4
6 ety message is located in the cab.
This saf The message is located at6the rear of the hood.

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Please do not put your hands near the running

fan. Do not touch the machine in operation.
Do not operate or work on this machine unless No Entry when Reversing
you have read and understand the instructions
and warnings in the Operation and Maintenance The message is located on the rear of the machine.
Manual. Failure to do so may result in personal
injury or death. Contact your SEM dealer for
E manual replacement. E
C Seat Belt Message C
This saf ety message is located in the cab.
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Do not get close to the machine
stops.
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A seat belt should be worn at all times during

machine operation to prevent serious injury or
death in the event of an accident or machine
overturn. Failure to wear a seat belt during
machine operation may result in serious injury or
death.

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No4Standing Under the Boom 4
No Entry when Working
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The message is located on the outside of the boom. The message is located in6the articulation position at
the middle of the machine.
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Never stand beneath the boom, which could

result in serious personal injury or death. Never enter into this area during machine
operation, which could result in serious personal
Lift Point Indicator injury or death.
The message is located on the inside of the machine.
Articulation Lock
The message is located in the articulation position at
the middle of the machine.
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4 message indicates the position of lifting
This 4
the whole machine.
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p Crush Hazard. One never stand p here when the
machine turns. Serious injury or death could
occur due to crushing. Lock out the steering
frame lock between front and rear frames before
transporting machine, or servicing machine in
articulation area.
Remove the steering lock and keep it in a suitable
place before resuming machine operation.

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Alternate Exit Hydraulic Oil Sign4
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The message is located in the cab on the right post 6the hydraulic tank.
This message is located by
by the window latch.
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Fuel Tank
If the primary exit becomes disabled, the window This message is located by the fuel tank.
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.

Parking Brake Sign

The message is located inside the cab. Battery Alert
This message is located by the battery
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Engage 0the parking brake while the machine is 0
parking. j Explosion Hazards! Improper j jumper cable
connections can cause an explosion resulting in
p personal injury or death. Thepbattery may be
located in different places. See the proper jump
start procedure in the Operation and Maintenance
Manual.

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General Precaution 4 Protective
Clothing and Personal
Equipment
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Safety Requirements • Do not wear loose clothing or jewelry. Do not keep
0 0 or get caught in the
long hair. They may snap into
• Only trained and appropriately qualified personnel
j and maintain the machine. controls or moving parts, causing
j serious injury or
could operate
death.
• Observe allpsafety rules, precautions and p
instructions when operating and maintaining the • Do not wear greasy clothing to prevent burning.
machine. • When you operate or maintain the machine, wear a
• Do not operate the machine if you do not feel well, hard saf ety helmet, protective goggles, protective
f eel dizzy after taking medication or after drinking. shoes, and gloves. Wear protective goggles, hard
hat, and heavy gloves when throwing metal chips
In this case, it will lead to the wrong judgment and
potential accident. and tiny debris, especially when hammering p ins
and removing air filter contaminants with
• When working with another operator or traffic compressed air. Also check to make sure no one is
commander on site, you must ensure that all near the machine.
personnel understand the hand signals being used.
• 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.
E • Use saf ety devices properly, such as lever locking E
devices and safety belts.
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• Never remove the safety device. Always keep it in
_ good working condition. Pressurized _ Air and Water
c • Improper use of safety devices can result in serious Pressurized air can c cause personal injury. When
rinjury or death. pressurized air is usedr for cleaning, wear protective
masks, protective clothing and protective shoes. The
Lock the safety devices when you exit
4
the operator seat.
maximum air pressure for 4 cleaning purposes must be
below 205 kPa. The maximum water pressure for
6
• Engage the parking brake switch before you exit cleaning purposes must be 6below 275 kPa.
0 If the control lever is accidentally touched,
the seat. • Avoid direct spraying of water0 on electrical
the work tools may suddenly move, causing serious connectors, connections, and components. When
injury. j j machine to cool to
using air f or cleaning, allow the
p the loader, lower the work tool reduce the possibility of fine debris
p igniting when
• When you leave
re-deposited on hot surfaces.
completely to the ground, engage the parking brake
switch, shut off the engine, lock all devices with the
key, and take the key with you.
Trapped Pressure
• If the right window is closed, make sure that the Pressure can be trapped in a hydraulic system.
hooks are f ully secured to prevent loosening. Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
• If the window is locked, be sure to tighten the lock caution if you disconnect hydraulic lines or fittings.
seat to prevent collision between the loose glass High-pressure oil that is released can cause a hose
and the lock seat. to whip. High-pressure oil that is released can cause
oil to spray. Fluid penetration can cause serious
injury and possible death.

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4 Penetration
Fluid Inhalation 4
Pressure6 can be trapped in the hydraulic circuit long 6
af ter the 0
engine has been stopped. The pressure can 0
cause hydraulic fluid or items such as pipe plugs to
j if the pressure is not relieved
escape rapidly j
correctly.
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Do not remove any hydraulic components or parts
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until pressure has been relieved, or personal injury
may occur.

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
Always use a board or cardboard when you check for SEM equipment and replacement parts shipped from
a leak. Leaking fluid that is under pressure can Caterpillar (Qingzhou) Ltd. are asbestos free.
penetrate body tissue. Fluid penetration can cause Caterpillar (Qingzhou) Ltd. recommends the use of
E serious injury and possible death. A pin hole leak can only SEMEreplacement parts. Use the following
cause severe injury. If fluid is injected into your skin, guidelines when you handle any replacement parts
C you must get treatment immediately. Seek treatment that containCasbestos or when you handle asbestos
debris. And use caution. Avoid inhaling dust that
_ f rom a doctor that is familiar with this type of injury. _
might be generated when you handle components
c Containing Fluid Spillage c fibers. Inhaling this dust can be
that contain asbestos
hazardous to your health. The components that may
r must be taken in order to ensure that fluids are
Care contain asbestos fibers r are brake pads, lining
contained during performance of inspection, material, clutch friction discs, and some gaskets etc.
4
maintenance, testing, adjusting, and repair of the The asbestos that is used 4 in these components is
equipment. Prepare to collect the fluid with suitable bound in a resin or sealed in some way.
6
containers before opening any compartment or
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If dust that may contain asbestos is present, there
0 any component that contains fluids.
disassembling 0 be followed:
are several guidelines that should
• Tools thatj are suitable for collecting fluids and • Never use compressed air for jcleaning.
equipment that is suitable for collecting fluids
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• Tools that are suitable for containing fluids and
p asbestos.
• Avoid brushing materials that contain
equipment that is suitable for containing fluids • Avoid grinding materials that contain asbestos.
Obey all local regulations for the disposal of liquids. • Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
ef f iciency particulate air f ilter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.

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• Wear
4 an approved respirator if there is no 4
Whenever there are equipment control linkages the
other way to control the dust. clearance in the linkage area will change with the
6 movement of the equipment 6 or the machine. Stay
• Comply with applicable rules and regulations for clear of areas that may have a sudden change in
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the workplace. 0 or equipment
clearance with machine movement
movement.
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Use the requirements found in the “Ordinance on j
Prevention of Health Impairment due to Asbestos” in Stay clear of all rotating and moving parts.
addition to theprequirements of the Industrial Safety p
and Health Act. If it is necessary to remove guards in order to perform
maintenance, always install the guards back after the
• Obey environmental regulations for the disposal of maintenance is completed. Keep objects away from
asbestos. moving fan blades. The f an blade will throw objects
or cut objects.
• Stay away f rom areas that might have asbestos
particles in the air. Burn Prevention
Dispose of Waste Properly 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 f uel system, or in the cooling system before
any lines, f ittings, or related items are disconnected.
Coolant
When the engine is at operating temperatures, the
engine coolant is hot and under pressure. The
E radiatorE
and all lines to the heaters or to the engine
contain hot coolant.
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Any contact with hot coolant or with steam can cause
Improperly disposing of waste can threaten the
_ environment. Potentially harmful fluids should be _ cooling system components to
severe burns. Allow
disposed of according to local regulations. cool before the cooling system is drained.
c c
Check the coolant level only after the engine has
Always use leakproof containers when you drain
f rluids. Do not pour waste onto the ground, down a been stopped. r
drain, or into any source of water.
4 Ensure that the f iller cap 4 is cool before removing the
f iller cap. The f iller cap must be cool enough to
Crushing
6 Prevention and touch with a bare hand. Remove 6 the filler cap slowly
Cutting 0 Prevention
in order to relieve the pressure.
0
Cooling system conditioner contains alkali. Alkali can
Support the equipment properly before you perform
j
any work or maintenance beneath that
cause personal injury. j
equipment. Dopnot depend on the hydraulic cylinders p skin, the eyes,
Do not allow the alkali to contact the
to hold up the equipment. Unit can fall if a control is or the mouth.
moved, or if hydraulic lines break.
Oils
Do not work beneath the cab of the machine unless
the cab is properly supported. Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
Unless you are instructed otherwise, never attempt do not allow hot components to contact the skin.
adjustments while the machine is moving or while the
engine is running. Remove the hydraulic tank filler cap only after the
engine has been stopped. The f iller cap must be cool
Never jump across the starter solenoid terminals in enough to touch with a bare hand. Follow the
order to start the engine. Unexpected machine standard procedure in this manual in order to remove
movement could result. the hydraulic tank filler cap.

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Battery • Keep shields in place.4Exhaust shields (if equipped)
protect hot exhaust components from oil spray or
6 in a battery is an electrolyte. Electrolyte is
The liquid 6 in a line, in a hose, or
f uel spray in case of a break
an acid that in a seal. Exhaust shields must be installed
0 can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
0 cut on tanks or lines
correctly. Do not weld or flame
Do not smoke j while checking the battery electrolyte that contain f lammable fluids orj flammable material.
Empty and purge the lines and tanks. Then clean
levels. Batteries
p give off flammable fumes which can p
the lines and tanks with a nonflammable solvent
explode. prior to welding or flame cutting. Ensure that the
components are properly grounded in order to
Fire Prevention and Explosion avoid unwanted arcs.
Prevention • Dust that is generated from repairing nonmetallic
hoods or f enders 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.
All f uels, most lubricants, and some coolant mixtures
are f lammable. • Store f uels and lubricants in properly marked
To minimize the risk of fire or explosion, Caterpillar containers away from unauthorized personnel.
E (Qingzhou) Ltd. recommends the following actions. Store E
oily rags and flammable materials in
protective containers. Do not smoke in areas that
C • Always perform a Walk-Around Inspection, which are used Cf or storing flammable materials.
_ may help you identify a f ire hazard. Do not operate _
a machine when a f ire hazard exists. Consult your
c SEM dealer for details. c
•rUnderstand the use of the primary exit and r
alternative exit on the machine.
4 4
• Do not operate a machine with a fluid leak. Repair
leaks 6 and clean up fluids before resuming machine 6
operation. Fluids that are leaking or spilled onto hot
surf aces0 or onto electrical components can cause a 0
f ire. A f irejmay cause personal injury or death. j
• Remove flammable
p material such as leaves, twigs, p
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
• Keep the access doors to major machine not smoke while you are f ueling a machine. Do not
compartments closed and access doors in working f uel a machine near open flames or sparks. Do not
use cell phones or other electronic devices while
condition in order to permit the use of fire
suppression equipment, in case a fire should occur. you are ref ueling. Always stop the engine before
Clean all accumulations of flammable materials ref ueling. Fill the fuel tank outdoors. Properly clean
areas of spillage.
such as f uel, oil, and debris from the machine.
Do not operate the machine near any flame.

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• Avoid
4 static electricity risk when f ueling. Ultra-low • Fraying 4
sulf ur diesel (ULSD) poses a greater static ignition
6 than earlier diesel formulations with a
hazard • Abrasion 6
higher sulf ur content. Avoid death or serious injury • Cracking
0 or explosion. Consult with your fuel or fuel
f rom fire 0
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system supplier to ensure that the delivery system • Discoloration j
is in compliance with fueling standards for proper
grounding andp bonding practices. • Cuts on the insulation of the cable
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Never store f lammable fluids in the operator • Fouling
compartment of the machine.
• Corroded terminals, damaged terminals, and loose
Battery and Battery Cables 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.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
E Caterpillar (Qingzhou) Ltd. recommends the following disconnect
E switch to be bypassed if the exposed area
in order to minimize the risk of fire or an explosion comes into contact with a grounded surface. This
C related to the battery. Can unsafe condition for servicing the
may result in
machine. Repair
_ Do not operate a machine if battery cables or related _
components or replace components before servicing
parts show signs of wear or damage. Consult your
c SEM dealer for details. the machine. c
r
Follow safe procedures for engine starting with r
jump-start cables. Improper jumper cable
4
connections can cause an explosion that can result in 4
Fire on a machine can result in personal injury or
injury.6Ref er to Operation and Maintenance Manual, death. Exposed battery6cables that come into
“Engine Starting with Jump Start Cables” for specific contact with a grounded connection can result in
0
instructions. fires. 0
Do not charge
j a frozen battery. This may cause an j of the following
Check electrical wires daily. If any
explosion.
conditions exist, replace parts before you operate the
Gases f rom apbattery can explode. Keep any open machine. p
f lames or sparks away from the top of a battery. Do
not smoke in battery charging areas. Do not use cell • Fraying
phones or other electronic devices in battery • Signs of abrasion or wear
charging areas.
Never check the battery charge by placing a metal
• Cracking
object across the terminal posts. Use a voltmeter in • Discoloration
order to check the battery charge.
• Cuts on insulation
Daily inspect battery cables that are in areas that are
visible. Inspect cables, clips, straps, and other • Other damage
restraints for damage. Replace all damaged parts.
Check f or signs of the following, which can occur
over time due to use and environmental factors:

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4 sure that all clamps, guards, clips, and straps
Make 4 guards, and heat shields
Make sure that all clamps,
are reinstalled correctly. This will help to prevent are installed correctly. During machine operation,
6 rubbing against other parts, and excessive
vibration, 6
this will help to prevent vibration, rubbing against
heat during machine operation. other parts, excessive heat, and failure of lines, tubes,
0 and hoses. 0
Attaching electrical wiring to hoses and tubes that
j
contain flammable fluids or combustible fluids should Do not operate a machine whenja f ire hazard exists.
be avoided. Repair any lines that are corroded, loose, or
p damaged. Leaks may provide fuelpfor fires. Consult
Consult your SEM dealer for repair or replacement
your SEM dealer for repair or replacement parts. Use
parts. Keep wiring and electrical connections free of
genuine SEM parts, for capabilities of both the
debris. pressure limit and temperature limit.
Lines, Tubes, and Hoses Ether
Do not bend high-pressure lines. Do not strike Ether (if equipped) is commonly used in cold-weather
high-pressure lines. Do not install any lines that are applications. Ether is flammable and poisonous.
bent or damaged. Use the appropriate
backup wrenches to tighten all connections to the Only use approved ether cylinders for the ether
recommended torque. dispensing system fitted to your machine. Do not
spray ether manually into an engine. Follow the
correct cold engine starting procedures.
Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder. Do not store
ether cylinders in living areas or in the operator
compartment of a machine. Do not store ether
cylinders in direct sunlight or in temperatures above
E E F). Keep ether cylinders away from
49°C (120.2°
open f lames or sparks. Dispose of used ether
C C Do not puncture an ether cylinder.
cylinders properly.
Keep ether cylinders away from unauthorized
_ personnel. _
c Check lines, tubes, and hoses carefully. Wear Fire Extinguisher c and First Aid
Personal Protection Equipment (PPE) to check for
r Always use a board or cardboard when you
leaks.
Kit r
check f or a leak. Leaking fluid that is under pressure
can4penetrate body tissue. Fluid penetration can 4
In the event of injury or fire, take actions according to
cause6serious injury and possible death. A pin hole the f ollowing precautions. 6
leak can cause severe injury. If fluid is injected into
your skin,0you must get treatment immediately. Seek • Keep a f ire extinguisher on0the machine. Read the
treatment f rom a doctor that is familiar with this type instructions carefully and make sure to know how to
of injury. j use. j
p
Replace the affected parts if any of the following • Always have a f irst aid kit at thepwork site. Check
conditions are present: regularly and, if necessary, supplement some
medicines.
• Fittings are damaged or leaking.
• Outer coverings are chafed or cut. • Know what to do in case of a f ire or injury.
• Make available the phone numbers of some people
• Wires are exposed. (such as doctors, emergency centers, fire stations,
• Outer coverings are swelling or ballooning. etc.) to contact in case of emergency. Put these
contact numbers in the specified places and make
• Flexible parts of the hoses are kinked. sure all people know the numbers and the correct
method of contact.
• Outer covers have exposed embedded armoring.
• Fittings are displaced.

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4 Safety
Fire 4 to do anything else,
Remember, if you are unable
shut off the machine before exiting. By shutting off
Note: 6
Locate the alternative exit and learn the the machine, f uels will not6
continue to be pumped
usage of0the alternative exit before you operate into the f ire.
the machine.
0
If the f ire grows out of control, be aware of the
Note: Locatej the fire extinguishers and learn how f ollowing risks: j
to use a fire extinguisher
p before you operate the • Tires on wheeled machines posepa risk of explosion
machine. as tires burn. Hot shrapnel and debris can be
If you f ind that you are involved in a machine fire, thrown great distances in an explosion.
your safety and that others on site is the top priority.
The f ollowing actions should only be performed if the
• Tanks, accumulators, hoses, and fittings can
rupture in a f ire, spraying fuels and shrapnel over a
actions do not present a danger or risk to you and
any nearby people. At all times you should assess large area.
the risk of personal injury and move away to a safe • Remember that nearly all of the fluids on the
distance as soon as you feel unsafe. machine are f lammable, including coolant and oils.
Move the machine away from the combustibles such Additionally, plastics, rubbers, fabrics, and resins in
as gas stations, buildings, garbage bins, covering, f iberglass panels are also flammable.
and lumber. Lower all implements as soon as
possible and turn off the engine. If you leave the Unauthorized Modification
engine running, the engine will continue to f eed a f ire. Any modifications not approved by Caterpillar
Any damaged hoses that are connected to the engine (Qingzhou) Ltd. may result in danger. Before
or pump can cause a f ire. modifying the machine, consult your dealer
Turn the battery disconnect switch to the OFF designated by Caterpillar (Qingzhou) Ltd.
position, if possible. Disconnecting the battery will Caterpillar (Qingzhou) Ltd. assumes no liability for
E eliminate the ignition source in the event of a short E resulting from unauthorized
any damages
circuit. Disconnecting the battery will eliminate a modifications.
C second ignition source if electrical wiring is damaged C
_ by the f ire, resulting in a short circuit. Fire Extinguisher
_ Location
c Notif y emergency personnel of the fire and your
location. If your machine is equipped with a fire
Make sure that a f ire extinguisher is available on the
c
machine. Be familiar with the operation of the fire
suppression
r system, follow the fire suppression extinguisher. Inspect rthe fire extinguisher and service
procedure to activate the system. the f ire extinguisher on a regular basis. Obey the
4 The fire suppression systems need to be
Note: recommendations on the 4 instruction plate.
6 inspected by qualified personnel. You
regularly
must be trained to operate the fire suppression
Mount the f ire extinguisher6in the cab.

system. 0 Strap the mounting plate to a0 leg of the ROPS in

order to mount the fire extinguisher, as needed. If
j
Use the on-board fire extinguisher and use the j exceeds 4.5 kg (10
the weight of the fire extinguisher
f ollowing procedure: lb), mount the fire extinguisher near the bottom of the
p
1. Pull the pin.
p
ROPS leg. Do not mount the fire extinguisher at the
upper one-third area of the ROPS leg.
2. Aim the extinguisher or nozzle at the base of the
f ire. Note: Do not weld the fire extinguisher to the
ROPS. Also, do not drill holes in the ROPS
3. Squeeze the handle and release the structure in order to mount the fire extinguisher
extinguishing agent. on the ROPS.
4. Sweep the extinguisher from side to side across
the base of the fire until the fire is put out.

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Tire 4 Information 4
Dry nitrogen gas is recommended for inflation of tires.
If the tires were originally inflated with air, nitrogen is
6 of pneumatic tires have resulted from
Explosions still preferred for adjusting6the pressure. Nitrogen
heat-induced mixes properly with air.
0 gas combustion inside the tires.
Explosions can be caused by heat that is generated
0
Nitrogen inflated tires reduce the potential of a tire
by welding, jby heating rim components, by external explosion because nitrogen doesj not aid combustion.
f ire, or by excessive use of brakes etc. Nitrogen helps to prevent oxidation of the rubber,
p
A tire explosion is much more violent than a blowout.
p of rim
deterioration of rubber, and corrosion
The explosion can propel the tire, the rim components.
components, and the axle components from the To avoid over inflation, proper nitrogen inflation
machine. Stay outside the area with flying objects. equipment and training in the usage of the equipment
Both the force of the explosion and the flying debris are necessary. A tire blowout or a rim failure can
can cause property damage, personal injury, or result f rom improper equipment or from misused
death. equipment.
Typical example of tire is shown below. When you inf late a tire, stand behind the tread and
use a self -attaching chuck.
Servicing tires and rims can be dangerous. Only
trained personnel that use proper tools and proper
procedures should perform this maintenance.
If correct procedures are not used for servicing tires
and rims, the assemblies could burst with explosive
f orce. This explosive force can cause serious
personal injury or death.
E LightningE Damage Prevention
C Do not approach a warm or an apparently damaged
C is striking in the vicinity of the
When lightning
_ tire. machine, the operator
_ should never attempt the
f ollowing operations:
c Caterpillar (Qingzhou) Ltd. recommends against
using water or calcium as a ballast for the tires except
c
• Mount the machine.
inr machines designed for this additional mass. For r
those applicable machines, the maintenance • Dismount the machine.
4 will contain instructions on the correct tire
section 4 station during an electrical
If you are in the operator’s
inf lation and filling procedures. Ballast, such as fluid storm, stay in the operator’s
6 station. If you are on the
in the 6tires, increases overall machine weight and ground during an electrical storm, stay away from the
may affect 0braking, steering, power train components,
or the certif ication of the protective structure such as
vicinity of the machine. 0
the ROPS. The j use of tire/rim rust preventatives or Before Starting Engine j
other liquid additives is not required.
p The steering frame lock must be inpthe unlocked
position in order to steer the machine.
Start the engine only from the operator compartment.
To avoid ordination, proper nitrogen inflation
Never short across the starter terminals or across the
equipment and training for the usage of the batteries. Shorting could bypass the engine neutral
equipment are necessary. A tire blowout or a rim start system. Shorting could also damage the
failure can result from improper equipment or
electrical system.
from misused equipment, which could result in
personal injury or death. Due to the high pressure Inspect the condition of the seat belt and the
of approximately 15000 kPa (2200 psi) in the condition of the mounting hardware. Replace any
nitrogen tank when fully filled, improper use of damaged parts or worn parts. Regardless of
the inflation equipment can result in tire blowout appearance, replace the seat belt after three years of
and/ rim failure. use. The design of seat belt meets ISO 6683-2005.

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Do4not use a seat belt extension on a retractable seat 4
belt. Adjust the seat so that full pedal travel can be
Restricted Visibility
6 when the operator's back is against the
achieved The size and the configuration 6 of this machine may
back of the seat. result in areas that cannot be 0 seen when the operator
0 is seated. The illustration provides an approximate
Make sure that the machine is equipped with a
j that is adequate for the job conditions.
lighting system j
visual indication of areas of significant restricted
Make sure that all lights are working properly. visibility. The illustration indicates restricted visibility
p areas at ground level inside a radius p of 12 m (40 ft)
Bef ore you start the engine or before you move the f rom the operator on a machine without the use of
machine, make sure that no one is on the machine, optional visual aids. This illustration does not provide
underneath the machine, or around the machine. areas of restricted visibility for distances outside a
Ensure that there are no personnel in the area. radius of 12 m (40 f t). Compilable with ISO
5006-2006 and ISO 14401-1&2-2004.
Visibility Information
Bef ore you start the machine, perform a walk-around
inspection in order to ensure that there are no
hazards around the machine.
While the machine is in operation, constantly survey
the area around the machine in order to identify
potential hazards as hazards become visible around
the machine.
Bef ore operating the machine, ensure that the visual
aids are in proper working condition and that the
visual aids are clean. Adjust the visual aids using the
E procedures that are located in this Operation and E
Maintenance Manual. It may not be possible to Note: The shaded areas indicate the approximate
C provide direct visibility on large machines to all areas location ofCareas with significant restricted
around the machine. Appropriate job site visibility.
_ organization is required in order to minimize hazard s _
c that are caused by restricted visibility. Job site
organization is a collection of rules and procedures
Engine Starting c
that
r coordinates machines and people that work r
If a warning tag is attached to the engine start switch
together in the same area. Examples of job site or to the controls, do not start the engine and do not
4
organization include the following: move any controls. 4
• Saf ety
6 instructions Move all hydraulic controls6to the HOLD position
bef ore you start the engine.
• Controlled
0 patterns of machine movement and 0
vehicle movement Move transmission control into the NEUTRAL
j position. Engage the parking brake.j
• Workers that direct traffic to move when it is safe
p Diesel engine exhaust contains products
p of
• Restricted areas combustion which can be harmful to your health.
Always operate the engine in a well-ventilated area. If
• Operator training you are in an enclosed area, vent the exhaust to the
• Warning symbols or warning signs on machines or outside.
on vehicles Brief ly sound the horn before you start the engine.
Check f or the presence of personnel. Ensure that all
• Communication system personnel are clear of the machine.
• Communication between workers and operators
prior to approaching the machine
Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
evaluated.

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4
Before Operation 4 Never allow other
Never straddle a wire cable.
personnel to straddle a wire cable.
Ensure 6that there are no personnel on the machine or 6
Know the maximum dimensions of your machine.
in the area
0 around the machine. 0
Remove any debris that builds up in and around the Fueling Machine
j
hoses and fittings to reduce damage or wear to the j
hoses and fittings.
p p
Clear all obstacles from the path of the machine.
Beware of hazards such as wires, ditches, etc. Ultra-Low Sulfur Diesel (ULSD) poses a greater
static ignition hazard than earlier diesel
Ensure that all windows are clean. Secure the doors formulations with a higher sulfur content, which
and the windows in the open position or in the shut may result in a fire or explosion. Consult with
position. your fuel or fuel system supplier for details on
proper grounding and bonding practices.
Adjust the rear-view mirrors (if equipped) for the best
vision of the area near the machine.
Ensure that the horn, the backup alarm (if equipped),
and all other warning devices are working properly. To avoid possible injury or death, do not
Fasten the seat belt securely. smoke while in an area that contains flammable
liquids.
Operation
All f uels, most lubricants, and some coolants are
Only operate the machine while you are sitting in the f lammable.
operator seat. The seat belt must be fastened while
you operate the machine. Only operate the controls if Keep all f uels and lubricants stored in properly
marked containers and away from unauthorized
E the engine is running.
persons.
E
C While you operate the machine slowly in an open
Fuel leakedC
or spilled onto hot surfaces or electrical
area, check for proper operation of all controls and all
_ protective devices. components can_ cause a fire.
Store all oily rags or other flammable materials in a
c Bef ore you move the machine, make sure that no protective containerc in a safe place.
one will be endangered. The rider must be seated,
r the seat belt must be fastened.
and Remove all flammable r materials such as fuel, oil, and
other debris before they accumulate on the machine.
4 use the work tool as a work platform. Note any
Never 4
needed repairs during machine operation. Report any Do not expose the machine to flames, burning brush,
needed6 repairs. etc., if at all possible. 6
0 tools at approximately 40 cm above
Carry work 0
Locate the fuel filler on the machine, and remove the
ground level. f iller cap. After fueling the machine, replace the filler
j
Do not go close to the edge of a cliff, an excavation,
j
cap and lock the filler cap into position.
p
or an overhang. The f iller cap may be hot. To avoidpinjury, use
personal protective equipment. Allow the cap to cool
Avoid operating the machine across the slope. When
possible, operate the machine up the slopes and bef ore fueling the machine.
down the slopes. If the machine begins to sideslip on
a downgrade, immediately remove the load and turn Engine Stopping
the machine downhill. Do not stop the engine immediately after the machine
Avoid any conditions that can lead to tipping the has been operated under load. This can cause
machine. The machine can tip when you work on hills, overheating and accelerated wear of engine
on banks and on slopes. Also, the machine can components.
tip when you cross ditches, ridges, or other Af ter the machine is parked and the parking brake is
unexpected obstructions. Maintain control of the engaged, allow the engine to run for five minutes
machine. Do not overload the machine beyond the bef ore shutdown. This allows hot areas of the engine
machine capacity. to cool gradually.

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4 Installed equipment –4 The f ollowing aspects
Parking may weaken the balance of the machine: the
6 machine on a level surface. If you must park
Park the equipment installed on the6machine, machine
the machine conf iguration, weight and counterweight.
0 on a grade, block the tires. Please
consider the following factors:
0
Nature of surface – Ground that has been newly
• Size of tirej j weight of the
compacted may collapse from the
machine.
p
• Weight of machine p
Surface material – Rocks and moisture of the
• Condition of surface surf ace material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may
Apply the service brake in order to stop the machine. promote side slipping of the machine.
Move the transmission control device (lever) to the
NEUTRAL position. Move the throttle control to the Slippage due to excessive loads – This may cause
low idle position. Engage the parking brake. downhill tracks or downhill tires to be stuck in the
ground, which will increase the angle of the machine.
Lower all work tools to the ground. Activate any
control locks. Stop the engine. Width of tracks or tires – Narrow tracks or narrow
tires f urther increase the risk of being stuck in the
Turn the engine start switch to the OFF position and ground, which causes the machine to be less stable.
remove the engine start switch key.
Implements attached to the drawbar – This may
Always turn the battery disconnect switch to the OFF decrease the weight on the uphill tracks. This may
position before leaving the machine. If the also decrease the weight on the uphill tires. The
machine will not be operated for a month or more, decreased weight will cause the machine to be less
remove the battery disconnect switch key. stable.

Slope Operation Height of the working load of the machine – When

E E loads are in higher positions, the stability
the working
The saf e operation of the machine in various of the machine is reduced.
C application conditions depends on the following C
Operated equipment – Be aware of performance
conditions: machine type, configuration, machine
_ maintenance, machine operating speed, ground
_
features of the equipment in operation and the effects
on machine stability.
c condition, liquid level and tire inflation pressure. The c
Operating techniques – In order to achieve
most important criteria are the skill and judgment of
r operator.
the r all attachments or traction
optimum stability, keep
loads as low to the ground as possible.
4
A well-trained operator that follows the instructions in 4
Capabilities of machine systems have limitations
the Operation and Maintenance Manual has the
6 impact on stability. Operator training can
greatest 6 the proper f unction
on slopes – Slopes can affect
provide the following abilities for the operator: and operation of the various machine systems.
observe 0 working conditions and ambient conditions, 0
These machine systems are needed for machine
understand jmachine performance, after identifying control.
potential hazards and making the right decisions,
j
Note: Safe operation on steep slopes may require
saf ely operatepthe machine. p
special machine maintenance. Excellent skill of
When you work on side hills and when you work on the operator and proper equipment for specific
slopes, consider the following important points: applications are also required. Consult the
Operation and Maintenance Manual sections for
Speed of travel – At high speed, forces of inertia can the proper fluid level requirements and intended
reduce the stability of the machine. machine use.
Roughness of ground or surface – Uneven ground
can reduce the stability of the machine.
Direction of travel – Avoid operating the machine
across the slope. When possible, operate the
machine up the slopes and down the slopes. Place
the heaviest end of the machine uphill when you
are working on an incline.

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4 Tools
Work Equipment Lowering 4 with
6 work tools recommended by Caterpillar
Only the Engine Stopped6
(Qingzhou)
0 Ltd. can be used on SEM machines. Any 0 to ON position.
use of work tools including buckets that are not 1. Turn the engine start switch
recommendedj by Caterpillar (Qingzhou) Ltd. j
2. Push the lif t control to the LOWER position in
or whose weight, size, flow rate, pressure, etc. order to lower the bucket or the work tool to the
p
exceed the specified specifications may result in ground. p
diminished performance of the machine, including but
not limited to, reduced production, stability, reliability, 3. Turn the engine start switch to the OFF position.
and component durability. Caterpillar (Qingzhou) Ltd. Bef ore lowering any equipment with the engine
recommends appropriate work tools for our machines stopped, clear the area around the equipment of all
to maximize the value our customers receive from personnel. The procedure to use will vary with the
our products. Caterpillar (Qingzhou) Ltd. understands type of equipment to be lowered. Remember
that customers may use work tools that exceed our that most systems use high-pressure fluid or air to
specifications under special circumstances. In these raise or lower the equipment. The procedure will
cases, customers must be aware that such choices cause high-pressure air, hydraulic oil, or some other
can reduce the machine performance and can affect media to be released in order to lower the equipment.
their warranty claims when they detect premature Wear appropriate protective clothing.
f ailures on the machine.
Make sure to use work tools and work tool control Sound Information and
systems that are compatible with SEM machine for Vibration Information
saf e machine operation and/or reliable machine
operation. Consult your SEM dealer with any The sound values indicated below are f or specific
questions that concern the compatibility of a operating conditions only. Machine and operator
particular work tool with your machine. Make sure sound levels
E that all protective guards are secured in place on the
E will vary with the speed of engine and/or
cooling fan. The cab was properly installed and
C machine and on the work tools. maintained.C The test was conducted with the cab
doors and the cab windows closed. Hearing
_ Secure all windows and doors of the machine in the
shut position. A polycarbonate guard needs to be protection may_ be needed when the machine is
operated with a cab that is not properly maintained,
c installed when the machine is not or when the doorscand windows are open for
equipped with windows and when a work tool that
r
creates f lying objects is used. extended periods or in
r a noisy environment.
Do4not exceed the maximum operating weight as The operator equivalent sound pressure level is less
4
than 77 dB (A) when ISO6396:2008 is used to
specified.
6 measure the value f or the 6
earthmoving
If your machine is equipped with an extendable stick, equipment with a cab.
install the0driver pin when you are using the 0
f ollowing work tools: hydraulic hammer, auger, and The exterior sound pressure level is less than 111 dB
compactor. jAlways wear the goggles. Always wear
(A) when ISO6395:2008 is usedjto measure the
value f or the earthmoving equipment.
the protective equipment that is recommended in the
operation manualp for the work tool. Wear other p
protective equipment that is required for working
Cab
condition. Any modifications to the inside of the operator station
To avoid injury caused by flying objects, ensure that should not project into the operator space or into the
all personnel are out of the work area. space for the companion seat (if equipped). The
def ined operator and companion seat space (if
While you are performing any maintenance, testing, equipped) will be maintained. if the addition of a radio,
or adjustments to the work tool, stay clear of the f ire extinguisher, and other equipment must be
f ollowing areas: cutting edges, pinching surfaces, installed. Any item that is brought into the cab should
and crushing surfaces. not project into the defined operator space or the
Never use the work tool as a work platform. space for the companion seat (if equipped). Loose
items must be secured. Objects must not pose an
impact hazard in rough terrain or in the event of a
rollover. The design of ROPS/FOPS meets ISO
3471-2008 and ISO 3449-2005 standards.

25
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4
Product Information 4
6 6
General 0 Information 0
j
The main mechanisms on SEM656D machine are
equipped with the following features and advanced
j
technologies:p p
• It uses the engine that meets CEV-Stage IV
of f-road emission regulation requirements and has
been optimized to match the conventional system
more reasonably for a higher efficiency.
• An articulated frame is used to achieve a small
turning radius, mobility and flexibility. Easy to work
in close quarters.
• The hydraulic mechanical transmission can
automatically change the speed continuously
according to the external resistance, making full
use of the engine power, improving the mobility of
the whole machine, simplifying the operation of the
loader, while protecting the engine and driveline
components.
• Featured with load-sensing full hydraulic steering,
E and a combination of working and steering for E
better energy-saving. Optimized fixed-shaft
C power-shift transmission, and reliable work C
hydraulic control of work tool make the operation of
_ the machine easy and flexible, the movement _
stable and reliable.
c c
• Equipped with service braking system, emergency
rand parking braking system to provide safe and r
reliable
4 braking performance. 4
6 6
0 0
j j
p p

26
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4
Component Names of the Machine 4
6 6
0 0
j j
p p

E E
C C
_ 1. Rocker Arm 5. Engine Hood
_9. Boom
c 2. Bucket Cylinder
3. Cab
6. Rear Wheels
7. Ladder
cBucket
10.

r
4. Engine 8. Front Wheels r
4 4
6 6
0 0
j j
p p

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4 Engine
Diesel Cab 4
6
This machine is equipped with six-cylinder, The standard cab is a fresh 6air f eatured cab. The cab
f our-stroke, water-cooled, turbocharged, inter-cooled is equipped with vibration reducing system and can
0 engine provides the good cold start
engine. This 0 noise levels inside
greatly reduce the vibration and
perf ormance, low fuel consumption, low noise, the cab and improve the comfort of the cab and the
j
reduced pollution emissions, high reliability and operator's work efficiency through j modal analysis
durability. and test verification. In order to give the operator a
p p
good view when operating the machine, our
Hydraulic System designers equip the machine with glass windows and
The hydraulic system is composed of working doors that are optimized in design.
hydraulics, steering hydraulics and drive hydraulics. Sheets
The work hydraulic system and steering hydraulic
Sheet metal components include engine hood,
system use a dual pump converging technology
lubricating oil tank, diesel tank, handrail etc.
in which the steering takes priority.
Driveline Electrical System
The electrical system on the machine is powered by
The drive system includes torque converter, drive
two 12V batteries in series, rated voltage is 24V. It
shaf t, transmission and drive axle.
contains power supply system, starting system,
The transmission is a fixed shaft type, with four control system, lighting system, instrument and
f orward gears and four reverse gears. indicator system, etc. Each control switch controls
individual appliance.
The drive axle adopts first stage gear reducer and
f irst stage planetary gear reducer. Machine Product Dataplate
Cooling System Product dataplate contains model number, engine
E number,Emonth and year of manufacture, machine
Radiator includes engine coolant radiator, hydraulic operating mass and product identification number,
C oil radiator, drive oil radiator and intake air etc. C
af tercooled radiator.
_ _
Ensure an optimized heat balance between water
c and oil temperature and an optimized working c
temperature for each component and maintain the
f rluid quality within the lifecycle of the components. r
4 System
Brake 4
6 system consists of the service brake and
The braking 6
parking brake. The service braking system is a
0 caliper disc type. When the brake
double-circuit 0
pedal is depressed,
j the compressed air from the air j
cylinder enters the air booster pump through the
braking valve,pand the braking oil enters the brake to p
stop the machine; The parking brake is a drum type
brake, installed on the transmission output shaft
f lange. The parking brake is engaged by operating
the parking brake button.

28
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4
Usage and Main Technical 4
6
Parameters 6
Usage 0 0
This loader jis a large construction machine mainly j
used f or handling of bulk material. Mainly used for
p bulldozing, loading and dumping,
digging, leveling, p
and towing operations.
Working Environment Requirements
1. Altitude: ≤3000m
2. Ambient temperature: Standard configuration －
15°C ～ 43°C (non-high temperature cooler
or without cold startup heating device)
3. Fording depth: ≤ 650mm
This loader is a general construction machine and is
not applicable to flammable, explosive, high dust or
toxic gas environment.
Restricted Operation
1. Used with overload.
2. Lif t heavy objects with lifting sling hanging directly
E on the bucket tip. E
C 3. Lif t the bucket and excavate above the machine. C
_ Notice _
c The precautions regarding the operation, c
maintenance and safety regulations provided in
r manual are only applicable to the machine
this r
used for specified purposes. Caterpillar
4
(Qingzhou) Ltd. will not take any safety liabilities 4
if the user uses this machine outside the scope of
6
use specified in this manual. The use will take the
6
0
safety liabilities in such operations. Under no 0
circumstances, the operations forbidden in this
manual shallj be taken. j
p p

29
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4 Specifications
Main 4
6 Technical Specification of SEM656D Wheel Loader 6
Main Parameters
0 0
Rated Load kg 5000
Operating Weightj kg j 17161

p
Standard bucket Capacity m3 p 3.0
Full load bucket Capacity (110% fill factor) m3 3.30
Maximum Gradeability 29
Dimensions (the dimensions are for standard configuration, and refer to the machine dataplate for detailed
information)
Machine Length mm 8279
Bucket Width mm 2963
Machine Height mm 3463

Operational Parameters (for standard configuration)

Maximum Breakout Force kN 178
Maximum Dumping Height mm 3111
Dump Reach mm 1369
Maximum Height of B Pin mm 4162
Minimum Turning Radius (over tire) mm 6238
Minimum Turning Radius (over bucket) mm 6886
E Digging depth E
mm 33
Overall Dimensions
C Wheelbase mm
C 2250
_ Overall Height (Maximum lift of bucket with no load) mm _ 5608

c Overall Height Engine Hood mm c 2467

Minimum Ground Clearance mm 468
r r
4
Engine 4
Emission CEV-Stage IV
6
Diesel Ratings kw
6 170
0
Rated diesel engine speed r/min 0 1950
Bore x Stroke
j mm
j 108×136
Displacement L 7.47
p
Maximum Diesel Engine Torque @ rpm Nm/rpm p
1128/1400
Diesel Engine Fan Diameter (blower) mm 812
Operating Speed
Forward gear I speed km/h 7.6
Forward gear II speed km/h 14
Forward gear III speed km/h 22
Forward gear IV speed km/h 37
Reverse I speed km/h 7.6
Reverse II speed km/h 14
Forward gear III speed km/h 22
Forward gear IV speed km/h 37
Implement Hydraulic System
Implement pump model Gear pump

30
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4 Technical Specification of SEM656D Wheel Loader4
Sum of three implement actions s 9.3±0.5
6 6
Brake System
0
Service brake type 0 Caliper-disc
j
Parking brake type j Drum
Steering System
p
Steering Hydraulic System type
p
Co-axial flow-amplified steering
Variable Displacement Piston
Steering Pump Type
Pumps
Steering Angle 38
Drive Axle
Main Drive Type Single stage spiral deceleration
Hub Reducer Type Single stage planetary reducer
Gear Ratio 23.64
Main drive reduction ratio 4.2
Hub Reduction Ratio 5.6
Tire Pressure Mpa F:0.45 R:0.3
Fuel Refill Capacity L 264
Coolant L 48
DEF L 30
Electrical System Voltage v 24
Battery model 6-QW-120B
E Diesel engine starting type
E Electric Start
C Working medium of air conditioning system C R134a

_ Heating capacity of air conditioning system kilowatt _ 5

Cooling capacity of air conditioning system kilowatt 4.5
c c
r r
4 4
6 6
0 0
j j
p p

31
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4
Operation Section 4
6 6
0 0
j j
p p

E E
C Notice C
_ Before operating this machine, please read _
c carefully and understand the content of this
manual so that you can operate the machine c
correctly.
r Correct operation is critical to ensure r
safety, achieve high work efficiency, and increase
the4service life of the machine. 4
6 6
0 0
j j
p p

32
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4 • 4 all of the coolant levels,
Check all of the oil levels,
Before Operation and all of the fuel levels.
6 and Dismounting
Mounting •
6
Remove any trash buildup and debris. Make all
0 necessary repairs before0
you operate the
machine.
j j
• Ensure that all covers and guards are securely
p attached. p
• Adjust the mirrors for the correct rear view of the
machine.
• Lubricate the work tools daily.
Locked Steering Frame
Mount and dismount the machine only at locations
that have steps and/or handholds. Before you mount
the machine, clean the steps and the handholds. One never stands here when the machine turns.
Inspect the steps and handholds. Make all necessary Serious injury or death could occur due to
repairs. crushing.
Face the machine whenever you get on the machine
and whenever you get off the machine.
Maintain a three-point contact with the steps and with
the handholds. UNLOCKED

Note: Three-point contact can be 2 feet and 1 hand.

E Three-point contact can also be 1 foot and 2 hands. E
LOCKED
C Do not mount a moving machine. Never dismount a C
moving machine. Never jump off the machine. Do not
_ carry tools or supplies when mounting or dismounting _
c the machine. Use a hand line to pull equipment onto
the platform. Do not use any controls as
c
r
handholds when you enter and exit the operator Lock out the steeringrframe lock between front and
compartment. rear f rames before lifting and transporting machine.
4 The steering frame lock4also needs to be
Daily Check engaged when servicing machine in articulation area.
6 6
For a maximum service life of the machine, complete Disengage the steering frame lock before you
0 walk-around inspection before you mount
a thorough operate the machine. Move the0 steering f rame lock to
the machine and before you start the engine. the unlocked position and install the pin.
j j
• Inspect the area around the machine and under
p Look for loose bolts, trash buildup,
the machine. p
oil, coolant leakage, broken parts, or worn parts.
Note: Pay close attention to leakage. If leaks are
observed, find the source of the leak and correct the
leak. If you suspect a leak or you observe a leak,
check the fluid levels more frequently.
• Inspect the condition of the equipment and of the
hydraulic components.
• Check the condition of the tires. Adjust the tire
inf lation pressure, if necessary.

33
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4
Control Devices and Monitoring System 4
6 of the In-Cab Control Devices and Monitoring System of SEM656D
Layout 6
0 0
j j
p p

E E
C C
_ _
c Symbol Name cFunction
r Coolant Temperature Warning
r
Engine coolant temperatures in the green area are normal and
4 Lamp those in the red4area are high.

6 6
0 Transmission Oil Temperature
Warning Lamp
Turns on when the transmission oil 0temperature is too high.

j j
p p
Multifunction Display Display work hours/DEF level/engine fault code

Steering Left Indicates the machine is turn ing left

Steering Right Indicates the machine is turning right

The indicator light illuminates when the engine is running to

Charging Indicator indicate that the alternator is not supplying power and the
engine needs to be stopped and checked immediately

34
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4 Symbol Name 4
Function

6 6
Illuminates when the oil pressure is above 0.78Mpa or below
Engine Oil Pressure Indicator
0 0.16Mpa 0
j j
p Drive Oil Pressure Warning
Indicator Light
p
A warning for oil pressure. Lamp illumination indicates
abnormal oil pressure

The indicator light flashes when damage to the component

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

Engine's Fault Indicator The light turns on when an engine fault occurs

Braking Air Pressure Indicator Alert when brake air pressure becomes low

Parking Brake Indicator Light The light turns on when parking brake is engaged

E E
C Low Beam Lights CLow beam lights are on
_ _
High Beam Lights High beam lights are on
c c
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4 Water in Oil Warning Light 4 needs to be drained
Indicates the primary filter

6 6
0 0
j Economy Mode j mode
The power switch is in economic

p p

Heavy Duty Mode The power switch is in heavy duty mode

"Driver alert system is not activated (OFF)", "Driver alert system

has been activated (solid)", "DEF level is low (flashing)", use
the yellow NCD light; "Primary driving performance limit
Driver Alert System Indicator activated (torque limit) ) (solid)", "Advanced driving
Light (NOx Control Diagnosis) performance limit activated (speed limit) (flashing)", use the red
NCD light.
When this light turns on, it indicates th at the machine
malfunction is related to emissions. The torque may be
OBD Indicator Light
limited when the light is on, and timely treatment and repair is
needed.

35
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4 Symbol Name Function4
6 6
The SCR system is malfunctioning, and the possible causes
include low DEF level, substandard DEF concentration,
0 Driver Alert Indicator Light
0
low DEF consumption, SCR system sensor and related circuit
fault lights. Timely repair required.
j j
p p

E 1. Steering wheel 4. Horn switch E 7. High/low speed control lever

2. Shift control lever 5. Pilot joystick 8. Start switch
C 3. Combination switch 6. Work on slope switch valve
C 9. Parking brake lever
_ _
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4 4
6 6
0 0
j j
p p

1. Front work lights 4. Front wiper switch 7. Rear washer switch

2. Rear work lights 5. Front washer switch 8. Warning light
3. Hazard light 6. Rear wiper switch

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4
Parking Brake Lever 4 the start switch key
3. ON - The f irst position
reaches when turned clockwise after it is inserted.
6 brake lever is located on the right control
The parking 6 system of the whole
In this position, the electrical
console. When the lever is pushed forward, the machine is powered on and functions normally.
0 is disengaged, releasing braking.
parking brake 0
When the lever is pulled backward, the parking brake 4. START - The second position the start switch key
is engaged,japplying braking. reaches when turned clockwise j after it is inserted.
Start the machine at this position. The starting
p also serves as the emergency
The parking brake motor is powered on and starts pthe engine.
brake. In case of emergency during the operation of Please release the starting switch key
the machine, pull up the parking brake lever to apply immediately after the engine is started
emergency brake. successfully. As this position can not be held
When the service brake is malfunctioning and the air automatically, the starting switch key will turn
pressure in the service brake circuit is below 0.4Mpa, back to the ON position of the starting switch after
the parking brake will automatically apply, to realize it is released.
emergency stop and ensure safe operation.
Notice
Start Switch Please make sure the negative switch is in the ON
The starting switch (also called electric lock) is position and the speed control lever is in the
located on the control console. The switch has four neutral position before starting the engine.
positions in clockwise order.

If the engine fails to start, the start switch must

be turned to the OFF position before restarting
the engine. Damage to the start switch can occur.
E E attempt must not be longer than 15
Each starting
C C at least 30 seconds between two
seconds. Wait
starting attempts, and the number of consecutive
_ _ must not exceed 3 times. After
starting attempts
three starting attempts, the starting motor and
c c
shut-down electromagnet should be allowed to
cool down completely before starting again.
r r
Otherwise the service life of the battery will be
4 shortened, and damage 4 to the starting motor and
1. Auxiliary - A position that the start switch key shut-down electromagnet can also occur.
6
reaches when turned counterclockwise after it is
6
When starting on a high slope, do not use the
0 This position is self-resetting (returning
inserted. 0 safety.
power cut-off function to ensure
to the OFF position automatically when
j
released). Accelerator Pedal j
2. OFF - When p the switch is in this position, the The accelerator pedal is located inpf ront of the driver's
power supply control circuit of the whole machine seat, on the right side. When the pedal is in its natural
is cut off, and only the roof light and horn still position, the engine will idle. When the accelerator
f unction normally. pedal is depressed, the fuel supply to the diesel
Notice engine is increased for a bigger power output of the
diesel engine.
The switch key can only be inserted or removed
in the OFF position.

37
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4 on Slope Switch Valve
Work 4 and bucket auto-leveling
use of the boom float device
device to effectively reduce the work load of
6 controlling the work tools. 6
0 0
j j
Whatever state the machine is in, make sure that
p p around, over
there is no obstacles or personnel
and below the machine, before operating the
boom and bucket, otherwise damage to the
equipment or personal injury can occur!!!

Horn Switch
It is located on the control console. During normal The horn switch is in the middle of the steering wheel.
operation, the switch valve button is in the ON Push the horn switch and the horn will sound. The
position, and the transmission power will be cut off combination switch can also function as a horn
during braking to avoid the slipping of the switch.
transmission clutch and increase the service life of
the transmission. During on-slope operation, the Shifting Control Lever
switch valve button is in the OFF position, and the
transmission power will not be cut off during braking The shif ting control lever is installed under the
to prevent the danger caused by sudden failure of the steering wheel. Moving the lever forward or backward,
service brake and ensure safe operation. in combination with the high/low speed control lever,
can operate the machine in the first, second, third
High/low Speed Control Lever and fourth forward gear, f irst, second, third and fourth
reverse gear, and neutral position respectively.
Push f orward to get high speed and pull backward to
E get low speed. The middle position is neutral. E Wheel
Steering
C Put the machine in idling state. Press the brake pedal, The machine C uses articulated coaxial flow
at the same time push the shift lever forward or amplification steering with the steering wheel
_ reverse with the lef t hand and push the high/low installed in the_cab. The steering wheel is
c speed lever with the right hand. If it is hard to engage
low/high speed gear, please repeatedly push the
connected with thec coaxial flow amplification
steering gear. During normal operation, turning
r t lever forward or reverse until the high or low
shif r
the steering wheel clockwise will cause the
gear is engaged. machine to turn right; and turning the
4 4
steering wheel counterclockwise will cause the
Pilot Joystick machine to turn left.
6
The pilot joystick is installed on the control console,
6
The coaxial flow amplification steering has the
to control0the work tool to carry out the work. Move f ollowing features: 0
the pilot joystick backward to raise the boom and
j the boom; move left to rollback the
f orward to lower 1. The angle the steering wheelj turns is not equal to
bucket and right to dump the bucket. The original the angle the machine turns. Turn the
position of thepjoystick is at the HOLD (Neutral) p increase the
steering wheel continuously will
position. turning angle of the machine until it reaches the
desired steering position.
Push the pilot joystick forward to the foremost
position to put the boom in the float state. Pull the 2. The f aster the turning speed of the steering wheel,
pilot joystick back to the middle position to remove the f aster the machine turns.
the boom float state. 3. The steering wheel will not restore to the original
When lowering the boom, the pilot joystick can be position automatically after it is turned and the
pushed to the float position, and the boom will drop machine will hold the turning angle.
under the action of gravity. At this time, the right hand Theref ore, when the steering of the machine is
of the operator can perform other operations (e.g. completed, the steering wheel should be turned
leveling the bucket) to increase work efficiency. in the opposite direction so that the machine can
drive in a straight direction.
During scraping or loading operation, push the pilot
joystick to the float position to allow the bucket to
f ollow the ground contours and avoid damage to the
ground surface. During loading operation, make full
38
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4
Combination Switch The negative switch is 4 different from the starting
switch. Turning off the negative switch will turn off the
6
The combination switch includes turn signals, 6 machine.
electrical system of the whole
position light, hi/lo beam lamps and horn. However, when the starting switch is turned off, the
0 0electrical system of
battery is still connected to the
the whole machine and some electrical components
j can still f unction.
j
p p
Brake Pedal
When the complete machine is shut down and
The service brake pedal is located in front of the during flushing of the machine, the negative
operator's seat on the left. When the service brake switch needs to be turned to the OFF position.
pedal is depressed, the frond and rear drive
axle wheel brakes will engage to brake. The braking Do not turn off the battery negative switch when
light switch will be turned on at the same time to the engine is still running. Otherwise, it will
illuminate the braking light. Release the service brake damage the electrical system of the complete
pedal will disengage the service brakes. machine!!!

In case of braking system malfunction, the repair Usage of Cat® Product Link
should be performed in a timely manner to ensure Communication Devices
enough braking capability of the machine.
Cat ® Product Link communication device
Battery Negative Switch uses cellular and satellite positioning technology
The battery negative switch is installed in battery to communicate the information to Caterpillar
case and can be seen once the battery case cover is (Qingzhou) Ltd. , Caterpillar (Qingzhou) Ltd. dealers,
opened. and Caterpillar (Qingzhou) Ltd. customers. The
E E may include: device serial numbers,
inf ormation
C device locations
C and work data, fault codes,
etc. which will be used to provide services to
_ _ the health of equipment, help
customers, detect
maintain equipment, and improve equipment
c ef f iciency. c
r r
4 4
For machines equipped with Cat® Product Link
6 6
device, if electric detonators are used in the
blasting operation, the radio frequency
0 0 electric detonators,
device will interfere with the
causing serious injury and death. The
j communication device
j shall be
OFF status of the negative switch:
p deactivated within the distances p mandated by
To cut off the power supply for the electrical system applicable national or regional regulations. In the
of the whole machine, it is necessary to turn the absence of regulatory requirements, Caterpillar
negative switch handle counterclockwise to the OFF (Qingzhou) Ltd. recommends that users to
position. conduct their own risk assessment to determine
the safe operating distance.
ON status of the negative switch:
Bef ore starting the machine, the negative switch
handle must be turned clockwise to the ON position.

39
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4 Lock Function of Cat® Product Link
Vehicle 4
Air Conditioning System Switch
Communication Devices
6
As shown in the figure: when this light flashes, it
The air conditioning system6 of the machine has three
functions, including cooling, heating and natural wind.
0 vehicle is locked out and cannot be
means your 0
Turn the air volume switch clockwise to increase the
started.
j air volume and counterclockwisej to reduce the air
volume. There are three air volume positions, i.e.
p p to the OFF
high, medium and low. Turn the switch
position to turn off the fan.
The selection switch has two positions, natural wind
(O position) and cooling (AC position).
The specific functions and operation instructions
are as follow:
Cooling:
1. Move the air volume switch to a suitable air
volume position after starting the engine.
2. Turn the selection switch clockwise to the cooling
position. The ref rigerating system will start
to work and cold air will flow out of the air outlet.
Heating:
1. Move the air volume switch to a suitable air
volume position after the engine has been started
The warning light flashes to indicate that your f or aE
period of time.
E vehicle has been locked out and the machine
cannot be started. In order to avoid possible 2. Turn the selection switch counterclockwise to the
C injury or death, do not try to start the machine or C position (O position). The heating
natural wind
_ move the machine. Alert and forbid anyone who system will _start to work and hot air will f low out of
tries to operate the machine, and immediately the air outlet continuously.
c contact SEM dealers. Failure to follow Notice: Open thec
hot water valve before turning
these warnings may result in product damage or
r
personal injury. Caterpillar (Qingzhou) Ltd. shall
on the heating. r
not be held responsible for such non-compliance. Natural wind:
4 4
The air conditioning system of the machine is
6 equipped with internal and6external circulation
devices. In cool seasons like spring and
Since our0 device uses satellite positioning and 0
autumn, when you only need the natural wind and
cellular technology for communication, our
j device may not work properly in
communication
use it to adjust the air f low in thej cab, turn the air
volume switch to a suitable position and turn the
areas or periods
p where or when there is no selection switch to the natural wind pposition.
communication signal, communication signal
is weak, communication signal is unstable, or is
susceptible to interference. Caterpillar (Qingzhou)
Ltd. does not bear any liability for problems
When the ambient temperature is below 0°C and
arising from this, including device not being able
the engine is not running, if antifreeze is not
to function properly and receive remote
added to the engine coolant, the engine water
commands (including shutdown or start
tank should be emptied, and the hot water valve
commands) or user notices, and the resulting
and electromagnetic water valve should be
personal injury or property damage.
opened to drain the coolant in the evaporator.
Otherwise the radiator plumbing can be frozen
and cracked due to the low temperature.

40
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4
Backup Automatic Alarm System Operator Seat4Adjustment
6 alarm is mounted on the rear sealing
The backup 6
The operator seat on this machine can be adjusted in
plate. When the steering and shifting lever is
operated0to reverse the machine, the backup terms of hardness and softness 0 (i.e. stiffness),
alarm will sound automatically. f orward and backward position, backrest angle and
j headrest height to accommodatej the needs of
dif ferent operators and different working situations.
p p
The backup alarm is close to the radiator. When
adjusting the sound volume of the backup alarm,
the engine must be shut down and protection
against high temperature must be used to avoid
burning.
Arm
Rest
Use of the Door Lock Safety
Seat Belt
If the door lock is engaged, the key cylinder can not Cushion Upper Slide
be pushed down. At this time, insert the key and turn Forward
and Back
180°in clockwise direction before removing the key. Adjustment
Handle
Hold the door lock with your hand, and push down Body Weight
the key cylinder with the thumb, and at the same time Adjustment
Handle
pull the door outward to open the door. To lock the
door, first close the door, then insert the key and turn
180°in the counterclockwise direction before
removing the key.

E Use of the Position Lock E Adjustment

1. Weight
C When open the door to the 90°position, the position C
Turn the adjustment handle according to the weight
lock on the door will contact and lock the buckle
of the user. Turn the handle clockwise to increase
_ outside the cab and fix the door to this position. Hold _
the weight adjustment scale and on the contrary,
the inside door handle with your hand with the thumb
c pushing down the key cylinder. Pull the door outward it will reduce, untilcyou feel comfortable. For weight
adjustment, refer to damper stiffness adjustment
at the same time to open the door.
r ref erence table. r
4 Body Weight 4
Adjustment
6 and windows must be closed when the
The doors Handle 6
driver is operating the machine to ensure safety.
0 0
Mirror Adjustment
j Body Weight
j
Reference Display Port
There is one mirror in the top of the cab, and one on
p
each of the left and right side of the cab. Before
p
operating the machine to perform any work, the
mirrors must be adjusted to ensure the driver has a
good rear view.
Loosen the bolts that connecting the rear view mirror
bracket with the cab, turn the bracket to adjust the
position of the mirror relative to the cab; Loosen the
bolts that connecting the rear view mirror with the
bracket, turn the mirror, to adjust the pitch of the rear
view mirror. Tighten the bolts after the adjustment is
complete.

41
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2. 4Height Adjustment 4
2. Backrest Angle Adjustment
While seated in the seat with the back rested against
6 height can be adjusted between three
The seat 6
the backrest, pull up the backrest adjustment
positions. When the seat is at its lowest position, it is
in position0 1. Lift the cushion with hand until a click is 0 forward or backward
handle with lef t hand, and lean
heard, and the seat is in position 2. Lift further up until until the backrest is in a comfortable position before
j and the seat is in position 3. Lift
a click is heard releasing the handle. j
f urther to the highest point (neutral position) and
p
release, the seat will return to position 1
p
automatically. Backrest Angle
Adjustment

Precautions
1. During the seat forward and backward
adjustment and the backrest angle adjustment,
the adjustment handle should be pulled into place
to make sure that the lockout teeth are
3. Armrest Adjustment disengaged completely before adjustment.
Turn the adjustment wheel below the armrest 2. Af ter the adjustment, the handle should be
clockwise to lower the armrest and counterclockwise returned to the original position to make sure that
to raise it. (Notice: The armrest is used to support the the lockout mechanism locks securely.
arms and must not be used to support other heavy
E objects, otherwise, breakage of the armrest can 3. WhenEthe weight adjustment scale reaches the
occur.) red warning line, it must not be adjusted further.
C C
_ Seat Belt_
c Seat Belt Adjustment
c for Non-retractable
Seat Belt
r Adjustment Wheel r
Adjust both ends of the seat belt. The seat belt
4 4
should be snug but comfortable.

6 Lengthening Seat Belt 6

Mechanical Handle Seat Adjustment
Method0 0
1. Forwardj and backward Adjustment j
p and backward adjustment
Pull up the f orward p
handle with hand, move the seat back and forth.
Release the handle and the seat will lock to a desired
position automatically.

Forward and Back

Adjustment Handle

42
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1. 4Unf asten the seat belt. Fastening Seat Belt 4
6 6
0 0
j j
p p

2. Rotate the buckle (2) to remove the slack in outer Fasten seat belt catch (3) into buckle (2). Make sure
loop (1). This will free the lock bar. Retrieve the that the seat belt is placed low across the lap of the
seat belt from the buckle. operator.
3. Remove the slack in the outer belt loop by pulling Releasing Seat Belt
on the buckle.
4. Loosen the other half of the seat belt in the same
manner. If the seat belt can not be fastened
snugly with the buckle in the center, readjust the
seat belt.
Shortening Seat Belt

E E
C C release lever. This will release the seat
Pull up on the
belt.
_ _
Seat Belt Adjustment for Retractable
c Seat Belt c
r Fastening Seat Belt
r
1. Fasten
4 the seat belt. Pull out on the outer belt loop 4
in order to tighten the seat belt.
6
2. Adjust the other half of the seat belt in the same
6
manner. 0 0
3. If the seatj belt can not be fastened snugly with the j
buckle in the center, readjust the seat belt.
p p

Pull seat belt (4) out of the retractors in a continuous

motion.
Fasten seat belt catch (3) into buckle (2). Make sure
that the seat belt is placed low across the lap of the
operator.
The retractor will adjust the length of the belt and lock
it in place. The comfortable ride will allow the
operator to have a limited range of activities.

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4
Releasing Seat Belt 8. Check the bolts and4nuts of all components for
tightness.
6 6
Perform the following after eight hours of run-in
0 of the new machine: 0
j 1. Completely check the bolts and j nuts of all
components for tightness, especially the diesel
p p pipe bolts,
engine cylinder head bolts, exhaust
f ront and rear axle mounting bolts, rim nuts,
driving shaft connecting bolts, diesel engine
mounting bolts, transmission mounting bolts,
f ront and rear f rame articulation bolts etc. should
be checked completely once.
Push the release button on the buckle in order to
release the seat belt. The seat belt will automatically 2. Check the tension of the fan belt, engine belt and
retract into the retractor. air conditioning compressor belt.
3. Check the oil level of transmission oil, drive axle
Run-in of New Machine oil and diesel engine oil.
The run-in of new machine is of great importance for 4. Check the hydraulic system and braking system
increasing the service life of the machine, eliminating f or leak tightness.
potential failure trouble, and avoiding severe failures.
Af ter buying the machine, the user must perform the 5. Check all the control levers and acceleration
operation and maintenance of the machine according lever f or secure connection.
to the new machine run-in procedures specified in 6. Check the temperature and connection of
this manual before normal use of the machine. components in the electrical system, check the
Run-in Requirements of New Machine power supply of the alternator, and check the
E 1. The run-in period of the new machine is 10 hours.
E and turning signal lights etc. for normal
lamps
C operation.
C
2. Idle the machine f or 5 minutes after starting.
_ _ Notice
3. During the run-in period, each of the forward I, II,
c III, IV and reverse I, II, III, IV gears should be
used evenly for run in.
When checking the oil levels, the appropriate
c
operation specifications should be followed.
r The machine should start with low speed and
4. r after the run-in period is
Perform the following
4small throttle and accelerate gradually. Sudden
starting, accelerating, turning and braking should
over: 4
be6avoided unless in case of emergency. 1. Completely check the bolts and nuts of all
6
components for tightness, especially the diesel
5. During the run-in period, it is preferably to load
0
some loose material and the operation must not
engine cylinder head bolts, 0 exhaust pipe bolts,
f ront and rear axle mounting bolts, rim nuts,
j and too quick. During the run-in
be too hard driving shaft connecting bolts,j diesel engine
period, the loading weight must not exceed 70% mounting bolts, transmission mounting bolts,
pload and the traveling speed must not
of the rated p bolts etc. should
f ront and rear f rame articulation
exceed 70% of the rated maximum machine be checked completely once.
speed.
2. Check the tension of the fan belt, engine belt and
6. Pay attention to the lubrication of the machine. air conditioning compressor belt.
Replace or add lubricating oil or grease as per
the specified time interval. 3. Check the hydraulic system and braking system
f or leak tightness.
7. Frequent attentions must be paid to the
temperatures of the transmission, torque 4. Inspect or change the transmission drive oil and
converter, front and rear axle, wheel hub, parking drive axle lubricating oil.
brake, central driveshaft, hydraulic oil, engine
coolant and engine lubricating oil. If overheating
is f ound, identify the cause promptly and repair
as necessary.

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5. 4Inspect or replace the filter elements of the 4
transmission oil filter, diesel engine oil filter and
6 f uel filter.
diesel Axle Case 6
6. Clean0the oil drain f ilter element of the hydraulic 0
oil tank.
j j
Notice
p
When changing the transmission oil, drive axle
p
lubricating oil and diesel engine oil, the
appropriate operation specifications should be Checks before starting the engine
followed. Perf orm the following checks every day before
starting the engine. Failure to perform these checks
Operating Precautions may lead to serious injury or damage.
• Check the area around the engine and battery for
Before starting the engine buildup of flammable material, check for fuel,
Job Site Safety lubricating oil and hydraulic oil for leaks, and check
the mirrors, handrails and steps for contamination
• Bef ore starting operation, check the area around by f uel.
the machine carefully for any abnormal conditions
that may cause danger. • Do not leave parts and tools around the operator
seat. Due to the vibration during traveling and
• Check the terrain and ground surf ace of the job site operating, these objects may fall down and cause
and determine the best and safest operation damage to the control levers or switches, or cause
method. the control levers to move to start the work
tools, which will result in accidents.
E • Bef ore starting operation, ensure the ground E
surf ace as solid and level as possible. If there is • Bef ore mounting the machine, remove the dirt and
C heavy dust at the job site, water should be sprayed Cattached to the shoes, as they will
f ine sands
bef ore starting operation. accumulate at the supporting points of the
_ _ and braking pedal, preventing
acceleration pedal
• If the work is to be completed on the street, there the pedals returning
c must be a special person to direct the traffic, or a c to the original positions. If
there is dirt and sand accumulation at these points,
rfprotect
ence should be set up with the "No Entry" sign to
the pedestrians and vehicles.
it should be removedr immediately.
4 sites with buried facilities underneath, such • Check the coolant level,
4 fuel level and the oil level
• For in the engine oil pan. Check the air filter for
6 pipe, gas pipe, high voltage cable pipe,
as water plugging and the wiring 6for damage.
the relevant authority should be contacted to locate
0 f acilities. And attentions should be paid
the buried • Adjust the operator seat to 0
a position where easy
not to damage these facilities during the operation. operation can be performed. Check the seat belt
j and the mounting hardware forj damage. The seat
• When working in water or passing sand bank, belt must be replaced after three years of use.
p condition, water depth and water
check the surface p
f low velocity first. The allowed fording depth must • Check all the instrumentation for normal operation.
not be exceeded. When working in puddle or Check if the control levers are in the correct
swamp site, the water depth must not exceed the position.
bottom of the axle housing. Clean and check the
lubrication check points after the operation is • Remove all the dirt on the window glass and lights
complete. to ensure good visibility.
• Adjust the position of the mirrors so that best views
can be achieved from the operator seat. Clean the
surf ace of the mirrors. Replace the glass of the
mirror with new one if damaged.

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• Check
4 the headlights and working lights for proper • The engine should run
4 at idle speed to warm-up
illumination. Repair if any abnormal results are af ter starting (at least 5 minutes recommended).
6
f ound. 6
• Listen to check if the engine operates
0
• A f ire extinguisher must be available and its use 0 low speed, and check
properly while it is running at
method must be mastered. the transmission of abnormal noise.
j j
• Do not place the machine close to open fire. • Check all the instrumentation for proper operation,
p p
and check the lighting devices, indicators,
During Engine Starting horn, wipers, braking lights for proper operation.
• Bef ore mounting the machine, perform Notice
another walk-around inspection of your machine
and check for any personnel or objects on, below or Special attention should be paid to the
near the machine. Check if there is any person in instrument panel for engine malfunction indicator
the working area. lamps.

• If a "Do Not Operate" warning message is attached

to the control lever, the engine must not be started. • In f reezing seasons, preheating of the hydraulic oil
should be performed. Pull back the work valve
• Sound the horn when starting the engine to give an bucket control lever and hold it in position for 4-5
alert. minutes. Meantime increase the throttle to keep the
• The engine can only be started and operated with stop block of the bucket against the boom and
the operator sitting in the operator seat. make the hydraulic oil overflow, which will increase
the hydraulic oil temperature rapidly.
• No person other than the operator should stay in
the cab. No one is allowed to sit on the machine • Check the service brake and parking brake system
body. f or proper operation.
E E
• The engine can only be started within the cab. • If there is no obstacles around the machine, turn
C Never start the engine by short-circuit the starting
C wheel slowly to see if the machine
the steering
turns accordingly.
_ motor, which will lead to damage to the electrical _
system of the machine by starting the system with After Starting the Engine
c bypass circuit. In addition, this operation is very c
dangerous. Checks after starting the engine
r r
• Make sure the backup alarm, if equipped, functions Failure to perform the appropriate checks after
4
properly. starting the engine will 4
delay the discovery of the
abnormal phenomena. And this can result in serious
6 Notice injury or machine damage.
6
0 attempt should not be longer than 15
One starting When conducting the checks,0it should be performed
seconds (the continuous time of starting motor in an open area without obstacles. No one should get
should notj exceed 15 seconds). If the starter close to the machine.
j
does not start
p at that time, the starting switch p
should be released immediately. Wait at least 30 • Check the operation of the instrumentation and
seconds before attempt to start again. This is equipment. Check the operation of the bucket,
jointly determined by the features of the starting boom, braking system, driving system and steering
motor and the battery. If the engine fails to start system.
after three consecutive attempts, it should be
checked. After the malfunction is corrected, and • Check the machine for unusual noise, vibration,
at least three minutes later, the engine can be heating, smell or instrumentation operation. Check
started again. f or hydraulic oil, lubricating oil, air or fuel leaks.

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• If4any abnormality is found, repair immediately. If 4
the machine is operated under unsuitable • Do not operate the work control joystick of the work
6
conditions, serious injury or machine damage may 6 work control lever of
tool during traveling. If the
occur. the work tool must be operated, the machine
0 should be stopped before the 0 operation.
• Bef ore traveling or starting operation, the lockout
j be locked in the UNLOCK position
lever should j suddenly. If
• Do not operate the steering wheel
securely. p p the ground
doing so, the work tool may touch
surf ace and the machine may lose balance, or
When starting traveling damage to the machines or structures around may
• Before starting traveling, check around the machine occur.
again to make sure there is no personnel and • When traveling on the uneven surface, keep the
obstacles. speed low and avoid sudden steering.
• When starting traveling, sound the horn to give an • Try to avoid driving over obstacles. If it is necessary
alert.
f or the machine to drive over an obstacle, try to
• The machine can only be operated with the keep the bucket close to the ground surface.
operator sitting in the operator's seat. • A distance should be kept from other machines or
• Seat belt must be fastened. structures during traveling or operating to avoid
collision.
• No person other than the operator should stay in
the cab. No one is allowed to sit on the machine • If working in water, the allowed water depth must
body. not be exceeded. The water depth must not exceed
the bottom of the axle housing.
• Check the backup alarm, if equipped, for normal
operation. • When driving on bridges or structures on private
E Precautions during traveling
E first check the strength to see if it is
properties,
enough to support the weight of the machine.
C • The key in the starting switch must not be turned to
C on public roads, the rules of the
When driving
appropriate authorities must be met, and
_ the OFF position while the machine is traveling. It is _
appropriate regulations must be followed.
very dangerous if the engine is shut down during
c traveling, because the steering will be heavy. If the c be followed when driving on
• Traf f ic rules should
rengine dies, the brakes should be applied
immediately to stop the machine. r speed of the machine is
public roads. The driving
lower than the normal speed of automobiles. Drive
4 operating, it is dangerous to look left and
• When 4 to leave the center of the
on the side of the road
right, road to other vehicles.
6the operator must concentrate on the work 6
during operation. • If the machine runs at a high speed continuously fo r
0
• Driving too fast, sudden braking, sudden stopping,
0 will overheat, and the
a long period of time, the tires
internal pressure will become extremely high. This
j or zigzagging are all dangerous.
sharp turns
may lead to the blowout of thej tire. If the tire blows
• If any abnormality
p (noise, vibration, smell, incorrect p be
out, extreme destructive force will
display of instrumentation, air leak, oil leak etc.) is generated, which may result in severe injury or
f ound during the operation, the machine should be accident.
moved to a safe place and find the causes.
• If you plan to drive the machine continuously,
• Adjust the height of the working device to the please consult the authorized dealer of Caterpillar
position where the lowest point of the bucket is (Qingzhou) Ltd.
30-40cm above the ground, and travel on a flat
surf ace.

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4 when changing the direction
Checks • When traveling downhill,
4 never shift gears or put
To avoid injury or death, the following rules must be the transmission in the neutral position. Put the
6
f ollowed before moving the machine or the work tool,
6 gear before starting
transmission in the low speed
driving downhill.
0 machine is equipped with backup alarm
even if the 0
and mirrors: • Keep the speed low when driving downhill. If
j j to control the
necessary, use the braking pedal
• Sound the horn to alert the personnel on the site.
p
• Check around the machine. There should be no
driving speed. p
person. Check especially the area behind the • Do not drive at high speed on grassland, fallen
machine as it is not visible f rom the operator's seat. leaves or wet steel plate. If operating this way, even
a very small slope can cause the machine to slide
• Where there is a danger or the visibility is poor, one to one side, and the driving speed, therefore,
person should be specified to direct the traffic. should be kept low. When driving on a slope, drive
straight upward and downward.
• Persons without approval must not enter areas in
the turning direction or traveling direction. • When traveling on a slope, if the engine dies, the
braking pedal should be depressed fully
• The traveling direction must not be changed when immediately to apply the brake and the bucket
the machine is at high speed. should be lowered to the ground before applying
Forbidden operation the parking brake to secure the machine in position.

• The load of the machine must be kept within the • If the bucket is loaded when driving up or down a
specified maximum load to avoid fall-over of the slope, the bucket should always point to the uphill
machine and damage to the working device due to direction (i.e., facing front when going up, and
overloading. The specified capacity of the machine f acing back when going down). When driving on a
must not be exceeded during operation. slope with a loaded bucket, keep the bucket toward
E the downhill
E direction will cause the danger of
• Caterpillar (Qingzhou) Ltd. will not be responsible machine f all-over.
C f or any injury, accident or damage to the machine
Do not get C
close to high-voltage cables
resulting from overloading of the machine.
_ Traveling on slope • Do not allow _
the machine to touch the overhead
c • Traveling on slope may cause the machine to fall cables. Even justcgetting close to the cable can
cause electric shock. The safe distance as
rover or slide to one side. Be especially cautious. r table should be kept
specified in the following
between the machine and the cable.
• When
4 traveling on the slope, the lowest position of 4
the bucket should be kept 30-40cm over the Voltage V Minimum safe distance
surf6
ace ground. In case of emergency, lower the 100-200
6 2m 7ft
bucket to the ground quickly to help stop the Low Voltage
0
machine. 6600 0 2m 7ft

j 22000 j3m 10 ft

Error Right 66000 4m 14 ft

p p
154000 5m 17ft
High Voltage
187000 6m 20ft

275000 7m 23ft

500000 11 m 36ft

• Do not turn or travel transversely on a slope. Drive • To prevent accidents from occurring, please do the
the machine down to a level surface to complete f ollowing work well:
these operation.

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1. 4If there is a potential risk of the machine touching Wrong 4 Wrong
power cables on the working site, consult with the
6 company before starting the operation,
power 6
and check and determine the feasibility of the
0 according to the current relevant
operation
Wrong 0
Wrong

regulations.
j j
2. Wear rubber boots and rubber gloves. Place a
rubber padpon the operator's seat, and pay p
attention not to allow any exposed part of the • If the working device falls or stops suddenly, the
body contact the metal chassis. reacting force can cause the machine to fall over.
Especially when the machine is loaded, extreme
3. Specify a signalman who will give warning attention must be paid to the operation of the work
signals when the machine gets too close to the tool.
power cable.
4. If the work tool makes contact with the cable, the
• Do not use the bucket or boom for lifting purpose.
operator must not leave the cab. • The machine can only undertake specified work.
5. When working in the vicinity of high-voltage Other operation beyond the scope of use of the
cables, do not allow any person to get close to machine can damage the machine. See "Usage
the machine. and Main Technical Features and Parameters" for
specified work.
6. Consult the power company for the voltage of the
cable before starting operation. • Pay attention to the following aspects to ensure
good visibility:
Operating Precautions
1. When working in dark places, turn on the working
light and the headlights, and install lighting device
E Eworking site if necessary.
at the

C C in a foggy, hazy, snowy, heavy rainy

2. Do not work
day or other circumstances with poor visibility.
_ Wait until it _
is clear and bright and there is
enough visibility before starting the work.
c c
• Do not get too close to the edge of a cliff. During • Pay attention to the following to prevent
rdike-building or earth-filling, or dumping into a cliff, the working devicerfrom collide with other objects:
pile the earth into a dump, and push the dump
4
through another dump. 1. When working in the 4tunnel, under the bridge,
under the cable or in other places where the
• When6 pushing the earth down a cliff or to the top of 6 attention should be paid
height is limited, special
a slope, not to allow the bucket hit any objects.
0the load of the machine can become light
suddenly. In such cases, it can be dangerous as
0
2. When loading a dump truck, check to make sure
the drivingj speed will increase suddenly. Therefore, j machine. Pay
there is no person around the
the speed must be kept low. attention not to allow the bucket to touch the cab
p
• When the bucket is fully loaded, the machine must of the dump truck.
p
not start, turn or stop suddenly. 3. To avoid accidents resulting from collision with
• When moving unstable load, e.g. round or other objects, the machine should work at a
cylindrical object, layered sheet, raising the working speed of safe operation, especially in limited
device can cause the danger of the load falling on space, indoor or places with other vehicles.
the top of the cab, resulting in serious injury or
damage. When moving unstable load, pay attention
not to raise the work tool too high or tilt the bucket
backward too much.

49
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4 method of the brakes
Using • Piles of earth on the ground
4 and near the trench
are soft and loose. It can collapse due to the weight
• Do not
6 put your foot on the braking pedal unless 6 causing the machine to
or vibration of the machine,
really necessary.
f all over.
0
• Do not depress the pedal repeatedly unless really
0
• If there is a danger of falling stone at the working
j
necessary. j structure (FOPS)
site, the f alling object protective
• When driving
p downhill, use the engine as a brake should be installed. p
and never shif t gears or put the transmission in the • If there is a danger of falling stone or rollover at
neutral position.
the working site, the rollover protective structure
Use caution in snowy days (ROPS) should be installed and the seat belt
should be fastened.
• When working on roads with snow or ice, even a
small slope can cause the machine to slide away.
Theref ore, the speed must be kept low and sudden
Storage of the Machine
start, stop or turn must be avoided. There will be a • Park the machine on a level surface and lower
danger of slippery, especially when going up or the working device to the ground. The location
down a slope. should be free of falling stone or landslip. If in
• On f rozen roads, the ground surface will become low-lying area, there also should be free of the
sof t as the temperature rises and the traveling danger of flood.
conditions will become unstable. Under such • If it is necessary to park the machine on a slope,
circumstances, special cautions must be used chock the wheels to prevent the machine from
during driving. moving. Then lower the work tool to the ground.
• The road shoulder and roadside items will be • When parking on the roads, a fence, signal, flag
covered and become unclear after heavy snow. or warning
E Theref ore the snow must be cleaned carefully. E light should be set up and other
necessary signals should be placed to make sure
C • When driving on snow-covered roads, antiskid tire C can be clearly seen by the passing
the machine
vehicles. In addition, the machine, fence, or flag
_ chain should be used. _ the traffic.
must not hamper
c • When driving on snow-covered slopes, never apply
the brake suddenly. To decelerate, depress the
c machine, lower the bucket
• When leaving the
completely to the ground, and lock the control
rbraking pedal intermittently for several times. If r device to hold it in the
levers with the locking
necessary, lower the bucket onto the ground to
4 the machine.
stop braking position. Lock4all equipment with the key.
Remove the key and take it with you.
• The 6 traction of the ground varies greatly with the 6
Perform the following required operation if the
inf luence of the snow. Therefore, the load needs to machine needs to be stored0for a long period:
0 accordingly to avoid skidding of the
be adjusted
machine during traveling.
j 1. Before Storage j
Do not work on soft and loose ground
p • Clean each part of the vehicle and
p dry in the air.
• Do not operate the machine on soft and loose Store the machine in a dry warehouse. If the
ground. As the machine tends to get stuck on such machine can only be stored outdoors, it should be
ground and it can be difficult to get out. parked on a concrete surf ace that drains easily and
covered by canvas.
• Do not let the machine get too close to the edge of
a clif f, or the suspended part and deep trench. If • Bef ore storage, fill up the fuel tank, grease each
these places collapse due to the weight or vibration moving pin shafts and drive shafts, and change the
of the machine, the machine can drop or fall over, hydraulic oil.
resulting in serious injury or death. Remember, the • Move the joystick to the NEUTRAL position.
ground will become soft after heavy rain, explosion
or earthquake.

50
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• Pull
4 the park brake button to apply the park brake. 4
Precautions for cold areas

• Level
6 the bucket on the ground and put the work • Af ter completion of the work,
6 remove all the water,
valve control lever in the neutral position. snow or sludge attached to the wiring, wire
0 0 as well as the
connectors, switches or sensors
• Put all switches in neutral or OFF position. Lock all covering panel of these parts. If these are not
doors. j removed, the water containedjin them will freeze
and cause the machine to fail during the next usage
• Apply a thinpfilm of grease on the exposed part of p
and may result in unexpected malfunctions.
the hydraulic oil cylinders.
Remove the frozen clot of the working device and
• Remove the battery from the vehicle and store driving system before starting.
separately.
• Warm up completely. If the machine is not warmed
• If the ambient temperature may decrease below up completely before operating the control levers,
0C, add coolant in the engine and make sure the the response of the machine can be slow, which
coolant reaches the engine body and the can lead to unexpected accidents.
evaporator of the air conditioning system. Or drain
the cooling system completely. Also drain the air
conditioning system.
• Secure the f ront and rear vehicle frames with the
f rame lockout lever.
2. During storage
• Start the machine once every month. Run each
system and maintain each lube points, so that the
moving components get lubricated and the battery
E gets charged. E
C • Bef ore starting the vehicle, wipe off the grease on C
_ the piston rod of the hydraulic oil cylinders. Apply a Shipping_of the Machine
thin f ilm of grease again after the operation is
c complete. c route for overpass height, width
Investigate the travel
and the allowable load before shipping. The total
•rApply anti-rust oil to rust-prone areas. r etc. with the machine loaded
height, width and weight
4 Notice on a shipping vehicle must
4 not exceed the relevant
regulations. In case of over-height or over-width,
If anti-rust
6 oil is used indoors, open the doors please consult Caterpillar 6
(Qingzhou) Ltd. or its
and windows for ventilation to remove the toxic dealers f or solution.
gases. 0 0
To prevent the safety accident of the machine
j
3. After Storage j or other slippery
slipping in transit, remove ice, snow,
material from the loading dock and f rom the truck bed
p
Perf orm the following operations when the long bef ore shipping. p
period storage of the machine is over:
Notice
• Change the engine, transmission and drive axle
lubricating oil, as well as hydraulic oil and Obey all local and national laws and regulations
antif reeze. that govern the height, width, length and weight
of a load while shipping.
• Grease all the moving pin shafts and drive shafts.
• Bef ore starting the vehicle, wipe off the grease on
the piston rod of the hydraulic oil cylinders.

51
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4 the following procedure in shipping:
Follow • If lif ting device is needed
4 during the loading and
1. Bef ore loading the machine, chock the unloading of the machine, please follow the lifting
6
trailer wheels or the truck wheels. diagram. 6
2. When0the machine is driven onto the trailer or 0
truck, steering
j operation is not allowed midway. If j
the steering operation is required, the machine
p to the level ground before the
should return p
steering operation can be performed.
3. Secure the f ront and rear vehicle frames with the
f rame lockout lever after the machine is parked.
4. Level the bucket on the transport vehicle and put
the speed control lever to the neutral position.

Notice
Incorrect lifting can cause the machine to drift,
resulting in personal injury and damage. Improper lifting or tie-down can allow the load to
move and cause personal injury or machine
5. During towing, all personnel should stay away damage. Install the steering frame locks before
f rom both sides of the tow rope to avoid injury lifting. Before lifting the machine, make sure the
caused by the breakage of the rope. lift arm is in the fully lowered position.

6. Typically, the tractor should be the same size of Check all of the laws that govern the load
the machine being towed. The tractor should characteristics (height, weight, width, and length).
have the suf ficient braking capacity, weight and
E power to control the uphill operation and traveling E instructions, refer to Shipping of
For shipping
Machine section in the Operation and Maintenance
C distance of both machines.
Manual. C
7. While the machine being towed is going downhill,
_ in order to obtain sufficient control and braking _
Lift the Machine.
c capacities, there should be a larger trailer or
another machine behind the machine being
Note: Do not usec
the handle or ladder to lift the
machine. Do not use the work tool as a lifting
r towed, to prevent the machine from rolling point. r
down when the control is lost.
4
8. If the direction of the machine being towed can be
4 that is listed is
Note: The shipping weight
the weight of the most commonly configured
6
controlled by the operator, the operator must machine. If attachments6 have been installed on
steer in the direction of the wire cable. your machine, the weight of your machine and
0 the center of gravity of your0machine may vary.
Shipping Considerations
j
Loading and Unloading Machine
j
• References: Ref er to Specifications section in
p the Operation and Maintenancep
Manual for
machine dimensions and weight information.
• The lif ting points are marked by hooks for easy
Improper lifting and tie-down can cause the load identification.
to move, causing personal injury or damage to
the machine. Only the correct rated wire • Lif ting points - When lifting the machine, the lifting
cables and slings can be used on the lifting and device must be attached to the lifting points.
fastening points provided.
Tie down the machine in the correct process
outlined in lifting and tying down the machine in
the Operation and Maintenance Manual. Refer to
Specifications section in the Operation and
Maintenance Manual for specific weight
information.

52
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• Use
4 properly rated cables and slings to lift the 4
References: Ref er to Specifications section in
machine. the Operation and Maintenance Manual for machine
6 6
dimensions and weight information.
• Remove the structure above the rear lifting points
0 to allow the slings to go through the
as needed, 0positions to tie
Note: Only use the specified
lif ting points. down the machine. Do not use any other
j j In order to tie
positions to tie down the machine.
• Place the hoist or lifting device to raise the machine down the machine, attach the tie-downs to the
p position.
in a horizontal p wire cables
tie-down points. Use correctly rated
and shackles to tie down the machine.
• The width of the spreader bar must be sufficient to
prevent the lifting cables or the lifting straps from Secure the machine at the tie-down points. The
contacting the machine. positions are identified on the machine by a label.

• No one is allowed to be around the machine. Use the f ront lifting eyes and the rear lifting eyes on
the f rame of the machine. Use corner protection as
1. Engage the parking brake before you sling the necessary. Avoid placing the wire cables on the tires.
machine and before you secure the machine with Avoid contacting with the work tools. Fasten all these
tie-downs. f our positions. Place wheel chocks before
2. Install the f rame lock pin prior to lifting the and behind the machine.
machine. Consult the local SEM dealer for shipping instructions
3. Attach 2 lifting cables to the rear of the machine. f or your machine.
There is one lif ting bracket on each side of the Note: The shipping weight that is listed is the weight
rear of the machine. of the most commonly configured machine. If
4. Attach 2 lifting cables to the front of the machine. attachments have been installed on your machine,
There is one lif ting bracket on each side of the the weight of your machine and the center of gravity
of your machine may vary.
E f ront of the machine. E
5. Connect 4 lifting cables to the spreader bars. The References: Ref er to Specifications in the Operation
C spreader bars must be centered over the
C Manual for machine dimensions
and Maintenance
and weight.
_ machine. _
6. If equipped, secure any attachments. Note: Only use the specified positions to tie down the
c c any other positions to tie down
machine. Do not use
7. Lif t the machine. Move the machine to the the machine. In order to tie down the machine, attach
r desired position. r
the tie-downs to the tie-down points. Use correctly
8. 4When the machine is positioned, place the blocks rated wire cables and shackles
4 to tie down the
behind the tires. machine.
6 6
Secure the machine at the tie-down points. The
Tying0Down the Machine positions are identified on the0machine by a label.
Note: Do not use a handle or ladder to tie Shipment
j
down the machine. Do not use the work tool to tie
j
p
down the machine. Do not wrap the chain around • If the machine is transported with
pa tractor, obey
the rear axle to tie down the machine. Avoid the national and local regulations on the weight,
using the front axle as a tie-down point if height, width and length of heavy objects. Also
possible. obey all related traffic regulations.
There can be multiple ways to tie down the • Consider the weight, height, width and length of the
machine. Determine the best method according to machine when determining the shipping route.
the local regulations. Comply with all local and
regional government regulations. • When driving on bridges or structures on private
properties, first check the strength to see if it is
Note: The shipping weight that is listed is enough to support the weight of the machine.
the weight of the most commonly configured When traveling on the public road, always meet
machine. If attachments have been installed on and f ollow the related regulations of the local
your machine, the weight of your machine and authority.
the center of gravity of your machine may vary.

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• The
4 machine may be separated into several parts • If the battery electrolyte
4 is f rozen, do not charge the
during shipping. For this reason, when shipping this battery or use other power supply to start the
6 contact the designated dealers of
machine, 6 because it can set the
engine. This is dangerous,
Caterpillar (Qingzhou) Ltd. to perform these works. battery on fire. When charging the battery or using
0 other power supply to start 0
the engine, melt the
Batteryj Use and Maintenance j leaks before
battery electrolyte and check for
starting the engine.
Considerations
p p
• Remove the battery from the machine before
Precautions charging.
The machine uses maintenance free Start with Booster Cable
batteries, without the need to add electrolyte.
If there is anything wrong with the connection of
• Battery electrolyte contains sulfuric acid and the booster cable, a fire can result. Therefore, the
battery can generate hydrogen. Therefore, f ollowing method must be taken.
improper handling of the batteries can lead to
heavy injury or fire. For this reason, the following • The starting operation requires two technicians to
considerations must be followed. Never put a complete (one sitting on the operator chair).
lighted cigarette or flame near the battery. • Those two machines are not allowed to make
• If the work requires making contact with the battery, contact with each other when starting the other
always wear saf ety glasses and rubber gloves. machine.

• If the electrolyte inside the battery splashes on the • When connecting the booster cable, turn OFF both
clothes or skin, flush with plenty of clean water the START switches of the functional machine and
immediately. malf unctioned machine.

E • Battery electrolyte splashing into the eyes can • When E

installing the booster cable, always connect
result in blindness. If the electrolyte splashes into the positive (+) cable first. When removing the
C the eyes, f lush with plenty of clean water and see a C always disconnect the ground wire
booster cable,
doctor immediately. or negative (-) cable first.
_ _
• Finally connect the ground wire to the engine
If drinking the electrolyte accidentally, drink plenty
c of water, milk, raw eggs or vegetable oil and see a cylinder block ofcthe malfunctioned machine. But,
doctor or call the emergency center immediately. this will cause spark, so keep away f rom the battery
r r connecting.
as f ar as possible during
• Shut down the engine before performing any work
4 to the engine.
related 4 cable, be careful not to
• When removing the booster
let the clips of the booster cable touch each other
6 accidental contact with metal objects (e.g.
• Avoid or touch the machine.
6
tools) which can result in a short circuit between
0
positive (+) terminal and negative (-) terminal of the Charging Battery 0
battery. j
Improper handling of the batteryjcan lead to battery
• When installing
p the battery, connect the positive (+) explosion when charging the battery. Therefore,
p
terminal f irst. When removing the battery, perf orm the charging in accordance with the battery
disconnect the negative (-) terminal (ground wire handling regulations and charging regulations in the
side) f irst. instructions, and obey the following considerations.

• When installing or removing the battery, • Charge the battery in a well-ventilated area with the
check which one is positive (+) terminal or negative top cover removed. This can spread the hydrogen
(-) terminal f irst and then tighten the nut securely. and prevent the explosion. Gases from a battery
can explode.
• Use a cloth when cleaning the top surface of the
battery. Never use gasoline, solvent or any other • There should not be flame or spark above the
organic solvent or detergent. Tighten the battery battery pack. Do not smoke during charging.
top cover securely.

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• Set
4 the voltage of the charger to match that of the • If the malf unctioned machine
4 is towed by another
battery being charged. If the voltage setting machine, the wire cable used must be capable of
6 the charger can overheat and burn, and
is wrong, 6malfunctioned machine.
carrying the weight of the
even explode.
0 0 have broken wire
• The wire cable used must not
strands, kinked or reduced diameter.
j j
• Do not stand on the wire cable.
p p
• While connecting to the machine to be towed,
never allow anybody to stand between the towing
machine and the towed machine.
• Keep the hook of the towed machine flush with the
trailing part and hold it in place.

• Connect the positive (+) clip to the positive (+) Machine Traveling Operation
terminal of the battery and negative (-) clip to
negative (-) terminal of the battery. Make sure to 1. Operate the work valve joystick to turn the bucket
tighten both the terminals tightly. to stop state and raise the boom to transport
position (i.e. the lowest point of the bucket is
E • If the charging rate of the battery is lower than 10%, aboutE30-40 cm above the ground).
perf orm high-speed charging and set the value
C below the battery rated capacity. If the charging C
current is excessive, electrolyte can leak or
_ evaporate, which can lead to burning or explosion.
_
c c
Trailing
r r
When Towing
4 2. Depress the service4brake pedal and meantime
If the disabled machine is towed in a wrong method,
press the park brake button
6 to release the park
or the6 selected wire cable is incorrect, injury or death
brake. Release the service brake pedal slowly
can result. Theref ore, the following considerations
must be 0
and see if the machine is0
moving.
obeyed.
j
• Operate according to the instructions on towing in j
this Operation
p and Maintenance Manual. p the service
If the machine is moving, depress
• Wear leather gloves while handling the wire cable. brake pedal immediately and pull the park brake
• While preparing for the towing with other button to apply the park brake. Then check if the
technicians, determine the signals to be used shift control system of the machine is
malfunctioned. If the machine is uphill, block
bef ore performing the work.
the wheels to prevent the machine from moving
• If the engine of the malfunctioned machine cannot before checking the machine.
start or the braking system is malfunctioned,
contact the designated dealers of Caterpillar
(Qingzhou) Ltd. for repair.
• It is dangerous to tow a machine on a slope, so do
it on a smooth surface. If this kind of place is
unavailable, choose a place with minimum grade.

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3. 4Push the variable speed control handle forward to 4
I position or push it backward to reverse
6 while depressing the accelerator pedal
position 6
Never steer at a slope. Drive the machine down to
suitably, in order that the machine can travel
0 or backward.
f orward
the smooth ground to perform0 these work.
4. Drive thej machine to an open and smooth site. If j
Machine Braking Operation
the steering performance check is not performed
during thepprevious operation due to narrow site, p
To apply braking, release the accelerator pedal first
turn the steering wheel at this point, to check if and then smoothly depress the service brake pedal.
the machine is able to counterrotate to the left or
right.
5. Check the performance of the service
While traveling at a higher speed, do not depress
brake. Drive the machine at forward shift position the brake pedal to the ground rapidly unless
1 or 2 in an open and smooth site. Release the there is emergency to avoid accidents and
accelerator pedal f irst and then smoothly depress
damage to the machine.
the service brake pedal. The machine should
decelerate obviously and stop. Parking the Machine
Notice 1. Drive the machine to a smooth area where there
If obvious deceleration can not be felt after the should be free of falling stones, landslide and
service brake pedal is depressed, pull the park f lood.
brake button immediately to apply emergency 2. Use the service brake to stop the machine.
brake. Meantime operate the work joystick to
lower the boom to the lowest point and turn over 3. Move the joystick to the NEUTRAL position.
the bucket forward to make the bucket teeth 4. Pull the park brake button to apply the park
E insert into or against the ground to force the E
brake.
machine to stop for safety.
C 5. OperateC the work joystick to lower the boom and
6. Check the engagement of each shift put the bucket evenly on the ground and then
_ position. Drive the machine to an open and _ down the bucket.
slightly push
c smooth site. Engage each shift position
individually to check the shift response of the
6. Let the enginec
idle for 5 minutes to allow the parts
to cool down evenly.
r machine. r
7. Turn the electric key counterclockwise to the OFF
Machine
4 Steering Operation position to stop the4engine. Cut off the power to
If turning the machine and remove the key.
6 the machine is required due to the curve
ahead, operate in accordance with the related local
6
8. Put each switch in neutral or "OFF" position.
0 and regulations.
traf f ic laws 0
9. Close the left and right doors and climb down the
Bef ore turning,
j push the turn light switch to the j
ladder according to the regulations.
appropriate direction (pushing left is to turn left,
pushing right pis to turn right) and meanwhile the turn 10. If the machine is going to be stored
p for a long
lights on the left or right side at the front and rear of period of time (for example, overnight), open the
the machine as well as the turn light on the right battery case cover to move the battery
dashboard will illuminate to alert the adjacent negative switch to OFF position.
vehicles and pedestrians that the machine is going to 11. If there is no coolant in the machine, immediately
turn. Then turn the steering wheel in the desired open all engine water drain valves and drain all
direction and the steering starts. coolant in the evaporators of cooling system and
To steer at a higher traveling speed, the accelerator air conditioning system after the machine stops
pedal must be released first and apply the service in winter climate.
brake as necessary to ensure traveling safety. 12. Lock all equipment and take the key with you.
Notice
Place the machine on the level ground. If parking
the machine on a slope is necessary, block
the wheels to prevent the machine from moving.

56
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4
Machine Operation 4
The operation before inserting into the material is the
same with common loading method. The operator
6
1. Preparation Before Operation pushes the bucket joystick6backward after the bucket
inserts into the pile and then push it back to the
0 the work, use this machine to level the
Bef ore doing 0 so that it can
neutral position to raise the bucket
site, including removing the protrusion, filling the insert f orward further. Then the operator pushes the
j
holes and removing the wet and slippery ground
j
joystick left and then push it back to the neutral
p large and sharp stones from the
surf ace. Remove p so that the
position to rotate the bucket backward
site to avoid tire scratches. bucket can continue to insert forward. Repeat the
insert, raise, insert and rotation operations until the
If using this machine to load or unload the truck or
bucket is filled with material.
hopper, adjust the kickout height of the boom raise
kickout to allow the hopper of the loader to enter or • Exiting from the pile
exit f rom the truck or hopper safely and not to
damage the truck or hopper due to excessive Af ter the bucket is filled with material, the operator
unloading height. operates the bucket joystick to turn the bucket
backward until the bucket kickout touches the boom,
2. General Techniques and then move the bucket joystick to the neutral
position. Now maximum retract angle can be
• Common loading method obtained.
Common loading method is suitable for carrying Raise the boom to certain height to allow the bucket
loose materials. to avoid the pile when the machine is moving
While the loader is approaching the loose material in backward. The operator moves the joystick backward
f orward gear 2 with the center of bucket targeting the to reverse position with left hand to reverse the
pile, the operator holds the steering wheel with left machine while holding the steering wheel with right
hand and operate the work valve boom control hand.
E lever with right hand to lower the boom to 300 mm
above the ground.
E from the pile, the operator operates the
Af ter exiting
boom control lever to lower the bucket to the
C Do not lower the boom until the machine is about one
C the lowest point of the bucket is
position where
30-40cm above the ground.
_ meter away f rom the pile, and allow the bucket to _
touch the ground and shift from forward 2 to forward • Material Handling
c 1. c
Self -handling can be used in the following conditions:
r Notice r
1. The truck cannot be used due to soft and
4 the bucket touches the ground, avoid
When unleveled site. 4
excessive pressure from the bucket to
6 which will cause unnecessary restriction
ground 6 500 meters and it is
2. Handling distance is within
and teeth wear. Meantime, the front and rear not economic to use the truck.
0 be straightened, leaving no angle
frame should 0
During handling, keep the lowest point of the bucket
between the
j front and rear frame. j the ground) and
at transport position 30-40cm above
turn the bucket backward to stop position (bucket
Depress the accelerator
p pedal to insert the bucket psure the handling
kickout touches the boom) to make
into the pile completely. When the machine can not
operation is smooth and safe and not easily-spilling.
move f urther, the operator toggles the bucket joystick
lef t to rotate the bucket backward and then push the The machine speed during handling depends on the
joystick back to the neutral position. Then the handling distance and road condition. When the
machine will continue to insert into the pile. Repeat machine travels over a hole or a bump, release the
the insert and rotation operations until the bucket is accelerator pedal and slightly apply the service brake
f illed with material. as necessary to slow down the machine and reduce
the impact to the machine and the spilling when
• Combined loading method passing over the restrictions.
Combined loading method is suitable for loading hard
or sticky material.

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4 4
Notice
6 6 kickout should not
During dumping, the bucket
hit the boom excessively and the number of hit
0 0 not to damage the
should be limited in order
machine.
j j
Af ter dumping, the operator pushes the bucket
p p the bucket
joystick to the rearmost position until
kickout hits the boom and then move the bucket
joystick back to neutral position. Then the operator
moves the shift lever to reverse position and release
the brake pedal to move the machine away from the
Never handle material with the bucket raised to truck or hopper. When the machine is leaving the
higher position which can cause machine truck or hopper, the operator should drive the
rollover. machine caref ully and watch for the bucket
movement in order that the bucket will not touch the
truck or hopper edge. When the bucket completely
• Dump leaves the truck or hopper, the operator can lower the
1. Dump to the truck or hopper boom while driving to prepare for the next cycle.
When the loader f illed with material is 15 meters 2. Dump at low position
away f rom the truck or hopper, release the
accelerator pedal and slightly apply the service brake When handling material between sites, dumping at
low position can be possible which means
if necessary to slow down the machine so that the
dumping with the bucket close to the ground. In this
machine can approach the truck or hopper at low
case, rotate the bucket backward to the horizontal
speed. Meanwhile, the operator pushes the bucket
position before raising the boom. Otherwise, the
E joystick to the rearmost position and the joystick will
be caught up by the electromagnet. Now the operator
boom mayE not be raised due to the interference
of work tool linkage.
C can release his hand and the joystick will not bounce C
back to the neutral position. During this process, the • Pushing operation
_ operator should drive the machine carefully to _
Place the bucket against the ground horizontally and
c observe the process in which the bucket is
approaching the truck or hopper and the operator can
c at forward gear 1 and depress
variable speed joystick
the accelerator pedal to move the machine ahead. If
r the joystick back at any time to prevent the
move r
restrictions are f ound during bulldozing, slightly raise
bucket from touching the truck or hopper.
4
With the bucket over the truck or hopper, the operator
the boom to continue. The4 pilot valve boom control
lever should be operated between RAISE and
6 the brake pedal to slow down the machine.
depresses LOWER position instead of 6any RAISE or LOWER
Then move the bucket joystick forward to tilt the position, in order to ensure smooth bulldozing
0 and to pour the material into the truck
bucket forward operation. 0
and hopper. At this point, the drive should watch for
j
the bucket movement in order that the bucket will not • Blading operation j
touch the truck
p or hopper edge. If the material is too Raise the boom and rotate the bucketp forward until
sticky, push the bucket joystick back and forth the blade touches the ground and the angle between
repeatedly to allow the bucket kickout to hit the boom the blade and ground should be kept at about 40.
repeatedly to remove the material sticking to the
For hard surf ace road, put the bucket joystick at
bucket.
FLOAT position; for soft surf ace road, put it at neutral
If the body length of the truck is more than twice position. Move the shift lever to reverse position and
the width of the bucket, start dumping from the front depress the accelerator pedal to reverse the machine
of the body. and blade the ground with the blade.

• Towing Operation
A 20-ton f latbed trailer can be configured to tow the
machine. The method is as follows:

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1. 4Securely connect to the tow pin of the machine. This method needs less 4loading time which reduces
the duty cycle time efficiently.
2. Equipped with brake system of good
6
perf ormance.
6
0 bucket at transport position.
3. Put the 0
4. Moderatej action is required for start and stop and j
braking should be applied when going down a
slope. p p
Notice
When applying the brake, apply to the flatbed
trailer first and then the machine.

Operating method

Cold Weather Operation

Low Temperature Considerations
If the ambient temperature is too low, it is difficult for
the engine to start and the radiator may freeze.
Theref ore, the following precautions must be taken:
1. All parts use low-cohesive fuel, hydraulic oil and
lubricant, and add coolant to the water. For
specific oil type, see the Fluids Specification in
the Operation and Maintenance Manual.
E E
2. Precautions for Coolant Usage: Do not mix
C dif ferentCbrand and grades of coolant.
• V-shaped method
_ _ Notice
As illustrated, the loader faces the pile and the angle
c between the truck and the traveling direction of the The coolant mustc be away from the flame and
loader is 60 degrees. Stop moving when it is 12-15 smoking is forbidden when adding the coolant.
r
meters away f rom the pile and when the loader is
r
4 with material, reverse the loader to where there
f illed 4
is 12-15 meters away f rom the pile. Drive to the 3. Battery Use Considerations
6 steering and raising the bucket. After
truck while 6
• When the ambient temperature reduces, the
dumping the material, reverse to the original position
0
f or next loading. battery capacity reduces too.0 If the charging rate of
the battery is low, the electrolyte may freeze,
j j
theref ore try to maintain the charging rate at 100%
and keep it warm if possible so that the engine is
p easily to be started next day.
p
• In the extreme cold area, use batteries that can
overcome extreme cold.
Considerations After Daily Work
To prevent the silt, water or snow sticking to the
machine f rom affecting engine start the next day, the
• Vertical loading f ollowing measures must be taken:

The loader f aces the pile and travels in a straight line 1. Thoroughly remove the silt, water or snow
at reverse position. Then drive a truck between the sticking to the machine. Prevent the silt, water or
loader and pile. snow f rom entering the seals and freezing in
them which can damage the sealing capacity.

59
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2. 4Park the vehicle on a dry and hard surface. If this 4
is not possible, park the machine on a board.
6 a board can prevent the machine from
Using 6
f reezing on the ground and makes the start the
0 easier.
next day 0
j
3. At low temperature, battery capacity will reduce j
significantly as parking time grows. Cover the
battery orpmove it to a warmer place and install it p
back the next day.
After Cold Weather
When the weather gets warm, the following work
needs to be done:
1. All components change to use semi-cohesive fuel,
hydraulic oil and lubricant. For specific oil type,
see the Fluids Specification in the Operation and
Maintenance Manual.
2. If the permanent coolant is not used, completely
drain and clean the cooling system and
replace with new coolant.

E E
C C
_ _
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4 4
6 6
0 0
j j
p p

60
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4
Maintenance Section 4
6 6
0 0
j j
p p

E Notice E
During the use of this machine, maintain the
C machine according to the maintenance intervals C
_ and procedures specified in this manual. Good _
maintenance of the machine is very important to
c the extended machine service life and job safety. c
r r
4 4
6 6
0 0
j j
p p

61
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4
SEM656D Periodic 4
6
Maintenance 6
0
The maintenance intervals listed in this manual are
0
determined jby using the service hour meter or the j
calendar (day, month etc.). Caterpillar (Qingzhou) Ltd.
p should always be performed at
requires the service p
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
periodic maintenance points:PM1：250H; PM2:500H;
PM3:1000H; PM4:2000H.
During the maintenance, the daily routine
maintenance and first-time maintenance of the
corresponding parts should be strictly followed, and
then different periodic maintenance plans should be
executed according to the specific working hours.
Periodic maintenance is based on working hours or
perf orm the maintenance every year/2,000 working
hours. The appropriate periodic maintenance plans
E are: 250-PM1, 500-PM2, 750-PM1, 1000-PM3, E
1250-PM1, 1500-PM2, 1750-PM1, 2000-PM4.
C C
_ _
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4 4
6 6
0 0
j j
p p

62
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4
Replace immediately or daily 4
First 100 Service Hours
• Engine
6 Oil Level - Check • Gap between Brake Shoe
6 Lining and Brake Drum -
Check/Adjust
• Coolant0Level - Check 0
• Engine Oil Filter - Replace
• Hydraulic jOil Level - Check j
• Engine Oil - Replace
• Fuel level - Check
p p
• Transmission Hydraulic Drive Fluid- Replace
• Transmission Oil Level - Check
• Hydraulic Drive Cartridge - Replace
• DEF Tank Level - Check
• Drive Axle Lubrication Oil - Replace
• Brake Booster Oil Level - Check
• Hydraulic Oil Return Filter Element - Replace
• Water and Impurities in Fuel Prefilter - Drain
• Pilot Hydraulic Filter Element - Replace
• Water and Impurities in Fuel Tank - Drain
Every 250 Service Hours or Monthly
• Operation of Lighting and Instrumentation - Inspect
• Gap between Brake Shoe Lining and Brake Drum -
• Tire Pressure and Damage Condition - Inspect Check/Adjust
• Backup Alarm Operation - Inspect • Tightening Torque of Hub Retaining Bolts - Check
• Lubrication at Each Lubrication Points - Inspect/Fill • Battery Posts - Clean
• Shif t Control System -Check/Adjust • Battery Posts - Apply Vaseline
• Steering Wheel Retaining Bolts - Inspect/Tighten • EngineECylinder Head - Clean
E
• Abnormality or Leakage in Each System - Inspect • Radiator Set - Clean
C C
• Engine Fan Drive Belt - Check • Diesel Tank Filler Screen - Clean
_ _
• Drive Shaft Connection Bolt - Tighten • Hydraulic Oil Tank Filler Screen - Clean
c • Battery and Battery Cable - Inspect c
• Tightening Torque of Transmission and Engine
r
• Battery - Recover
r
Mounting Bolts - Check
4
• Engine Air Filter Element - Inspect/Clean/Replace
4 and mounting bolts of
• Check the loading welding
the work tool, frame, and track roller frame for
6
• Fuel System Filter Element - Inspect
6
cracks and looseness - Check
0 - Inspect
• Radiator • Front & Rear Drive Axle Oil0Level - Check
• Seat Beltsj - Inspect/Respect j
• Engine Intake System - Inspect
• Work Toolsp- Inspect/Respect p belt, air
• Tension and damage of engine fan
conditioning compressor belt - Check
• Fuses and Circuit Breakers -
Inspect/Replace/Reset • Service/Parking Brake Capacity - Test
• Wipers - Inspect/Replace
• Brake System - Check
Every 50 Service Hours
Air Conditioner Filter Element - Clean

63
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4 500 Service Hours or 3 Months
Every 4
• Engine
6 Oil and Oil Filter - Replace Every 2000 Service Hours
6 or 1 Year
• Fuel Filter
0 - Replace • Engine Vibration Damper - 0
Inspect

• Fuel Filterj- Replace • Friction Disc Wear of Service Brake

j System -
Check
• Fuel Pref ilter
p - Replace p
• Service Brake System Lines - Inspect/Replace
• Air Filter - Replace
• Steering System Flexibility - Inspect/Adjust
• Check the retaining bolts of frame articulation pin
f or looseness - Check/Tighten • Tightness of Hydraulic Cylinder and Hydraulic
System - Inspect
• Connection Bolts Securing Front and Rear Axles to
Frames - Check/Tighten • Alternator, Starter Motor - Inspect
• Screen inside Air Booster Pump Breather – Clean • Turbocharger - Inspect/Clean
• DEF Pump Filter Element - Replace • Hydraulic Oil Tank Filler Filter Element - Replace
• DEF Tank/Fill Filter/DEF Pump – Clean • Fuel Tank Filler Filter Element - Replace
• DEF Tank Sensor Suction Screen– Replace • Cooling System - Clean
• DEF Tank Inlet Filter-Clean • Hydraulic Oil - Change
• DEF Nozzle- Clean • Hydraulic Oil Tank - Clean
Every 1000 Service Hours or Half a Year • Hydraulic Oil Tank Suction Pipe – Inspect
E E
• Engine Valve Lash - Adjust Important Notice!
C C
Do not use maintenance parts that are not
• Tensioner Bearing and Fan Shaft Housing of
_ Engine - Inspect _
approved by Caterpillar (Qingzhou) Ltd. or
designated dealers of Caterpillar (Qingzhou) Ltd.
c • All Battery Mounting Bolts - Tighten c
The use of unauthorized maintenance parts may
create safety problems that are detrimental to the
•rBattery Top - Clean normal operation ofrthe machine and affect the
4 Tank - Clean
• Diesel
service life. 4
6
• Transmission and Torque Converter Breather - 6
Clean
0 0
• Transmission Hydraulic Drive Fluid- Replace
j j
• Air Dryer- Replace
p p
• Hydraulic Drive Cartridge - Replace
• Transmission Oil Suction Filter Element - Clean
• Hydraulic Oil Tank Drain Filter Element - Replace
• Pilot Hydraulic System Filter Element - Replace
• Drive Axle Lubrication Oil – Replace
• DEF Pump Filter Element - Replace
• DEF Tank/Fill Filter/DEF Pump – Clean
• DEF Sensor Filter– Clean
• DEF Tank Coolant Inlet Filter-Clean/ Replace

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4 4
Keep the work site clean and organized
Maintenance
6 Considerations 6
• Do not leave any service or maintenance tool
1 Before 0 Maintenance 0 wipe off any
around the work site. Thoroughly
Malfunction grease, oil and other items that can make people
j notice slip. Always keep the work sitejclean and organized
If the maintenance being performed is not specified in so that the job can be safely done.
the Operationpand Maintenance Manual, unexpected p
malf unctions can occur. • If the work site is not clean or organized, people
can trip, slip or tumble and get injured.
Contact the designated SEM dealers for repair.
Designate a responsible person when
• If another person starts the engine or operates the co-working with other people
lever while the operator is maintaining the machine
or adding oil, the operator can be severely injured • Designate a responsible person who will be
or killed. listened to by everybody while repairing the
machine or installing/removing the work tool.
• Post a warning label on the lever in the cab to alert
the other people that you are accessing the • Mutual misunderstanding can cause serious
machine. Post a warning label around the machine accidents when co-working with other people.
too, if necessary. Shut down the engine before accessing or
Access and Cleaning Before Maintenance maintaining the machine

• Clean the machine before access and maintenance. • Place the machine on a level ground where there
This can ensure that dirt will not enter the machine should be free of rock fall or landslide when
and maintenance job can be safely done. accessing or maintaining the machine. If the terrain
is low, there should be free of flood risk, either.
E • If the machine is still dirty when accessing and E the engine.
Shut off
maintaining, it can be difficult to locate the problem
C and dirt or silt can spill into the eyes, and people • Lower theC
work tool to the ground after the engine
can slip and get injured. turns off.
_ _
Operate the work tool lever to RAISE, Lower
c The following needs to be noticed when cleaning
the machine: c
• Pull the park brake switch to apply the brake and
r Wear anti-skid shoes to avoid slipping on a wet
1. put a wedge underrthe tire.
surf ace.
4 4 f rames with locking lever.
• Lock the front and rear
2. Wear protective clothes when flushing the
6 with high-pressure water. This can
machine • Take extreme care during6maintenance not to be hit
protect you from the impact from the or hooked by moving parts.
0
high-pressure water and prevent the dirt and silt
0
j into your eyes.
f rom spilling j
3. Do not spray water directly onto the electrical
p
system elements (e.g. sensor, wire connector).
p
If water enters the electrical system, it can be
f ailed.

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4 lighting. 4
6 • Move all flammable material
6 to a safe place before
grinding or welding on the flame.
0 UNLOCKED
0
• There must be a f ire extinguisher in the job
j
LOCKED
j
site where accessing or maintenance will be
perf ormed.
p p
2 When Performing Maintenance
WHO
Support Work Tool • Maintenance and service of the machine should
only be carried out by qualified technicians. Keep
• While raising the bucket to perform inspection and anyone not involved in the maintenance and
maintenance, support the boom with a bracket to
service away from the area. Designate a person to
prevent the work tool from falling.
attend the area if necessary.
• Place the lever at “NEUTRAL” position. • Pay particular attention when grinding, welding or
Suitable Tools using a sledgehammer.
Use only the tools suitable for the task. Using Attaching Parts
damaged, poor quality, failed or temporary tools can
cause personal injury. • Designate a responsible person before starting the
removal or installation of the accessory.
Lighting Use
• Do not allow anyone who is not involved in the job
• Use a lighting device with anti-explosion to stand near the machine or accessory.
f eature when checking the fuel, lubricating oil,
E battery electrolyte or window glass detergent. If not, • Put theEaccessory removed from the machine in a
saf e place and make sure it does not fall. Install
C explosion can occur. C
rails around the accessory with a "No Entry" mark
_ • If performing the job at a dark place without lighting, on the rail to _
prevent the unauthorized person from
people can get injured, therefore, proper lighting getting close.
c device should be installed. c
Working under the Machine
•rNever use a lighter or flame for lighting even in a r the hard and level ground.
dark place. It could cause a fire and when the • Park the machine at
4 exiting from the battery encounters a f ire,
gases 4 the ground before
Lower all work tools to
explosion could happen. perf orming maintenance or repair under the
6 machine. 6
• When using the machine for lighting supply, obey
0
the instructions in the Operation and Maintenance • Block the tires with wedges.0
Manual. j • If the machine is only supported
j by the work
Fire Prevention tools with the tires above the ground, it is very
p p
dangerous to work under the machine. Never work
Fuel or gases exiting from the battery could cause a under a poorly supported machine.
f ire during the maintenance, therefore the following
considerations must be obeyed while accessing or
maintaining.
• The f uel, lubricating oil and other flammable
materials must be stored away from the flame.
• Use nonf lammable material as part detergent. Do
not use diesel or gasoline which could cause a f ire.
• Do not smoke while accessing or maintaining.
Smoke at the designated place.
• Use a lighting device with anti-explosion
f eature when checking the fuel, lubricating oil,
battery electrolyte. Never use a lighter or flame for
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4
Performing Maintenance with Frame Raised 4
Maintenance During Engine Operation
• Bef ore
6 performing the job with work tool or frame Do not perform maintenance during engine operation
6
raised, lock the front and rear f rames with locking to avoid injury. If it is necessary to perform
0 the lever at “NEUTRAL” position. Block
lever. Place 0
maintenance during engine operation, the following
the work tools and frames with wedges. considerations must be taken:
j j
• Bef ore raising, block the wheel with a wedge at the • Ask a technician to sit on the operator seat and turn
p After raising, put wedges under the
opposite side. p
of f the engine at any time. All technicians must be
machine. in touch with other person.
Working on the Top of the Machine • Use extreme care when the task point is near the
rotating parts because there is the risk of getting
• When working on the top of the machine, make caught in rotating parts.
sure that the f oothold is clean and free of
restrictions and the following considerations must • Never allow any tool or any part of the body to
be obeyed to avoid falling. touch the fan blade or fan belt. Serious injury can
be caused.
1. There should not be spilled lubricating oil or
grease.
2. No tools around.
3. Watch out for the step while walking.
• Never jump f rom the machine. When getting on/off
the machine, always use the ladder and armrest
and keep three-point (two f eet and one hand or two
hands and one foot) contact any time.
• Prevent the work tool from moving when cleaning
E • Use protective devices if necessary. E of the radiator. Also pull the park brake
the interior
C switch to Capply the park brake.
• The top of the engine hood is slippery and
_ dangerous so standing on it is forbidden. • Do not touch_any lever. If operating the lever is
necessary, signal the other technicians to alert
• The top of the tire is slippery and dangerous so
c standing on it is forbidden. ca safe place.
them to walk into
Hammer Use Considerations
•rStand on the fender of the front frame when r
cleaning
4 the front window glass of the cab. • Always wear safety glasses,
4 helmet and other
protective clothes when using a hammer and put a
Do not drop foreign material into the machine
6 copper stick between the6hammer and the object
• Take care not to drop any foreign material (e.g. nut, being hit on.
0 yarn or tool into the machine when
bolt, cotton 0
• There could be a risk of debris flying into the eyes
opening thej access window or oil fill of the tank. If j to hit a hard part,
causing injury if using a hammer
such kind of material is dropped into the machine,
f or example a pin or bearing.
p failed operation and other
machine damage, p
malf unction can occur. Welding Repair
• If any f oreign material is dropped into the machine, The welding must be performed by a qualified
it must be taken out of the machine. technician and in a place equipped with appropriate
equipment. Welding can generate gases and there
• While accessing, do now carry any unnecessary exists the risk of fire and electric shock, therefore
tool or part in the pocket. never allow the unqualified technician to perform
the welding. The qualified technician must follow the
f ollowing the considerations.
• Disconnect the terminals of the battery to avoid
battery explosion. Remove the paint from the
position to be welded to prevent the generation of
hazardous gas.

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• Welding
4 on the hydraulic device or lines or places 4
High-pressure Hose Handling
very near to it can generate flammable vapor and
6 which can cause a f ire, therefore,
spark
• If the high-pressure hose6leaks, failed operation
could occur which will cause personal injury or
avoid welding on such place.
0 equipment damage. If damaged0 hose or loosened
• If the spark generated during the welding directly bolt is found, stop operation and contact the
j rubber hose, wire or pressurized piping,
f alls on the j (Qingzhou) Ltd.
designated dealers of Caterpillar
f or repair.
p and the insulation of the wire can
they can rupture
be damaged, therefore, cover them with an anti-fire
p
baf fle.
• Sophisticated technique is required when replacing
the high-pressure hose and installing torque is
• Wear protective clothes during welding. determined by the type and size of the hose,
theref ore, do not repair by yourself. Contact the
• Make sure the site where the welding is performed designated dealers of Caterpillar (Qingzhou) Ltd.
is well-ventilated. f or repair.
• Clear all f lammable materials and make sure there High-Pressure Oil Considerations
is a f ire extinguisher at the job site.
When accessing or replacing the hydraulic system
Battery Considerations lines, check if the system pressure has been
released. If there is still pressure in the lines, serious
When repairing the electrical system or injury or damage can occur. Theref ore, perform as
perf orming welding on the machine, remove the
f ollows:
negative (-) of the battery or turn off the main power
switch to prevent current flow.
When Found It Abnormal
• If any abnormal condition is found during accessing,
E repair it. Especially when a problem is found in the E
brake system, steering system or work tool system,
C serious accidents could occur. C
_ • Depending on the f ault type, contact the designated _
dealers of Caterpillar (Qingzhou) Ltd. for repair.
c c
Regulations on Adding fuel or Lubricating Oil
r
Fuel, lubricating oil, hydraulic oil, coolant, brake fluid
r
and4window glass detergent can be lit by a f lame. 4
The f ollowing regulations must be obeyed:
6 • For details of releasing pressure,
6 see "Turn off the
• Turn of f the engine when adding fuel or lubricating engine before check and maintenance" in the
oil. 0 0 Never access or
“Maintenance Considerations”.
replace before the pressure is released completely.
j
• No smoking. j
• Wear the saf ety and leather gloves.
• Wipe off anypspilled f uel, lubricating oil, hydraulic oil, p
coolant, brake fluid or window glass detergent. • If there is oil leak in the line, the line and the
surrounding area will be wet, therefore, check the
• Securely tighten all top covers of the containers for tube or hose for cracks and hose for bulge. If it is
fuel, lubricating oil, hydraulic oil, coolant, brake fluid dif ficult to locate the leak, contact the designated
or window glass detergent. dealers of Caterpillar (Qingzhou) Ltd. for repair.
• The place where the f uel, lubricating oil, hydraulic • Use a plate or cardboard to check the leak instead
oil, coolant, brake fluid or window glass detergent is of bare hands.
added or stored must be well-ventilated.
• If shot by the spilled high-pressure oil, see a doctor
immediately.

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4
Precautions for accessing at high temperature or 3 Tires 4
high pressure
6
• The coolant and oil at various positions is under
Tire Handling 6
Wrong handling of the tire or rim can result in a blue
0
high temperature and high pressure just after the 0
or ruptured tire and the hub can be damaged and
operation is stopped. Opening the engine hood,
j oil or coolant, or replacing the filter at
draining the j injury or death.
scattered which could cause serious
this point can cause burns or other injuries. Wait for The f ollowing considerations must be obeyed for
p
it to cool down and access according to the maintenance safety.
p
procedure in the Operation and Maintenance
Manual. • The maintenance, removal, repair and installation
of the tire and rim require special equipment and
Scrap techniques, therefore ask a tire repair shop to do
To prevent pollution, especially in the area where the job.
humans or animals live, the following procedures • Only use the specified tires and inflate them to the
must be followed. specified pressure. For the specified tire and
• Never dump the used fuel or oil into the drains, pressure, see Usage and Main Technical Features
rivers, etc. and Parameters.

• Collect the drained oil into a container and never • Do not let anybody walk into the job site while
drain the oil directly to the ground. inf lating the tires. It is necessary to stand at the side
of the tire, use self-clamping collets and check the
• Dispose of the hazardous material such as tire pressure now and then to make sure that the
lubricating oil, fuel, coolant, solvent, filter and pressure will not be too high.
battery in accordance with the related laws and
regulations. • If the rim is installed incorrectly, the rim can be
damaged or scattered after the tire is inflated.
E Inspection After Access and Maintenance TherefE
ore, put protective plates around the tire and
do not work at the side of the rim.
C If the comprehensive access and maintenance is not C
perf ormed and the function of each maintenance • The abnormal decrease of the inflation pressure
_ position is not checked, unexpected problems can _ fit of the rim indicate that there is
and the abnormal
occur which could cause personal injury or machine
c damage. Therefore, always consider the following a malf unction incthe tire or rim. In this case, ask a
tire repair shop to repair the tire.
questions.
r r
• Do not adjust the inflation pressure after
• Inspection
4 After Engine Shutdown high-speed traveling 4
or high duty operation.
1. Check all access and maintenance positions.
6 • The f ully inflated tire can6explode because the air
2. Correctly perform all access and maintenance inside the tire is heated and burnt. The heating is
0
items. caused by heating or welding0 the rim, external
flame, or air heat expansion or burn due to frequent
3. Conf irmjthat no tooling or part dropped into the j
braking.
machine. It is especially dangerous if it is stuck
p of the lever.
on the linkage p
4. Repair water and oil leakage and ensure that
bolts are properly tightened.
• Inspection During Engine Operation
Ensure that the access and maintenance positions
operate properly.
There is no oil leaking in the hydraulic system when
the engine speed accelerates, and high load is
applied.

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• Tire
4 explosion is much more forceful than • If the tire is going to fall,
4 stand aside as soon as
discharging the tire. Explosion can force the tires, possible. The industrial tire is very heavy. Trying to
rims6and f inal drive parts away from the machine hold it can cause serious6injury.
more than 500m and the explosion force and debris
0 personal injury or death and property
can cause 0
damage. j j
• It is recommended
p to use dry nitrogen (N2) to p
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
inf lated with nitrogen can reduce the possibility of
explosion because nitrogen is nonflammable.
Nitrogen can also prevent oxidation, deterioration
of rubber and corrosion to the rim components.

• Flat tire or rim damage is due to improper inflating

equipment or improper use, therefore, to avoid over
inf lation, make sure that proper equipment is used
and the tire is inf lated by trained person.

E E
C Tire Storage Considerations C
_ • As a guideline, the tires must be stored in _
the warehouse where unauthorized person can
c enter. If it is necessary to store the tires outside, set c
f ences around the tires and put a “NO ENTRY”
rsign. r
4 4
6 6
0 0
j j
p p

BLOCK-SPACER

• Put the tires uptight on a level surface and hold

them with wedges so that they will not fall even if
touched by unauthorized person. If the tire is
placed on its side, it will be crushed, and the
quality will reduce.

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Key 4 Safety Part Catalog and 4
Change 6 Interval 6
0 the saf ety of the loader during use, the
• To ensure 0
user mustjperform regular maintenance. In addition, j
to ensure f urther safety, the user should also
change the p parts outlined in the chart periodically. p
These parts area essential to the safety 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. Therefore,
no matter what their condition is, they must be
changed periodically to ensure their performance.
• 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.
E E
• Contact the designated SEM dealers for the
C replacement of safety parts.
C
_ _
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r r
4 4
6 6
0 0
j j
p p

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4
Serial
Key safety part needed to be changed periodically Quantity
4Change Interval
Number
6 6
Every 6 months or 1,000 hours, whichever
1 Hydraulic oil tank filter element 1
0 0 first
occurs
2 Fan belt 1
j j
3 Fuel line (fuel tank - fuel filter) 1
4
p
Fuel line (fuel filter - transfer pump) 1
p
5 fuel line (fuel drain line) 1
6 Steering cylinder seal 2
7 Steering hose (pump - priority valve) 1
8 Steering hose (priority valve - steering gear) 1
9 Steering hose (steering gear - hydraulic tank) 1
10 Steering hose (steering gear - steering cylinder) 6
11 Brake hose (air reservoir - dryer canister) 1 Every 2 years or 4000 working
12 Brake hose (air reservoir - air brake valve) 1 hours, whichever occurs first.

13 Brake hose (air brake valve - air booster pump) 1

14 Brake hose (air booster pump - front and rear T fitting) 2
15 Brake hose (air brake valve - switch valve) 1
16 Brake hose (switch valve - air control shutoff valve) 1
E 17
Brake hose (air control shutoff valve - park brake air
1
E
chamber)
C C
Brake hose (air control shutoff valve - variable speed
18 1
_ valve) _
c 19
Brake hose (hand control brake valve - air control shutoff
valve T fitting)
1 c
r 20 Air reservoir 1
r
Every 3 years or 6000 hours, whichever
occurs first.
4 4
6 6
0 0
j j
p p

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4
Engine Coolant Maintenance 4
Proper 6maintenance of engine cooling system is 6
extremely important. Overheat, overcooling, pitting,
cavitation,0 cylinder head cracks, piston sticking, and 0
j are common faults in the cooling
radiator clogged
system, which not only reduce the engine's work
j
ef f iciency but p
also cause severe engine damage. p
Coolant
The main purpose of the antifreeze is to reduce the
condensation point and raise the boiling point of the
coolant. Use coolant even at a common ambient
temperature, because it can raise the boiling point of 3. Check the seal of the radiator water fill cap and
the coolant and the additives in the coolant can replace it if damaged.
reduce the possibility of corrosion and cracks on 4. Tighten the radiator water fill cap.
machine body.
5. If the coolant needs to be added daily, check for
The perf ormance of the coolant brands leaks in the engine cooling system. If a leak is
recommended by Caterpillar (Qingzhou) Ltd. is as present, correct it and add coolant to an
f ollows: appropriate level.
Minimum Ambient
Coolant Type
Temperature for Use ( C)

－45 YF-2A
Wait for the radiator to cool down and release the
－35 YF-2 internal pressure, then open the radiator top cap.
E Change the coolant with a good-quality one and refill E
Add Coolant
according to the instructions.
C C coolant to a new machine or an
Bef ore adding
Notice engine with a cleaned cooling system, select the
_ _
coolant based on the local record low ambient
The coolant is flammable. Do not leave it close to
c a flame. temperature (10Ccbelow the record low ambient
temperature is better).
r
Coolant Level Check Method r
Notice
The4radiator is located at the tail of the machine. 4
Never use water alone for coolant. Damage from
6 the engine coolant temperature drops below
1. After 6 of using water alone
corrosion can be the result
50C, loosen the radiator water f iller cap slowly to for coolant. We will not provide the warranty of
0 the pressure. to prevent the burns
release 0
the cooling system components if using water
caused by hot vapor or hot spilled coolant. alone for coolant.
j j
The steps of adding coolant is as follows:
p p
1. Connect the power negative switch; Insert key
into start switch and turn it clockwise to first gear,
connect the machine power; put the toggle switch
of the air conditioner system at HEAT position.
2. Turn the hand valve of the engine water inlet line
to the ON position (the valve handle is in the
same direction of the line route at ON position).
3. Open the radiator water fill cap to add coolant
slowly until the level reaches the middle level of
the sight glass and keeps stable in 10 minutes.
2. Check whether the coolant level is in the middle
level of the sight glass. If it is lower than the sight Notice
glass, add coolant to the middle level of the sight While adding coolant, the air must be purged
glass. from the tube of the engine cooling system.
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4. 4Start the engine with the radiator water filler cap 5. Open the water drain 4 valve at the bottom of the
open and run it at low idle speed for 5 minutes radiator and the drain valve of the engine oil
6 and then run at high idle speed for 5 minutes
f irst 6 coolant and collect
cooler to drain the engine
to make the coolant temperature above 85C. it with a container.
0 0
5. Check the coolant level again and continue to 6. Af ter all coolant is drained, close the water drain
j if necessary, until the level reaches
add coolant j and the drain
valve at the bottom of the radiator
the middleplevel of the sight glass. valve of the engine oil cooler.
p
6. Check the seal of the radiator water fill cap and 7. Check all the water pipes and clamps for damage
replace it if damaged. and replace if necessary. Check the radiator for
leaks, damage and dirt accumulation. Clean and
Notice repair if necessary.
Do not add cold coolant to a hot engine, 8. Fill the engine cooling system with a cleaning
otherwise, the engine body can be damaged. Wait mixture of water and sodium carbonate and the
until the engine temperature is below 50C. mixing ratio is 0.5 liter of sodium carbonate in
every 23 liters of water. The level should reach
engine operating level and keep stable within 10
Notice minutes.
Caterpillar (Qingzhou) Ltd. will not be responsible Notice
for the loss caused by coolant leaks and the drop
of coolant concentration due to the user's While adding the cleaning solution to the cooling
misuse. system, the air must be purged from the tube of
engine cooling system.
During the whole cleaning process of the cooling
Coolant Change or System Cleaning system, the engine is running with the
E Completely change the coolant in the cooling system radiatorE
water filler cap removed.
C and clean the cooling system every 10,000 hours or 5
9. Start theCengine with the radiator water fill cap
years, whichever occurs first.
removed, and run the engine for another 5
_ Before this interval, if the coolant is contaminated, the
_
minutes af ter the coolant temperature is above
c engine is overheated, or there is bubbles in the 80C. c
radiator, clean the cooling system right now.
r 10. Turn of f the engine
r and drain the cleaning
Note: For other types of coolant, please refer to solution.
4 coolant maintenance interval for
relative 4 system with clean water to
11. Fill the engine cooling
maintenance.
6 normal operating level6and keep it stable within
The steps of cleaning the cooling system are as 10 minutes. Start the engine with the
f ollows: 0 0 and run the
radiator water fill cap removed,
1. Connectj the power negative switch; Insert key engine f or another 5 minutes after the coolant
into start switch and turn it clockwise to first gear, temperature is above 80C. j
connect thep machine power; put the toggle switch p water in the
12. Turn of f the engine and drain the
of the air conditioner system at HEAT position. cooling system. If the water being drained is still
2. Turn the hand valve of the engine water inlet line dirty, the system must be flushed again until
to the ON position (the valve handle is in the the water comes out clean.
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 to Engine coolant is toxic and undrinkable. Dispose
energize the machine power and put the toggle of it according to the local laws and regulations.
switch of the air conditioner system at HEAT
position to open the magnetic water valve of the Cleaning Radiator Fins
air conditioner.
If there is dirt sticking to the radiator, clean in the
4. Wait until the coolant temperature drops below f ollowing method.
50C, then slowly loosen the radiator water fill
cap, to relieve the pressure. 1. Remove the bolts and remove the rear grid form
the rear of the machine. Meanwhile remove the

74
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4connector of rear work light. 1. The inlet end of the4primary filter is facing
downwards, shake and tap the filter gently to
2. Remove the dirt and leaves, etc. on the radiator
6
f ins with compressed air, vapor or water.
make the dust fall; 6
0 2. Use compressed air less 0 than 0.5Kpa to blow out
the dust inside and outside the filter f rom the air
j outlet at the rear of the filter;j
p p the inner cavity
3. Bef ore reinstalling the filter, clean
of the air f ilter to prevent the internal dust from
not being filtered by the primary filter element;
4. Af ter cleaning, press the indicator to reset it.
The primary f ilter should be replaced immediately in
the f ollowing situations:
The primary f ilter is damaged;
Install the cleaned f ilter and will still alarm after the
3. Also check the rubber hose. If cracks on the hose alarm is reset;
or deterioration or hardening is found, replace the Replace the f ilter after 5 times of cleaning.
hose with a new one. Also tighten the loosened Note:
pipe clamp. It is forbidden to clean the filter from the inlet end
of the front of the filter.
Maintenance of Engine Air The safety filter element must not be
disassembled and cleaned, and ensure that it is
The air f ilter is in the engine hood. replaced with the primary filter element.
Do not knock or hit the filter element hard to
avoid damage to the filter element.
E The air filter can only be serviced when the
E element is contaminated by oily smoke
If the filter
or oily dust, please replace the filter immediately
C engine is shut down. Otherwise, the engine may regardlessCof whether the maintenance or
be damaged as a result. replacement time is reached.
_ _
Service the air cleaner filter element when the Maintenance of Air Pre-filter
c blue plunger on the engine air filter service c
indicator enters the red zone. Check whether there is dust or blockage in the inner
r r
pipe and use compressed air of less than 205Kpa to
Never use the engine without an air filter,
4
otherwise dust and impurities entering the
clean it. It is forbidden to4use oily liquids for cleaning，
engine will cause engine wear! If the filter the pre-filter is not damaged and does not need to be
6
element is contaminated by oily smoke or oily replaced. 6
0
dust, please replace the filter immediately 0
regardless of whether the maintenance or Diesel Tank
replacementj time is reached. j
The diesel fuel tank breather should be
Cleaning ofpthe Primary Filter Element p
maintained as the following procedure:
Typically change the 1 breather every 2000 hours or
12 months, but if it operates under badly
contaminated conditions, it is recommended to
change 1 piece every 1000 hours or 6 months. When
slow ref illing speed is felt, remove the breather and
continue to refill. Blow out the dust etc. clogging the
screen with high-pressure air when maintaining the
breather weekly.
The f uel f iller screen and the fuel tank should be
cleaned periodically. The f uel tank can be
cleaned with the following method:
Remove the flange disc at the front end of the fuel
1.Air Pre-f ilter 2. Air Primary Filter 3. Air Safety Filter tank and flush the inner surf ace of the tank with clean

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4 Loosen the drain plug at the bottom of the
diesel. system. 4
tank to drain the fuel. Flush repeatedly until the
6 f uel is clean.
drained Replacement of Fuel6Filter and Fuel
Prefilter
0 Water and Contaminants in
Removing 0
the Diesel
j j
Fuel pump and injection pump are very precise
p is water or contaminants in the
devices. If there p
diesel, the fuel pump and injection pump will not
operate properly and will be prematurely worn.
Measure should be taken to remove the water and
contaminants in the diesel. The method is as follows:
The diesel should be settled for 24 hours before
being added to the fuel tank if possible.
1. Bef ore refilling, open the drain plug at the bottom
of the fuel tank every week to drain the water and
contaminants.

1. Turn the f ilter cap counterclockwise, and filter will

be screwed out together with the upper cap.
2. Rotate in the opposite direction to remove the old
f ilter.
E E
C C
_ 2. Add diesel to FULL after the daily work to drain _
the moisture in the fuel tank.
c c
3. Wait for5 to 10 minutes before starting the engine
r af ter the f uel tank is filled to FULL, to make r
the water and contaminants settle to the bottom
4of the tank. 4
4. Af6 ter the daily work, loosen the water drain plug 6
at the bottom of the fuel prefilter and primary fuel
f ilter 0
to drain the water and contaminants. 0
Do not wait jto add fuel until the fuel tank is empty, or j
else the engine will die and there will be large amount
p
of water and contaminants at the bottom of the fuel p
1.Cover 2. Fuel secondary filter 3. Fuel primary filter 4.Housing
tank which will prevent the normal engine operation.
3. Check whether the sealing ring of the new f ilter
Diesel Sulfur is intact. Press the new filter into the filter base.
The diesel sulfur percentage can affect the choice of 4. Screw in the f ilter cap, and tighten the filter cap
engine oil and oil change interval. The sulfur can clockwise with a tightening torque of 25-35 Nm.
convert into sulfuric acid and sulfurous acid during
burning which will corrode the metal surface. 5. Loosen the bleed screw, press the hand pimp or
Theref ore, use the diesel fuel with low sulfur content. use the electric pump to bleed the air, and tighten
Caterpillar (Qingzhou) Ltd. recommends the use of the bleed screw after the air is drained.
f uel with a sulfur content of less than 10mg/kg. 6. Loosen the bolts at the fuel inlet of the fuel
Otherwise, in addition to affecting the f uel system, the injection pump and press the hand pump or use
unqualif ied fuel will cause DOC and SCR sulfur the electric pump to bleed the air. Start the
poisoning and low SCR conversion efficiency. If it engine to check whether there is fuel leak and
takes a long time, it will lead to torque limit and speed other f ault.
limit, which can only be replaced after-treatment
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4 the water cup.
Drain Oil dipstick 4
1. Open the drain plug at the bottom of water cup to
6
drain the water
6
0 0
j j
p p

4. If the oil level is below

Open “L” mark,
closeplease add oil; if

the oil level is above “H” mark, loosen the oil

drain plug on the bottom of the oil pan and drain
2. Retighten the drain plug.
some oil.
Replace the water cup
Notice
3. Shut off the engine. Too much or too little oil can cause damage to
1. Drain the water f rom the cup. the engine.

2. If possible, remove the cup by hand, if it is too Change Engine Oil

tight, use the removal tool provided with the new
cup. Change the engine oil when the specified oil change
interval is met. Position the machine on a level
surf ace and start the engine until the water
temperature reaches 60C. Then turn off the engine.
E Pull the Epark brake button. Remove the oil drain plug
C at the bottomCof the oil pan to drain the oil and collect
it with a container. Replace the oil filter.
_ _
c c
r Lubricate the seal ring of the new water cup with
3. r
a f ew drops of oil.
4 4
4. Install the water cup by hand and tighten it with a
6
tool. 6
0
Maintenance of Engine Oil 0
j
Check the Engine Oil Level
j
p
1. Drive the machine to a level ground, turn off the
p
engine and pull the park brake button.
2. Wait 10 minutes af ter the engine is off to allow
the engine oil to flow back to the oil pan.
Tighten the oil drain plug and fill with clean oil through
3. Open the engine hood, pull out of the dipstick, the engine oil filler to the “H” mark on the dipstick.
clean up the dipstick with a clean cloth, insert it Operate the engine at idle speed to inspect for leaks
back into the engine oil filler to the end, and pull it at the oil f ilter and the drain plug.
out again to check if the level is between the “L”
mark and the “H” mark on the dipstick. Note: When adding oil, do not press the oil barrel
on the oil filling port.

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4 4
6 6
0 0
j j
p p

Wait f or approximately 10 minutes after shutting

down the engine to allow the engine oil to flow back
to the oil pan and check the engine oil level again. If
the oil is not sufficient, add oil to the “H” mark on the Maintenance of Engine
dipstick.
After-treatment System
Notice
Maintenance Considerations
There should be a reading present on the engine
Engine adopts DOC+SCR after-treatment system.
oil pressure gauge during15 seconds after
E starting the engine. If there is no reading, shut You shouldE pay attention to the followings during the
use and maintenance of the after-treat system:
down the engine immediately to avoid damage
C and inspect for correct oil level. 1. In orderC to ensure the normal operation of the
diesel engine and meet the emission
_ Replace Engine Oil Filter
_ please always use the diesel
requirements,
c exhaust f luid (DEF)
c meeting the requirements of
local standard. There is a risk of blocking DEF
r pump and nozzler by unqualified one, and
in which the metal impurities can easily lead to
4 permanent poisoning 4 of SCR catalyst and
decreased efficiency of SCR catalytic converter.
6 6 to fill the DEF
Notice: It is strictly forbidden
0 reservoir with other solutions 0 instead of DEF,
otherwise the after-treatment system will be
j affected, which even resulted jinto limited engine
torque due to lights failure, NOx exceedingly etc.
p It is recommended to fill the DEFpby using special
equipment instead of direct pouring to prevent
splashing. DEF is corrosive to the skin. If it
accidentally touches the skin or eyes during
Turn the f ilter cap counterclockwise, and filter will be filling, rinse with water and see a doctor as soon
screwed out together with the upper cap. Remove the as possible. If swallowed carelessly, do not
old f ilter. promote emesis and see the doctor immediately.
2. Check f or white crystal in the filling port and air
Check whether the rubber O-ring of the new filter is vent regularly; If yes, you could rinse it with
intact. Press the new filter into the filter base. clear water or wipe with clean wet cloth.
Replace the rubber O-ring of the new f ilter. Irregularly check the connectors and pipe joints
f or normal.
Screw in the f ilter cap, and tighten the filter cap 3. If the nozzle is blocked due to crystallized DEF,
clockwise with a tightening torque of 30-40Nm. you could have it soaked in 50～60℃
Start the engine to check whether there is fuel leak clean water. If the nozzle clogging cannot be
and other f ault. removed after 10 minutes, replace the nozzle.

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4. 4Clean the DEF reservoir regularly to avoid 4 DEF is corrosive to the
professional filling equipment.
clogging and abrasion of the DEF pump caused skin. If you accidentally touch your skin or eyes while
by6particulate matter and impurities in the adding it, rinse with water 6
as soon as possible; if the
reservoir. pain persists, please seek medical help. If swallowed
5. The DEF0 reservoir sensor is an intelligent one, accidentally, do not emetic and0 seek medical
used f or measuring the level and concentration, attention immediately.
j
corresponding to that of engine ECU. If the
j
improper p DEF reservoir is replaced with, it may Check the Level of DEF p
cause OBD failure, which may result into limited
The level must be maintained between 30% and 80%
engine torque. If necessary, please replace of the total volume of the DEF tank.
it with a genuine one.
6. Af ter the engine is turned off, the SCR
system will automatically enter the suck-back
state to suck the DEF in the pump and pipeline When the level is lower than 10%, the NCD
back to the reservoir. This state will last for 3 indicator will flash to indicate that needs to
minutes, during which the machine power supply add DEF as soon as possible; when it is lower
main switch is prohibited to turn off. than 5%, the torque will be limited immediately.
Don’t fill the DEF exceeding the safety volume of the
DEF Storage tank, f illing up to be prohibited.
The relationship between the shelf life of DEF and
the ambient temperature is shown in the table below. Replace of DEF Pump Filter
If the shelf life is exceeded, the machine should be The DEF pump filter needs to be replaced for every
drained through the drain valve at the bottom of 500 service hours. If the environment is harsh and
the DEF tank before working, and the qualified DEF the DEF is heavily polluted, it needs to be replaced
should be replaced. When the ambient temperature according to actual conditions. Before replacement, it
is greater than 35°C, the DEF in the tank should be is necessary to clean the outer surface of the pump
checked before the machine works. If it fails, the and prevent the filter area from being polluted by the
E qualif ied DEF should also be replaced. outside E during the installation process.
C Ambient Temperature for Shelf Life（month）
1. Use water C to clean the area of the DEF pump
f ilter cover and unscrew the filter cover;
_ Storage(℃) _
c ≤10 36 c
≤25a 18
r
≤30 12
r
4
≤35 6 4
≥35 6 b 6
2. Take out the rubber cone insert；
Note: For0the shelf life specified in the table, the main 0
consideration are the ambient storage temperature
j j
and the initial alkalinity of the DEF. Another
p
consideration is evaporation f rom ventilated and
p
unventilated storage containers.
a. In order to prevent the decomposition of DEF,
avoid long-term transportation or storage above 25℃
3. Extend the correct tool end into the filter element
b. Check whether the DEF is qualified before
and pull out the filter element；
each work.

DEF should be stored in a tightly closed container in

a cool and dry place, away from strong oxidants.
When f illing, such as pouring DEF directly into
the DEF tank and splashing it will cause
environmental pollution. It is recommended to use
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4 4 comparing with the data in
concentration of DEF, and
4. Clean the outer surf ace of the filter the engine ECU. If an unmatched DEF tank is
6 with water;
cover replaced, it may cause 6 OBD f ailure, resulting in
5. Af ter0 engine torque date. If you need to replace it, always
lubricating the O-rings at both ends of the
f ilter and install the filter; replace the DEF tank with one0of same manufacturer
6. Tighten jthe f ilter cover. and same model.
j
Notice
p p
After the engine is turned off, SCR system will
Cleaning/Replacing of DEF Sensor Filter
1. Release the plastic buckle and pull out the automatically enter into the reverse suction
f ilter screen. status, and the DEF solution in the DEF pump
and DEF pipeline will be drawn back into the DEF
tank. This stage will last for 2 minutes. During
this period, it is prohibited to turn off the main
power switch of the machine.

1. Use water to flush the filler cap and filler filter and
the surrounding dirt;
2. Empty the DEF in the tank, remove the drain bolt
at the bottom of the tank and drain the DEF;

2. Wash the filter screen with purif ied water until the
surf ace is free of impurities or replace one new
E f ilter. E
C C
_ _
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3. Remove the DEF sensor and the sensor pipe;
r r
4 4
6 6
0 0
j j
p p
3. Install the clean filter screen and be careful not to 4. Flush the inner wall and bottom of the DEF
leave any shaf t sleeve and sealing ring behind. tank with certain pressure water from the sensor
4. Press and rotate the urea solution tank sensor installation hole until the side walls and bottom
clockwise to assemble it on the urea solution impurities are washed down. The cleaning water
tank. Be careful not to leave any rubber sealing runs out f rom the drain bolt.
ring behind. 5. Install the drain bolt after cleaning.
5. Reinstall the urea solution inlet and return pipes
and two cooling water pipes to the urea solution Cleaning of DEF Tank Inlet Filter
tank sensor. 1. Loosen the clamp and remove the sensor inlet
Maintenance of DEF Tank pipe with a screwdriver.
Clean the DEF tank regularly to avoid blocking and 2. Pull out of the filter.
abrasion of the DEF pump caused by particles in the
tank.
The DEF tank sensor is an intelligent sensor, used
for measuring the height of the liquid level and the
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4 4 be started.
so that the engine can
3. Position the machine on a level surface, put the
6 the filter for good, inside for impurities and
3. Check 6
variable speed joystick to the neutral position, pull
damaged hole; flush or replace with new one as
0 if necessary, clean the filter using a
necessary;
the park brake button and0install the frame
locking lever to prevent the machine from moving
rubber brush.
j j
and rotating. Engine is at idle.
4. Blow dry or have the filler filter dried in the sun,
p
then the cleaning is completed. 4. Start the engine and run it about p 5 minutes.
5. Install the f ilter. Inspect if the transmission oil level is near the
6. Install the water pipe and lock the clamp. middle position of the dipstick. If the oil level is
high, drain some transmission oil by loosening
Maintenance of Air the oil drain plug at the bottom of the
Conditioning System transmission. If the oil level is low, add some
transmission oil.
Clean the internal and external element every 50
hours
If the environment is poor, tap the element with hand
or clean it with dry compressed air. Replace it in
advance if obvious insufficient air flow is felt or
broken.
Ask the SEM dealer to check the air conditioner
every year.

E E
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Notice
r r
Over high or low level can cause damage to the
4 transmission. Maintain 4 the transmission oil level
at a correct position.
6 6
While checking the transmission oil level and
Maintenance
0 of Transmission changing transmission oil,0unique care must be
Check thej Transmission Oil Level taken not to allow the contaminants to enter the
transmission system which canj cause damage to
p
Check the transmission oil level in a prescribed
interval to ensure the oil volume. The level can be
the transmission. p
checked by observing the dipstick of the transmission Changing the Transmission Oil
(transmission oil level should be in the middle The transmission oil is not only the working medium
position of the dipstick during machine operation). of hydraulic torque converter - transmission hydraulic
Check the transmission oil level as follows: system, it is also used to cool down and lubricate the
torque converter - transmission parts, therefore, the
1. Before starting the cold machine, the cold oil level selection of transmission oil should meet the
should be inspected first to make sure requirements and change the transmission oil
there is enough oil upon startup. It is especially according to the specified change interval, or else,
important for a loader that is not used for quite a the service life of transmission will be shortened.
long time.
Change the transmission oil as follows:
2. The oil level should be at the upper position of the
dipstick before starting the engine is 1. Start the engine to operate the machine for
started which means that the engine can be several hours to make the contaminants, metal
started. Otherwise, add oil to the upper position debris and sediments suspend in the oil.

81
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2. 4Position the machine on a level surface, put the 4
variable speed joystick to the neutral position, pull
the6park brake button and install the frame 6
locking lever to prevent the machine from moving
0
and rotating. 0
3. Turn of fjthe engine and loosen the oil drain plug j
under the transmission and collect it with a
container.p p

3. Clean the transmission bottom. Install a new

suction screen and tighten the oil pan bolts.
4. Add oil in the same way of changing transmission
oil.
Notice
Before changing transmission oil, cover the park
brake so that the friction plate of the park
brake will not be contaminated by oil which can
cause reduction of braking performance.
E The transmission oil is still hot at this point, E
therefore wear protective devices and use care to Replacing the Drive Oil Filter
C avoid personal injury. C
1. Clean the area near the drive oil filter head.
_ 4. Use a magnet to remove the iron scurf sticking to 2. Remove the_drive oil filter housing with a
c the oil drain plug and remove the iron scurf on the
inner wall of transmission.
strap wrench and
c remove the element.
r Install the oil drain plug of transmission and the
5. r
4related seals. 4
6. Open the transmission oil f iller cap and add clean
6
transmission oil through the filler tube. The 6
0
transmission oil level should be at the highest
level that the oil level allows.
0
j
7. Start the engine and run it about 5 minutes.
j
Inspect if p
the transmission oil level is near the p
middle position of the dipstick. If the oil level is
high, drain some transmission oil by loosening
the oil drain plug at the bottom of the 3. Clean the gasket surface on the head with a
transmission. If the oil level is low, add some clean cloth and install a new element.
transmission oil.
8. Tighten the oil filler cap clockwise.
Replacing the Transmission Oil Suction
Element
1. Drain the oil in the same way of changing
transmission oil.
2. Loosen the transmission oil pan suction bolts and
remove the oil pan. Take out the transmission
suction screen and clean or replace it.
4. Install the drive oil filter housing.
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4 drive axle curb end4 cover point vertically
Notice downward. Pull the park brake button to prevent
6 the machine f rom moving 6 and stop for 15 minutes
The drive oil filter is directional. During (the f ront and rear drive axle oil level needs to be
0 the direction of the arrow should face
installation, checked twice). 0
away from the drive pump.
j 2. Clean the area near the oil level j plugs at both
sides of drive axle curb and remove the oil level
p plug to check if the oil level in pthe drive axle is 8
Maintenance of Drive Axle mm f rom the lower edge of the oil drain. Small
amount of spillage is allowable. If the oil level is
Check the oil level and replace the drive axle oil on
much lower than the lower edge of the oil drain,
time according to the requirements in the “Regular
add drive axle oil. Observe for about 5 minutes
Maintenance”.
af ter adding oil until the oil level is stable (check
Check the Drive Axle Oil the oil level by using any oil plug).
There are three oil drain plugs and oil fill plugs for 3. Tighten the oil level plug.
f ront and rear drive axles, respectively located at the 4. Check the rear drive axle oil level by using the
middle of axle housing and both sides of curb. The oil same steps above.
f ill plug can also be used to observe the oil level. As
shown in the f igure below: 1 is the oil drain plug of Replacing Drive Axle Oil
f inal drive, 2 is the oil fill/oil level plug of final drive, 3
1. Drive the machine for a period of time to allow all
is the oil drain/oil fill plug of the hub reducer, 4 is the
oil level plug of the hub reducer. sediments in the axle housing to suspend. Then
drive the machine to a flat surface and slowly
move the machine to set the oil drain plug at the
drive axle curb end face at the lowest position.
The f ront and rear drive axle oil needs to be
E E
drained several times because the oil drain plugs
C at the lefC
t and right and front and rear drive axle
curb end f ace can not be at the lowest position
_ _
simultaneously.
c c put the variable speed
2. Turn of f the engine,
joystick to the neutral position and pull the park
r r
brake button to prevent the machine from
moving.
4 4
3. Remove the oil drain plugs at the drive axle curb
6 6 of the axle housing to
end f aces and the middle
drain oil and collect with a container.
0 0
j j
p The drive axle oil may be still p
hot at this point,
therefore wear protective devices and use care to
avoid personal injury.

4. Install all the oil drain plugs at the drive axle.

5. Slowly move the machine to make the arrow on
the either side of the curb end cover point
vertically downward.
6. Add clean drive axle oil through the oil level plug
or oil drain plug at the axle curb end face until the
oil level reaches the lower edge of the oil level
plug of the front axle curb end face. Observe for
Checking the drive axle oil about 5 minutes after adding oil until the oil level
1. Drive the machine to a flat surface and slowly is stable (see the Operation and Maintenance
move the machine to make the arrow on the front manual f or the amount of refilling).

83
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7. 4Install the plugs at the drive axle curb ends. 4
8. Change the other drive axle oil in the same
6
manner above.
6
0 0
Maintenance of Hydraulic
Systemj j
p p
Check the oil level and replace the hydraulic oil on
time according to the requirements in the “Regular
Maintenance”.
Check the Hydraulic Oil Level
There is a level meter in the hydraulic oil tank to
indicate the hydraulic oil level.
4. Install new element, spring and cover.
5. Press the cover while installing the bolts and
tighten the bolts evenly.
6. Check the oil level and add oil to the specified
level.
7. Check the assembly joint at the oil filter cover for
oil leaks.
Regular Replacement of Hydraulic Oil
E ReplaceE the hydraulic oil once every 2000 service
hours or every year. The method is as follows:
C C
1. Remove any debris in the bucket. put the variable
_ To check the hydraulic oil level, position the machine
_ to the neutral position and pull the
speed joystick
park brake button and install the frame locking
c on a f lat surface and put the bucket on the ground lever. Start thecengine and idle it for 10 minutes
horizontally. Meantime, the front and rear f rame during which repeat the actions of lifting boom,
r be straightened, leaving no angle between the
should r bucket forward and tilting
lowering boom, tilting
f ront and rear f rame. Now the hydraulic oil level bucket backward several times.
4 be at 2/3 of the oil level gauge.
should 4
2. Finally, raise the boom the highest position, tilt
6
Replacing the Hydraulic Oil Tank Drain 6 position and turn off
the bucket to the maximum
Element0 the engine. 0
1. Raise the boom and put the bucket at retract 3. Push the bucket joystick of the control valve
j
position. Support the boom with a bracket to f orward to allow the bucket to j tilt forward with its
prevent thep work tool from falling. Put the work own weight to drain the f luid in p
the bucket cylinder;
tool lever at neutral position. Apply the park brake Af ter the bucket tilts to the desired position, push
and turn off the engine. the boom joystick of the implement valve forward
to allow the boom to descend with its own weight
2. Remove the mounting bolts on the oil filter cover to drain the fluid in the boom cylinder.
at the side of the tank and remove the cover. The
cover can bounce due to the force of spring, so 4. Clean the opening of the oil drain tube under the
press the cover while removing the bolts. hydraulic oil tank and remove the oil drain plug to
drain the hydraulic oil and collect with a container.
3. Remove the spring and element. Meantime open the oil filler cap to accelerate the
oil draining.
5. Remove the oil inlet tube of the hydraulic oil
cooler to completely drain the oil residue in the
radiator.
6. Remove the oil drain element from the hydraulic
oil tank and replace with a new one. Open the oil

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4f iller cap and remove the oil filler screen for 4 and idle it for 10 minutes
lever. Start the engine
cleaning. during which repeat the actions of lifting boom,
6
7. Remove the tank clean-out flange disc under the
6 forward and tilting
lowering boom, tilting bucket
bucket backward several times.
0 and flush the bottom and walls of the
oil f iller 0
hydraulic oil tank and wipe with a clean cloth. 2. Finally, raise the boom the highest position, tilt
j
8. Install the oil drain plug of the hydraulic oil tank,
j
the bucket to the maximum position and turn off
the engine.
p and top cover, oil filler screen, tank
oil drain f ilter p
clean-out flange mouth and the oil inlet tube of 3. Push the bucket joystick of the implement control
the hydraulic oil cooler. valve f orward to allow the bucket to tilt
forward with its own weight to drain the f luid in the
9. Add clean hydraulic oil through the oil filler of
bucket cylinder; After the bucket tilts to the
hydraulic oil tank. The hydraulic oil can only enter
desired position, push the boom joystick of the
f rom the underside of the barrel structure due to
implement valve forward to allow the boom to
the right-side oil filler built in the barrel structure,
descend with its own weight to drain the fluid in
and there is an air vent plug at the middle of the the boom cylinder.
f lange at the top of the barrel. When releasing
hydraulic oil is required during repair, open the air 4. Clean the oil drain under the hydraulic oil tank
vent plug to release a small amount of hydraulic and remove the oil drain plug to drain the
oil. To change with new hydraulic oil, open the air hydraulic oil and collect with a container.
vent plug before adding the new oil. The level Meantime open the oil filler cap to accelerate the
af ter added should be at the top of the dipstick. oil draining.
Tighten the air vent plug after f illing. After idling
f or 5 minutes, operate the work valve joystick to 5. Open one end of all the tubes to drain the oil
raise and lower the boom, tilt the bucket forward residue in the steering cylinder, hydraulic oil
and backward and steer left and right to the cooler and any tube.
largest angle for 2-3 times, to fill the cylinder and 6. Af ter the oil draining finishes, install the oil drain
E lines with hydraulic oil. E
plug under the hydraulic oil tank and all opened
C 10. Turn of f the engine, open the oil filler cap of the tubes. C
hydraulic oil tank, and add clean hydraulic oil to 7. Open the oil
_ the center-upper position of the oil level gauge in _filler cap of hydraulic oil tank and
add clean hydraulic oil to the lower mark of the oil
c hydraulic oil tank. level gauge. c
Note: 8. Perf orm oil change
r r one more time according to
the procedure in the Regular Change of
1. To repair the hydraulic system, such as pump,
4hydraulic oil line, etc., the air vent plug must Hydraulic Oil, replace4 the oil drain element and
be opened to reduce the hydraulic oil drain clean the f iller screen and hydraulic oil tank.
6 in the hydraulic oil tank, or else, the
flow 6
hydraulic
0 oil in the tank will be completely Knowledge of Tire 0
drained. Maintenance and Inflation
j
2. The air vent plug must be opened to add
j
hydraulicpoil. The level should be at the top of The maintenance, removal, repair and installation of
the dipstick after filling. The air vent plug
p
the tire and rim require special equipment and
must be closed after filling and before starting techniques, therefore ask a tire repair shop or a
the machine, or else air will be drawn into the specially trained person to do the job and obey all
hydraulic system, causing serious damage to related regulations.
the machine. It is recommended to use dry nitrogen (N2) to inflate
the tire. If there is air remaining in the tire, it is
Replacing the Seriously Contaminated recommended to use nitrogen that can be mixed with
Hydraulic Oil air to regulate the tire pressure. The tire inflated with
If the work environment is poor, or the hydraulic oil is nitrogen can reduce the possibility of explosion
deteriorated due to serious contamination, such as because nitrogen is nonf lammable. Nitrogen can also
darkening color or bubbles, replace the hydraulic oil prevent oxidation, deterioration of rubber and
in time. corrosion to the rim components.

1. Remove any debris in the bucket. put the variable Wait f or the tires to cool down sufficiently before
speed joystick to the neutral position and pull the checking and adjusting the tire inflation pressure. The
park brake button and install the frame locking tire inf lation pressure of using nitrogen is same with
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that4of using with air. Caterpillar (Qingzhou) Ltd. 4
recommends determining the tire inflation pressure
based6on the operating condition of the machine. 6
0 Notice 0
j
If the machine travels at high speed for an j
extended period of time, stop the machine for 30
p 45 km, to cool down the tires.
minutes every p
Bucket Kickout Adjustment
This machine has a bucket self-leveling function.
Rational use of this function during operation can Checking Park Brake Performance
improve the work efficiency significantly.
1. The park brake performance should be checked
1. Position the machine on a level surface and put f requently to ensure park safety and the braking
the variable speed joystick to the neutral position. capability in case of emergency barking.
Operate the implement valve joystick to level the
2. Adjust the tire pressure of the machine to the
bucket on the ground, pull the park brake button,
specified value and level the bucket about 300
and turn off the engine; Install the frame locking
mm above the ground. Verify the machine has
lever.
good service brake performance.
2. Loosen the arrow bolt on the caliper, move the
3. Start the engine and make the machine face a
arrow to the middle position of the tilting cylinder
20%-grade slope which should be flat and dry.
small chamber connector body and tighten the
arrow bolt. 4. Depress the service brake pedal to stop the
machine. Put the variable speed joystick to the
E 3. Af ter completion, remove the frame locking lever, E position and turn off the engine.
neutral
start the engine, and check for proper
C adjustment. 5. Pull theCpark brake button and slowly release the
service brake pedal to check if the machine is still
_ Brake System Check _ position.
at the original
c Drain the Air Reservoir Usage, Servicecand Maintenance of Air
r the drain valve to drain the water completely,
Open
Booster Pump r
and then install the drain valve. It is recommended to 1. Usage Precautions
perf4orm draining daily. 4
The air booster pump needs to be adjusted after
6 6 inject the brake fluid
replacement. Before adjustment,
into the oil reservoir, and open the bleed screws
0 (including the bleed screw in 0 the brake actuator) at
j the same time. The brake fluid shall
j be replenished
continuously during the bleeding process. When
p p close the bleed
conf irming that all air has been bled,
screws quickly. Finally, tighten the oil reservoir cap.
The f luid level shall be above the Min line but below
the Max line;
The specified brake fluid shall be used in the product.
Ensure its cleanliness. It is strictly forbidden to mix
dif ferent types of brake fluid.
Check Brake Fluid Level
Check the f luid storage capacity of the oil reservoir
When the f luid level is below the MIN lower limit, add every day to ensure that there is always sufficient
up brake f luid to the specified position. brake fluid in the oil reservoir. It is strictly forbidden to
operate without brake fluid or with little fluid. Replace
the brake f luid regularly;
The brake f luid used shall comply with national
standards. The brake fluid shall not be mixed with
f oreign materials. If operating in a low temperature
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4
environment, antifreeze brake fluid should be used; 4
Note: During the connection process, the
hydraulic gauge and connecting pipe must be
It is required f or users to discharge the air in the
6
hydraulic pipeline through the bleed screws during
6 assembly. Ensure that
lower than the oil reservoir
there is no remaining air in the pipeline
0 test or maintenance, so that there is no
installation,
before working. 0
air in the hydraulic system, otherwise the driving the
vehicle is notj allowed. When the air pressure of the booster j pump is
abnormal, it indicates that the air circuit is
p for Service and Maintenance
2. Precautions p
malf unctioning. First, check if the oil-water separator
Frequently clean the sludge and dust deposits on the is leaking air or the air circuit is blocked;
surf ace of the air booster, to ensure that the vent on
When the air pressure of the booster pump is normal
the oil reservoir cap and the passage of the breather
but the oil pressure is abnormal, it indicates that the
are not blocked;
oil circuit is malfunctioning. First, check if there is oil
If the pressure is insufficient or the brake effect leakage at the brake caliper. If there is oil leakage,
is weak, stop immediately and check. If the wear and the brake caliper piston oil seal is damaged. If not, it
tear parts are f ound worn, replace the wear and tear is caused by damage to the hydraulic chamber seal
parts. Clean, maintain and repair the air cylinder, of the booster pump;
piston (seal), and hydraulic cylinder. When
The brake f luid filled in the air booster pump must be
assembling, apply a proper amount of grease to
special fluid of same brand, without mixing with other
moving parts such as air cylinder (seals). Apply a brake f luid. In addition, it is strictly forbidden to add
proper amount of brake fluid to hydraulic cylinder
other oil into the booster pump, to avoid corrosion of
(seals) to keep the piston moving smoothly;
the booster pump and brake caliper piston seals (and
When replacing the wear and tear parts, replace other f luid can cause expansion and deformation of
them accordingly based on the physical objects. The the booster pump and brake caliper seals), resulting
f asteners (retaining rings, bolts) damaged during the in seal def ormation and pump damage;
replacement process must be replaced. Ensure that
E they are installed into place, firmly and reliably, E of the pressure values of the hydraulic
If the ratio
gauge to the air pressure gauge reaches 90% of the
C and without damaging other parts.
boost ratio,Cit indicates that the performance of the
It is recommended to clean the breather screen booster is normal;
_ assembly at least once a month according to _
If the ratio of the pressure value of the hydraulic
c the working conditions. It is recommended to shorten
the interval under the severe working conditions. If
c
gauge to the air pressure gauge is less than 90% of
the boost ratio, it indicates that the performance of
r screen is damaged, do not reuse it, and replace
the
the booster fades; r
it with new one.
4
3. Fault Diagnosis for Air Booster Pump
When there is no pressure4 value at the hydraulic
gauge, the piston may be stuck, or the hydraulic
6
Remove the oil outlet pipe of the booster pump.
6 assembly may be
rubber ring or the oil inlet valve
Connect 0a hydraulic gauge (0～25MPa, accuracy no damaged, or the hydraulic rubber0 ring and the push
less than 0.4) at the oil outlet. Observe the pressure rod seat expanded, resulting in no oil entry;
j air pressure gauge and the oil outlet
values of the j
If the pressure values of the air pressure gauge and
hydraulic gauge.
p p
the hydraulic gauge drop simultaneously,
that the air chamber cavity is leaking air;
it indicates

If the pressure value of the air pressure gauge does

not drop, but the pressure value of the hydraulic
gauge drops, it indicates that the hydraulic chamber
of the booster pump is leaking oil.
Make a preliminary judgment on the performance of
the booster, then repair the products according to the
troubleshooting methods of common faults.
Checking Service Brake Performance
Make sure that the park brake system is operational
bef ore checking the service brake performance to
apply the park brake at emergency.
Drive the machine at 20 km/h on a flat, straight and
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day4on a cement pavement and depress the service 4
brake pedal. After the machine stops, push the
6 speed joystick to the neutral position, pull the
variable 6
park brake button, and then release the service brake
0 the machine's brake distance which
pedal. Check 0
should not exceed 9 meters.
j j
Drive the machine at 32 km/h and slightly apply the
service brake,pthe machine should be stopped p
instantly without deflecting.
Checking Park Brake Friction Plate
The 3 longitudinal gutters on the caliper friction plate
are marks for grinding amount, it needs to
replace with new plate if the gutters on it are smooth.
Maintenance of the Air Dryer
Introduction
In the braking system of machine, the condensate in Note: please use SEM genuine parts when
compressed air from the air compressor is the main replacing the air dryer.
cause of pipeline corrosion and lubrication failure.
Especially when the ambient temperature is low, the
pipeline may be frozen. This will decrease the Maintenance of Pin Shaft
reliability and service life of the braking system, and
even brake f ailure. The air dryer can effectively
and Drive Shaft
remove the moisture and oil in the compressed air. Perf orm the maintenance for the machine, and
E improveE the service life and reliability of the
Maintenance Interval machine, we
C Crecommend all users to operate
according to the following instructions.
The air dryer should be replaced every 1000 service
_ hours or 6 months. _
Reference point for articulation pin shaft
c Check whether there is water in the air tank regularly. c
grease fill position:
It is recommended to check every 250 service hours
r once a month. When water is found in the air tank,
or r
it means the dryer has failed and should be replaced
4
immediately. 4
6 6
0 0
j j
p p
There are grease f ill positions at articulation pin
shaf ts. Please add grease according to the positions
outlined in the table below during each maintenance
Note: It is recommended to shorten the event and make sure that each joint is properly
maintenance interval if the working conditions is lubricated:
harsh.
Serial Number Fill position
Replacement Procedure
1 Bucket and boom joint
The air dryer and lower shell are connected by screw
2 Bucket and drawbar joint
threads. When replacing the air dryer, first unscrew
the old one, then wipe the sealing ring between the 3 Drawbar and rocker lever joint
air dryer and the lower shell and put it back, and 4 Rocker lever and boom joint
f inally screw on the new air dryer with a torque of
25NM. 5 Raising cylinder and boom joint
6 Tilting cylinder and rocker lever joint

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4 7 Boom and front frame joint
Welding Operation 4
68 Tilting cylinder and front frame joint
6 perform as specified
When welding on the machine,
9 Raising cylinder and front frame joint below, to avoid machine damage or accidents.
0
10 Steering cylinder and front frame joint
0
1. Read and understand the related safety
11 j Steering cylinder and rear frame joint j machine
regulations on welding on the
bef ore welding.
12
p Swing frame and rear frame joint
p
13 Front and rear frame joint 2. The engine start switch must be turned off and
the power negative switch must be disconnected
Grease Fill Device bef ore welding.
3. The dashboard connectors must be removed
bef ore welding to avoid dashboard damage. Or
disconnect the cab harness (at the lower right of
cab and near the f rame articulation;) from the
machine harness.
4. Do not use voltage greater than 200 V constantly.
5. Weld area is within 1m meter from the ground
cable.
6. The ring seal and bearing should not be located
between the weld area and ground cable.
The use of SEM grease gun equipped on the
machine is preferred as shown that has been tested 7. Never weld or cut any pipe or container filled with
on site and been proved to meet the machine grease f uel, oil and hydraulic oil.
E f ill requirement. Eweld or cut any sealed or poorly-ventilated
8. Never
container.
C Grease Gun Use Considerations C
9. Please disconnect ECU, ECM and other harness
_ Clean the grease nozzle before filling to make sure connectors_before welding.
that no contaminants obstruct the grease nozzle or
c passage. Maintenance-free c Battery
Check
r that the equipment is in good condition, r
especially the connections of the soft (hard) adapter
Charging Regulations
and4the grease joint are tightly fastened before using; 4
This machine uses maintenance-free battery. The
bef ore adding the grease, first drain the air inside the f ollowing regulations must be obeyed during use.
grease6gun to ensure that the pressure of filling is 6
reached. Reason for Battery Discharge
0 0
1. Abnormal use, for example, the electric
Connect one end of the hose/tube to the grease
j
nozzle and adding grease by operating the handle. appliances on the vehicle arej on for an extended
Increasing restriction will be f elt during filling and stop period of time before the vehicle is started.
p
f illing when the grease spills from the pin shaft
p
2. Long time of vehicle stopping, excessive current
grease passage. leakage, or installation of additional appliances.
Grease fill interval 3. Frequent start of the vehicle.
Fill every 10 service hours or daily during work time 4. Malf unctioning charging system (for example,
(This interval must be performed stringently); fill f ailed alternator and electronic elements, over
every three months for the drive shafts. low charging voltage setting of the alternator
governor, loose engine drive belts) made the
Follow-up of Grease Fill battery charged improperly, causing battery
Remove the excessive grease at the grease nozzle discharge. The electrolyte indicator is black, and
af ter f ill so that the grease will not adsorb the machine even can not be started.
contaminants during operation clogging the nozzle or 5. The unused battery is stored for more than 6
allowing the contaminants to enter the grease months.
passage at next fill.
The discharged battery due to the reasons above can
be corrected by charging timely and properly.
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4 the battery appearance before charging
Check continue charging. 4
1. The battery with a broken case or acid leakage
6
can not be charged. Replace the battery after
Battery or Battery 6 Cable-
0 the reason.
identifying Inspect/ Replace 0
2. The battery
j with a broken post can not be j
charged. Replace the battery after identifying the
reason. p p
Personal injury may occur from failure to
3. Clean the post and remove the oxide coating on properly service the batteries.
the surf ace before charging.
Batteries give off flammable fumes which can
Charging Precautions explode. Electrolyte is an acid and can cause
1. Wear saf ety glasses. personal injury if it contacts the skin or eyes.

2. Keep the area well-ventilated while charging and Prevent sparks near batteries. Sparks could
charge at normal temperature. cause vapors to explode.
3. Never smoke while charging. Do not allow jumper cable ends to contact each
other or the engine.
4. When connecting after charging, first connect the
positive connection; when disconnecting before Improper jumper cable connections can cause an
charging, first disconnect the negative explosion.
connection.
Always wear protective glasses when working
Battery Charging Regulations with batteries.
1. Conf irm that the battery post is clean and the
charging return circuit is well connected. 1. Turn engine start switch key to OFF position.
E 2. The charger positive connects the battery 2. TurnE
all of the switches to the OFF position.
C positive and the charger negative connects the 3. Turn theCbattery disconnect switch to OFF
battery negative. Never charge the battery in position. Remove the key.
_ series (24V). _
4. Disconnect the negative battery cable from the
c 3. It is recommended to use a charger rated at c switch.
battery disconnect
constant voltage 16.0 volts (The voltage cannot
r exceed 16.2 volts, or the water will be r disconnected battery cable to
Note: Do not allow the
contact the battery disconnect switch.
4electrolyzed, causing level drop and battery
f ailure) and current limit 25 amperes to charge
4
5. Disconnect the negative battery cable at the
the6battery until the electrolyte indicator is green. battery. 6
Turning green means the electricity is sufficient.
0
4. For the battery with a battery voltage less than
0 cable from the
6. Disconnect the positive battery
battery.
j the battery may not be able to charge
11.0 volts, j
7. Inspect the battery terminals for corrosion.
the electricity at initial phase. The reason is that
the sulf ur p
ratio in a badly discharged battery is p or damage.
Inspect the battery cables for wear
close to pure water. The battery inner resistance 8. Make any necessary repairs. If necessary,
is very high. This can be resolved by reducing the replace the battery cables or the battery.
charging current or changing for an
alternator with a larger power. As the charging is 9. Connect the positive battery cable at the battery.
going on, the sulfur ratio in the battery increases 10. Connect the negative battery cable at the battery.
and the charging current will restore to a normal
level gradually. 11. Connect the battery cable at the battery
disconnect switch.
5. If a large amount of acid spills from the vent hole
of the battery while charging, stop charging 12. Install the key and turn the battery disconnect
immediately and find the reason. switch to ON position.
6. When the battery temperature is above 45
degrees centigrade while charging, stop charging.
When the battery temperature drops to the room
temperature, cut the charging current in half and

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4
Recycling of Battery 4
Always6 recycle a battery. Never discard a battery. 6
Always return used batteries to one of the following
locations:0 0
• A battery j supplier j
p battery collection facility
• An authorized p
• Recycling facility

E E
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4 4
6 6
0 0
j j
p p

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4
Fluids Specifications 4
6 specifications and types specif ied in the table
Use the 6
below when adding or changing various oils in this
machine,0to ensure normal machine operation. 0
j j
p
Use Position Ambient Temperature Lubricating oil specification p
Notes
-20°C-40°C API CI-4 SAE15W-40
-25°C-40°C API CI-4 SAE10W-40
Engine
-30°C-40°C API CI-4 SAE5W-40
-35°C-40°C API CI-4 SAE0W-40
-25°C～40°C Number 8 hydraulic drive fluid
Transmission
-40°C-40°C SAE0W-20
-15°C～49°C GL-5 85W-90
Drive axle -25°C～49°C GL-5 80W-90

-45°C～10°C GL-5 75W-90

-5°C-40°C L-HM 46 Recommended oils:

Contact SEM dealers, and use the
Hydraulic system -26°C-40°C L-HV 46
special oils designated by
-40°C-40°C SAE0W-20 Caterpillar (Qingzhou) Ltd.
E Air booster pump
E
DOT4 or DOT3 brake oil that
meets SAEJ703 standard
C C
_ Generic grease NGLI2 _
c Coolant YF-2 or YF-2A c
r
DEF tank
AUS 32 that meets ISO 22241-1 r
standard
4 Above 4°C 0#
4
6
Fuel tank Above -14°C -20# 6
0 Above -29°C -35# 0
j j
Precautions
p p
1. Do not mix the oils with the same specifications
but f rom different brands. If the oil from another
brand must be used for some reason, flush the
system clean first.
2. 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.
3. The f uel should be chosen based on the local
record low air temperature.

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4 Reason and
Fault 4
6 6
Troubleshooting
0 0
Driveline
j j
1. Low speed change pressure at each shift position
p p
Fault Reason and Characteristics Troubleshooting Method
1. Low transmission oil level 1. Fill to the specified oil level
2. Oil leak in gallery 2. Check and repair
3. Clogged transmission suction screen 3. Clean or replace the screen
4. Damaged speed change valve 4. Access or replace the speed change valve
5. Improper adjustment of pressure valve 5. Readjust as specified

2. Low speed change pressure at one shift position

1. The piston ring seal is damaged at this shift position 1. Replace the ring seal
2. Damaged ring seal in the oil circuit 2. Replace the ring seal
3. Oil leak in the passage at this shift position 3. Check and repair

3. High oil temperature in torque converter

1. Low transmission oil level 1. Fill to the specified level
2. High transmission oil level 2. Drain to the specified level
3. Clogged oil cooler 3. Clean or replace the cooler
E 4. Clutch slippage E
4. Access and correct the speed change pressure
5. Excessive time of constant high-duty work 5. Stop or idle the engine for cooling
C C
_ 4. The machine can not travel after started _
1. Not into gear 1. Put into gear or adjust the shift lever into place
c 2. The speed change valve can not go back after shut off
c
2. Remove and check the speed change valve, and troubleshoot the
fault
r3. Low torque converter pressure
r
3. Adjust torque converter overflow valve
4
4. Low speed change pressure 4. See 1 and 2 4
6
5. Insufficient drive power 6
0
1. Low speed change pressure 1. See 1 and 2 0
2. High oil temperature in torque converter 2. See 3
j
3. Damaged torque converter impeller j
3. Remove and check the torque converter and replace the impeller
4. Poor engine output power 4. Access the engine
p
5. Unreleased service brake or park brake 5. Access the brake system
p
Brake System
1. Poor service brake capability
1. Brake oil leak 1. Replace seal
2. Air in the hydraulic brake lines 2. Vent air according to vent procedure
3. Low air pressure in the air line system 3. Check the air compressor
4. Worn cup of the air booster pump 4. Replace the cup
5. Oil on the friction plate 5. Identify the reason and correct it
6. Friction plate worn to the limit 6. Replace with new friction lining

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4
2. Unable to shift into gear after braking 4
6
1. Brake valve can not return to its original position
2. Stuck speed change valve air valve lever
1. Remove, check and repair
2. Remove, check and repair
6
0
3. Poor air pressure at the rear cavity of speed change shutoff valve 3. Access line system 0
lever
j j
3. Brake unable to be released normally
p p
1. Brake valve not in place, or stuck piston lever and failed return 1. Check, adjust or replace damaged parts
spring
2. Air booster pump piston can not return 2. Check, clean and correct
3. Caliper piston can not return freely 3. Clean or replace the rectangular ring seal

4. Reservoir pressure dropping fast after parking

1. Intake valve of brake valve stuck or damaged 1. Repeat braking several times, blow out the contaminants or
change the valve
2. Loose fitting or broken pipe 2. Tighten the fitting or replace the pipe
3. Unsealed unloader 3. Identify the reason and replace if necessary

5. Pressure rising slowly after startup

1. Air compressor not operating properly 1. Check the air compressor operation
2. Loose fittings 2. Tighten the fittings
3. Unsealed brake valve or unloader 3. Access or replace

6. Deflection in braking
E 1. Unequal brake torque for front and rear wheels E
1. Check the air compressor operation
2. Unequal air pressure for front and rear wheel 2. Inflate at specified pressure
C C
_ 7. Insufficient park brake capability _
1. Excessive gap between brake drum and brake disc 1. Readjust as specified
c 2. Oil on the brake disc 2. Clean the brake disc
c
r r
8. Air booster pump
Serial
4 Common Faults Failure Analysis
4
Troubleshooting Method and Treatment
Number
1
6 Air leaking from air chamber 1. Wear of the edge of air piston rubber ring
Actions
6
1. Replace the air piston rubber ring
0 2. Foreign materials on the edge of the air
piston rubber ring
0
2. Clean the edge of the air piston
3. Clean the inner surface of the cylinder
j 3. Unclean surface inside of the cylinder
4. No or little grease on the surface inside of the
j
4. Apply a proper amount of grease to the inner
surface of the cylinder
cylinder
2
p
No oil pressure 1. Seal damaged 1. Replace the seal
p
2. Piston stuck 2. Replace the product assembly
3 Oil leakage at the connection 1. Loose oil bowl assembly 1. Re-tighten the oil bowl assembly to a torque
between the hydraulic 2. Damaged skeleton rectangular ring of 50+5N.m
cylinder body and the joint 2. Replace the skeleton rectangular ring
cover
4 Oil leakage at the connection Deformed or damaged O-ring Replace the O-ring seal
between the oil bowl and the
hydraulic cylinder body
5 Oil carryover at the joint 1. The Y-shaped ring inside the joint cover 1. Replace the Y-shaped ring
cover damaged or fallen off 2. Replace the dust ring
2. The dust ring inside the joint cover damaged
or fallen off
Note: If the surface inside of the cylinder body is corroded or the piston is stuck, it is recommended to replace the assembly

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4 Tool and Hydraulic System
Work 4
1. Lift6
arm rotates bucket slowly or does not move 6
0
1. Damaged cylinder seal
2. Oil leak in pipeline system
1. Replace the oil seal
2. Check and repair
0
j
3. Serious oil leak in working pump 3. Replace with a new pump j
4. Improper adjustment of dump valve and low system pressure 4. Adjust the system operating pressure to specified value
p
5. Air in the working pump suction tube or clogged oil filter 5. Clean the oil filter or replace the suction tube p
6. Excessive fit clearance at hydraulic control valve 6. Access or replace the hydraulic control valve

2. Oil pump drawing oil or bubbles in oil

1. Low oil level 1. Fill to the specified level
2. Plugged oil filter 2. Clean the oil filter
3. Damaged oil pump 3. Access or replace with a new pump
4. Air leak in suction tube or damaged oil pump seal 4. Access or replace the damaged part
5. Poor oil or deteriorated oil 5. Change with new oil as specified

3. High oil temperature

1. Excessive time of operating at full load 1. Stop for cooling
2. System pressure adjusted too low 2. Adjust pressure as specified
3. Low oil level 3. Fill as specified
4. Damaged oil pump 4. Access or replace with a new pump
5. Plugged line or screen 5. Access, clean or replace
6. Small fan blast volume 6. Adjust belt tension as specified

E 4. Failed return E
C 1. Deformation of work valve return spring C
1. Replace with new parts
2. Contaminants present between work valve press lever and 2. Parts washed
_ mating hole _
3. Deformation of multi-way valve return spring 3. Replace with new parts
c 4. Contaminants present between multi-way valve levers 4. Parts washed c
r
5. Unreliable seating of work valve
r
4
1. Insufficient magnetic draw 1. Replace with new parts
4
6
2. Contaminant on the mating face between magnet and spring seat 2. Parts washed 6
3. Clearance between rocker and press lever not adjusted as 3. Adjust as specified
0
specified 0
j of work valve
6. Poor control j
p
1. Stuck or unsmooth metering valve core p
1. Check the cleanliness of fluid and clean valve core and valve hole
2. Deformed metering valve 2. Replace the spring
3. Low pressure of flow control valve 3. Check for normal operation of work oil supply system
4. Unsmooth operation of main valve 4. Clean valve body and valve stem

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4
Steering System 4
6 Steering
1. Hard 6
A. Hard steering with fast or slow action
0 0
1. Insufficient oil supply from oil pump 1. Repair or replace the oil pump
j
2. Inflexible movement of priority valve core
j
2. Correct the cause of inflexible movement of priority valve core, or
replace the priority valve
p
3. Low control pressure of priority valve 3. Adjust the control pressure of priority valve
p
4. Air in oil control circuit between priority valve and steering device 4. Rotate the steering wheel. When the rotating wheel reaches the
limit position, continue to rotate the steering wheel to force the
relief valve open in order to vent the air

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

C. Smooth under no load but heavy under load

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

D. Hard steering at small throttle but back to normal when throttle increases
1. Low volumetric efficiency of oil pump 1. Replace the fuel pump
2. Large clearance between priority valve core and body 2. Replace the priority valve
E E
C 2. No Stop Limit C
When the rotating wheel reaches the limit position, rotating the steering wheel is still easy
_ _
1. The pressure setting of the two-way snubber in the valve block 1. Readjust the two-way snubber, with its opening pressure no less
c mounted on the steering gear oil inlet surface lower than the c
than 1.25 time of the pressure setting of steering relief valve
pressure setting of steering relief valve
r2. Serious wear between valve body, valve envelope and valve r
2. Replace the damaged part or steering device
core, or between rotor and stator, causing large clearance
4 4
3. Steering Failure
6 6
A. Steering wheel not being able to return to neutral positron Pressure runout increase at middle
0
position 0
Broken spring discj Replace the damaged spring disc j
p runout increasing significantly, rotating is impossible
B. Pressure p
Broken or deformed cotter or coupled axle opening Replace the cotter or coupled axle

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

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4
2. Battery Not Being Charged or with Low Current 4
6
1. Damaged voltage regulator
2. Poorly connected wires or open circuit
1. Access or replace
6
2. Check the circuit between alternator and battery
0 0
3. Big Spark Between Alternator Brush and Commutator
j
Seriously worn commutator
j
Clean the commutator and remove the contaminants between the
p cells p
4. Overheated Alternator
1. High voltage regulation by voltage regulator 1. Adjust the regulator voltage
2. Bearing worn or insufficiently lubricated 2. Replace the bearing or add lubricating oil
3. Short circuit in commutator or armature coil 3. Repair or replace

5. Hard Engine Start

1. Low voltage or battery damage 1. Charge or replace with a battery
2. Damaged start switch 2. Access or replace
3. Poorly connected wires or open circuit 3. Check and repair
4. Air in engine oil inlet line 4. Vent air in the line

Air Conditioning System

1. Inability to Blow Cool Air
1. Loose or broken drive belt 1. Tension or replace the belt
2. Burnt fuse link, disconnected or broken wiring, damaged COOL 2. Replace the fuse link, repair the wiring, switch and blower motor
switch, or failed blower motor
E 3. Compressor not rotating, belt slipping on the pulley E
3. Remove the compressor for repair or replacement

C 4. Compressor not operating, with little change of high and low

pressure values while engine speed changing C
4. Repair or replace the compressor valve disc

_ 5. Broken refrigerant system lines, or refrigerant leaking to none,

high and low pressure value being zero
_
5. Repair the lines, check for system leaks, draw out vacuum and
add fluorine
c 6. Clogged reservoir dryer or expansion valve c
6. Remove for repair or replacement

r Insufficient Cool Air

2. r
4
1. Air leak in air passage connection 4
1. Clean or replace the air screen, remove the restriction in air
passage, reconnect the air passage
6
2. Abnormal operation of blower motor 2. Repair or replace the blower motor 6
3. Slipping compressor magnetic clutch 3. Repair or replace the magnetic clutch
0
4. Low efficiency of compressor 4. Repair or replace the compressor 0
j
5. Air in refrigerant system, too high reading on high pressure
gauge, fog in sight glass
5. Vent air, draw out vacuum and add fluorine
j
p
6. Insufficient refrigerant, air bubbles in sight glass, too high reading
on high pressure gauge
6. Add refrigerant until the bubble is gone p
7. Insufficient air flow around the condenser, too high reading on 7. Clean the condenser and engine water tank, or install an extra
high pressure gauge condensing fan

3. Intermittent Operation of Refrigerant System

1. Adjustable idle controller and temperature controller 1. Readjust or repair
2. Slipping compressor magnetic clutch 2. Remove the brace or replace
3. Disengaged magnetic clutch or poor grounding 3. Remove for repair or replacement
4. Water in refrigerant system causing intermittent clogging of 4. Replace the reservoir dryer
expansion valve by water

97
 C C
_ _
c c
r r
4 4
4. Louder
6 Noise 6
1. Loose or over worn drive belt 1. Tension or replace the belt
0
2. Loose compressor mounting brace 2. Tighten the brace mounting capscrew
0
j
3. Loose or worn blower motor 3. Repair or replace the motor j
4. Slippery magnetic clutch causing noise 4. Remove for repair or replacement
p
5. Worn internal compressor parts 5. Repair or replace the compressor p

E E
C C
_ _
c c
r r
4 4
6 6
0 0
j j
p p

98
 C C
_ _
c c
r r
4 Fault Code
Engine 4
6 Fault Code Fault Description
6
0 3 0
Short to ground in the in-cylinder exhaust brake valve

571 j 4 j
Shorted to power source in the in -cylinder exhaust brake valve

p 5 Open in the in-cylinder exhaust brake valve p

7 Throttle and brake signals are not trusted

91 3 The voltage of accelerator pedal 1 is higher than the upper limit of threshold

4 Accelerator pedal1 voltage value is lower than the lower threshold

3 Mass air flow sensor voltage out of range high

132
4 Mass air flow sensor voltage out of range lo w
7 Air inlet heating normally open fault

5 Intake air heater open circuit

2898
3 Intake air heater shorted to a voltage source

4 Intake air heater short circuit to ground

The signal relationship of doubling between throttle pedal 1 and throttle pedal 2
520252 2
is implausible
1 0 Oil temperature and cooling water temperature signals are not credible

3 Accelerator pedal2 voltage value is higher than the upper threshold

E 29 E
4 Accelerator pedal2 voltage value is lower than the lower threshold
C 102 2
C
Barometric Pressure Sensor Signal Unreasonable
_ 102 3 _
Intake air pressure sensor voltage above the upper threshold
c 102 4 c
Intake air pressure sensor voltage below the lower threshold

r 108
3 r
Barometric air pressure sensor voltage high the upper threshold

4 4 4
The voltage of atmospheric pressure sensor is belo w the lower limit of threshold

4 Battery voltage raw value is below the lower threshold

6168 6
3 Battery voltage original value exceeds the upper limit of threshold
0 0
Identification error of cruise control request, resulting in malfunction lamp
11
j keeping on. j
7 Cruise control suppression error before brake pedal is depressed
597
p 2 Brake signal is unreasonable
p
19 Brake signal error

14 Brake signal is unreasonable

The increase amplitude of cooling water temperature does not reach the
18
minimum value within a certain period of time
The cooling water temperature does not reach the minimum value within a
17
certain period of time
2 Cooling water temperature and oil temperature signals are unreasonable
110
Water temperature sensor works normally but water temperature exceeds
15
threshold
3 Cooling water temperature sensor voltage is beyond the upper thresh old

4 Cooling water temperature sensor voltage is below the lower threshold

190 2 Engine speed signal unavailable

99
 C C
_ _
c c
r r
4 Fault Code Fault Description 4
6598 2 6
Clutch status signal is implausible?

0 19 Clutch signal error from CAN

0
520198 11 OBD torque limit activation error
j j
5 Cold start Indicator light open circuit
626
p 3
p
Cold start Indicator light short circuit to power supply

4 Cold Start Indicator light short circuit to ground

520203 5 Off-vehicle start/stop button stuck

13 Only the camshaft signal, enter limp home mode

12 Crankshaft Signal Lost

4203 3 Crankshaft synchronization error

4 Crankshaft tooth number erro r

2 Crankshaft teeth cycle error

12 Camshaft signal missing

2 Camshaft cycle error

4201 11 Camshaft synchronization error

13 Camshaft and crankshaft synchronization error

E 14 E
The signal deviation of crankshaft and camshaft exceeds threshold

1769 11 Engine Speed Out of Range

C C
5 Engine speed sign al open circuit
_ _
1623 3 Shorted to source in engine speed signal circuit
c 4
c
Engine speed signal circuit shorted to ground
r 5
r
Exhaust brake butterfly valve open circuit
4 520208 3 4
Exhaust brake butterfly valve short circuit to power supply

6 4 6
Exhaust brake butterfly valve short circuit to ground

0 7 Fan actuator (PWMW wave) open circuit 0

9 Fan actuator (PWM wave) shorted to power source
j j
10 Fan actuator (PWM Wave) short to the ground
4815 p p
5 Fan actuator (digital signal) open circuit
3 Fan actuator (digital signal) short circuit to power supply

4 Fan actuator (digital signal) short circuit to ground

3 Cooling fan speed is higher than the upper threshold
1639
4 Cooling fan speed is below the lower threshold

5 Fuel heater relay (digital signal) o pen circuit

3 Fuel heater relay (digital signal) shorted to power source

520261 4 Fuel heater relay (digital signal) short to ground

10 Fuel heater actuator (PWM) short to ground

9 Fuel heater actuator (PWM) shorted to power source

100
 C C
_ _
c c
r r
4 Fault Code Fault Description 4
6 7 6
Fuel heater actuato r (PWM) open circuit

0 5 Fuel booster actuator open circuit

0
95 3 Fuel booster actuator shorted to power source
j j
4 Fuel booster actuator short to ground
p 11
p
Water in fuel sensor detects that th ere is water in the fuel.

19 Bus received throttle signal out-of-limit

520264 The original value of the water in fuel sensor voltage exceeds the upper
3
threshold.
The original value of the water in fuel sensor vo ltage less than the lower
4
threshold
14 CAN receiving frame CM1 data size error
522056
19 CAN receiving frame CM1 timeout error

14 CAN receiving frame Dash Dspl data size error

522052
19 CAN receiving frame DashDspl timeout error

14 CAN receiving frame DEC1 data size error

19 DEC1 message reception timeout

522062
18 DEC1 message failure when the neutral signal uses the message path

17 DEC1 message failure when T50 signal uses the message path
E 14 E
CAN receiving frame EBC1 data length error
522013
C 19 C
CAN receiving frame EBC1 timeout erro r

_ 14 _
Wrong data length
522015
c 19 c
Time Out Error
14 CAN receiving frame EGF1 data size error
r 522053 r
19 CAN receiving frame EGF1 timeout error
4 4
14 CAN receiving frame EngTemp2 data size error
6
522020
19
6
CAN receiving frame EngTemp2 timeout error
0 14 CAN receiving frame ERC1DR data size error
0
522021
j 19 CAN receiving frame ERC1DR timeout error j
p 14 ETC1 message data length error p
19 ETC1 message receipt timeout
522022
18 ETC1 message failure when the clutch signal uses the message path

17 ETC1 message failure when the neutral signal uses the message path
14 CAN receiving frame ETC2 data size error

522023 19 CAN receiving frame ETC2 timeout error

18 DEC2 message failure when the neutral signal uses the message path

14 CAN receiving frame ETC7 data size error

522063
19 ETC7 message receipt timeout

14 CAN receiving frame HRVD data size error

522051
19 CAN receiving frame HRVD timeout error

101
 C C
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c c
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4 Fault Code Fault Description 4
6
522065 19 6
Bus received remote accelerator signal out-of-limit

0 14 RxCCVS message data length error

0
19 RxCCVS message receipt timeout
522030 j j
17 CCVS message failure when the brake signal uses the message path
p 18
p
CCVS message failure when the clutch signal uses the message path

14 CAN receiving frame TRF1 data size error

520217
19 CAN receiving frame TRF1 timeout error
14 CAN receiving frame TSC1AE data size error
522035
19 CAN receiving frame TSC1AE timeout error

14 CAN receiving frame TSC1AR data size error

522036
19 CAN receiving frame TSC1AR timeout error

14 CAN receiving frame TTSC1DE data size error

522037
19 CAN receiving frame TSC1DE timeout error

14 CAN receiving frame TSC1DR data size error

522038
19 CAN receiving frame TSC1DR timeout error

14 CANTOTSC1PE data size error

522039
E 19 E
CANTOTSC1PE communication error

14 CANTOTSC1TE data size error

C 522040 C
19 CANTOTSC1TE timeout error
_ _
14 CANTOTSC1TR data size error
c 522041
19
c
CANTOTSC1TR timeout error
r 14
r
CANTOTSC1VE data size error
522042
4 19 CANTOTSC1VE timeout error4
6
522043
14 CANTOTSC1VR data size error 6
0 19 CANTOTSC1VR timeo ut error 0
3 Fuel temperature sensor voltage above the upper threshold
174 j j
4 Fuel temperature sensor voltage below the lower threshold
p p
520221 2 Time interval too long between gear shifting up
12 (Water in Fuel) indicator open circuit

624 3 (Water in Fuel) indicator shorted to power source

4 (Water in Fuel) indicator short to ground

520223 20 High voltage test error

14 EEPROM read error

2802
12 EEPROM write error
3 Intake air temperature sensor voltage exceeds the upper threshold
105
4 Intake air temperature sensor voltage below the lower thresho ld

520210 16 Over 20% nozzle hole wear after 20 times

102
 C C
_ _
c c
r r
4 Fault Code Fault Description 4
6 15 6
5% to 20% nozzle hole wear after lasting for 500ms

0 14 over 20% nozzle hole wear failure

0
13 0~20% nozzle hole wear failure
j j
9 INJdriverIC initialization revision number error
507
p 10 INJdriverIC initialization error after power-on
p
11 INJdriverIC repower-on error

15 Fuel injector 1 High -end short circuit to power supply

17 Fuel injector 1 High end shorts to ground

16 Fuel injector 1 low end shorted to power source

18 Fuel injector1low end shorts to ground

5 Fuel injector 1 open circuit
1413
11 Cylinder 1 fuel injector error
In the same bank, Cylinder 1 and other cylinders open circuit or shorted to weak
6
power supply
3 Cylinder 1 fuel injector shorted to power source

7 Cylinder #1 Injector short to Ground

4 Fuel injector 1 high and low ends short circuit

E 15 E
Fuel injector 2 High -end short circuit to power supply

C 17 C
Fuel injector 2 high end shorts to ground

_ 16 _
Fuel injector 2 Low-end short circuit to power supply

18 Fuel injector 2 low end shorts to ground

c c
5 Fuel injector 2 Open circuit
r 1414
11
r
No.2 Cylinder fuel injector error
4 6
4
In the Bank, 2 cylinder and other cylinder open or short to weak power supply
6 3 6
2 cylinder fuel injector shorts to power supply
0 7 Cylinder #2 Injector short 0
j 4 j
Fuel injector 2 High and low end Short Circuit

p 15 Fuel injector 3 high end shorts to power supply p

17 Fuel injector 3 high end shorts to ground

16 Fuel injector 3 Lo w-end short circuit to power supply

18 Fuel injector 3 low end shorts to ground

5 Fuel injector 3 Open circuit

1415
11 No.3 Cylinder fuel injector error
Cylinders three and other cylinders in the same cylinder bank are open or
6
shorted to weak power supply
3 3cylinder fuel injector shorts to power supply

7 Cylinder #3 Injector short to Ground

4 Fuel injector 3 High and low end Short Circuit

1416 15 Fuel injector 4 High-end short circuit to power supply

103
 C C
_ _
c c
r r
4 Fault Code Fault Description 4
6 17 6
Fuel injector4high end shorts to ground

0 16
0
Fuel injector 4 Low-end short circuit to power supply
18 Fuel injector4low end shorts to ground
j j
5 Fuel injector 4 Open circuit
p 11 No.4 Cylinder fuel injector error
p
Cylinders four and other cylinders in the same bank are open or shorted
6
to weak power supply
3 4cylinder fuel injector shorts to power supply
7 Cylinder #4 Injector short to Ground

4 Fuel injector 4 High and low end Short Circuit

15 Fuel injector 5 High -end short circuit to power supply

17 Fuel injector5high end shorts to ground

16 Fuel injector 5 Low-end short circuit to power supply

18 Fuel injector 5 low end shorts to ground

5 Fuel injector 5 Open circuit

1417
11 No.5 Cylinder fuel injector error
Cylinders five and o ther cylinders in the same bank are open o r shorted to weak
6
power supply
E 3 E
5cylinder fuel injector shorts to power supply
C 7 C
Cylinder #5 Injector short to Ground

_ 4 _
Fuel injector 5 High and low end Short Circuit

c 15 c
Fuel injector 6 High -end short circuit to power supply
17 Fuel injector6high end shorts to ground
r r
16 Fuel injector 6 Low-end short circuit to power supply
4 4
18 Fuel injector6low end shorts to ground
6 5
6
Fuel injector 6 Open circuit
14180 11 No.6 Cylinder fuel injector error
0
j 6 j
In the Bank,6cylinder and other cylinder open or shorts to weak power supply

p 3 6cylinder fuel injector shorts to power supply p

7 Cylinder #6 Injector short to Ground

4 Fuel injector 6 High and low end Short Circ uit

7 Fuel gauge open circuit

1442 9 Fuel gauge short circuit to power supply

10 Fuel gauge short circuit to ground

596 2 Cruise signal is not reliable (invalid switch combination)

5 OBD lamp open circuit

520219 3 OBD lamp shorted to power source

4 OBD lamp short to ground

1323 3 Cylinder 1 misfires

104
 C C
_ _
c c
r r
4 Fault Code Fault Description 4
61332 3 Cylinder 10 misfires 6
0
1333 3 Cylinder 11 misfires
0
1334 3 Cylinder 12 misfires
j j
1324 3 2cylinder misfires
1325
p 3 3cylinder misfires
p
1326 3 4cylinder misfires

1327 3 5cylinder misfires

1328 3 6cylinder misfires

1329 3 Cylinder 7 misfires

1330 3 Cylinder 8 misfires

1331 3 Cylinder 9 misfires

1322 3 The total number of misfiring exceeds the limit

19 Polymorphic switch signal is not credible

976 3 Polymorphic switch voltage exceeds the upper limit

4 Polymorphic switch voltage exceeds the lower limit

2 Oil level sensor signal unreliable

E 98 3 E
Oil level sensor voltage above th e upper limit

4 Oil level sensor voltage below the lower limit

C C
17 Very Low Oil Pressure
_ _
15 Oil pressure is too high or oil temperature signal is not credible
c 100
16
c
Oil pressure sensor voltage above the upper threshold
r 18
r
Oil pressure sensor voltage below the lower threshold
4 15 4
Oil Temperature Sensor Signal Unreasonable

6175 3 6
Oil temperature sensor voltage above the upper threshold

0 4 0
Oil temperature sensor voltage below the lower threshold

7 PCV valve open circuit

j j
1443 9 PCV valve shorted to power source
p p
10 PCV valve short to ground
523470 21 Common rail pressure relief valve does not open when p ressure fluctuates
The common rail relief valve opening times exceeds the maximum number of
11
technical requirements
520241 14 Common rail relief valve open
0 The open time of pressure limit valve exceeds limit
15 The voltage of rail pressure sensor exceeds maximum deviation

17 The voltage of rail pressure sensor exceeds the minimum deviation

157 3 The voltage of rail pressure sensor exceeds the upper limit of threshold
The voltage of rail pressure sensor with interruption acquisition mode ex ceeds
3
the upper limit of threshold
4 Rail pressure sensor voltage below the lower thresh old

105
 C C
_ _
c c
r r
4 Fault Code Fault Description 4
The voltage of rail pressure sensor with interruption acquisition mode is lower
6 4 6
than the lower limit of threshold
0 16 0
Rail pressure deviation exceeds the upper limit of threshold

j 7 j
The amount of oil in the fuel gauge exceeds the threshold
The rail pressure deviation exceeds the threshold and the amount of oil in the
p 5
fuel gauge exceeds the threshold p
The rail pressure deviation exceeds the upper threshold and the fueling
0
quantity exceeds the limit
The rail pressure deviation is lo wer than the lower threshold and the fueling
1
520243 quantity is lower than the threshold
20 Rail pressure peak is below the lower limit of threshold

21 Rail pressure peak exceeds the upper limit of threshold

18 Rail pressure falls too fast

23 Fuel metering unit in overspeed mode is not credible

24 At low idle fuel metering unit monitor error

3 Remote accelerator pedal 1 output voltage value above the upper l imit

520277 4 Remote accelerator pedal 1 output voltage value below the lower limit

7 Remote accelerator and brake reliability check

3 Remote accelerator pedal 2 output voltage value above the upper limit
520278
4 Remote accelerator pedal 2 output voltage value below the lower limit
E E
3 The voltage of sensor power supply 1 exceeds the upper limit of threshold
C 3509 C
4 Sensor supply 1 Voltage below the lower threshold
_ 3
_
Sensor supply 2 Voltage above the upper threshold
c 3510
4
c
Sensor supply 2 Voltage below the lower threshold
r 3 r
Sensor supply 3 Voltage above the upper threshold
3511
4 4 4
Sensor supply 3 Voltage below the lower threshold

6107 7 Air Cleaner Replacement 6

520289 11 Fuel Filter Replacement
0 0
1 Lock the machine and execute the lock mode 1
522014 j j
2 Lock the machine and execute the lock mode 2
p 11 Oil change
p
99
7 Oil filter replacemen t

3 Starter motor relay low-end power supply short

1675 4 Starter motor relay low-end short circuit to ground

5 Start motor relay open circuit

11 T50 ON time exceeds the limit

520253
2 Remote accelerator 2 times relationship implausible

4 ECU Temperature sensor voltage below the lower threshold

1136
3 The voltage of ECU temperature sensor exceeds the upper limit of threshold

4346 5 DEF return line (pump to tank) heater relay open circuit

106
 C C
_ _
c c
r r
4 Fault Code Fault Description 4
6 3 6
DEF return lint (pump to tank) heater relay shorted to power source

0 4
0
DEF return lint (pump to tank) heater relay short to ground
5 DEF pressure line (pump to nozzle) heater relay open circuit
j j
4344 3 DEF pressure line (pump to nozzle) heater relay shorted to power source
p 4
p
DEF pressure line (pump to no zzle) heater relay short to ground

5 DEF heater main relay open circuit

523003 3 DEF heater main relay shorted to power source

4 DEF heater main relay short to g round

5 DEF suction line (tank to pump) heater relay open circuit

4340 3 DEF suction line (tank to pump) heater relay shorted to power source
4 DEF suction line (tank to pump) heater relay short to ground

5 DEF tank water heater solenoid valve o pen circuit

3363 3 DEF tank water heater solenoid valve shorted to power source

4 DEF tank water heater solenoid valve short to ground

0 Vehicle speed 1 above the upper threshold

84
2 Vehicle speed 1 and fueling quantity and engine speed implausible

E 3 E
Pulse width of vehicle speed 3 signal above the upper threshold

1624 4 Pulse width of vehicle speed 3 signal below the lower threshold
C C
8 Average cycle of vehicle speed signal below the threshold
_ _
5 Action Lamp Open Circuit
c 520250 3
c
Action Lamp Power Supply Short
r 4
r
Action lamp sho rt circuit to ground
4 522000 12 CAN communication error4
6 14 6
Inconsistence failure between key message rec eived by the message and the
key calculated by the ECU.
520218
0 19 Key message timeout 0
14161 j 31 DEC1 message T50 sig nal receipt error j
Time duration when engine speed is 0 exceeds a certain value o n the premise
520218 p 0
that T15 is not powered off p
522032 14 TCO1 message timeout

522032 19 TCO1 message data length incorrect

59 19 CAN input signal error in neutral

520202 5 Idle speed sleep switch does not work properly at ECU power-on

25 High alternator voltage

523471
26 Low alternator voltage

27 High battery voltage

523472
28 Low battery voltage

107
 C C
_ _
c c
r r
4
SEM656D Regular 4
6
Maintenance Parts List 6
0
I. Maintenance Interval Schedule
0
j
A. Fluids (with different applicable temperatures,
j
the customer p
should choose oil based on the local p
condition)
This list contains SEM656D special oil used for
regular maintenance. For detailed change operation,
see the Operation and Maintenance Manual

Demand First
Ambient Interval
Where used Item Description Specifications Volume Maintenance
Temperature (h)
(L) (h)
Diesel Engine Oil API CI-4 SAE15W-40 -20°C-40°C

Diesel Engine Oil API CI-4 SAE10W-40 -25°C-40°C

Engine 25 100 500
Diesel Engine Oil API CI-4 SAE5W-40 -30°C-40°C

Diesel Engine Oil API CI-4 SAE0W-40 -35°C-40°C

Hydraulic Oil Number 8 hydraulic
-25°C～40°C
Transmission drive fluid 53 100 1000
Hydraulic Oil SAE0W-20 -40°C-40°C
E Gear Oil GL-5 85W-90 -15°C-49°C E
C Drive Axle
Gear Oil GL-5 80W-90 -25°C-49°C
C 44 * 2 100 1000

Gear Oil GL-5 75W-90 -45°C-10°C

_ Hydraulic Oil L-HM 46 -5°C-40°C
_
c Oil Tank
Hydraulic Oil L-HV 46 -26°C-40°C 161c 2000

r Hydraulic Oil SAE0W-20 -40°C-40°C r

B.
4Saf ety 4
6Where used Item Description Demand (L) Interval (h)
6 Notes
0 0
According to the According to actual
j pump
Air booster Brake oil DOT3
dipstick needs j
p 2pieces per According to actual
p
Calipers Brake discs
caliper needs

C. Coolant
It is recommended to use SEM long life organic coolants, and to completely change the coolant in the cooling
system and clean the cooling system every 10000 service hours or 5 years, whichever occurs first. If you choose
other types of coolant, please refer to its specified maintenance interval for replacement.

108
 C C
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D. 4Filters 4
This list contains SEM656D genuine element used
6
f or regular maintenance. For detailed change
6
operation,0 see the Operation and Maintenance 0
Manual
j
Notice: The air f ilter needs to be cleaned when the
j
air f ilter elementp indicator alerts, and needs to be p
replaced after 5 consecutive cleanings. For all other
f ilters, if the filter alarms indicate that they need to be
replaced, replace them immediately (filter elements).

First
Where used Item Description Quantity Maintenance Interval (h)
(h)
Engine Oil filter element 1 100 500

Air filter element 1

Fuel primary filter 1

Fuel secondary filter 1 500

Engine
Fuel prefilter 1

DEF pump filter element 1

DEF tank sensor suction filter screen 1

Drive Hydraulic Element 1 100 1000
E Transmission Element 1
E
100 1000
C Oil Tank Drain Element 1 100 C 1000

_ Hydraulic - Pilot Element 1 100 _ 1000

Brake System
c (If equipped)
Air dryer 1 1000 c 1000

r Oil Tank Oil filler filter 1 r 2000

4Diesel Tank Oil filler filter 1
4
6
II. Material 6
list required for the maintenance within 2000 hours (one year)
0 Demand Volume
0
j
Replacement time
Item Description Filter j Where used
(h) Oil (L) element
p (piece) p
Diesel engine oil 25 Engine

Oil filter element 1 Engine

Hydraulic drive fluid 53 Transmission

100
Element 1 Drive hydraulic

Gear Oil 44*2 Drive axle

Element 1 Hydraulic - Pilot

Drain Element 1 Oil tank

Diesel engine oil 25 Engine

Oil filter element 1 Engine

500
Air filter element 1 Engine

Fuel primary filter 1 Engine

109
 C C
_ _
c c
r r
4 Demand Volume 4
Replacement time
6
(h)
Item Description
Oil (L)
Filter
element
6 Where used

0 (piece) 0
Fuel secondary filter 1 Engine
j j
Fuel prefilter 1 Engine
p Filter Element 1
pDEF pump
DEF Tank Sensor Suction Filter Screen 1 DEF tank

Hydraulic drive fluid 53 Transmission

Gear Oil 44*2 Drive axle

Element 1 Transmission

Element 1 Drive hydraulic

Element 1 Hydraulic - Pilot

Drain Element 1 Oil tank

Air dryer 1 Brake System

1000 Filter Element 1 DEF pump

DEF Tank Sensor Suction Filter Screen 1 DEF tank

Diesel engine oil 25 Engine

Oil filter element 1 Engine

Air filter element 1 Engine
E Fuel primary filter
E 1 Engine
C Fuel secondary filter C 1 Engine

_ Fuel prefilter
_ 1 Engine

Diesel engine oil 25 Engine

c Oil filter element
c1 Engine
r Air filter element 1 r Engine

4 1500
Fuel primary filter 1 4 Engine

Fuel secondary filter 1 Engine

6 6
Fuel prefilter 1 Engine
0 Filter Element 1
0 DEF pump
j DEF Tank Sensor Suction Filter Screen 1 j DEF tank

p Anti-wear hydraulic oil 161 pOil tank

Oil filler filter 1 Oil tank
Oil filler filter 1 Diesel tank

Hydraulic drive fluid 53 Transmission

Gear Oil 44*2 Drive axle

Element 1 Transmission

2000 Element 1 Drive hydraulic

Element 1 Hydraulic - Pilot

Drain Element 1 Oil tank

Air dryer 1 Brake System

Filter Element 1 DEF pump

DEF Tank Sensor Suction Filter Screen 1 DEF tank

110
 C C
_ _
c c
r r
4 Demand Volume 4
Replacement time
6
(h)
Item Description
Oil (L)
Filter
element
6 Where used

0 (piece) 0
Diesel engine oil 25 Engine
j j
Oil filter element 1 Engine
p Air filter element 1
pEngine
Fuel primary filter 1 Engine

Fuel secondary filter 1 Engine

Fuel prefilter 1 Engine

E E
C C
_ _
c c
r r
4 4
6 6
0 0
j j
p p

111