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605-8849
Sep. 2019
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Operation and
Maintenance
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Manual K
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2 SEM653D Wheel Loader 2
F F
SL7(653D Stage Ⅱ Engine)
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I Important Safety Information I
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Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic O
safety rules or precautions.An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs.A person must be alert to potential hazards, including human factors that can affect
safety.This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify that you
are authorized to perform this work, and have read and understood the operation, lubrication,
maintenance and repair information.
Safety 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 Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

K Attention! Become Alert! Your Safety is Involved. K

The message that appears under the warning explains the hazard and can be either written or pictorially
M presented. M
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A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the
product and in this publication.
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Caterpillar (Qingzhou) Ltd. cannot anticipate every possible circumstance that might involve a potential
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hazard.The warnings in this publication and on the product are, therefore, not all inclusive.You must not
use this product in any manner different from that considered by this manual without first satisfying
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yourself that you have considered all safety rules and precautions applicable to the operation of the
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product in the location of use, including site-specific rules and precautions applicable to the worksite.If a
tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar
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(Qingzhou) Ltd. is used, you must satisfy yourself that it is safe for you and for others.You should also 1
ensure that you are authorized to perform this work, and that the product will not be damaged or become
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unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. 3
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The information, specifications, and illustrations in this publication are on the basis of information that was I
available at the time that the publication was written.The specifications, torques, pressures, measurements,
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adjustments, illustrations, and other items can change at any time.These changes can affect the service that is O
given to the product.Obtain the complete and most current information before you start any job.SEM dealers have
the most current information available.

When replacement parts are required for this

product, Caterpillar (Qingzhou) Ltd. recommends
using SEM replacement parts.
Failure to follow this warning may lead to
premature failures, product damage, personal
injury or death.
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Table of Contents I 24
Cab ...................................................................
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Product Information..............................
Safety Section......................................... 6
General information .......................................... 25
Description and location of the safety messages7
Usage and Main Technical Parameters ........... 28
General Precaution .......................................... 12
Safety Requirements ....................................... 12 Operation Section................................. 33
Safety Devices ................................................. 12
Control devices and monitoring system ........... 34
Clothing and Personal Protective Equipment.. 12
Driver seat adjustment ..................................... 41
Pressurized Air and Water ............................... 12
Operating Precautions ..................................... 43
Trapped Pressure ............................................ 13
1. Before Starting the Engine ........................... 43
Fluid Penetration .............................................. 13
2. When Starting the Engine ............................ 44
Containing Fluid Spillage ................................. 13
3. After Starting the Engine .............................. 45
Dispose of Waste Properly .............................. 14
4. Storage of the Machine ................................ 49
Crushing Prevention and Cutting Prevention .. 14
5. Shipping of the Machine .............................. 50
K Burn Prevention ............................................... 14 K
6. Battery Use and Maintenance Considerations52
M Batteries ........................................................... 15 M
7. Towing .......................................................... 53
2 Fire Prevention and Explosion Prevention ...... 15 2 Disposal ....................55
8.Decommissioning and
FBatteries and battery cables ............................ 16 F
Machine Operation ........................................... 55
Lines, Tubes, and Hoses ................................. 17
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Fire Extinguisher and First Aid Kit ................... 18 Maintenance Section ............................ 59
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Fire Safety ........................................................ 18 Maintenance Considerations ........................... 63
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Fire Extinguisher Location ............................... 19 Key Safety Part Catalog and Change Interval . 70
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Tire Information ................................................ 19 Important Maintenance Procedure .................. 72
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Lightning Damage Prevention ......................... 20
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Engine Coolant Maintenance ........................... 72
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Before Starting Engine ..................................... 20 Maintenance of Engine Air Cleaner ................. 74
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Visibility Information Use and Maintenance of Diesel ....................... 75
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Restricted Visibility ........................................... 20 Maintenance of Engine Oil ............................... 76
Engine Starting................................................. 21 Maintenance of Air Conditioning Heater System77
Before Operation.............................................. 21 Maintenance of Transmission .......................... 77
Operation ......................................................... 21 Maintenance of Drive Axle ............................... 79
Fueling Machine ............................................... 22 Maintenance of Hydraulic System ................... 80
Engine Stopping ............................................... 22 Knowledge of Tire Maintenance and Inflation.. 82
Parking ............................................................. 22 Bucket Kickout Adjustment............................... 82
Slope Operation ............................................... 22 Checking service brake performance .............. 82
Work Tools........................................................ 23 Checking park brake friction plate.................... 83
Sound Information............................................ 23 Fault Reason and Troubleshooting .................. 86
Vibration Information ........................................ 24 SEM653D Regular Maintenance Parts List ..... 92
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PREFACE Maintenance I
O The maintenance section is a guide to the equipment O
Literature Information care.The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
This manual contains safety information, operation interval.Items without specific intervals are listed
instructions, driving information, lubrication under the “When Required” service interval.The
information and maintenance information. Maintenance Interval Schedule also lists the page
This operation manual details the important aspects number for the step-by-step instructions required to
of safety, operation, maintenance, inspection, etc., accomplish the scheduled maintenance.Use the
and should be kept available and read regularly.If Maintenance Interval Schedule as an index or "one
this manual is missing or dirty and not legible, you safe source (spare parts, tools and fluids manuals)"
should re-purchase it at the dealer.When you sell the for all maintenance procedures.
machine, please ensure that the manual is also
forwarded to the new user. Maintenance Intervals
The technical parameters, specifications and The maintenance section of this manual is a
illustrations in this manual are on the basis of guideline for routine maintenance of the machine
information that was available at the time that the and is organized by maintenance intervals.The
manual was written.Continuing modification of maintenance intervals listed in this manual are
product design may affect the maintenance and determined by using the service hour meter.Calendar
repair of the machine which are not included in this intervals shown (daily, weekly, monthly, etc.) can be
manual.Whenever a question arises regarding your used instead of service hour meter intervals if they
provide more convenient servicing schedules and
K machine, or this manual, please consult with the K
approximate the indicated service hour meter
manufacturer or your dealer for the latest available
M information. M
reading.Caterpillar (Qingzhou) Ltd. recommends
service should always be performed at the interval
2 SECURITY 2
that occurs first.Under extremely severe, dusty or
wet operating conditions, more frequent lubrication
FCaterpillar (Qingzhou) Ltd. cannot anticipate every F
than is specified in the scheduled maintenance might
working circumstance that might involve a hazard. be necessary.Perform service on items at multiples
_ warnings in this manual and on the product are,
The _
of the original requirement.For example, at every 500
therefore, not all inclusive.If a tool, procedure, work
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method or operating technique that is not specifically
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service hours or 3 months, also service those items
listed under every 250 service hours or monthly,
3 by Caterpillar (Qingzhou) Ltd. is used,
recommended 3
every 50 service hours or weekly and every 10
you must satisfy yourself that it is safe for you and service hours or daily.
1 should also ensure that the machine
for others.You 1
will not be damaged or become unsafe by the
3 Engine Maintenance 3
operation, lubrication, maintenance or repair
procedures that you intend to use. Proper maintenance and repair is essential to keep
I the engine and machine systems operating I
Operation O correctly.As the heavy duty off-road diesel engine
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owner, you are responsible for the performance of
The operation section is a reference for new the required maintenance listed in the Operation and
operators and a refresher for experienced ones.This Maintenance Manual.It is prohibited for any person
section includes a discussion of gauges, switches, engaged in the business of repairing, servicing,
machine controls, attachment controls, transportation selling, leasing, or trading engines or machines to
and towing information. remove, alter, or render inoperative any emission
Photographs and illustrations guide the operator related device or element of design installed on or in
through correct procedures of checking, starting, an engine or machine that is in compliance with the
operating and stopping the machine. regulations.Certain elements of the machine and
engine such as the exhaust system, fuel system,
Operating techniques outlined in this publication are electrical system, intake air system and cooling
basic.Skill and techniques develop as the operator system may be emission related and should not be
gains knowledge of the machine and the capabilities altered unless approved by Caterpillar (Qingzhou)
of the machine. Ltd.

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Machine Capacity I
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Each loader has its own design capability. Additional O
attachments or modifications may exceed loader
design capacity which can adversely affect
performance characteristics. Included would be
operational stability, brakes and steering.Please
contact your dealer for updated information.As
shown below:

SEM PRODUCT IDENTIFICATION

NUMBER

① - World Manufacturing Code

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② - Machine Descriptor
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③ - Check Character
2 ④ - Machine Indicator Section
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Safety Section I
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Please read and become familiar with all safety
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instructions. Failure to do so could result in 3
serious injury or death.
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This Safety Section also includes precautions for
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optional attachments. 3
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I and location of the
Description I
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safety messages O
There are several specific safety messages on this
machine.The exact location of the hazards and the
description of the hazards are reviewed in this
section.Please become familiar with all safety
messages.
Make sure that all of the safety messages are
legible.Clean the safety messages or replace the
safety messages if you cannot read the
words.Replace the illustrations if the illustrations are
not legible.When you clean the safety messages,
use a cloth, water, and soap.Do not use solvent,
gasoline, or other harsh chemicals to clean the
safety messages.Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures
the warning sign.Loose adhesive will allow the
warning sign to fall.
Replace any safety message that is damaged or
missing.If a safety message is attached to a part of
K the machine that is replaced, install a safety K
message on the replacement part.Any SEM dealer
M can provide new safety messages. M
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Do Not Operate No Entry when Reversing message I
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This safety message is located in the cab. The message is located on the rear of the machine. O

Do not get close to the machine until the engine

stops.
Do not operate this machine unless you have
read and understand the instructions and
K warnings in the Operation and Maintenance Message for K
No Standing Under the
Manual.Failure to do so may result in personal
M injury or death.Contact any Caterpillar dealer for
Boom M
2 replacement manuals.Proper care is your
responsibility.
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The message is located on the outside of the boom.

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_ labels for Hands Hurt by Fan
Warn _
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The message is located at the rear of the hood. K
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Please do not put your hands near the running

fan. Do not touch the machine in operation.

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Lift Point Indicator Alternate Exits I
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The message is located on the inside of the machine. The message is located in the cab on the right post O
by the window latch.

This message indicates the position of lifting the

whole machine. If the primary exit becomes blocked, the window
on the right side can be used as an alternate
exit.Pull the latch backward, then push it outward
No Entry when Working to open the window to the partial open
position.Remove pin from the latch.Push the
The message is located in the articulation position at window open and exit the machine through the
the middle of the machine.
window.
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Parking Brake Sign
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The message is located inside the cab.
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Articulation Lockout Sign I
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The message is located in the articulation position at O
the middle of the machine. Engage the parking brake while the machine is
parking.

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Hydraulic Oil ISign I
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The message indicates the hydraulic oil and is O
located next to the hydraulic oil tank.

Fuel Tank Sign

This message is located by the fuel tank.

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FBattery F
_ message is located near the battery to indicate
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that the battery exists and electricity safety should be
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noticed.
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General Precaution Clothing and Personal I
O Protective Equipment O
Safety Requirements
• Do not wear loose clothing or jewelry. Do not keep
• Only trained and appropriately qualified personnel long hair.They may snap into or get caught in the
could operate and maintain the machine. controls or moving parts, causing serious injury or
death.
• Observe all safety rules, precautions and
instructions when operating and maintaining the • Do not wear greasy clothing to prevent burning.
machine.
• When you operate or maintain the machine, wear
• Do not operate the machine if you do not feel well, a hard hat, protective glasses, protective shoes,
feel dizzy after taking medication or after protective masks and gloves.Wear protective
drinking.In this case, it will lead to the wrong goggles, hard hat, and heavy gloves when
judgment and potential accident. throwing metal chips and tiny debris, especially
when hammering pins and removing air filter
• When working with another operator or traffic contaminants with compressed air.Also check to
commander on site, you must ensure that all make sure no one is near the machine.
personnel understand the hand signals being used.
• Observe all rules concerning safety.
Safety Devices
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• Make sure that all protective devices and hoods
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2 are damaged. 2
F• Use safety devices properly, such as lever locking
devices and safety belts.
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• Never remove the safety device. Always keep it in
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good working condition. Pressurized Air andKWater
• Improper
3 use of safety devices can result in Pressurized air can cause personal injury.When
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serious injury or death. pressurized air is used for cleaning, wear protective
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masks, protective clothing and protective shoes.The
Lock the safety devices when you exit maximum air pressure for cleaning purposes must
3 seat.
the operator 3
be below 205 kPa.The maximum water pressure for
cleaning purposes must be below 275 kPa.
I brake switch before you exit
• Engage the parking I
the seat.If the control lever is accidentally touched, • Avoid direct spraying of water on electrical
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the work tools may suddenly move, causing connectors, connections, and components.When O
serious injury. using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when
• When you leave the loader, lower the work tool 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.
• If the right window is closed, make sure that the
hooks are fully secured to prevent loosening.
• If the window is locked, be sure to tighten the
lock seat to prevent collision between the loose
glass and the lock seat.

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Trapped PressureI Refer to Special Publication SEM Dealer Service I
Tools Catalog for the following items:
O in a hydraulic
Pressure can be trapped O
• Tools that are suitable for collecting fluids and
system.Releasing trapped pressure can cause equipment that is suitable for collecting fluids
sudden machine movement or attachment
movement.Use caution if you disconnect hydraulic • Tools that are suitable for containing fluids and
lines or fittings.High-pressure oil that is released can equipment that is suitable for containing fluids
cause a hose to whip.High-pressure oil that is
Obey all local regulations for the disposal of liquids.
released can cause oil to spray.Fluid penetration can
cause serious injury and possible death. Inhalation
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped.The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur.Do not disassemble any hydraulic
components or parts until pressure has been
relieved or personal injury may occur.
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M Exhaust M
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Use caution.Exhaust fumes can be hazardous to
your health.If you operate the machine in an
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enclosed area, adequate ventilation is necessary.
_ Asbestos Materials _
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SEM equipment and replacement parts shipped from
Caterpillar (Qingzhou) Ltd. are asbestos
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free.Caterpillar (Qingzhou) Ltd., recommends the
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Always use a board or cardboard when you check 1
use of only genuine SEM replacement parts.Use the
following guidelines when you handle any
for a leak.Leaking fluid that is under pressure can
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penetrate body tissue.Fluid penetration can cause
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replacement parts that contain asbestos or when you
handle asbestos debris.Use caution.Avoid inhaling
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serious injury and possible death.A pin hole leak can
dust that might be generated when you handle I
cause severe injury.If fluid is injected into your skin,
O components that contain asbestos fibers.Inhaling this O
you must get treatment immediately.Seek treatment
dust can be hazardous to your health.The
from a doctor that is familiar with this type of injury.
components that may contain asbestos fibers are
brake pads, brake bands, lining material, clutch
Containing Fluid Spillage plates, and some gaskets.The asbestos that is used
Care must be taken in order to ensure that fluids are in these components is bound in a resin or sealed in
contained during performance of inspection, some way.Normal handling is not hazardous unless
maintenance, testing, adjusting, and repair of the airborne dust that contains asbestos is generated.
equipment.Prepare to collect the fluid with suitable If dust that may contain asbestos is present, there
containers before opening any compartment or are several guidelines that should be followed:
disassembling any component that contains fluids.
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.

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• Use a wet method
I in order to clean up asbestos Crushing Prevention and I
materials.
O Cutting Prevention O
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be Support the equipment properly before you perform
used. any work or maintenance beneath that equipment.Do
not depend on the hydraulic cylinders to hold up the
• Use exhaust ventilation on permanent machining equipment.Unit can fall if a control is moved, or if
jobs. hydraulic lines break.
• Wear an approved respirator if there is no other Do not work beneath the cab of the machine unless
way to control the dust. the cab is properly supported.
• Comply with applicable rules and regulations for Unless you are instructed otherwise, never attempt
the work place. adjustments while the machine is moving or while
the engine is running.
Use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos” in Never jump across the starter solenoid terminals in
addition to the requirements of the Industrial Safety order to start the engine.Unexpected machine
and Health Act. movement could result.
• Obey environmental regulations for the disposal of Whenever there are equipment control linkages the
asbestos. clearance in the linkage area will change with the
movement of the equipment or the machine.Stay
• Stay away from areas that might have asbestos clear of areas that may have a sudden change in
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clearance with machine movement or equipment
movement.
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Stay clear of all rotating and moving parts.
2 Dispose of Waste Properly 2
If it is necessary to remove guards in order to
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perform maintenance, always install the guards back
after the maintenance is completed.Keep objects
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away from moving fan blades.The fan blade will
throw objects or cut objects.
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3 Burn Prevention 3
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Do not touch any part of an operating engine.Allow
the engine to cool before any maintenance is
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performed on the engine.Relieve all pressure in the
air system, in the oil system, in the lubrication
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Improperly disposing of waste can threaten the system, in the fuel system, or in the cooling system I
O harmful fluids should be
environment.Potentially before any lines, fittings, or related items are O
disposed of according to local regulations. disconnected.

Always use leakproof containers when you drain

fluids. Do not pour waste onto the ground, down a Coolant
drain, or into any source of water. When the engine is at operating temperatures, the
engine coolant is hot and under pressure.The
radiator and all lines to the heaters or to the engine
contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns.Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level only after the engine has
been stopped.

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Ensure that the filler cap is cool before removing the • Understand the use of the primary exit and I
filler cap.The filler cap must be cool enough to touch alternative exit on the machine.Refer to Operation
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with a bare hand.Remove the filler cap slowly in and Maintenance Manual, “Alternative Exit”. O
order to relieve the pressure.
Cooling system conditioner contains alkali.Alkali can
• Do not operate a machine with a fluid leak.Repair
leaks and clean up fluids before resuming machine
cause personal injury.
operation.Fluids that are leaking or spilled onto hot
Do not allow the alkali to contact the skin, the eyes, surfaces or onto electrical components can cause
or the mouth. a fire.A fire may cause personal injury or death.
• Remove flammable material such as leaves, twigs,
Oil papers, trash, and so on.These items may
accumulate in the engine compartment or around
Hot oil and hot components can cause personal
other hot areas and hot parts on the machine.
injury.Do not allow hot oil to contact the skin.Also, do
not allow hot components to contact the skin. • Keep the access doors to major machine
Remove the hydraulic tank filler cap only after the compartments closed and access doors in working
engine has been stopped.The filler cap must be cool condition in order to permit the use of fire
enough to touch with a bare hand.Follow the suppression equipment, in case a fire should
standard procedure in this manual in order to remove occur.Clean all accumulations of flammable
the hydraulic tank filler cap. materials such as fuel, oil, and debris from the
machine.
Batteries Do not operate the machine near any flame.
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The liquid in a battery is an electrolyte.Electrolyte is • Keep shields in place.Exhaust shields (if equipped)
M an acid that can cause personal injury.Do not allow M
protect hot exhaust components from oil spray or
electrolyte to contact the skin or the eyes. fuel spray in case of a break in a line, in a hose, or
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in a seal.Exhaust shields must be installed
Do not smoke while checking the battery electrolyte
correctly.Do not weld or flame cut on tanks or lines
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levels.Batteries give off flammable fumes which can F
that contain flammable fluids or flammable
explode.
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material.Empty and purge the lines and tanks.Then
clean the lines and tanks with a nonflammable
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solvent prior to welding or flame cutting.Ensure
Fire Prevention and Explosion that the components are properly grounded in
3 order to avoid unwanted arcs. 3
Prevention
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• Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
3 explosive.Repair such components in a well
3
I ventilated area away from open flames or I
sparks.Use suitable Personal Protection
O Equipment (PPE). O
• 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
All fuels, most lubricants, and some coolant mixtures connections to the recommended torque.Damage
are flammable. to the protective cover or insulation may provide
To minimize the risk of fire or explosion, Caterpillar fuel for fires.
(Qingzhou) Ltd. recommends the following actions. • Store fuels and lubricants in properly marked
containers away from unauthorized
• Always perform a Walk-Around Inspection, which
personnel.Store oily rags and flammable materials
may help you identify a fire hazard.Do not operate
in protective containers.Do not smoke in areas that
a machine when a fire hazard exists.Consult your
are used for storing flammable materials.
SEM dealer for details..

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I Follow safe procedures for engine starting with jump- I
start cables.Improper jumper cable connections can
O cause an explosion that can result in injury.Refer to O
Operation and Maintenance Manual, “Engine
Starting with Jump Start Cables” for specific
instructions.
Do not charge a frozen battery.This may cause an
explosion.
Gases from a battery can explode.Keep any open
flames or sparks away from the top of a battery.Do
not smoke in battery charging areas.Do not use cell
phones or other electronic devices in battery
charging areas.
Never check the battery charge by placing a metal
• Use caution when you are fueling a machine.Do object across the terminal posts.Use a voltmeter in
not smoke while you are fueling a machine.Do not order to check the battery charge.
fuel a machine near open flames or sparks.Do not
use cell phones or other electronic devices while Daily inspect battery cables that are in areas that are
you are refueling.Always stop the engine before visible.Inspect cables, clips, straps, and other
refueling.Fill the fuel tank outdoors.Properly clean restraints for damage.Replace all damaged
areas of spillage. parts.Check for signs of the following, which can
occur over time due to use and environmental
K • Avoid static electricity risk when fueling.Ultra low factors: K
sulfur diesel (ULSD) poses a greater static ignition
M hazard than earlier diesel formulations with a • Fraying M
2 higher sulfur content.Avoid death or serious injury
from fire or explosion.Consult with your fuel or fuel
• Abrasion 2
F system supplier to ensure that the delivery system • Cracking F
is in compliance with fueling standards for proper
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grounding and bonding practices. • Discoloration _
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Never store flammable fluids in the operator K
• Cuts on the insulation of the cable
compartment of the machine.
3 • Fouling 3
Batteries
1 and battery cables • Corroded terminals, damaged terminals,
1 and loose
terminals
3 Replace damaged battery cables and replace any
3
I related parts.Eliminate any fouling, which may have I
caused insulation failure or related component
O damage or wear.Ensure that all components are O
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 fire hazard.
An exposed wire on the ground cable between the
Caterpillar (Qingzhou) Ltd. recommends the battery and the disconnect switch may cause the
following in order to minimize the risk of fire or an disconnect switch to be bypassed if the exposed
explosion related to the battery. area comes into contact with a grounded
Do not operate a machine if battery cables or related surface.This may result in an unsafe condition for
parts show signs of wear or damage.Consult your servicing the machine.Repair components or replace
SEM dealer for details. components before servicing the machine.

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I Check lines, tubes, and hoses carefully.Wear I
Personal Protection Equipment (PPE) to check for
O
Fire on a machine could result in personal injury
leaks.Always use a board or cardboard when you O
check for a leak.Leaking fluid that is under pressure
or death.Exposed battery cables that come into can penetrate body tissue.Fluid penetration can
contact with a grounded connection could result cause serious injury and possible death.A pin hole
in fires. leak can cause severe injury.If fluid is injected into
your skin, you must get treatment immediately.Seek
Check electrical wires daily.If any of the following
treatment from a doctor that is familiar with this type
conditions exist, replace parts before you operate the
of injury.
machine.
Replace the affected parts if any of the following
• Fraying conditions are present:
• Signs of abrasion or wear • End fittings are damaged or leaking.
• Cracking • Outer coverings are chafed or cut.
• Discoloration • Wires are exposed.
• Cuts on insulation • Outer coverings are swelling or ballooning.
• Other damage • Flexible parts of the hoses are kinked.
Make sure that all clamps, guards, clips, and straps
are reinstalled correctly.This will help to prevent
• Outer covers have exposed embedded armoring.
K vibration, rubbing against other parts, and excessive • End fittings areKdisplaced.
heat during machine operation.
M M
Make sure that all clamps, guards, and heat shields
Attaching electrical wiring to hoses and tubes that are installed correctly.During machine operation, this
2 contain flammable fluids or combustible fluids should 2
will help to prevent vibration, rubbing against other
be avoided.
F F
parts, excessive heat, and failure of lines, tubes, and
Consult your SEM dealer for repair or replacement hoses.
_
parts.Keep wiring and electrical connections free of _
Do not operate a machine when a fire hazard
debris.
K K
exists.Repair any lines that are corroded, loose, or
damaged.Leaks
Lines, 3 Tubes, and Hoses 3
may provide fuel for fires.Consult your SEM dealer
Do not bend 1high-pressure lines.Do not strike high- 1
for repair or replacement parts.Use genuine SEM
pressure lines.Do not install any lines that are bent parts or the equivalent, for capabilities of both the
or damaged.Use 3 the appropriate backup wrenches pressure limit and temperature limit. 3
to tighten all connections to the recommended
torque.
I I
Ether
O O
Ether (if equipped) is commonly used in cold-
weather applications.Ether is flammable and
poisonous.
Only use approved ether cylinders for the ether
dispensing system fitted to your machine. Do not
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
49°C (120.2°F).Keep ether cylinders away from open
flames or sparks.Dispose of used ether cylinders
properly.Do not puncture an ether cylinder.Keep
ether cylinders away from unauthorized personnel.

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I
Fire Extinguisher and First Aid Note: Fire suppression systems need to be regularlyI
inspected by qualified personnel.You must be trained
Kit O to operate the fire suppression system. O
In the event of injury or fire, take actions according to Use the on-board fire extinguisher and use the
the following precautions. following procedure:
1. Pull the pin.
• Keep a fire extinguisher on the machine. Read the
instructions carefully and make sure to know how 2. Aim the extinguisher or nozzle at the base of the
to use. fire.
• Always have a first aid kit at the work site.Check 3. Squeeze the handle and release the
regularly and, if necessary, supplement some extinguishing agent.
medicines. 4. Sweep the extinguisher from side to side across
• Know what to do in case of a fire or injury. the base of the fire until the fire is put out.
Remember, if you are unable to do anything else,
• Make available the phone numbers of some shut off the machine before exiting.By shutting off
people (such as doctors, emergency centers, fire
the machine, fuels will not continue to be pumped
stations, etc.) to contact in case of emergency.Put
into the fire.
these contact numbers in the specified places and
make sure all people know the numbers and the If the fire grows out of control, be aware of the
correct method of contact. following risks:

K Fire Safety • Tires on wheeled

K machines pose a risk of
explosion as tires burn. Hot shrapnel and debris
M Note: Locate secondary exits and how to use the M
can be thrown great distances in an explosion.
secondary exits before you operate the machine.
2 • Tanks, accumulators, hoses,
2 and fittings can
Note: Locate fire extinguishers and how to use a fire rupture in a fire, spraying fuels and shrapnel over a
F
extinguisher before you operate the machine. large area. F
_
If you find that you are involved in a machine fire, • Remember that nearly all of _
the fluids on the
your safety and that of others on site is the top machine are flammable, including coolant and oils.
K
priority.The following actions should only be K
Additionally, plastics, rubbers, fabrics, and resins in
performed if the actions do not present a danger or fiberglass panels are also flammable.
3
risk to you and any nearby people. At all times you 3
should assess the risk of personal injury and move
1
away to a safe distance as soon as you feel unsafe. Unauthorized Modification 1
3
Move the machine away from flammables, such as Any modifications not approved by Caterpillar 3
gas stations, buildings, garbage dumps, coverings (Qingzhou) Ltd. may result in danger.Before
I
and wood.Lower any implements and turn off the modifying the machine, consult your dealer
I
O
engine as soon as possible.If you leave the engine designated by Caterpillar (Qingzhou) Ltd.Caterpillar O
running, the engine will continue to feed a fire. Any (Qingzhou) Ltd. assumes no liability for any
damaged hoses that are connected to the engine or damages resulting from unauthorized modifications.
pump can cause a fire.
Turn the battery disconnect switch to the OFF
position, if possible.Disconnecting the battery will
eliminate the ignition source in the event of a short
circuit.Disconnecting the battery will eliminate a
second ignition source if electrical wiring is damaged
by the fire, resulting in a short circuit.
Notify emergency personnel of the fire and your
location.If your machine is equipped with a fire
suppression system, follow the manufacturer’s
procedure to activate the system.

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Fire Extinguisher Location Caterpillar (Qingzhou) Ltd. recommends against I
using water or calcium as a ballast for the tires
Oextinguisher is available on the
Make sure that a fire except in machines designed for this additional O
machine.Be familiar with the operation of the fire mass.For those applicable machines, the
extinguisher.Inspect the fire extinguisher and service maintenance section will contain instructions on the
the fire extinguisher on a regular basis. Obey the correct tire inflation and filling procedures.Ballast,
recommendations on the instruction plate. such as fluid in the tires, increases overall machine
weight and may affect braking, steering, power train
Mount the fire extinguisher in the cab. components, or the certification of the protective
Strap the mounting plate to a leg of the ROPS in structure such as the ROPS.The use of tire/rim rust
order to mount the fire extinguisher, as needed.If the preventatives or other liquid additives is not required.
weight of the fire extinguisher is more than 4.5 kg (10
lb), mount the fire extinguisher as low as possible on
one leg.Do not mount the fire extinguisher at the
upper one-third area of the ROPS leg. To avoid overinflation, proper nitrogen inflation
equipment and training in the usage of the
Note: Do not weld the ROPS structure in order to equipment are necessary.A tire blowout or a rim
install the fire extinguisher.Also, do not drill holes in failure can result from improper equipment or
the ROPS structure in order to mount the fire from misused equipment, which could result in
extinguisher on the ROPS. personal injury or death.Due to the high pressure
of approximately 15,000 kPa (2,200 psi) in the
Tire Information nitrogen tank when fully filled, improper use of
the inflation equipment can result in tire blowout
K Explosions of pneumatic tires have resulted from K
and/or rim failure.
heat-induced gas combustion inside the
M tires.Explosions can be caused by heat that is M
Dry nitrogen gas is recommended for inflation of
generated by welding, by heating rim components,
2 by external fire, or by excessive use of brakes. 2
tires.If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the
FA tire explosion is much more violent than a F
pressure.Nitrogen mixes properly with air.
blowout.The explosion can propel the tire, the rim
_
components, and the axle components from the _
Nitrogen inflated tires reduce the potential of a tire
explosion because nitrogen does not aid
K
machine.Stay outside the area with flying
objects.Both the force of the explosion and the flying
K
combustion.Nitrogen helps to prevent oxidation of
the rubber, deterioration of rubber, and corrosion of
3 cause property damage, personal injury,
debris can rim components. 3
or death.
1
Typical example of tire is shown below.
1
To avoid overinflation, proper nitrogen inflation
equipment and training in the usage of the
3 equipment are necessary.A tire blowout or a rim 3
failure can result from improper equipment or from
I misused equipment.
I
O When you inflate a tire, stand behind the tread and O
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
Do not approach a warm or an apparently damaged force.This explosive force can cause serious
tire. personal injury or death.Carefully obey the specific
instructions from your tire dealer.

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Lightning IDamage Prevention Visibility Information I
O in the vicinity of the
When lightning is striking Before you start the machine, perform a walk-around O
machine, the operator should never attempt the inspection in order to ensure that there are no
following operations: hazards around the machine.
• Mount the machine. While the machine is in operation, constantly survey
the area around the machine in order to identify
• Dismount the machine. potential hazards as hazards become visible around
If you are in the operator’s station during an the machine.
electrical storm, stay in the operator’s station.If you Before operating the machine, ensure that the visual
are on the ground during an electrical storm, stay aids are in proper working condition and that the
away from the vicinity of the machine. visual aids are clean.Adjust the visual aids using the
procedures that are located in this Operation and
Maintenance Manual.It may not be possible to
Before Starting Engine provide direct visibility on large machines to all areas
around the machine.Appropriate job site organization
The steering frame lock must be in the unlocked is required in order to minimize hazards that are
position in order to steer the machine. caused by restricted visibility.Job site organization is
a collection of rules and procedures that coordinates
Start the engine only from the operator
machines and people that work together in the same
compartment.Never short across the starter
area.Examples of job site organization include the
terminals or across the batteries.Shorting could
following:
K bypass the engine neutral start system.Shorting K
could also damage the electrical system. • Safety instructions
M M
Inspect the condition of the seat belt and the • Controlled patterns of machine movement and
2 condition of the mounting hardware.Replace any vehicle movement 2
damaged parts or worn parts.Regardless of
F
appearance, replace the seat belt after three years of • Workers that direct trafficF
to move when it is safe
use.
_ • Restricted areas _
Do not use a seat belt extension on a retractable
K
seat belt.Adjust the seat so that full pedal travel can • Operator training K
be achieved when the operator's back is against the
3
back of the seat. • Warning symbols or warning signs 3
on machines or
on vehicles
1
Make sure that the machine is equipped with a 1
• A system of communication
3
lighting system that is adequate for the job
conditions.Make sure that all lights are working
3
• Communication between workers and operators
properly. I prior to approaching the machine I
O
Before you start the engine or before you move the
machine, make sure that no one is on the machine,
Modifications of the machine configuration by the O
user that result in a restriction of visibility shall be
underneath the machine, or around the evaluated.
machine.Ensure that there are no personnel in the
area. Restricted Visibility
The size and the configuration of this machine may
result in areas that cannot be seen when the
operator is seated.The illustration provides an
approximate visual indication of areas of significant
restricted visibility.The illustration indicates restricted
visibility areas at ground level inside a radius of 12 m
(40 ft) from the operator on a machine without the
use of optional visual aids.This illustration does not
provide areas of restricted visibility for distances
outside a radius of 12 m (40 ft).

20
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I etc. I
Ensure that all windows are clean.Secure the doors
O and the windows in the open position or in the shut
O
position.
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.
Fasten the seat belt securely.

Operation
Only operate the machine while you are sitting in the
operator seat.The seat belt must be fastened while
you operate the machine.Only operate the controls if
the engine is running.
While you operate the machine slowly in an open
Note: The shaded areas indicate the approximate
area, check for proper operation of all controls and
location of areas with significant restricted
all protective devices.
visibility.
Before you move the machine, make sure that no
K K
one will be endangered.Do not allow riders on the
machine unless the machine has an additional seat
M Engine Starting M
with a seat belt.The rider must be seated and the
2 If a warning tag is attached to the engine start switch 2
seat belt must be fastened.
or to the controls, do not start the engine and do not Never use the work tool for a work platform.Note any
F
move any controls. F
needed repairs during machine operation.Report any
_
Move all hydraulic controls to the HOLD position needed repairs. _
before you start the engine. Carry work tools at approximately 40 cm above
K ground level.
K
Move transmission control into the NEUTRAL
3
position.Engage the parking brake. 3
Do not go close to the edge of a cliff, an excavation,
or an overhang.
1
Diesel engine exhaust contains products of 1
combustion which can be harmful to your Avoid operating the machine across the slope.When
3
health.Always operate the engine in a well ventilated possible, operate the machine up the slopes and 3
area.If you are in an enclosed area, vent the exhaust down the slopes.If the machine begins to sideslip on
to the outside. I a downgrade, immediately remove the load and turn
I
O
Briefly sound the horn before you start the the machine downhill. O
engine.Check for the presence of personnel.Ensure Avoid any conditions that can lead to tipping the
that all personnel are clear of the machine. machine.The machine can tip when you work on hills,
on banks and on slopes.Also, the machine can tip
Before Operation when you cross ditches, ridges, or other unexpected
obstructions.Maintain control of the machine.Do not
Ensure that there are no personnel on the machine overload the machine beyond the machine capacity.
or in the area around the machine.
Never straddle a wire cable.Never allow other
Remove any debris that builds up in and around the personnel to straddle a wire cable.
hoses and fittings to reduce damage or wear to the
hoses and fittings. Know the maximum dimensions of your machine.
Clear all obstacles from the path of the
machine.Beware of hazards such as wires, ditches,

21
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I
Fueling Machine • Weight of machine I
O • Condition of surface O
Apply the service brake in order to stop the
machine.Move the transmission control device (lever)
Ultra Low Sulfur Diesel (ULSD) poses a greater
to the NEUTRAL position.Move the throttle control to
static ignition hazard than earlier diesel
the low idle position.Engage the parking brake.
formulations with a higher sulfur content, which
may result in a fire or explosion.Consult with Lower all work tools to the ground.Activate any
your fuel or fuel system supplier for details on control locks.Stop the engine.
proper grounding and bonding practices.
Turn the engine start switch to the OFF position and
remove the engine start switch key.
Always turn the battery disconnect switch to the OFF
To avoid possible injury or death, do not smoke position before leaving the machine.If the machine
while in an area that contains flammable liquids. will not be operated for a month or more, remove the
battery disconnect switch key.
All fuels, most lubricants, and some coolants are
flammable. Slope Operation
Keep all fuels and lubricants stored in properly The safe machine operation in various applications
marked containers and away from unauthorized depends on the following conditions:the machine
persons. model, configuration, machine maintenance,
K Fuel leaked or spilled onto hot surfaces or electrical K
operating speed of the machine, conditions of the
terrain, fluid levels, and tire inflation pressures.The
M components can cause a fire. M
most important criteria are the skill and judgment of
Store all oily rags or other flammable materials in a the operator.
2 protective container in a safe place.
2
A well trained operator that follows the instructions in
FRemove all flammable materials such as fuel, oil, F
the Operation and Maintenance Manual has the
and other debris before they accumulate on the greatest impact on stability.Operator training
_
machine.
_
provides a person with the following
Do not K expose the machine to flames, burning brush, K
abilities:observation of working and environmental
conditions, feel for the machine, identification of
etc., if at all possible.
3 3
potential hazards, and operating the machine safely
Locate the fuel filler on the machine, and remove the by making appropriate decisions.
1 fueling the machine, replace the filler
filler cap.After 1
When you work on side hills and when you work on
cap and lock the 3 filler cap into position. slopes, consider the following important points: 3
The filler cap may be hot.To avoid injury, use
personal protective I equipment.Allow the cap to cool Speed of Travel - At higher speeds, forces of I
inertia tend to make the machine less stable.
O
before fueling the machine.
Roughness of terrain or surface – The machine
O
Engine Stopping may be less stable with uneven terrain.

Do not stop the engine immediately after the Direction of travel – Avoid operating the machine
machine has been operated under load.This can across the slope.When possible, operate the
cause overheating and accelerated wear of engine machine up the slopes and down the slopes.Place
components. the heaviest end of the machine uphill when you are
working on an incline.
After the machine is parked and the parking brake is
engaged, allow the engine to run for five minutes Mounted equipment – Balance of the machine may
before shutdown.This allows hot areas of the engine be impeded by the following components:equipment
to cool gradually. that is mounted on the machine, machine
configuration, weights, and counterweights.
Parking Nature of surface – Ground that has been newly
filled with earth may collapse from the weight of
Park the machine on a level surface.If you must park the machine.
the machine on a grade, block the tires.Please
consider the following factors: Surface material – Rocks and moisture of the
surface material may drastically affect the machine's
• Size of tire
22
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1 1
3 3
I
traction and machine's stability.Rocky surfaces may failures on the machine. I
promote side slipping of the machine.
Make sure to use work tools and work tool control
O
Slippage due to excessive loads – This may systems that are compatible with SEM machine for
O
cause downhill tracks or downhill tires to dig into safe machine operation and/or reliable machine
the ground, which will increase the angle of the operation.Consult your SEM dealer with any
machine. questions that concern the compatibility of a
particular work tool with your machine.Make sure
Width of tracks or tires – Narrower tracks or
that all protective guards are secured in place on the
narrower tires further increase the digging into
machine and on the work tools.
the ground which causes the machine to be less
stable. Secure all windows and doors of the machine in the
shut position.A polycarbonate guard needs to be
Implements attached to the drawbar – This may
installed when the machine is not equipped with
decrease the weight on the uphill tracks.This may
windows and when a work tool that creates flying
also decrease the weight on the uphill tires.The
objects is used.
decreased weight will cause the machine to be less
stable. Do not exceed the maximum operating weight as
specified.
Height of the working load of the machine –
When the working loads are in higher positions, If your machine is equipped with an extendable stick,
the stability of the machine is reduced. install the driver pin when you are using the following
work tools:When you are working with the hydraulic
Operated equipment – Be aware of performance
hammers, augers and compactors, you should
features of the equipment in operation and the
always wear the goggles.Always wear the protective
K effects on machine stability. K
equipment that is recommended in the operation
Operating techniques – Keep all attachments or manual for the work tool.Wear other protective
M pulled loads low to the ground for optimum
M
equipment that is required for working condition.
2 stability. 2
To avoid injury caused by flying objects, ensure that
Machine systems have limitations on slopes –
F all personnel are out of the work area.
F
Slopes can affect the proper function and
While you are performing any maintenance, any
_
operation of the various machine systems.These _
testing, or any adjustments to the work tool, stay
machine systems are needed for machine control.
K clear of the following areas:cutting edges, pinching
K
Note: Safe operation on steep slopes may require surfaces, and crushing surfaces.
3
special machine maintenance.Excellent skill of the 3
Never use the work tool for a work platform.
operator and proper equipment for specific
1
applications are also required. Consult the Operation 1
Equipment Lowering with
and Maintenance Manual sections for the proper
3
fluid level requirements and intended machine use. Engine Stopped 3
I
Work Tools Before lowering any equipment with the engine
I
O stopped, clear the area around the equipment of all O
Only work tools recommended by Caterpillar personnel.The procedure to use will vary with the
(Qingzhou) Ltd. may be used on SEM machines.Any type of equipment to be lowered.Keep in mind that
use of work tools including buckets that are not Most systems use high-pressure fluid or air to raise
recommended by Caterpillar (Qingzhou) Ltd. or or lower the equipment.The procedure will cause
whose weight, size, flow rate, pressure, etc. exceed high-pressure air, hydraulic oil, or some other media
the specified specifications may result in diminished to be released in order to lower the equipment.Wear
performance of the machine, including but not limited appropriate personal protective equipment and follow
to, reduced production, stability, reliability, and the established procedure in the Operation and
component durability.Caterpillar (Qingzhou) Ltd. Maintenance Manual, “Equipment Lowering with
recommends the use of Engine Stopped” in the Operation Section of the
manual.
suitable implements on our machine so that the
customer can obtain maximum value out of our
products.Caterpillar (Qingzhou) Ltd. understands
Sound Level Information
that customers may use work tools that exceed our Refer to the machine Operation and Maintenance
specifications under special circumstances.In these
Manual for the specific sound levels for your
cases, customers must be aware that such choices
machine. “ISO 6396:2008” is used to measure the
can reduce the machine performance and can affect
value for an enclosed cab.The value is 83 dB(A).
their warranty claims when they detect premature
23
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I
The measurement was conducted at the maximum weight and the size of the operator and inspect and I
engine cooling fan speed. The sound level may maintain the seat suspension and adjustment
O
vary at different engine cooling fan speeds. The mechanisms. O
measurement was conducted with the cab doors 5. Perform the following operations smoothly: steer,
and the cab windows closed. brake, accelerate, and shift the gears.
6. Move the attachments smoothly.
Refer to the machine Operation and Maintenance
7. Adjust the machine speed and the route to
Manual for the specific sound levels for your
minimize the vibration level by doing the following:
machine. The value is 83 dB(A) measured according
drive around obstacles and rough terrain and slow
to the dynamic test procedures and the conditions
down when necessary to go over rough terrain.
that are specified in “ISO 6395:2008”. The
8. Minimize vibrations for a long work cycle or a long
measurement was conducted at the maximum
travel distance by doing the following: use machines
engine cooling fan speed. The sound level may vary
that are equipped with suspension systems, if no ride
at different engine cooling fan speeds.
control system is available, reduce speed to prevent
When sound levels are specified using either
bounce and haul the machines between workplaces.
“ISO6395:2008” or “ISO 6396:2008”, the declared
9. Less operator comfort may be caused by other
level is a maximum sound level. The maximum sound
risk factors. The following guidelines can be effective
level includes both measurement uncertainty and
to provide better operator comfort: adjust the seat
uncertainty due to production variation.
and adjust the controls to achieve good posture,
adjust the mirrors to minimize twisted posture,
provide breaks to reduce long periods of sitting,
Vibration Information avoid jumping from the cab, minimize repeated
handling of loads and lifting of loads and minimize
K Information Concerning Seat Vibration K
any shocks and impacts during sports and leisure
activities.
M The suspension seat meets the criteria of "ISO 7096". M
Consult your local SEM dealer for more
This represents vertical vibration level under severe
2 operating conditions. This seat is tested with the 2
information about machine features that
input "spectral class EM3". The seat has a minimize vibration levels. Consult your local
F
transmissibility factor of “SEAT<1.0”.
F
SEM dealer about safe machine operation.
_ Cab _
Guidelines for Reducing Vibration Levels
K
on Earthmoving Equipment K
Any modifications to the inside of the operator station
3
Vibration levels are influenced by many different 3
should not project into the operator space or into the
space for the companion seat (if equipped).The
1
parameters, such as: operator training, operator
behaviour, operator mode and stress, job site defined operator and companion seat space (if1
equipped) will be maintained.if the addition of a radio,
3
organization, job site preparation, job site
fire extinguisher, and other equipment must be
3
environment, job site weather, job site material,
I
machine type, quality of the seat, quality of the I
installed.Any item that is brought into the cab should
suspension system, attachments, and condition of not project into the defined operator space or the
the equipment.
O space for the companion seat (if equipped).Loose O
items must be secured.Objects must not pose an
Properly adjust machines. Properly maintain impact hazard in rough terrain or in the event of a
machines. Operate machines smoothly. Maintain the rollover.
conditions of the terrain. The following guidelines can
help reduce the whole-body vibration level:
1. Use the right type and size of machine, equipment
and attachments.
2. Maintain machines according to the manufacturers
recommendations: tire pressures and brake and
steering systems, controls, hydraulic system, and
linkages.
3. Keep the terrain in good condition by performing
the following items: remove any large rocks or
obstacles, fill any ditches and holes and provide
machines and schedule time to maintain the
conditions of the terrain.
4. Keep the seat maintained and adjusted by doing
the following: adjust the seat and suspension for the
24
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I
Product Information I
O O
General information
The main mechanisms on SEM653D machine are
equipped with the following features and advanced
technologies:
• It uses engine that meets Stage Ⅱ off-road
emission regulation requirements and has been
optimized to match the conventional system more
reasonably for a higher efficiency.
• An articulated vehicle frame is used to achieve a
small turning radius, mobility and flexibility. Easy to
operate in narrow areas.
• 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
K components. K
M • Featured with load-sensing full hydraulic steering, M
2 and a combination of working and steering for
better energy-saving. Fixed shaft power shifting
2
F transmission with optimized technology by Cat, F
and reliable work hydraulic control of work tool
_
make the operation of the machine easy and _
flexible, the movement stable and reliable.
K K
• Equipped with service braking system, emergency
3
and parking braking system to provide safe and 3
reliable braking performance, fully meeting the
1 1
requirements of GB/T21152.
3 3
I I
O O

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ComponentI Names of the Machine I
O O

K K
M 1. Rocker Lever 5. Engine Hood M
9. Boom
2. Bucket Cylinder 6. Rear Wheel 10. Bucket
2 3. Cab 7. Ladder 2
4. Engine 8. Front wheel
F F
_ _
Right
K K
3 3
1
Front 1
3 3
I I
O O

Left

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I
Diesel Engines Cab I
O
This machine is equipped with the six-cylinder, four- The standard cab is a fresh air featured cab. The cab O
stroke, water-cooled, turbocharged, ATAAC engine. is equipped with vibration reducing system and can
This engine provides the good cold start greatly reduce the vibration and noise levels inside
performance, high altitude performance, low fuel the cab, and improve the comfort of the cab and the
consumption, low noise, reduced pollution emissions, operator's work efficiency through modal analysis
high reliability and durability. and test verification.In order to give the operator a
good view when operating the machine, our
Hydraulic System designers equip the machine with glass windows and
doors that are optimized in design.
Hydraulic system is composed of work hydraulic
system, steering hydraulic system, drive hydraulic Sheets
system and cooling hydraulic system.
Sheet metal components include engine hood,
The work hydraulic system and steering hydraulic
lubricating oil tank, diesel tank, hand rail etc.
system use bivariate junction technology in which the
steering takes priority. Electrical Systems
Drive System The electrical system of the machine is powered by
two 12 v batteries in series, rated at 24 v.It contains
The drive system includes torque converter, drive
power supply system, starting system, control
shaft, transmission and drive axle.
system, lighting system, instrument and indicator
The transmission is a fixed shaft type, with four system, etc.Each control switch controls individual
K forward gears and two reverse gears. appliance. K
M The drive axle adopts first stage gear reducer and M Dataplate
Machine Product
first stage planetary gear reducer.
2 2
Product dataplate contains machine weight,
Cooling System maximum vehicle speed, engine model, engine
F F
horsepower, machine size, production date, product
Radiator includes engine coolant radiator, hydraulic
identification number, etc.
_
oil radiator, drive oil radiator and intake air _
aftercooled radiator.
K K
Ensure an optimized heat balance between water
3
and oil temperature and an optimized working 3
temperature for each component and maintain the
1
fluid quality within the lifecycle of the components. 1
3
Brake System 3
I
The braking system consists of the service brake I
and parking brake.The service braking system is a
O
double-circuit caliper disc type. When the brake
O
Brand(A)____________________________
pedal is depressed, the compressed air from the air
cylinder enters the air booster pump through the Machine Mass(B)_____________________
braking valve, and the braking oil enters the brake to Engine Model(C)_____________________
stop the machine;The parking brake is a drum type
brake, installed on the transmission output shaft Dimension(D)________________________
flange. The parking brake is engaged by operating Product Identification Number(E)_________
the parking brake button.
Model(F)____________________________
Max Nominal Speed(G)________________
Engine Power(H)_____________________
Manufacture Date(I)___________________
Local regulation may require documentation of the
Month and/or Year of manufacture in the Opeation
and Maintenance Manual. Enter on line (I) above if
required.

27
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1 1
3 3
Usage andI Main Technical Parameters I
O O

K K
M M
2 2
F F
_ _
K K
3 3
1 1
3 Attention 3
I
This section is of great significance for the
correct use, maintenance and repair of the
I
machine. O O

28
 K K
3 3
1 1
3 3
Purpose I I
O
This loader is a large construction machine mainly O
used for handling of bulk material.Mainly used
for:digging, levelling, bulldozing, loading and
dumping, towing operation.
Working environment requirements
1. Altitude: ≤3000m
2. Ambient Temperature: Standard Configuration -
15℃~43℃ ( If not equipped with high ambient
radiator or pre-heater.)
3. Fording Depth:≤650mm
This loader is a general construction machine and is
not applicable to flammable, explosive, high dust or
toxic gas environment.
Restricted Operation
1. Used with overload.
2. Lift heavy objects with lifting sling hanging
K directly on the bucket tip. K
3. Lift the bucket and excavate above the machine.
M M
Attention
2 2
The precautions regarding the operation,
F
maintenance and safety regulations provided in F
this manual are only applicable to the machine
used_ for specified purposes.Caterpillar _
K
(Qingzhou) Ltd. will not take any safety liabilities
if the user uses this machine outside the scope
K
3
of use specified in this manual. The use will take 3
the safety liabilities in such operations.Under no
1
circumstances, the operations forbidden in this 1
manual shall be taken.
3 3
I I
O O

29
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I
Main specifications I
O SEM653D Loader Specifications O
Main Parameters

Rated load kg 5000

Operating weight kg 16640

Standard bucket capacity m3 2.7

Full load bucket capacity (110% fill factor) m3 2.97

Maximum gradability ° 26.6

Dimensions
Machine Length mm 8085

Bucket Width mm 2963

Machine Height mm 3463

Operational Parameters
Maximum Breakout Force kN 177

Maximum Dumping Height mm 2976

K Dump Reach mm K 1332

M Maximum Height of B Pin mm M 4162

Minimum Turning Radius (over tire) mm 3225

2 2
Minimum Turning Radius (over bucket) mm 6732
F Digging Depth mm
F 32
_
Overall Dimensions _
KWheel Base mm K 3200
Overall Height (Maximum lift of bucket with no load) mm 5376
3
Overall Height Engine Hood mm
3
3463

Minimum1Ground Clearance mm 4681

3 3
Engine
I I
Emissions Stage Ⅱ
O O
Diesel Ratings kw 162

Net Power kw 147

Rated diesel engine speed r/min 2000

Bore x Stroke mm 126×130

Displacement L 9.726

Maximum diesel engine torque @ rpm N.m/rpm 980/1300-1500

0# diesel fuel（-5℃ above） ,

Diesel engine fuel type
20# diesel fue（less than -5℃）

Diesel engine fan diameter (blower) mm 780

Transmission

Transmission Type Fixed shaft power shifting

Transmission gears F4/R4

30
 K K
3 3
1 1
3 3
I
Torque converter type
Single-stage three elementI
centripetal
O
Torque converter conversion factor 3.2±0.05
O
Cooling of torque converter Air cooling with pressure circulation

Operating Speed

Forward gear I speed km/h 7.9±0.5

Forward gear II speed km/h 15±0.5

Forward gear III speed km/h 23±0.5

Forward gear IV speed km/h 39±1

Reverse I speed km/h 7.9±0.5

Reverse II speed km/h 15±0.05

Forward gear III speed km/h 23±0.5

Forward gear IV speed km/h 39±1

Working Hydraulic System

Implement pump model Gear

Implement distribution valve model Direction control

K Number of boom cylinders-inside diameter X stroke mm K 2-Φ170×721

M Number of bucket tilt cylinders-inside diameter X stroke mm M 1-Φ190×563

2 Hydraulic Cycle Times

2
Boom raise time s 5.13±0.5
F Dump s
F 1.07±0.5
_ Lower s _ 3.14±0.5

K
Sum of three implement actions s K9.3±0.5
Brake System
3 3
Service brake type Air to oil Caliper Brake
1
Parking brake type Drum
1
Diameter of3brake drum mm 402 3

I I
Steering System
O O
Steering Hydraulic System type Co-axial flow-amplified steering

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

Steering pump type Gear

Operating pressure of the steering hydraulic system Mpa 16

Steering Angle ° 38

Drive axle

Main drive type Single stage spiral deceleration

Hub reducer type Single stage planetary reducer

Gear Ratio 22.85

Main drive reduction ratio 4.625

Hub Reduction Ratio 4.94

31
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Tires I I
Size of tire
O 23.5-25
O
Tire Model L-3

Ply 16

Tire Air Pressure Mpa F:0.40 R:0.35

Fuel refill capacity L 253

Hydraulic oil refill capacity L 166

Coolant L 48

Crankcase refill capacity L 21

Transmission system refill capacity L 53

Differential and final drive

Front axle refill capacity L 36

Rear axle refill capacity L 36

Electrical System Voltage v 24

Battery model 6-QW-120B

K K
Bulb voltage v 24
M Diesel engine starting type
M Electric Start
2 Working medium of air conditioning system 2 R134a

F Heating capacity of air conditioning system kilowatt F 5

Cooling capacity of air conditioning system kilowatt 4.5

_ _
Voltage of air conditioning system v 24
K K
3 3
1 1
3 3
I I
O O

32
 K K
3 3
1 1
3 3
I Section
Operation I
O O

K K
M M
2 2
F F
_ _
K K
3 3
1 1
3 3
Attention
I I
Before operating this machine, please read
O
carefully and understand the content of this O
manual so that you can operate the machine
correctly.Correct operation is critical to ensure
safety, achieve high work efficiency, and increase
the service life of the machine.

33
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I
Control devices and monitoring system I
O Control Devices and Monitoring System of SEM653D
Layout of the In-Cab O

K K
M M
2 Symbol Description 2
Function

F Coolant Temperature Warning F

Engine coolant temperatures in the green area are normal and
Lamp those in the red area are high.
_ _
K Transmission Oil Temperature K
Turns on when the transmission oil temperature is too high.
Warning Lamp
3 3
1 1
LED Display Display working time
3 3
I I
O O
Engine RPM/Fuel Gauge Display RPM/ Fuel Level

Steering Left Indicates the machine is turning left

Steering Right Indicates the machine is turning right

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

The indicator light illuminates when the diesel engine is running

to indicate that the alternator is not supplying power and the
Charging Indicator engine needs to be stopped and checked immediately; It is
normal for the lamp to be illuminated when the engine is not
running

34
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1 1
3 3
Symbol I Description Function I
O Engine Oil Pressure Indicator Alarm when oil pressure is above or below normal value
O

Drive train oil pressure Illuminate when oil pressure is abnormal

Low Beam Lights Low beam lights are on

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

Preheat Indicator Preheating indicator before engine start

High Beam Lights High beam lights are on

Water in oil warning light Indicates the primary filter needs to be drained
K K
M M
The indicator light flashes when damage to the component
Level Two or Three Warning Lamp occurs, or certain operation needs to be stopped immediately, or
2 potential accident exists. 2
F F
The light turns on when the engine fails Need to stop and check
_ Engine Fault Indicator
immediately _
K K
3 Economy Mode The power switch is in economic mode 3
1 1
3 Heavy Duty Mode The power switch is in heavy duty mode 3
I I
O O

35
 K K
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1 1
3 3
1. High/low beam switch I
2. Front work light switch
4. Gauge light switch
5. Front wiper
7. Turn indicator switch I
3. Rear work light switch O 6. Troubleshooting switch (optional) O

K K
1. Shifting control lever 4. Bucket joystick 7. Start switch
M 2. Steering wheel 5. Raise joystick M
8. Parking brake button
3. Horn switch 6. High/low-speed joystick 9. Switch valve
2 2
F F
_ _
K K
3 3
1 1
3 3
I I
O O

36
 K K
3 3
1 1
3 3
I Button
Parking Brake 3. ON - The first position the start switch key I
reaches when turned clockwise after it is
O
The parking brake button is located on the control inserted.In this position, the electrical system of O
console.When the button is pulled up, the parking the whole machine is powered on and functions
brake is engaged and braking is applied;When it is normally.
pushed down, the parking brake is released and the
braking is removed. 4. START - The second position the start switch
key reaches when turned clockwise after it is
The parking brake also serves as the emergency inserted.Start the machine at this position. The
brake.In case of emergency during the operation of starting motor is powered on and starts the
the machine, manually pull up the parking brake engine. Please release the starting switch key
button to apply emergency brake. immediately after the engine is started
If there is a malfunction in the service brake system, successfully. As this position can not be held
and the air pressure in the service brake circuit is automatically, the starting switch key will turn
less than 0.4Mpa, the parking brake will engage back to the ON position of the starting switch
automatically.The loader will take emergency stop to after it is released.
ensure safe operation.

Attention
Start Switch Please make sure the negative switch is in the
ON position and the speed control lever is in the
The starting switch (also called electric lock) is
neutral position before starting the engine.
located on the control console. The switch has four
K positions in clockwise order. K
M M
If the engine fails to start, the starting switch
2 2
must be turned to the OFF position before
F starting the engine again. Otherwise damage to
F
the starting switch may occur.
_ _
Each starting attempt must not be longer than 15
K K
seconds. Wait at least 30 seconds between two
starting attempts, and the number of consecutive
3 3
starting attempts must not exceed 3 times.After
three starting attempts, the starting motor and
1 shut-down electromagnet should be allowed to 1
3 cool down completely before starting again. 3
Otherwise the service life of the battery will be
I
1. Auxiliary - A position that the start switch key
shortened, and damage to the starting motor and I
shut-down electromagnet can also occur.
O
reaches when turned counterclockwise after it is O
inserted. This position is self-resetting (returning When starting on a high slope, do not use the
to the OFF position automatically when released). power cut-off function to ensure safety.
2. OFF - When the switch is in this position, the
power supply control circuit of the whole machine Accelerator Pedal
is cut off, and only the roof light and horn still The acceleration pedal is located in front of the
function normally. driver's seat, on the right side.When the pedal is in
Attention its natural position, the engine will idle.When the
acceleration pedal is depressed, the fuel supply to
The switch key can only be inserted or removed the diesel engine is increased for a bigger power
in the OFF position. output of the diesel engine.

37
 K K
3 3
1 1
3 3
I
Switch Valve During loading operation, make full use of the boom I
float device and bucket auto-levelling device to
O effectively reduce the work load of controlling the O
work tools and increase the comfortability of
operation.

Before the operation of the boom and bucket, it

must be confirmed that there is no obstacles or
personnel around, over and below the machine,
otherwise damage to the equipment or personal
injury may occur, whatever state the machine is
in!
It is located on the control console. During normal
operation, the switch valve button is in the ON
position, and the transmission power will be cut off Horn switch
during braking to avoid the slipping of the The horn switch is in the middle of the steering wheel.
transmission clutch and increase the service life of Push the horn switch and the horn will sound.
the transmission. During on-slope operation, the
switch valve button is in the OFF position, and the Shifting control lever
transmission power will not be cut off during braking
to prevent the danger caused by sudden failure of The shifting control lever is installed under the
steering wheel.Moving the lever forward or backward,
K the service brake and ensure safe operation. K
in combination with the high/low speed control lever,
M M
can operate the machine in forward gear I, gear II,
High/low speed control lever gear III and gear IV;reverse gear I, gear II,gear III
2 and gear IV and neutral.2
Push forward to get low speed and pull backward to
F
get high speed. The middle position is neutral. F
When the high/low speed lever is in the low speed
position, push the shifting control lever forward, the
_ _
first position is forward first gear, and the second
Operating Joysticks position is forward second gear; push the shifting
K K
control lever backward, the first position is reverse
The work joysticks contain the raise joystick and second gear, and the second position is reverse one
3
bucket joystick. The joysticks are installed on the 3
gear. When the high/low speed lever is pushed to the
control console to control the operation of the work
1
tool.Pull the lift liver backward to raise the boom;and
1
high speed position, the machine gears can be set in
forward third and fourth gears, backward third and
3
push forward to lower the boom;Pull the bucket lift fourth gears follow above operation. 3
liver backward to tilt back the bucket;and push
I
forward to dump the bucket.The lever will return to I
the HOLD position when the lever is released.
O Steering Wheel O
Push the lift leverforward through the detent. The
boom will in the FLOAT position. The lift lever will The machine uses articulated coaxial flow
remain in the FLOAT position until the lever is moved amplification steering with the steering wheel
out of the detent and return to the HOLD position. installed in the cab. The steering wheel is
connected with the coaxial flow amplification
When lowering the boom, push the lift lever forward steering gear.During normal operation, turning
to the FLOAT position.The boom will float with the the steering wheel clockwise will cause the
contour of the ground.At this time, the right hand of machine to turn right;turning the steering wheel
the operator can perform other operations (e.g. counterclockwise will cause the machine to turn
levelling the bucket) to increase work efficiency. left.
During scraping or loading operation, push the raise The coaxial flow amplification steering has the
joystick to the float position to allow the bucket to following features:
raise and fall with the ground grade change and
avoid damage to the ground. 1. The angle the steering wheel turns is not equal
to the angle the machine turns. Turn the steering
wheel continuously will increase the turning
angle of the machine until it reaches the desired
steering position.

38
 K K
3 3
1 1
3 3
I
2. The faster the turning speed of the steering The negative switch is different from the starting I
wheel, the faster the machine turns. switch.Turning off the negative switch will turn off the
O
3. The steering wheel will not restore to the original
electrical system of the whole machine.However, O
when the starting switch is turned off, the battery is
position automatically after it is turned and the
still connected to the electrical system of the whole
machine will hold the turning angle.Therefore,
machine and some electrical components can still
when the steering of the machine is completed,
function.
the steering wheel should be turned in the
opposite direction so that the machine can drive
in a straight direction.

Brake Pedal When the whole machine is shut down and

during flushing of the machine, the negative
The service brake pedal is located in front of the switch needs to be put in the OFF position.
operator's seat on the left.When the service brake
pedal is depressed, the frond and rear drive axle Do not turn off the battery negative switch when
wheel brakes will engage to brake.The braking light the engine is still running. Otherwise damage to
switch will be turned on at the same time to the electrical system of the whole machine can
illuminate the braking light.Release the service brake occur!
pedal will disengage the service brakes.
Usage of Cat® Product Link
In case of braking system malfunction, the repair
should be performed in a timely manner to ensure Communication Devices
enough braking capability of the machine. Cat® Product Link communication device
K Battery negative switch K
uses cellular and satellite positioning technology
to communicate the information to Caterpillar
M The battery negative switch in installed in the battery M
(Qingzhou) Ltd., Caterpillar (Qingzhou) Ltd. dealers,
case on the right side of the loader and can be seen and Caterpillar (Qingzhou) Ltd. customers. The
2 once the battery case cover is opened.
2
information may include: device serial numbers,
device locations and work data, fault codes, etc.
F F
which will be used to provide services to customers,
_ _
detect the health of equipment, help maintain
equipment, and improve equipment efficiency.
K K
3 3
1 For machines equipped with Cat® Product Link 1
device, if electric detonators are used in the
3 blasting operation, the radio frequency device 3
will interfere with the electric detonators, causing
I serious injury and death. The communication I
device shall be deactivated within the distances
O mandated by applicable national or regional
O
regulations. In the absence of regulatory
OFF status of the negative switch: requirements, Caterpillar (Qingzhou) Ltd.
To cut off the power supply for the electrical system recommends that users to conduct their own risk
of the whole machine, it is necessary to turn the assessment to determine the safe operating
negative switch handle counterclockwise to the OFF distance.
position.
When the negative switch is in OFF status, the
handle of the switch points to the right bottom Since our device uses satellite positioning and
direction of the negative switch mounting plate. cellular technology for communication, our
ON status of the negative switch: communication device may not work properly in
areas or periods where or when there is no
Before starting the machine, the negative switch communication signal, communication signal is
handle must be turned clockwise to the ON weak, communication signal is unstable, or is
position.When the negative switch is in ON status, susceptible to interference. Caterpillar (Qingzhou)
the handle of the switch points to the left bottom Ltd. does not bear any liability for problems
direction of the negative switch mounting plate. arising from this, including device not being able

39
 K K
3 3
1 1
3 3
I
to function properly and receive remote natural wind position (O position). The heating I
commands (including shutdown or start system will start to work and hot air will flow out
O
commands) or user notices, and the resulting of the air outlet continuously. O
personal injury or property damage.
Natural wind:
Lighting of the whole machine The air conditioning system of the machine is
The lighting of the whole machine consists of the equipped with internal and external circulation
front combination lights (one piece on each side), devices. In cool seasons like spring and autumn,
rear combination lights (one piece on each side), when you only need the natural wind and use it to
indoor light, fog-proof light (one on each side), rear adjust the air flow in the cab, turn the air volume
working light (one on each side) and the beacon. switch to a suitable position and turn the selection
switch to the natural wind position.
Of which, the front combination lights include the
headlights, front small lights, and front turning lights,
and the rear combination lights include the rear small
lights, rear turning lights, braking light and backup When the ambient temperature is below 0C and
light. the engine is not running, if antifreeze is not
Air conditioning system switch added to the engine coolant, the engine water
tank should be emptied, and the hot water valve
The air conditioning system of the machine has three and electromagnetic water valve should be
functions, including cooling, heating and natural wind. opened to drain the coolant in the evaporator.
The air conditioner control panel is shown below. Otherwise the radiator plumbing can be frozen
and cracked due to the low temperature.
K K
Backup automatic alarm system
M M
The backup alarm is mounted on the rear sealing
2 2
plate. When the steering and shifting lever is
operated to reverse the machine, the backup alarm
F will sound automatically.
F
_ _
K K
The backup alarm is close to the radiator. When
3 3
adjusting the sound volume of the backup alarm,
Turn the air volume switch clockwise to increase the
1
air volume and counterclockwise to reduce the air
the engine must be shut down and protection 1
against high temperature must be used to avoid
volume. There are three air volume positions, i.e.
3
high, medium and low. Turn the switch to the OFF
burning. 3
I
position to turn off the fan. I
The selection switch has two positions, natural wind
O
(O position) and cooling (AC position).
O
The specific functions and operation instructions
are as follows:
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 refrigerating 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 for a period of time.
2. Turn the selection switch counterclockwise to the

40
 K K
3 3
1 1
3 3
Driver seatI adjustment I
O
The operator seat on this machine can be adjusted
O
in terms of hardness and softness (i.e. stiffness),
forward and backward position, backrest angle and
headrest height to accommodate the needs of
different operators and different working situations.

3. Armrest Adjustment
Turn the adjustment wheel below the armrest
Grab clockwise to lower the armrest and counterclockwise
handles to raise it. (Note:The armrest is used to support the
arms and must not be used to support other heavy
Seat Belt
SEAT
CUSHION objects, otherwise, breakage of the armrest can
Upper Slide
Forward and occur.)
Back
Adjustment
Handle

Body Weight
Adjustment
Handle

K K Adjustment Wheel

M M
2 1. Weight Adjustment
2
Mechanical handle seat adjustment
FTurn the adjustment handle according to the weight method F
of the user. Turn the handle clockwise to increase
_
the weight adjustment scale and the other way to
_
1. Forward and Backward Adjustment
K until you feel comfortable. For weight
reduce, K
Pull up the forward and backward adjustment handle
adjustment, refer to with hand, move the seat back and forth. Release
3
damper stiffness adjustment reference table.
3
the handle and the seat will lock to a desired position
1 automatically. 1
Body Weight
Adjustment Handle
3 3
Forward and Back
I Adjustment Handle I
O
Body Weight Reference
O
Display Port

2. Height Adjustment
The seat height can be adjusted between three
positions. When the seat is at its lowest position, it is
in position 1. Lift the cushion with hand until a click is
heard, and the seat in position 2. Lift further up until
a click is heard and the seat in position 3. Lift further
to the highest point (neutral position) and release,
the seat will return to position 1 automatically.

41
 K K
3 3
1 1
3 3
I adjustment reference
Damper stiffness Open the door to the 90°position. The position lock I
table on the door will contact the buckle outside the cab
O and lock the door to this position.Hold the inside door O
Driver Weight handle with your hand with the thumb pushing down
Stiffness Indication
Value the key cylinder.Pull the door outward at the same
time to open the door.

The doors and windows must be closed when

the driver is operating the machine to ensure
safety.

Mirror adjustment
There is one mirror in the top of the cab, and one on
2. Backrest Angle Adjustment each of the left and right side of the cab. Before
operating the machine to perform any work, the
While seated in the seat with the back rested against mirrors must be adjusted to ensure the driver has a
the backrest, pull up the backrest adjustment handle good rear view.
with left hand, and lean forward or backward until the
K backrest is in a comfortable position before releasing
K
Loosen the bolt connecting the mirror bracket and
the cab, and move the bracket to adjust the mirror
M the handle. M
position relative to the cab; Loosen the connecting
2 Backrest Angle
2
bolt between the mirror and the bracket, and move
the mirror to adjust the angle of the mirror.Tighten
F Adjustment
F
the bolts after the adjustment is complete.

_ _
K Run-in of new machineK
The run-in of new machine is of great importance for
3 3
increasing the service life of the machine, eliminating
Considerations
1 1
potential failure trouble, and avoiding severe
1. During the seat forward and backward failures.After buying the machine, the user must
3
adjustment and the backrest angle adjustment, perform the operation and maintenance of the 3
the adjustment handle should be pulled into machine according to the new machine run-in
I
place to make sure that the lockout teeth are procedures specified in this manual before normal I
O
disengaged completely before adjustment. use of the machine. O
2. After the adjustment, the handle should be
returned to the original position to make sure that
the lockout mechanism locks securely.
3. When the weight adjustment scale reaches the
red warning line, it must not be adjusted further.
Use of Door Lock
If the door lock is engaged, the key cylinder can not
be pushed down.At this time, insert the key and turn
180°in clockwise direction before removing the key.
Hold the door lock with the thumb pushing down the
key cylinder and pull the door outward to open the
door.To lock the door, first close the door, then insert
the key and turn 180°in the counterclockwise
direction before removing the key.
Use of the position lock

42
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3 3
1 1
3 3
I
Run-in requirements of the new machine lamps and turning signal lights etc. for normal I
operation.
1. The run-in period of the new machine is 10 hours.
O O
2. Idle the machine for 5 minutes after starting. Attention

3. During the run-in period, each of the forward I, II, When checking the oil levels, the appropriate
III, IV and reverse I, II, III, IV gears should be operation specifications should be followed.
used evenly for run-in.
4. The machine should start with low speed and Perform the following after the run-in period is
small throttle, and accelerate gradually.Sudden over:
starting, accelerating, turning and braking should
be avoided unless in case of emergency. 1. Completely check the bolts and nuts of all
components for tightness, especially the diesel
5. During the run-in period, it is preferably to load engine cylinder head bolts, exhaust pipe bolts,
some loose material and the operation must not front and rear axle mounting bolts, rim nuts,
be too hard and too quick.During the run-in driving shaft connecting bolts, diesel engine
period, the loading weight must not exceed 70% mounting bolts, transmission mounting bolts,
of the rated load and the travelling speed must front and rear frame articulation bolts etc. should
not 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
K K
for leak tightness.
7. Frequent attentions must be paid to the
M temperatures of the transmission, torque M
4. Inspect or change the transmission drive oil and
converter, front and rear axle, wheel hub, parking drive axle lubricating oil.
2 brake, central supporting shaft, hydraulic oil, 2
5. Inspect or replace the filter elements of the
F engine coolant and engine lubricating oil. If F
transmission oil filter, diesel engine oil filter and
overheating is found, identify the cause and diesel fuel filter.
_
repair as necessary. _
6. Clean the oil drain filter element of the hydraulic
K
8. Check the bolts and nuts of all components for
tightness
oil tank. K
3 Attention 3
1
Perform the following after eight hours of run-in When changing the transmission oil, drive axle1
of the new machine: lubricating oil and diesel engine oil, the
3 appropriate operation specifications should be 3
1. Completely check the bolts and nuts of all followed.
I
components for tightness, especially the diesel I
engine cylinder head bolts, exhaust pipe bolts,
O
front and rear axle mounting bolts, rim nuts, Operating Precautions O
driving shaft connecting bolts, diesel engine
mounting bolts, transmission mounting bolts, 1. Before Starting the Engine
front and rear frame articulation bolts etc. should
be checked completely once. Job Site Safety
2. Check the tension of the fan belt, engine belt and • Before the work, check the area around the
air conditioning compressor belt. machine carefully for any abnormal conditions
3. Check the oil level of transmission oil, drive axle that may cause danger.
oil and diesel engine oil. • Check the terrain and ground condition of the
4. Check the hydraulic system and braking system job site and determine the best and safest work
for leak tightness. method.

5. Check all the control levers and acceleration • Before the work, prepare the ground as solid
lever for secure connection. and level as possible.If there is heavy dust at
the job site, water should be sprayed before
6. Check the temperature and connection of work.
components in the electrical system, check the
power supply of the alternator, and check the • If the job is to be completed on the street, there
43
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3 3
1 1
3 3
I
must be a special person to direct the traffic, or • Adjust the operator seat to a position where
I
a fence should be set up with the "Do not easy operation can be performed. Check the
O
enter" sign to protect the pedestrians and seat belt and the mounting hardware for O
vehicles. damage.The seat belt must be replaced after
three years of use.
• For sites with buried facilities underneath, such
as water pipe, gas pipe, high voltage cable pipe, • Check all the instruments for normal operation.
the relevant authority should be contacted to Check if the control levers are in the correct
locate the buried facilities.Meanwhile use care position.
not to damage these facilities during work.
• Remove any dirt on the window glass and
• When working in water or passing sand bank, lights to ensure good visibility.
check the surface condition, water depth and water
flow velocity first.The allowed fording depth must • Adjust the position of the mirrors so that best
not be exceeded.When working in puddle or views can be achieved from the operator's
swamp site, the water depth must not exceed the seat.Wipe clean the surface of the
bottom of the axle housing.Clean and check the mirrors.Replace the glass of the mirror with
lubrication check points after the operation is new one if damaged.
complete.
• Check the headlights and working lights for
proper illumination.Repair if any abnormal
Axle Case results are found.
• A fire extinguisher must be available and its
K K
use method must be mastered.

M • Do not place the M

machine close to open fire.

2 2
F 2. When StartingF the Engine
Checks before starting the engine
_ • Before mounting the machine,
_ perform another
Perform the following checks everyday before walk-around inspection of your machine and
K
starting the engine.Failure to perform these checks K
check for any personnel or objects on, below
may lead to serious injury or damage. or near the machine. Check if there is any
3 person in the working area. 3
• Check the
1 area around the engine and battery
for buildup of flammable material, check for • If a "Do not operate" warning label 1
is attached
to the control lever, the engine must not be
3
fuel, lubricating oil and hydraulic oil for leaks,
started.
3
and check the mirrors, hand rails and steps for
I
contamination by fuel. • Sound the horn when starting the engineIto
O and tools around the
• Do not leave parts give an alert. O
operator's seat.Due to the vibration during • The engine can only be started and operated
travelling and operating, these objects may fall with the operator sitting in the operator's seat.
down and cause damage to the control levers
or switches, or cause the control levers to • No person other than the operator should stay
move to start the work tools, which will result in the cab.No one is allowed to sit on the
in accidents. machine body.
• Before mounting the machine, remove the dirt • The engine can only be started within the cab.
and fine sands attached to the shoes, as they Never start the engine by short-circuit the
will accumulate at the supporting points of the starting motor, which will lead to damage to the
acceleration pedal and brake pedal, preventing electrical system of the machine by starting the
the pedals returning to the original positions.If system with bypass circuit.In addition, this
there is dirt and sand accumulation at these operation is very dangerous.
points, remove immediately.
• Make sure the backup alarm, if equipped,
• Check the coolant level, fuel level and the oil functions properly.
level in the engine oil pan. Check the air filter
for plugging and the wiring for damage. •

44
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3 3
I Attention • Check the operation of the instrumentation
I and
equipment. Check the operation of the bucket,
O
One starting attempt should not be longer than boom, braking system, driving system and O
15 seconds (the time that the starting motor steering system.
works continuously should not exceed 15
seconds). If the starter does not start the engine • Check the machine for unusual noise, vibration,
after 15 seconds, the starting switch should be heating, smell or instrumentation operation.
released immediately. Wait at least 30 seconds Check for hydraulic oil, lubricating oil, air or
before another starting attempt.This is jointly fuel leaks.
determined by the features of the starting motor
and the battery. If the engine fails to start after • If any abnormality is found, repair
three consecutive attempts, it should be checked. immediately.If the machine is operated under
After the malfunction is corrected, and at least unsuitable conditions, serious injury or
three minutes later, the engine can be started machine damage may occur.
again.
• Before traveling or starting the work, the
lockout lever should be locked in the RELEASE
• The engine should run at idle speed to warm-up position securely.
after starting(at least 5 minutes recommended)
• Listen to check if the engine operates properly When starting travelling
while it is running at low speed, and check the
transmission of abnormal noise.
• Before starting traveling, check around the
machine again to make sure there is no people
K • Check all the instrumentation for proper operation, and obstacles. K
and check the lighting devices, indicators, horn,
M • When starting traveling,
M sound the horn to give
wipers, braking lights for proper operation.
an alert.
2 2
Attention • The machine can only be operated with the
FSpecial attention should be paid to the F
operator sitting in the operator's seat.
_
instrumentation
indicator lamps.
panel for engine malfunction _ equipped)
• Seat belt must be fastened.(If
K K should stay
• No person other than the operator
in the cab.No one is allowed to sit on the
3 seasons, preheating of the hydraulic oil
• In freezing machine body. 3
should be performed.Pull back the work valve
1 lever and hold it in position for 4-5
bucket control 1 for
• Check the backup alarm, if equipped,
minutes. Meantime, increase the throttle to keep normal operation.
3
the stop block of the bucket against the boom and
3
I oil overflow, which will increase
make the hydraulic Considerations During Traveling I
the hydraulic oil temperature rapidly.
O O
• The key in the start switch must not be turned
• Check the service brake and parking brake system to the OFF position while the machine is
for proper operation. traveling.It is very dangerous if the engine dies
• If there is no obstacles around the machine, turn during traveling, because the steering will be
the steering wheel slowly to see if the machine heavy.If the engine dies, the brakes should be
turns accordingly. applied immediately to stop the machine.
• The operator must concentrate on the work
3. After Starting the Engine during operation.
Checks after starting the engine • Driving too fast, sudden braking, sudden
Failure to perform the appropriate checks after stopping, sharp turns or zigzagging are all
starting the engine will delay the discovery of the dangerous.
abnormal phenomena.And this can result in serious • If any abnormality (noise, vibration, smell,
injury or machine damage. incorrect display of instrumentation, air leak,
When conducting the checks, it should be performed oil leak etc.) is found during the operation, the
in an open area without obstacles.No one should get machine should be moved to a safe place and
close to the machine. find the causes.

45
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1 1
3 3
• Adjust the height
I of the work tool to the result in severe injury or accident. I
position where the lowest point of the bucket is
O
300-400 mm above the ground, and travel on a
• If you plan to drive the machine continuously,
O
please consult the authorized dealer of
flat surface.
Caterpillar (Qingzhou) Ltd.

Checks when changing the direction

To avoid injury or death, the following rules must be
followed before moving the machine or the work tool,
even if the machine is equipped with backup alarm
and mirrors:
• Sound the horn to alert the personnel on the
• Do not operate the work control lever of the site.
work tool during traveling.If the work control
• Check around the machine. There should be no
lever of the work tool must be operated, the
person.Check especially the area behind the
machine should be stopped before the
machine as it is not visible from the operator
operation.
seat.
• Do not operate the steering wheel suddenly.If • Where there is a danger or the visibility is poor,
doing so, the work tool may touch the ground
one person should be designated to direct the
surface and the machine may lose balance, or
traffic.
damage to the machines or structures around
K may occur.
K
• Persons without approval must not enter areas
M • When traveling on the uneven surface, keep the M
in the turning direction or traveling direction.

2 speed low and avoid sudden steering. • The traveling direction

2 must not be changed
when the machine is at high speed.
F• Try to avoid driving over obstacles.If it is
necessary for the machine to drive over an
F
_obstacle, try to keep the bucket close to the Forbidden operation _
ground.
K • The load of the machine mustKbe kept within
• A distance should be kept from other machines the specified maximum load to avoid fall-over
3
or structures during traveling or work to avoid 3
of the machine and damage to the work tool
collision. due to overloading.The specified capacity of
1 1
the machine must not be exceeded during the
• If working in water, the allowed water depth use of the machine.
must not be3exceeded.The water depth must 3
not exceed the bottom of the axle housing.
I • Caterpillar (Qingzhou) Ltd. will not be I
responsible for any injury, accident or damage
• When driving onO bridges or structures on to the machine resulting from overloading of O
private properties, first check the strength to the machine.
see if it is enough to support the weight of the
machine.When driving on public roads, the Travelling on slope
rules of the appropriate authorities must be
• Traveling on slope may cause the machine to
met and appropriate regulations must be
fall over or slide to one side. Be especially
followed.
cautious.
• Traffic rules should be followed when driving • When traveling on the slope, the lowest
on public roads.The driving speed of the
position of the bucket should be kept 200-300
machine is lower than the normal speed of
mm above the ground.In case of emergency,
automobiles. Drive on the side of the road to
lower the bucket to the ground quickly to help
leave the center of the road to other vehicles.
stop the machine.
• If the machine runs at a high speed
continuously for a long period of time, the tires
will overheat and the internal pressure will
become extremely high.This may lead to the
blowout of the tire.If the tire blows out, extreme
destructive force will be generated, which may

46
 K K
3 3
1 1
3 3
Error
I Correct
187,000 6m I
20 ft

O 275,000 7m
O
23 ft

500,000 11m 36 ft

• To prevent accidents, please take the following

precautions:
1. If there is a potential risk of the machine touching
• Do not turn or travel transversely on a power cables on the working site, consult with
slope.Drive the machine down to a level the power company before starting the operation,
surface to complete these operations. and check and determine the feasibility of the
operation according to the current relevant
• When traveling downhill, never shift gears or regulations.
put the transmission in the neutral position.Put
the transmission in the low speed gear before 2. Wear rubber boots and rubber gloves.Place a
starting driving downhill. rubber pad on the operator's seat, and pay
attention not to allow any exposed part of the
• Keep speed low when driving downhill.If body contact the metal chassis.
necessary, use the brake pedal to control the
speed. 3. Specify a signalman who will give warning
signals when the machine gets too close to the
• Do not drive at high speed on grassland, fallen power cable.
leaves or wet steel plate.If operating this way,
K even a very small slope can cause the machine K
4. If the work tool makes contact with the cable, the
to slide to one side, and the driving speed, operator must not leave the cab.
M therefore, should be kept low.When driving on M
5. When working in the vicinity of high-voltage
2 a slope, drive straight upward and downward. 2
cables, do not allow any person to get close to
the machine.
F• When travelling on a slope, if the engine dies,
the brake pedal should be depressed fully
F
6. Consult the power company for the voltage of the
_
immediately to apply the brake and the bucket cable before starting operation._
should be lowered to the ground before
K
applying the parking brake to secure the K
machine in position. Precautions During Operation
3 3
• If the bucket is loaded when driving up or down
1
a slope, the bucket should always point to the 1
uphill direction (i.e., facing front when going up,
3 3
and facing back when going down).When
I
driving on a slope with a loaded bucket, keep I
the bucket toward the downhill direction will
O
cause the danger of machine fall-over. O
• Do not get too close to the edge of a
Do not get close to high-voltage cables cliff.During dike-building or earth-filling, or
dumping into a cliff, pile the earth into a dump,
• Do not allow the machine to touch the and push the dump through another dump.
overhead cables.Even just getting close to the
cable can cause electric shock.The safe • When pushing the earth down a cliff or to the
distance as specified in the following table top of a slope, the load of the machine can
should be kept between the machine and the become light suddenly.In such cases, it can be
cable. dangerous as the driving speed will increase
suddenly. Therefore, the speed must be kept
Voltage (V) Minimum safe distance low.

Low Voltage
100-200 2m 7 ft • When the bucket is fully loaded, the machine
6,600 2m 7 ft must not start, turn or stop suddenly.
22,000 3m 10 ft

High Voltage 66,000 4m 14 ft

154,000 5m 17 ft

47
 K K
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1 1
3 3
• When moving Iunstable load, e.g. round or Using method of the brakes I
cylindrical object, layered sheet, raising the • Do not put your foot on the brake pedal unless
O
work tool can cause the danger of the load O
really necessary.
falling on the top of the cab, resulting in
serious injury or damage.When moving • Do not depress the pedal repeatedly unless
unstable load, pay attention not to raise the really necessary.
work tool too high or tilt the bucket backward
too much. • When driving downhill, use the engine as a
brake and never shift gears or put the
Error Error
transmission in the neutral position.

Error Error
Use caution in snowy days
• When working on roads with snow or ice, even
a small slope can cause the machine to slide
away. Therefore, the speed must be kept low
and sudden start, stop or turn must be
• If the work tool falls or stops suddenly, the avoided.There will be a danger of slippery,
reacting force can cause the machine to fall especially when going up or down a slope.
over.Especially when the machine is loaded,
extreme attention must be paid to the operation • On frozen roads, the ground will become soft
of the work tool. as the temperature rises and the traveling
conditions will become unstable.Under such
K • Do not use the bucket or boom for lifting K
circumstances, special cautions must be used
purpose.
M during driving. M
• The machine can only undertake specified • The road shoulder and
2 work. Other operation beyond the use scope of 2 roadside items will be
covered and become unclear after heavy snow.
F the machine can damage the machine.See
"Usage and Main Technical Features and
F
Therefore the snow must be cleaned carefully.

_
Parameters" for specified work. • When driving on snow-covered
_ roads, antiskit
tire chain should be used.
• Pay
Kattention to the following aspects to K
ensure good visibility: • When driving on snow-covered slopes, never
3
1. When working in dark places, turn on the
3
apply the brake suddenly.To decelerate,
depress the brake pedal intermittently for
1
working light and the headlights, and install 1
several times.If necessary, lower the bucket
lighting device at the working site if necessary.
3 onto the ground to stop the machine. 3
2. Do not work in a foggy, hazy, snowy, heavy rainy
I
day or other circumstances with poor • The traction of the ground varies greatly Iwith
visibility.Wait until it is clear and bright and there the influence of the snow. Therefore the load
O
is enough visibility before starting the work. needs to be adjusted accordingly to avoid O
skidding of the machine during travelling.
• Pay attention to the following points to prevent Do not work on soft and loose ground
the work tool from colliding with other objects:
1. When working in the tunnel, under the bridge, • Do not operate the machine on a soft and loose
ground.As the machine tends to get stuck into
under the cable or in other places where the
such ground and it can be difficult to get out.
height is limited, special attention should be paid
not to allow the bucket hit any objects. • Do not let the machine get too close to the
2. When loading a dump truck, check to make sure edge of a cliff, or the suspended location and
there is no person around the machine. Pay deep trench.If these places collapse due to the
attention not to allow the bucket to touch the cab weight or vibration of the machine, the machine
of the dump truck. can drop or fall over, resulting in serious injury
or death.Remember, the ground will become
3. To avoid accidents resulting from collision with soft after heavy rain, explosion or earthquake.
other objects, the machine should work at a
speed of safe operation, especially in limited
space, indoor or places with other vehicles.

48
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1 1
3 3
I the ground and near the
• Piles of earth on • Level the bucket on the ground and put the Iwork
trench are soft and loose.It can collapse due to valve control lever in the neutral position.
O
the weight or vibration of the machine, causing O
the machine to fall over. • Put all switches in neutral or OFF position.Lock all
doors.
• If there is a danger of falling stone at the work
site, the falling object protective structure • Apply a thin film of grease on the exposed part of
(FOPS) should be installed. the hydraulic oil cylinders.

• If there is a danger of falling stone or rollover at • Remove the battery from the vehicle and store
the working site, the rollover protective separately.
structure (ROPS) should be installed and the • If the ambient temperature can possibly go below
seat belt should be fastened. 0 C, add antifreeze to the engine and make sure
the antifreeze reaches the engine body and the
evaporator of the air conditioning system.Or drain
4. Storage of the Machine the cooling system completely. Also drain the air
conditioning system.
• Park the machine on a level surface and lower
the work tool to the ground.The location should • Secure the front and rear vehicle frames with the
be free of falling stone or landslip.If in low-lying frame lockout lever.
area, there also should be free of the danger of 2. During storage
flood.
• Start the machine once every month. Run each
K • If it is necessary to park the machine on a K
system and grease each moving pin shafts and
slope, chock the wheels to prevent the machine drive shafts so that the moving components get
M from moving.Then lower the work tool to the M
lubricated and the battery gets charged.
ground.
2 2 wipe off the grease on
• Before starting the vehicle,
• When parking on the roads, a fence, signal, flag the piston rod of the hydraulic oil cylinders.Apply a
F or warning light should be set up and other F
thin film of grease again after the operation is
necessary signals should be placed to make
_
sure the machine can be clearly seen by the
complete. _
K
passing vehicles.In addition, the machine, • Apply anti-rust oil to rust-prone K
areas.
fence, or flag must not hamper the traffic.
3 Attention 3
• When leaving the machine, lower the bucket
1
completely to the ground, and lock the control If anti-rust oil is used indoors, open the doors
1
levers with the locking device to hold it in the and windows for ventilation to remove the toxic
3
braking position.Lock all the devices with a gases. 3
key.Remove the key and take it with you.
I 3. After Storage I
Perform the following operations as required if
O
the machine needs to be stored for a long period:
Perform the following operations when the long
period storage of the machine is over:
O
1. Before Storage
• Change the engine, transmission and drive axle
• Clean each part of the vehicle and dry in the air. lubricating oil, as well as hydraulic oil and
Store the machine in a dry warehouse.If the antifreeze.
machine can only be stored outdoors, it should be
parked on a concrete surface that drains easily
• Grease all the moving pin shafts and drive shafts.
and covered by canvas. • Before starting the vehicle, wipe off the grease on
the piston rod of the hydraulic oil cylinders.
• Before storage, fill up the fuel tank, grease each
moving pin shafts and drive shafts, and change the
hydraulic oil.
• Move the joystick to the NEUTRAL position.
• Pull the park brake button to apply the park brake.

49
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I
Precautions for cold areas Obey all local and national laws and regulations I
that govern the height, width, length and weight
• After completionOof the work, remove all the of a load while shipping. O
water, snow or sludge attached to the wiring,
wire connectors, switches or sensors as well Follow the following procedure in shipping:
as the covering parts of these parts.If these are
1. Before loading the machine, chock the trailer
not removed, the water contained in them will
wheels or the truck wheels.
freeze and cause the machine to fail during the
next usage, and may result in unexpected 2. When the machine is driven onto the trailer or
malfunctions. truck, steering operation is not allowed midway. If
the steering operation is required, the machine
Remove the frozen clot of the work tool and driving
should return to the level ground before the
system before starting.
steering operation can be performed.
• Warm up completely.If the machine is not 3. Secure the front and rear vehicle frames with the
warmed up completely before operating the frame lockout lever after the machine is parked.
control levers, the response of the machine can
be slow, which can lead to unexpected 4. Level the bucket on the transport vehicle and put
accidents. the speed control lever to the neutral position.

Incorrect lifting can cause the machine to drift,

resulting in personal injury and damage.
K K
5. During towing, all personnel should stay away
M M
from both sides of the tow rope to avoid injury
caused by the breakage of the rope.
2 2
6. Typically, the tractor should be the same size of
F F
the machine being towed.The tractor should
have the sufficient braking capacity, weight and
_ _
power to control the uphill operation and
K
Specified Storage Period K
traveling distance of both machines.

3
The specified storage period of this machine is 1 7. While the machine being towed is going downhill,
3
year. After this specified storage period has expired, in order to obtain sufficient control and braking
1
consult your SEM Dealer for inspect, repair, rebuild, 1
capacities, there should be a larger trailer or
install remanufactured, install new components, and another machine behind the machine being
3
disposal options and to establish a new specified 3
towed, to prevent the machine from rolling down
storage period. If a decision is made to remove this when the control is lost.
I
machine from service, see the Decommissioning and
I
8. If the direction of the machine being towed
O
Disposal section of this Operations and Maintenance can be controlled by the operator, the O
Manual. operator must steer in the direction of the
wire cable.

5. Shipping of the Machine

Investigate the travel route for overpass height, width
and the allowable load before shipping. The total
height, width and weight etc. with the machine
loaded on a shipping vehicle must not exceed the
relevant regulations. In case of over-height or over-
width, please consult Caterpillar (Qingzhou) Ltd. or
its dealers for solution.
To prevent the safety accident of the machine
slipping in transit, remove ice, snow, or other slippery
material from the loading dock and from the truck
bed before shipping.

Attention
50
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1 1
3 3
I
Shipping Considerations Manual, "Specifications" for the dimensions and I
weight of the machine
O The lifting points are identified by a label that shows
O
a hook.
Lifting Point - In order to lift the machine, attach the
• Improper lifting and improper tie-downs can lifting devices to the lifting points.
allow the load to shift or fail and cause injury or
Use properly rated cables and properly rated slings
damage. Use only properly rated cables and
to lift the machine.
slings with lift and tie down points provided.
Remove structures above the rear lifting points as
• Follow the instructions in Operation and necessary in order to route lifting cables to the
Maintenance Manual, "Lifting and Tying Down lifting points.
the Machine" for the proper technique for
securing the machine. Refer to Operation and Position the crane or the lifting device in order to lift
Maintenance Manual, "Specifications" for the machine in a level position.
specific weight information. The width of the spreader bar must be sufficient to
If lifting is required for loading and unloading the prevent the lifting cables or the lifting straps from
machine, please hoist according to the lifting contacting the machine.
diagram. Do not allow any personnel in the area around the
machine.

K K
1. Engage the parking brake before you sling
the machine and before you secure the
M M
machine with tie-downs.
2. Install the frame lock pin prior to lifting the
2 machine.
2
F F
3. Attach two lifting cables to the rear of the
machine. There is one lifting eye on each
_ _
side of the rear of the machine.
4. Attach two lifting cables to the front of the
K K
machine. There is one eye on each side of
3 the front of the machine. 3
NOTICE 5. Connect the four lifting cables to the
1
Improper lifting or tie-downs can allow the shift 1
spreader bars. The spreader bars must be
centered over the machine.
3
and cause injure or damage .Install the steering
frame lock link before lifting.
6. If equipped, secure any attachments. 3
7. Lift the machine. Move the machine to the
I
Ensure that the lift arms are in fully lowered desired position. I
O
position before lifting the machine. 8. When the machine is positioned, place the
blocks behind the tires.
O
Check all of the laws that govern the load
characteristics (height, weight, width, and
length). Tying Down the Machine

Reference: For shipping instructions, refer to Note: Do not use handles or steps in order to tie
Operation and Maintenance Manual, "Shipping down the machine. Do not use the work tool to
the Machine". tie down the machine. Do not wrap chains
Lifting the Machine around the rear axle to tie down the machine.
Avoid using the front axle as a tie down location
Note: Do not use handles or steps in order to lift the whenever possible.
machine. Do not use the work tool for a lifting point.
Note: The machine shipping weight that is listed is There may be more than one way to tie down the
the weight of the most common configuration of the machine. Local regulations should be used to
machine. If attachments have been installed on determine the best method. Obey all local and
your machine, the weight of your machine and the regional governmental regulations.
center of gravity of your machine may vary.
Reference: Refer to Operation and Maintenance Note: The machine shipping weight that is listed
is the weight of the most common configuration
51
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3 3
1 1
3 3
I
of the machine. If attachments have been Precautions I
installed on your machine, the weight of your
O
machine and the center of gravity of your The machine uses maintenance free batteries, O
machine may vary. without the need to add electrolyte.
• Battery electrolyte contains sulfuric acid and
Reference: Refer to Operation and Maintenance the battery can generate hydrogen.Therefore,
Manual, "Specifications" for the dimensions and improper handling of the batteries can lead to
weight of the machine. heavy injury or fire.For this reason, the
Note: Use only the specified locations for tying down following considerations must be
the machine. Do not use any other locations in order followed.Never put a lighted cigarette or flame
to tie down the machine. near the battery.

Tie Down Point – In order to tie down the machine, • If the work requires making contact with the
attach the tie-downs to the tie down points. battery, always wear safety glasses and rubber
gloves.
Use properly rated cables and shackles for tying
down the machine. • If the electrolyte inside the battery splashes on
the clothes or skin, flush with plenty of clean
Secure the machine at the tie-down positions. The water immediately.
positions are identified on the machine by a label.
• Battery electrolyte splashing into the eyes can
Use the front eyes and the rear eyes that are result in blindness.If the electrolyte splashes
provided on the lower frame of your machine. Use into the eyes, flush with plenty of clean water
corner protection when necessary. Avoid routing and see a doctor immediately.
K cables over tires. Avoid contact with the work tool to K
If drinking the electrolyte accidentally, drink plenty of
M prevent false tension. M
water, milk, raw eggs or vegetable oil and see a
Install tie-downs at all four locations. Place wheel
2 chocks in front of the machine and behind the 2
doctor or call the emergency center immediately.

F
machine. • Shut down the engine before
F performing any
work related to the engine.
Consult your SEM dealer for shipping instructions for
_
your machine.
_
• Avoid accidental contact with metal objects
ShipmentK K
(e.g. tools) which can result in a short circuit
between positive (+) terminal and negative (-)
• If the 3
machine is transported with a tractor, terminal of the battery. 3
obey the national and local regulations on the
1
weight, height, width and length of heavy • When installing the battery, connect1the
positive (+) terminal first.When removing the
3
objects.Also obey all related traffic regulations.
battery, disconnect the negative (-) terminal 3
• Consider the weight,
I height, width and length (ground wire side) first.
I
of the machine when determining the shipping
• When installing or removing the battery, check
route. O which one is positive (+) terminal or negative (-)
O
• When driving on bridges or structures on terminal first and then tighten the nut securely.
private properties, first check the strength to
see if it is enough to support the weight of the • Use a cloth to clean the top surface of the
battery.Never use gasoline, solvent or any
machine.When traveling on the public road,
other organic solvent or detergent.Tighten the
always meet and follow the related regulations
battery top cover securely.
of the local authority.
• The machine may be separated into several • If the battery electrolyte is frozen, do not
charge the battery or use other power supply to
parts during shipping.Therefore, contact the
start the engine.This is dangerous, because it
designated dealers of Caterpillar (Qingzhou)
can set the battery on fire.When charging the
Ltd. to perform these work.
battery or using other power supply to start the
engine, melt the battery electrolyte and check
for leaks before starting the engine.
6. Battery Use and • Remove the battery from the machine before
Maintenance Considerations charging.

52
 K K
3 3
1 1
3 3
I
Start with Booster Cable I
If there is anything wrong with the connection of
O
booster cable, a fire can result. Therefore, the
O
following method must be taken.
• The starting operation requires two technicians
to complete (one sitting on the operator's seat).
• Two machines are not allowed to make contact
with each other when starting the other
machine.
• When connecting the booster cable, turn OFF
both the START switches of the functional
machine and malfunctioned machine.
• When installing the booster cable, always
connect the positive (+) cable first.When
• Connect the positive (+) clip to the positive (+)
removing the booster cable, always disconnect terminal of the battery and negative (-) clip to
the ground wire or negative (-) cable first. negative (-) terminal of the battery.Make sure
that both the terminals are tightened tightly.
• Finally connect the ground wire to the engine
cylinder block of the malfunctioned • If the charging rate of the battery is lower than
machine.But, this will cause spark, so keep 1/10, perform high-speed charging and set the
K away from the battery as far as possible during K
value below the battery rated capacity.If the
connecting.
M M
charging current is excessive, electrolyte can
leak or evaporate, which can lead to burning or
2 • When removing the booster cable, be careful 2
explosion.
not to let the clips of the booster cable touch
F each other or touch the machine.
7. Towing F
Charging
_ Battery _
When Towing
Improper handling of the battery can lead to battery
K
explosion when charging the battery.Therefore,
K
If the disabled machine is towed in a wrong method,
or the selected wire cable is incorrect, injury or death
3
perform the charging in accordance with the battery 3
can result. Therefore, the following considerations
handling regulations and charging regulations in the
1
instructions, and obey the following considerations. must be obeyed. 1
• Charge the 3
battery in a well-ventilated area with • Operate according to the instructions 3
on
the top cover removed.This can spread the towing in this Operation and Maintenance
I
hydrogen and prevent the explosion.Gases Manual. I
from a battery can explode. • Wear leather gloves while handling the wireO
O
• There should not be flame or spark above the cable.
battery pack.Do not smoke during charging. • While preparing for the towing with other
• Set the voltage of the charger to match that of technicians, determine the signals to be used
the battery being charged.If the voltage setting before performing the work.
is wrong, the charger can overheat and burn, • If the engine of the malfunctioned machine can
and even explode. not 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.
• If the malfunctioned machine is towed by
another machine, the wire cable used must be
capable of carrying the weight of the

53
 K K
3 3
1 1
3 3
I
malfunctioned machine. I
the machine is able to counterrotate to the left or
right.
• The wire cable used
O must not have broken wire O
strands, kinked or reduced diameter. 5. Check the performance of the service
brake.Drive the machine at forward shift position
• Do not stand on the wire cable. 1 or 2 in an open and smooth site. Release the
accelerator pedal first and then smoothly
• While connecting to the machine to be towed, depress the service brake pedal. The machine
never allow anybody to stand between the
should decelerate obviously and stop.
towing machine and the towed machine.
• Keep the hook of the towed machine flush with Attention
the trailing part and hold it in place. If obvious deceleration can not be felt after the
service brake pedal is depressed, pull the park
brake button immediately to apply emergency
brake.Meantime operate the work joystick to
lower the boom to the lowest point and turn over
the bucket forward to make the bucket teeth
insert into or against the ground to force the
machine to stop for safety.

6. Check the engagement of each shift

Machine Traveling Operation position.Drive the machine to an open and
smooth site. Engage each shift position
K 1. Operate the work valve joystick to turn the
bucket to stop state and raise the boom to
K
individually to check the shift response of the
machine.
M transport position (i.e. the lowest point of the M
7. Machine Steering Operation
bucket is about 300-400 mm above the ground).
2 2
If turning the machine is required due to the curve
F F
ahead, operate in accordance with the related local
traffic laws and regulations.
_ _
Before turning, push the turn light switch to the
K K
appropriate direction (pushing left is to turn left,
pushing right is to turn right) and meanwhile the turn
3 3
lights on the left or right side at the front and rear of
2. Depress the service brake pedal and meantime the machine as well as the turn light on the
1
press the park brake button to release the park
1
dashboard will illuminate to alert the adjacent
vehicles and pedestrians that the machine is going to
3
brake.Release the service brake pedal slowly
turn.Then turn the steering wheel in the desired
3
and see if the machine is moving.
I direction and the steering starts. I
To steer at a higher traveling speed, the accelerator
O pedal must be released and apply the service brake
O
If the machine is moving, depress the service if necessary to ensure travel safety.
brake pedal immediately and pull the park brake
button to apply the park brake.Then check if the
variable speed control system of the machine is
malfunctioned.If the machine is uphill, block the Never steer at a slope. Drive the machine down
wheels to prevent the machine from moving to the smooth ground to perform these work.
before checking the machine.
8. Machine Braking Operation
3. Push the variable speed control handle forward
To apply braking, release the accelerator pedal first
to I position or push it backward to reverse
position while depressing the accelerator pedal and then smoothly depress the service brake pedal.
suitably, in order that the machine can travel
forward or backward.
4. Drive the machine to an open and smooth site. If While travelling at a higher speed, do not
the steering performance check is not performed depress the brake pedal to the ground rapidly
during the previous operation due to narrow site, unless there is emergency to avoid accidents
turn the steering wheel at this point, to check if
54
 K K
3 3
1 1
3 3
I
and damage to the machine. Consult the nearest SEM dealer for additional I
Parking the Machine O information. Including information for component O
1. Drive the machine to a smooth area where there remanufacturing and recycling options
should be free of falling stones, landslide and
flood.
Machine Operation
2. Use the service brake to stop the machine. 1. Preparation Before Operation

3. Move the joystick to the NEUTRAL position. Before doing the work, use this machine to level the
site, including removing the protrusion, filling the
4. Pull the park brake button to apply the park holes and removing the wet and slippery ground
brake. surface.Remove large and sharp stones from the site
5. Operate the work joystick to lower the boom and to avoid tire scratches.
put the bucket evenly on the ground and then If using this machine to load or unload the truck or
slightly push down the bucket. hopper, adjust the kickout height of the boom raise
6. Let the engine idle for 5 minutes to allow the kickout to allow the hopper of the loader to enter or
parts to cool down evenly. exit from the truck or hopper safely and not to
damage the truck or hopper due to excessive
7. Turn the electric key counterclockwise to OFF unloading height.
position to stop the engine and cut down the
power of the machine and remove the key.
8. Move each switch to neutral or OFF position.
K K
9. Close the left and right doors and climb down the
M ladder according to the regulations. M
2 10. If the machine is going to be stored for a long 2
period of time (for example, overnight), open the
F right batteryPile
case cover to move the battery F
negative switch to OFF position.
_ _
11. If there is no antifreeze in the machine,
K
immediately open all engine water drain valves K
and drain all coolant in the evaporators of cooling
3
system and air conditioning system after the 3
ShotinRock
1
machine stops winter climate. 1
12. Lock all equipment and take the key with you.
3 3
Attention
I I
Place the machine on the smooth ground. If
O
parking the machine on a slope is necessary, O
block the wheels to prevent the machine from
moving.

8.Decommissioning and
Disposal
When the product is removed from service, local 2. General Techniques
regulations for the product decommissioning will vary.
Disposal of the product will vary with local • Common loading method
regulations.
Common loading method is suitable for carrying
Improperly disposing of waste can threaten the loose materials.
environment. Obey all local regulations for the
While the loader is approaching the loose material in
decommissioning and disposal of materials.Utilize
forward gear 2 with the center of bucket targeting the
appropriate personal protective equipment when
pile, the operator holds the steering wheel with left
decommissioning and disposing product.
hand and operate the work valve boom control lever
with right hand to lower the boom to 300 mm above
55
 K K
3 3
1 1
3 3
the ground. I I
Self-handling can be used in the following conditions:
Do not lower the boom until the machine is about 1. The truck can not be used due to soft and
O
one meter away from the pile, and allow the bucket unleveled site.
O
to touch the ground and shift from forward 2 to
2. Handling distance is within 500 meters and it is
forward 1.
not economic to use the truck.
Attention During handling, keep the lowest point of the bucket
When the bucket touches the ground, avoid at transport position (300-400 mm above the ground)
excessive pressure from the bucket to ground and turn the bucket backward to stop position
which will cause unnecessary restriction and (bucket kickout touches the boom) to make sure the
teeth wear.Meantime, the front and rear frame handling operation is smooth and safe and not
should be straightened, leaving no angle easily-spilling.
between the front and rear frame. The machine speed during handling depends on the
handling distance and road condition. When the
Depress the accelerator pedal to allow the bucket to
machine travels over a hole or a bump, release the
insert into the pile completely.When the machine can
accelerator pedal and slightly apply the service brake
not move further, the operator toggles the bucket
as necessary to slow down the machine and reduce
joystick backward to rotate the bucket backward and
the impact to the machine and the spilling when
then push the joystick back to the neutral position.
passing over the restrictions.
Then the machine will continue to insert into the pile.
Repeat the insert and rotation operation until the
bucket is filled with material.
K • Combined loading method K
M Combined loading method is suitable for loading M
hard or sticky material.
2 2
The operation before inserting into the material is the
F
same with common loading method.The operator F
pushes the bucket joystick backward after the bucket
_
inserts into the pile and then push it back to the _
K
neutral position to raise the bucket so that it can
insert forward further. Then the operator pushes the
K
3
joystick backward and then push it back to the 3
Never handle material with the bucket raised to
neutral position to rotate the bucket backward so that higher position which can cause machine
1
the bucket can continue to insert forward.Repeat the rollover.
1
insert, raise, insert and rotation operations until the
3
bucket is filled with material.
3
• Dump
• Exiting from theI pile 1. Dump to the truck or hopper
I
O
After the bucket is filled with material, the operator When the loader filled with material is 15 meters O
operates the bucket joystick to turn the bucket away from the truck or hopper, release the
backward until the bucket kickout touches the boom, accelerator pedal and slightly apply the service brake
and then move the bucket joystick to the neutral if necessary to slow down the machine so that the
position.Now maximum retract angle can be machine can approach the truck or hopper at low
obtained. speed.Meanwhile, the operator pushes the bucket
Raise the boom to certain height to allow the bucket joystick to the rearmost position and the joystick will
to avoid the pile when the machine is moving be caught up by the electromagnet. Now the
backward.The operator moves the joystick backward operator can release his hand and the joystick will
to reverse position with left hand to reverse the not bounce back to the neutral position.During this
machine while holding the steering wheel with right process, the operator should drive the machine
hand. carefully to observe the process in which the bucket
is approaching the truck or hopper and the operator
After exiting from the pile, the operator operates the can move the joystick back at any time to prevent the
boom control lever to lower the bucket to the position bucket from touching the truck or hopper.
where the lowest point of the bucket is 300-400 mm
above the ground.
• Material Handling
56
 K K
3 3
1 1
3 3
I
With the bucket over the truck or hopper, the the blade and ground should be kept at about 40 I
operator depresses the brake pedal to slow down the degrees. For hard surface road, put the bucket
O
machine.Then move the bucket joystick forward to tilt control lever at FLOAT position; for soft surface road, O
the bucket forward and to pour the material into the put it at neutral position. Move the joystick to reverse
truck and hopper. At this point, the drive should position and depress the accelerator pedal to
watch for the bucket movement in order that the reverse the machine and blade the ground with the
bucket will not touch the truck or hopper edge.If the blade.
material is too sticky, push the bucket joystick back
and forth repeatedly to allow the bucket kickout to hit • Towing Operation
the boom repeatedly to remove the material sticking A 20-ton flatbed trailer can be configured to tow the
to the bucket. machine.The method is as follows:
If the body length of the truck is more than twice the 1. Securely connect to the tow pin of the machine.
width of the bucket, start dumping from the front of
the body. 2. Equipped with brake system of good
performance.
Attention
3. Put the bucket at transport position.
During dumping, the bucket kickout should not
4. Moderate action is required for start and stop
hit the boom excessively and the number of hit
and braking should be applied when going down
should be limited in order not to damage the
a slope.
machine.
Attention
After dumping, the operator pushes the bucket
K joystick to the rearmost position until the bucket
kickout hits the boom and then move the bucket
K
When applying the brake, apply to the flatbed
trailer first and then the machine.
M joystick back to neutral position.Then the operator M
moves the variable speed joystick to reverse position
2 and release the brake pedal to move the machine Operating method
2
away from the truck or hopper.When the machine is
F
leaving the truck or hopper, the operator should drive
F
_
the machine carefully and watch for the bucket _
movement in order that the bucket will not touch the
K
truck or hopper edge. When the bucket completely K
leaves the truck or hopper, the operator can lower
3
the boom while driving to prepare for the next cycle. 3
1
2. Dump at low position 1
3
When handling material between sites, dumping at 3
low position can be possible which means dumping
I
with the bucket close to the ground.In this case, I
rotate the bucket backward to the horizontal position
O
before raising the boom.Otherwise, the boom may O
not be raised due to the interference of work tool
linkage. • V-shaped method
• Pushing operation As illustrated, the loader faces the pile and the angle
between the truck and the traveling direction of the
Place the bucket against the ground horizontally and loader is 60 degrees. Stop moving when it is 12-15
variable speed joystick at forward gear 1 and meters away from the pile and when the loader is
depress the accelerator pedal to move the machine filled with material, reverse the loader to where there
ahead. If restrictions are found during bulldozing, is 12-15 meters away from the pile. Drive to the truck
slightly raise the boom to continue. The pilot valve while steering and raising the bucket.After dumping
boom control lever should be operated between the material, reverse to the original position for next
RAISE and LOWER position instead of any RAISE loading.
or LOWER position, in order to ensure smooth
bulldozing operation.
• Blading operation
Raise the boom and rotate the bucket forward until
the blade touches the ground and the angle between

57
 K K
3 3
1 1
3 3
I therefore try to maintain the charging rate at 100%I
and keep it warm if possible so that the engine is
O easily to be started next day. O
• 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 from affecting engine start the next day, the
• Vertical loading following measures must be taken:

The loader faces 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 from entering the seals and freezing in
them which can damage the sealing capacity.
This method needs less loading time which reduces
the duty cycle time efficiently. 2. Park the vehicle on a dry and hard surface.If this
is not possible, park the machine on a
board.Using a board can prevent the machine
from freezing on the ground and makes the start
the next day easier.
3. At low temperature, battery capacity will reduce
significantly as parking time grows. Cover the
K K
battery or move it to a warmer place and install it
M back the next day.M
2 After Cold Weather
2
F F
When the weather gets warm, the following work
needs to be done:
_ _
1. All components change to use semi-cohesive
K K
fuel, hydraulic oil and lubricant.For specific oil
type, see the Fluids Specification in the
3 Operation and Maintenance Manual.
3
Cold Weather Operation
1 2. If the permanent antifreeze is not used, 1
Low Temperature Considerations completely drain and clean the cooling system
3 and replace with new coolant.
3
If the ambient temperature is too low, it is difficult for
I
the engine to start and the radiator may freeze. I
Therefore, the following precautions must be taken:
O O
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.
2. Antifreeze Use ConsiderationsDo not mix
antifreezes of different category.

Attention
The antifreeze must be away from the flame and
smoking is forbidden when adding the antifreeze.

3. Battery Use Considerations

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

58
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3 3
1 1
3 3
I
Maintenance Section I
O O

K K
Attention
M M
During the use of this machine, maintain the
2 machine according to the maintenance intervals 2
and procedures specified in this manual.Good
F
maintenance of the machine is very important to
F
_
the extended machine service life and job safety. _
K K
3 3
1 1
3 3
I I
O O

59
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3 3
I
SEM653D Regular Maintenance I
O
The maintenance intervals listed in this manual are O
determined by using the service hour meter or the
calendar (day, month etc.).Caterpillar (Qingzhou) Ltd.
requires the service should always be performed at
the interval that occurs first among the above two
interval determination methods.Under extremely
severe, dusty or wet operating conditions, more
frequent lubrication than is specified in the scheduled
maintenance might be necessary.
Besides the daily maintenance, we also specify four
maintenance points: PM1:250H; PM2:500H;
PM3:1000H; PM4:2000H.
During the maintenance, the daily routine
maintenance and first-time maintenance of the
corresponding parts should be strictly followed, and
then different regular maintenance plans should be
executed according to the specific working hours.
Regular maintenance is based on working hours,or
perform the maintenance every year/2,000 working
K hours.The appropriate regular maintenance plans
are: 250-PM1, 500-PM2, 750-PM1, 1000-PM3,
K
M 1250-PM1, 1500-PM2, 1750-PM1, 2000-PM4. M
2 2
The specific maintenance plans can be found in the attached chart
FANNEXES F
_ Daily
_
Maintenance Items PM1 PM2
K Maintenance KPM3 PM4

√ √ √ √ √
3
Check the Engine Level
3
Check the coolant level √ √ √ √ √
1
Check hydraulic oil fluid level √ √ √ √
1 √
3 the fuel and debris in the fuel prefilter
Check fuel level, drain √ √ √ √ 3 √

Check the operation ofI lights and gauges √ √ √ √ I √

Check the tire pressure and for damage √ √ √ √ √

O O
Check the reverse alarm operation √ √ √ √ √

Check the transmission oil level √ √ √ √ √

Check the lubrication of each greasing point and add grease to each
greasing point as directed by machine maintenance chart posted on √ √ √ √ √
the machine.

Check the brake booster oil level √ √ √ √ √

Check the variable speed control system and adjust as necessary √ √ √ √ √

Check and tighten steering wheel retaining nut √ √ √ √ √

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

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

Add grease to each drive shaft as directed by machine maintenance
√ √ √ √ √
chart posted on the machine.

Tighten all drive shaft bolts √ √ √ √ √

Check the clearance between brake shoes and brake drum of park √ √ √ √

60
 K K
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1 1
3 3
I Maintenance Items Daily
PM1 PM2 PM3
IPM4
Maintenance
O
brake at the first 50 working hours and adjust as necessary.
O
Check the torque of hub retaining bolts Initial Check √ √ √ √

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

Initial
Initial change of drive system filter
Change

Initial change of the drain filter element of the hydraulic oil tank Initial
(upper element in the oil tank) Change
Initial
Initial change of the work hydraulic system filter element Wash
Change

Keep the battery post clean and apply vaseline to it to avoid post
√ √ √ √
corrosion by acid mist

Sweep the engine cylinder head √ √ √ √

Sweep the radiator set √ √ √ √
Clean the fuel tank fill screen √ √ √ √

Clean the oil tank fill screen √ √ √ √

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

K Check all the stressed welds and mounting bolts of the work tool and
√
K √ √ √
the front and rear frames for cracks and looseness
M M
Check the oil level of front and rear axles √ √ √ √
2 Check the engine air intake system √
2√ √ √
FCheck the tension of engine drive belts and air conditioner √ √
F √ √
compressor belts and for damage
_
Check the capability of service brake and park brake √ √
_ √ √
K the engine oil and oil filter
Replace √ √ K√ √
Clean the 3
air conditioner inner filter element √ √ √ 3
√ √

Replace the fuel prefilter √ √ √ √

1 1
Replace the engine water processor √ √ √ √
3
Check the retaining bolts of frame articulation pin for looseness √ √
3 √
I
Check the brake oil level. √ √ I √

Othe front and rear axles to the frames

Tighten the bolts securing √ √ O
√

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

Replace the fuel filter √ √ √

Replace the air cleaner element √ √ √

Adjust the engine valve lash √ √

Check the engine tensioner bearing and fan shaft housing √ √

Tighten all battery retaining bolts and clean the top of the battery √ √

Clean the fuel tank √ √

Clean the transmission and torque converter breather √ √

Initial
Replace the oil in the transmission torque converter and radiator √
Change

Replace the drive system filter. √ √

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

Replace the axle oil Initial √

61
 K K
3 3
1 1
3 3
I Maintenance Items Daily
PM1 PM2 PM3
IPM4
Maintenance
O Change
O
Replace the work hydraulic system filter element √ √

Check the engine vibration damper √

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

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

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

Check the sealing capability of the distribution valve and operating

√
cylinder by measuring the natural recess of the cylinder

Check /Replace the oil tank breather (fill screen) √

Check /Replace the fuel tank breather (fill screen) √

Replace the coolant and coolant filter; clean the cooling

systemReplace the coolant at least every two years if the working √
K hours do not meet the change interval K
M Replace the hydraulic oil, clean the oil tank and check the suction
line
M √

2 2
FImportant Notice! F
Do not use maintenance parts that are not
_
approved by Caterpillar (Qingzhou) Ltd. or
_
K
designated dealers of Caterpillar (Qingzhou) K
Ltd.The use of unauthorized maintenance parts
3 safety problems that are detrimental
may create 3
to the normal operation of the machine and affect
the service1life. 1
3 3
I I
O O

62
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1 1
3 3
MaintenanceI Considerations Keep the work site clean and organized I
O • Do not leave any service or maintenance tool
O
1 Before Maintenance around the work site.Thoroughly wipe off any
grease, oil and other items that can make
Malfunction notice
people slip.Always keep the work site clean
If the maintenance being performed is not specified and organized so that the job can be safely
in the Operation and Maintenance Manual, done.
unexpected malfunctions can occur.
• If the work site is not clean or organized,
Contact the designated dealers of Caterpillar people can trip, slip or tumble and get injured.
(Qingzhou) Ltd. for repair.
• If another person starts the engine or operates Designate a responsible person when co-
the lever while the operator is maintaining the working with other people
machine or adding oil, the operator can be
severely injured or killed. • Designate a responsible person who will be
listened to by everybody while repairing the
• Post a warning label on the lever in the cab to machine or installing/removing the work tool.
alert the other people that you are accessing
the machine.Post a warning label around the • Mutual misunderstanding can cause serious
machine too, if necessary. accidents when co-working with other people.

K Access and Cleaning Before Maintenance K

Coolant Level in the Radiator

M • Clean the machine before accessing and M

Secondary Water Tank
maintenance.This can ensure that dirt will not
2 enter the machine and maintenance job can be 2
safely done. Filler Neck Water Filler Cap
F F
• If the machine is still dirty when accessing and High Water
_maintaining, it can be difficult to locate the Water Filler Tube
_
problem and dirt or silt can spill into the eyes,
andKpeople can slip and get injured. K Low Water
3
• The following needs to be noticed when 3
cleaning1 the machine: • To check the coolant level in the radiator, shut
1 and
down the engine and wait for the engine
1. Wear anti-skid shoes to avoid slipping on a wet radiator to cool down.Do not open the3 radiator
surface. 3 top cover under normal circumstances.
2. Wear protective I clothes when flushing the I
• If there is no need to open the radiator top
machine with high-pressure water.This can
Othe impact from the high-
protect you from
cover, perform as follows: O
pressure water and prevent the dirt and silt from 1. Wait the radiator to cool down before checking
spilling into your eyes. the coolant level.(To check if the water
temperature has reduced, put your hand close to
3. Do not spray water directly onto the electrical the engine or radiator to check air
system elements (e.g. sensor, wire connector).If temperature.Be careful not to touch the engine or
water enters the electrical system, it can be radiator for burn prevention).
failed.
2. When the water fill cap is cold enough that can
be touched with bare hands, slowly loosen the
cap to release the internal pressure.
• Wait for the radiator to cool down and then
release the internal pressure so that the
radiator top cover can be opened.

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I
Shut down the engine before accessing or Lighting Use I
maintaining the machine
O • Use a lighting device with anti-explosion O
• Place the machine on a level ground where feature when checking the fuel, lubricating oil,
there should be free of rock fall or landslide battery electrolyte or window glass detergent.If
when accessing or maintaining the machine.If not, explosion can occur.
the terrain is low, there should be free of flood
risk, either.Shut the engine OFF. • If performing the job at a dark place without
lighting, people can get injured, therefore,
• Lower the work tool to the ground after the proper lighting device should be installed.
engine is turned off.
• Never use a lighter or flame for lighting even in
Operate the work tool lever to RAISE, LOWER and a dark place.It could cause a fire and when the
RETRACT several times to release the retaining gases exiting from the battery encounters a fire,
pressure inside the hydraulic oil lines. explosion could happen.
• Pull the park brake switch to apply the brake • When using the machine for lighting supply,
and put a wedge under the tire. obey the instructions in the Operation and
Maintenance Manual.
• Lock the front and rear frames with locking
lever.
• Take extreme care during maintenance not to Fire Prevention
be hit or hooked by moving parts. Fuel or gases exiting from the battery could cause a
fire during the maintenance, therefore the following
K K
considerations must be obeyed while accessing or
M maintaining. M
2
UNLOCKED
• The fuel, lubricating 2
oil and other flammable
materials must be stored away from the flame.
F LOCKED F as part
• Use nonflammable material
_ _
detergent.Do not use diesel or gasoline which
could cause a fire.
K • Do not smoke while accessing or
K
3 3
maintaining.Smoke at the designated place.
Support the Work Tool
1 • Use a lighting device with anti-explosion
1
• While raising feature when checking the fuel, lubricating oil,
3 the bucket to perform inspection
and maintenance, support the boom with a
3
battery electrolyte.Never use a lighter or flame
for lighting.
I
bracket to prevent the work tool from falling. I
• Place the lever at • Move all flammable material to a safe place
ONEUTRAL position. before grinding or welding on the flame. O
• There must be a fire extinguisher in the job site
Suitable Tools where accessing or maintenance will be
Use only the tools suitable for the task.Using performed.
damaged, poor quality, failed or temporary tools can
cause personal injury.

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I
2. When Performing Maintenance Working on the Top of the Machine I
WHO O • When working on the top of the machine, make
O
sure that the foothold is clean and free of
• Maintenance and service of the machine restrictions and the following considerations
should only be carried out by qualified must be obeyed to avoid falling.
technicians.Keep anyone not involved in the
maintenance and service away from the 1. There should not be spilled lubricating oil or
area.Designate a person to attend the area if grease.
necessary. 2. No tools around.
• Pay particular attention when grinding, welding 3. Watch out for the step while walking.
or using a sledge hammer.
• Never jump from the machine.When getting
on/off the machine, always use the ladder and
Attachments armrest and keep three-point (two feet and one
hand or two hands and one foot) contact any
• Designate a responsible person before starting time.
the removal or installation of the accessory.
• Use protective devices if necessary.
• Do not allow anyone who is not involved in the
job to stand near the machine or accessory. • The top of the engine hood is slippery and
dangerous so standing on it is forbidden.
• Put the accessory removed from the machine
in a safe place and make sure it does not • The top of the tire is slippery and dangerous so
K fall.Install rails around the accessory with a K
standing on it is forbidden.
M "NO Entry" tag on the rail to prevent the
unauthorized person from getting close.
M of the front frame when
• Stand on the fender
cleaning the front window glass of the cab.
2 2
FWorking under the Machine F
Do not drop foreign material into the machine
•_Park the machine at the hard and level ground. _
• Take care not to drop any foreign material (e.g.
Lower all work tools to the ground before
K
performing maintenance or repair under the K
nut, bolt, cotton yarn or tool )into the machine
when opening the access window or oil fill of
3
machine. 3
the tank.If such kind of material is dropped into
• Block the1tires with wedges. the machine, machine damage, failed operation
1
and other malfunction can occur.
• If the machine
3 is only supported by the work
tools with the tires above the ground, it is very • If any foreign material is dropped into 3
the
machine, it must be taken out of the machine.
I under the machine.Never
dangerous to work I
work under a poorly-supported machine.
O • While accessing, do not carry any unnecessary
O
tool or part in the pocket.
Performing Maintenance with Frame Raised
• Before performing the job with work tool or
frame raised, lock the front and rear frames
with locking lever.Place the lever at NEUTRAL
position.Block the work tools and frames with
wedges.
• Before raising, block the wheel with a wedge at
the opposite side.After raising, put wedges
under the machine.

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I
Maintenance During Engine Operation Welding Repair I
Do not perform maintenance during engine operation The welding must be performed by a qualified
O
to avoid injury.If it is necessary to perform technician and in a place equipped with appropriate
O
maintenance during engine operation, the following equipment.Welding can generate gases and there
considerations must be taken: exists the risk of fire and electric shock, therefore
never allow the unqualified technician to perform the
• Ask a technician to sit on the operator's seat welding.The qualified technician must follow the
and turn off the engine at any time.All following the considerations.
technicians must be in touch with other person.
• Disconnect the terminals of the battery to avoid
• Use extreme care when the work point is near battery explosion.Remove the paint from the
the rotating parts because there is the risk of position to be welded to prevent the generation
getting caught in rotating parts. of hazardous gas.
• Never allow any tool or any part of the body to • Welding on the hydraulic device or lines or
touch the fan blade or fan belt.Serious injury places very near to it can generate flammable
can be caused. vapor and spark which can cause a fire,
therefore, avoid to weld on such place.
• If the spark generated during the welding
directly falls on the rubber hose, wire or
pressurized piping, they can rupture and the
insulation of the wire can be damaged,
K K
therefore, cover them with an anti-fire baffle.

M • Wear protective clothes

M during welding.
• Prevent the work tool from moving when • Make sure the site where
2 cleaning the interior of the radiator.Also pull 2 the welding is
performed is well-ventilated.
F the park brake switch to apply the park brake. F
• Clear all flammable materials and make sure
•_
Do not touch any lever.If operating the lever is
_
there is a fire extinguisher at the job site.
necessary, signal the other technicians to alert
K
them to walk into a safe place. K
Battery Considerations
3 3
Hammer Use Considerations When repairing the electrical system or performing
1 1
welding on the machine, remove the negative (-) of
• Always wear safety glasses, helmet and other the battery or turn off the main power switch to
3
protective clothes when using a hammer and prevent current flow. 3
put a copper stick between the hammer and the
I
object being hit on.
I
• There could be aOrisk of debris flying into the O
When Found It Abnormal
eyes causing injury if using a hammer to hit a • If any abnormal condition is found during
hard part, For example a pin or bearing. accessing, repair it.Especially when a problem
is found in the brake system , steering system
or work tool system, serious accidents could
occur.
• Depending on the fault type, contact the
designated dealers of Caterpillar (Qingzhou)
Ltd. for repair.

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I
Regulations on Adding fuel or Lubricating Oil High-Pressure Oil Considerations I
Fuel, lubricating oil, hydraulic oil, antifreeze, brake When accessing or replacing the hydraulic system
O
fluid and window glass detergent can be lit by a lines, check if the system pressure has been
O
flame.The following regulations must be obeyed: released.If there is still pressure in the lines, serious
injury or damage can occur. Therefore, perform as
• Turn off the engine when adding fuel or follows:
lubricating oil.
• No smoking.
• Wipe off any spilled fuel, lubricating oil,
hydraulic oil, antifreeze, brake fluid or window
glass detergent immediately.
• Securely tighten all top covers of the
containers for fuel, lubricating oil, hydraulic oil,
antifreeze, brake fluid or window glass
detergent.
• The place where the fuel, lubricating oil,
hydraulic oil, antifreeze, brake fluid or window
glass detergent is added or stored must be
well-ventilated.
• For details of releasing pressure, see "Turn off
K K
the engine before check and maintenance" in
High-pressure Hose Handling the Maintenance Considerations.Never access
M M
or replace before the pressure is released
• If the high-pressure hose leaks, failed completely.
2 operation could occur which will cause 2
personal injury or equipment damage.If • Wear the safety and leather gloves.
F damaged hose or loosened bolt is found, stop
F
• If there is oil leak in the line, the line and the
_
operation and contact the designated dealers _
surrounding area will be wet, therefore, check
of Caterpillar (Qingzhou) Ltd. for repair. the tube or hose for cracks and hose for
K
• Sophisticated technique is required when
K
bulge.If it is difficult to locate the leak, contact
3
replacing the high-pressure hose and installing 3
the designated dealers of Caterpillar (Qingzhou)
Ltd. for repair.
torque is determined by the type and size of the
1
hose, therefore, do not repair by yourself.
• Use a plate or cardboard to check for leak
1
Contact the designated dealers of Caterpillar
3
(Qingzhou) Ltd. for repair.
instead of bare hands. 3
I • If shot by the spilled high-pressure oil, see
I a
doctor immediately.
O O
Precautions for accessing at high temperature or
high pressure
• The coolant and oil at various positions is
under high temperature and high pressure just
after the operation is stopped.Opening the
engine hood, draining the oil or coolant, or
replacing the filter at this point can cause
burns or other injuries.Wait for it to cool down
and access according to the procedure in the
Operation and Maintenance Manual.
• For other inspection items, see the Regular
Maintenance section and the related content in
the Operation and Maintenance Manual.

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Scrap I 3 Tires I
To prevent pollution, especially in the area where
O
humans or animals live, the following procedures
Tire Handling O
must be followed. Wrong handling of the tire or rim can result in a blew
or ruptured tire and the hub can be damaged and
• Never dump the used fuel or oil into the drains, scattered which could cause serious injury or death.
rivers, etc.
The following considerations must be obeyed for
• Collect the drained oil into a container and maintenance safety.
never drain the oil directly to the ground.
• The maintenance, removal, repair and
• Dispose of the hazardous material such as installation of the tire and rim require special
lubricating oil, fuel, coolant, solvent, filter and equipment and techniques, therefore ask a tire
battery in accordance with the related laws and repair shop to do the job.
regulations.
• Only use the specified tires and inflate them to
the specified pressure.For the specified tire
Inspection After Access and Maintenance and pressure, see Usage and Main Technical
Features and Parameters.
If the comprehensive access and maintenance is not
performed and the function of each maintenance • Do not let anybody walk into the job site while
position is not checked, unexpected problems can inflating the tires.It is necessary to stand at the
occur which could cause personal injury or machine side of the tire, use self-clamping collets and
damage. Therefore, always consider the following check the tire pressure now and then to make
K questions. K
sure that the pressure will not be too high.
M • Inspection After Engine Shutdown M incorrectly, the rim can be
• If the rim is installed
damaged or scattered after the tire is
2 1. Have all access and maintenance positions been 2
inflated.Therefore, put protective plates around
checked?
F2. Have all access and maintenance items been F
the tire and do not work at the side of the rim.

_ performed correctly? • The abnormal decrease of _

the inflation
pressure and the abnormal fit of the rim
3. IsKthere any tool or part falling into the K
indicate that there is a malfunction in the tire or
machine?It is especially dangerous if the tool or rim.In this case, ask a tire repair shop to repair
part 3
sticks into the linkage of the lever. the tire. 3
4. Have the 1 coolant leak and oil leak been • Do not adjust the inflation pressure1after high-
repaired?Have all the bolts been tightened? speed traveling or high duty operation.
3 3
• Inspection During Engine Operation • The fully inflated tire can explode because the
I
See the Maintenance During Engine Operation air inside the tire is heated and burnt.The I
heating is caused by heating or welding the rim,
O Considerations.Consider the
section of Maintenance
external flame, or air heat expansion or burn
O
following questions while ensuring safety:
due to frequent braking.
1. Is the operation of the access and maintenance
positions normal? • Tire explosion is much more forceful than
discharging the tire. Explosion can force the
2. Does the hydraulic system leak oil when the tires, rims and final drive parts away from the
engine speed accelerates and high load is machine more than 500 meters and the
applied? explosion force and pieces can cause personal
injury and property damage.
• It is recommended to use dry nitrogen (N2) to
inflate the tire.If there is air remaining in the tire,
it is recommended to use nitrogen that can be
mixed with air to regulate the tire pressure.The
tire inflated 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.

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• Flat tire or rimIdamage is due to improper I
inflating equipment or improper use, therefore,
O
to avoid over inflation, make sure that proper O
equipment is used and the tire is inflated by
trained person.

Tire Storage Considerations

• As a guideline, the tires must be stored in the
warehouse where unauthorized person cannot
enter.If it is necessary to store the tires outside,
set fences around the tires and put a NO
ENTRY sign on it.

K K
M M
2 2
F F
_ _
Block
K K
3 3
1 1
• Put the tires3uptight on a level surface and hold 3
them with wedges so that they will not fall even
I
if touched by unauthorized person.If the tire is I
O
placed on its side, it will be crushed and the
quality will reduce.
O
• If the tire is going to fall, stand aside as soon
as possible.The industrial tire is very heavy.
Trying to hold it can cause serious injury.

69
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Key SafetyI Part Catalog and I
O
Change Interval O
• To ensure the safety of the loader during use,
the user must perform regular maintenance.In
addition, to ensure further safety, the user
should also change the parts outlined in the
chart periodically.These parts area essential to
the 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.

K • If there is any damage (for example, K

deformation or cracks) to the clip securing the
M hose, replace it with the hose. M
2 • The O-ring, gasket or other similar parts must 2
be replaced with the hose.
F• Contact the designated dealers of Caterpillar F
_(Qingzhou) Ltd. for the replacement of key _
safety parts.
K K
3 3
1 1
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I I
O O

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I
Regular Change Chart of Key Safety Part I
No O
Key safety part needed to be changed periodically Quantity Change Interval O
Every 6 months or 1,000 hours,
1 Hydraulic oil return filter 1
whichever occurs first
2 Fan Belt 1
3 Fuel line (fuel tank - primary fuel filter) 1
5 Fuel line (high-pressure fuel pump - fuel tank) 1
6 Steering cylinder seal 1
Steering hose (front steering cylinder connector - rear steering
7 2
cylinder connector)
Steering hose (rear steering cylinder connector - pressure test
8 2
connector)
Steering hose (pressure test connector - flow amplification
9 1
steering device)
Steering hose (priority valve - flow amplification steering
10 2
device)
11 Steering hose (gear pump - priority valve) 1
Steering hose (hydraulic oil tank - flow amplification steering
12
device) Every 2 years or 4000 hours,
whichever occurs first.
13 Brake hose (air control shutoff valve - park brake air chamber) 1
Brake hose (air control shutoff valve - manual control brake
14 2
valve)
K 15 Brake hose (air brake valve - air booster pump) 2 K
M 16 Brake hose (air booster pump - drive axle brake) 2
M
17 Brake hose (air shutoff valve - manual control brake valve) 1
2 18 Brake hose (air brake valve - switch valve) 1 2
F 19
20
Brake hose (air control shutoff valve - park air chamber)
Brake hose (air control shutoff valve - switch valve)
1
1
F
_ 21 Brake hose (air control shutoff valve - manual control brake
1
_
valve)
K
22 Brake hose (air reservoir - air brake valve) 1 K
23 3 Brake hose (air reservoir - fuel-water separator combination
valve)
1 3
24 1
Air reservoir 1 1
Every 3 years or 6000 hours,
whichever occurs first.
3 3
I I
O O

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ImportantI Maintenance Coolant Level Check Method I
The radiator is located at the tail of the machine.
ProcedureO 1. After the engine coolant temperature drops
O
below 50°C, loosen the radiator water fill cap
Engine Coolant Maintenance slowly to release the pressure to prevent the
burns caused by hot vapor or hot spilled coolant.
Proper maintenance of engine cooling system is
extremely important. Overheat, overcooling, pitting, 2. Check if the coolant level is between the high
cavitation, cylinder head cracks, piston sticking and mark and low mark on the secondary water tank
radiator clogged are common faults in the cooling as shown. Add coolant to the high mark if it is
system, which not only reduce the engine's work below the low mark.
efficiency but also cause severe engine damage. 3. Check the seal of the radiator water fill cap and
replace it if damaged.
Anti-freeze
4. Tighten the radiator water fill cap.
The main purpose of the antifreeze is to reduce the
condensation point and raise the boiling point of the 5. If the coolant needs to be added daily, check for
coolant.Use antifreeze even at a common ambient leaks in the engine cooling system.If a leak is
temperature, because it can raise the boiling point of present, correct it and add antifreeze to an
the coolant and the additives in the antifreeze can appropriate level.
reduce the possibility of corrosion and cracks on
machine body. Add Coolant
Before adding coolant to a new machine or an
K The performance of the antifreeze brands K
engine with a cleaned cooling system, determine the
recommended by Caterpillar (Qingzhou) Ltd. is as
M follows: M
concentration of the antifreeze in the coolant based
on the local record low ambient temperature (10°C
2 Minimum Ambient
Antifreeze
2
below the record low ambient temperature is better)
Temperature for Use (°C) and calculate the desired antifreeze amount based
F －50 YF-3
F
on the total capacity of the engine cooling system.
_ －45 YF-2A _
Attention
K －40 YF-2B K
Never use water alone for coolant.Damage from
3 －35 YF-2 3
corrosion can be the result of using water alone
－25 for coolant.We will not provide the warranty of
1 YF-1
the cooling system components if using water
1
3
Change the antifreeze with a good-quality one and
alone for coolant. 3
I
refill according to the instructions. The steps of adding coolant is as follows: I
OAttention 1. Turn on the negative switch of the power;Insert
the key into the start switch and turn it to position
O
The antifreeze is flammable. Do not leave it close 1 clockwise to energize the machine power;Push
to a flame. the air conditioner system toggle switch to 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 high mark on
the secondary water tank and keeps stable in 10
minutes.

Attention
While adding coolant, the air must be vented
from the engine coolant piping.

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1. Start the engine with the radiator water fill cap I
6. After all coolant is drained, close the water drain
opened and run it at low idle speed for 5 minutes valve at the bottom of the radiator and the drain
O
first and then run at high idle speed for 5 minutes valve of the engine oil cooler. O
to make the coolant temperature above 85°C.
7. Check all the water pipes and clamps for
2. Check the coolant level again and continue to damage and replace if necessary.Check the
add coolant if necessary until the level reaches radiator for leaks, damage and dirt accumulation.
the high mark on the secondary water tank. Clean and repair if necessary.
3. Check the seal of the radiator water fill cap and 8. Fill the engine cooling system with a cleaning
replace it if damaged. mixture of water and sodium carbonate and the
mixing ratio is 0.5 liter of sodium carbonate in
Attention every 23 liters of water.The level should reach
Do not add cold coolant to a hot engine, or else, engine operating level and keep stable within 10
the engine body can be damaged.Wait until the minutes.
engine temperature is below 50°C.
Attention
While adding the cleaning solution to the cooling
Attention system, the air must be vented from the engine
coolant piping.
Caterpillar (Qingzhou) Ltd. will not be
responsible for the loss caused by coolant leaks During the whole cleaning process, the engine is
and the drop of antifreeze concentration due to running with the radiator water fill cap removed.
the user's misuse.
K K
1. Start the engine with the radiator water fill cap
opened, and run the engine for another 5
M Coolant Change or System Cleaning M
minutes after the coolant temperature is above
80 C.
2 Completely change the coolant in the cooling system 2
and clean the cooling system every 10,000 hours or 2. Turn off the engine and drain the cleaning
F
5 years, whichever occurs first. solution. F
_
Before this interval, if the coolant is contaminated, _
3. Fill the engine cooling system with clean water to
the engine is overheated, or there is bubbles in the normal operating level and keep it stable within
K
radiator, clean the cooling system right now. K
10 minutes.Start the engine with the radiator
water fill cap opened, and run the engine for
3
The steps of cleaning the cooling system are as 3
another 5 minutes after the coolant temperature
follows:
1 is above 80 C. 1
1. Turn on the negative switch of the power;Insert
4. Turn off the engine and drain the water in the
3
the key into the start switch and turn it to position 3
cooling system.If the water being drained is still
1 clockwise to energize the machine power;Push
I
the air conditioner system toggle switch to HEAT
dirty, the system must be flushed again until the I
water comes out clean.
position.
O O
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. Start the engine and shut it down after idling it for Engine coolant is toxic and undrinkable. Dispose
5 minutes.Turn the START switch to position 1 to of it according to the local laws and regulations.
energize the machine power, and put the toggle
switch of the air conditioner system at HEAT
position to open the magnetic water valve of the
air conditioner.
4. After the coolant temperature drops below 50°C,
loosen the radiator water fill cap slowly to release
the pressure.
5. Open the water drain valve at the bottom of the
radiator and the drain valve of the engine oil
cooler to drain the engine coolant and collect it
with a container.

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I
Cleaning Radiator Fins I
O
If there is dirt sticking to the radiator, clean in the
The air filter can only be serviced when the
O
following method.
engine is shut down.Otherwise, the engine may
1. Remove the bolts and remove the rear grid form be damaged as a result.
the rear of the machine.Meanwhile remove the
connector of rear work light. Service the air cleaner filter element when the
blue plunger on the engine air filter service
2. Remove the dirt and leaves, etc. on the radiator
indicator enters the red zone.
fins with compressed air, vapor or water.

Cleaning the air filter primary element

3. Also check the rubber hose.If cracks on the hose

K or deterioration or hardening is found, replace K
M the hose with a new one.Also tighten the
loosened pipe clamp.
M
2 Note: In order to avoid potential safety risks, it is 2
1. Loosen all clips connecting the rear cover to the
housing, remove the rear cover, and remove any
F
prohibited to work on tires during coolant filling and
air filter maintenance. Customers are required to use
F
dust on the rear cover. Attention:When stopping
the machine to check, the dust can be removed
_
a dedicated maintenance platform that meets _
by dust valve in time. Replace the dust valve
national safety standards. immediately when it is damaged or missing.
K K
Maintenance of Engine Air 2. Counterclockwise rotate the seal cover and
3 3
remove, and then the external element can be
Cleaner seen.
1 1
Attention 3. Catch the clamps of external element rear cover
3 and pull the external element out of the air 3
Turn off the engine when maintaining the air
I damage.
cleaner to prevent
cleaner cavity. I
4. Maintain the external element according to the
O maintenance instructions of air filter. O
Maintenance and Replacement of Engine 5. Before installing back the external element,
Air Filter Element clean the inside of the cleaner and remove the
dust accumulating on the internal threads with a
The air filter is in the engine hood.
bristle brush or a rag to make sure that the
When the alarm appears red, use compressed air of thread is smooth, and prevent dust from entering
less than 205 kPa, along the direction of the pleats, the inside of the element.
to clean the filter element from inside out.Do not use
6. Install back all parts in the opposite order of
other tools to knock the filter element when removing
removal and make sure that they are installed
the filter element.Clean the inner wall of the filter
correctly to ensure a correct sealing. Do not omit
outlet pipe and the sealing surface.Replace the filter
any part.
element after 6 times of cleaning or 250 (high dust) -
500 (low dust) working hours.Check the connections Attention
to ensure that the filter cap matches the engine
intake and is airtight. Caterpillar (Qingzhou) Ltd. recommends the use
of a certified air cleaner and cleaning service
provided by an authorized Caterpillar (Qingzhou)
Ltd. dealer.

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I
The cleaning process of Caterpillar (Qingzhou) Ltd. I
Use and Maintenance of Diesel
employs proven procedures that ensure consistent
O
quality and long cleaner life.Observe the following O
guidelines if you attempt to clean the filter element: Diesel tank
Do not tap or strike the filter element in order to The diesel fuel tank breather should be
remove dust. maintained as the following procedure defines:

Do not wash the filter element.Use low pressure Typically change the breather annually, but if it is
compressed air to remove the dust from the filter badly contaminated, it is recommended to change it
element.The air pressure must not exceed 205 every 1,000 hours or 3 months. When slow refilling
kPa.Direct the air flow up the pleats and down the speed is felt, remove the breather and continue to
pleats from the inside of the filter element.Take refill. Blow out the dust etc. clogging the screen with
extreme care in order to avoid damage to the pleats. high-pressure air when maintaining the breather daily.
The fuel filler screen and the fuel tank should be
cleaned periodically. The fuel tank can be cleaned
Replacement of Safety Element
with the following method:
1. Open the engine hood.
Remove the flange disc at the front end of the fuel
2. Remove the air cleaner cover from the air tank and flush the inner surface of the tank with
cleaner housing.Remove the primary filter clean diesel. Loosen the drain plug at the bottom of
element from the air cleaner housing. the tank to drain the fuel.Flush repeatedly until the
drained fuel is clean.
3. Remove the secondary filter element.
K K
Removing Water and Contaminants in
M the Diesel
M
2 2
Fuel pump and injection pump are very precise
F devices. If there is water or contaminants in the
F
diesel, the fuel pump and injection pump will not
_ _
operate properly and will be prematurely
worn.Measure should be taken to remove the water
K K
and contaminants in the diesel.The method is as
follows:
3 3
1. The diesel should be settled for 24 hours before
1
4. Cover the air inlet opening.Clean the inside of
the air cleaner housing.
added to the fuel tank if possible. 1
3
5. Remove the cover from the air inlet opening. 3
2. Before refilling, open the drain plug at the bottom
of the fuel tank every week to drain the water
I
6. Inspect the operator compartment for a buildup and contaminants. I
of trash.
O 3. Add diesel to FULL after the daily work to drain O
7. Install the primary filter element. the moisture in the fuel tank.
8. Install the air cleaner cover and tighten it. 4. Wait 5 to 10 minutes before starting the engine
after the fuel tank is filled to FULL, to make the
9. Close the engine hood.
water and contaminants settle to the bottom of
Attention the tank.

Always replace the secondary element.Never 5. After the daily work, loosen the water drain plug
attempt to reuse the secondary filter element by at the bottom of the fuel prefilter and primary fuel
cleaning the element.When the secondary filter filter to drain the water and contaminants.
element is replaced, the primary filter element Do not wait to add fuel until the fuel tank is empty, or
should also be replaced.The secondary filter else the engine will die and there will be large
element should also be replaced if the exhaust amount of water and contaminants at the bottom of
smoke is still black. the fuel tank which will prevent the normal engine
operation.

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Diesel Sulfur I
Maintenance of Engine Oil I
O
The diesel sulfur percentage can affect the choice of O
engine oil and oil change interval.The sulfur can Check the Engine level
convert into sulphuric acid and sulfurous acid during
1. Drive the machine to a level ground, turn off the
burning which will corrode the metal
engine and pull the park brake button.
surface.Therefore, use the diesel fuel with low sulfur
content. 2. Wait 10 minutes after the engine is off to allow
the engine oil to flow back to the oil pan.
Some additives in the oil contain alkaline compound
which can neutralize the acid.Therefore, the oil 3. Open the engine hood, pull out of the dipstick,
change interval should be adjusted based on the wipe the dipstick clean, insert it back into the oil
diesel sulfur: filler to the end, and pull it out again to check if
the level is between the L mark and the H mark
1. If the diesel sulfur is below 0.5%, change oil
on the dipstick.
according to the interval specified in the Regular
Maintenance in this manual. 4. If the oil level is below the L mark, add oil;If the
2. If the diesel sulfur is between 0.5%~1.5%, oil level is above the H mark, loosen the oil drain
plug at the bottom of the oil pan to drain partial
change oil at 1/2 of the interval specified in the
oil.
Regular Maintenance in this manual.
3. If the diesel sulfur is above 1.5%, change oil at Attention
1/4 of the interval specified in the Regular Too much or too little oil can cause damage to
Maintenance in this manual. the engine.
K K
M Replacement of Fuel Filter and Fuel M
Changing Engine Oil
2 Prefilter 2
Change the engine oil when the specified oil change
1. Clean the surrounding area of the filter and the
F F
interval is met.Position the machine on a level
filter head first. surface and start the engine until the water
_
2. Remove the filter from the head with a strap _
temperature reaches 60 C. Then turn off the
engine.Pull the park brake button.Remove the oil
K
wrench. K
drain plug at the bottom of the oil pan to drain the oil
3. Remove the gasket from the threaded connector
3
of the head.Clean the sealing surface of the 3
and collect it with a container. Replace the oil filter.
Install the oil drain plug and fill with clean oil through
1
head with a lint-free cloth. 1
the oil filler to the H mark on the dipstick.Operate the
3 3
engine at idle speed to inspect for leaks at the oil
filter and the drain plug.
I Wait 10 minutes after the engine is off to allow the
I
O engine oil to flow back to the oil pan and check the O
engine oil level again. If the oil is not sufficient, add
oil to the H mark on the dipstick.

Attention
There should be a reading present on the engine
oil pressure gauge after 15 seconds the engine is
4. Install a new gasket to the threaded connector of started.If there is no reading, shut down the
the prefilter head;Apply a film of engine oil to the engine immediately to avoid damage and inspect
sealing surface of the filter;Fill the filter with clean for correct oil level.
diesel.
5. Tighten the filter to the filter head with hand and
tighten another 1/2-3/4 of a turn after the filter
gasket just touches the head.Do not overtighten
with mechanical method or else the filter can be
damaged.

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I oil filter
Replace engine
Maintenance of Air I
O
1. Clean the area near the oil filter head.
Conditioning Heater SystemO
2. Remove the oil filter with a strap wrench.
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 Shangong Machinery dealer to check the air
conditioner every year.

3. Clean the gasket surface on the head with a

clean cloth.If the old O-ring seal sticking to the
head, remove it.

K K
M M
2 2
F F
_ Maintenance of Transmission _
4. Install a new O-ring seal.
K Checking the Transmission K Oil Level
5. Install the oil filter to the filter head and tighten it
3
until the oil filter gasket surface touches the head 3 top of the left
The transmission oil filler is at the rear
with hand and then tighten it to the requirement floor. Check the transmission oil level at the specified
1
with a strap wrench. interval to ensure oil amount.The level can1 be
3 Attention
checked by observing the dipstick at the right3 of the
transmission body (transmission oil level should be
I
Excessive mechanical tightening may damage in the middle position during machine operation). I
thread or the seal of the filter element.
O Check the transmission oil level as follows: O
1. Check the cold oil surface before the cold
machine is started;The purpose is to make sure
that there is sufficient oil when the machine is
started.It is especially important for a loader that
is not used for quite a long time.
2. The oil level should be at the upper position of
the dipstick before starting the engine is started
which means that the engine can be started.If
the oil level is not at the upper position of the
dipstick, add oil to the upper position so that the
engine can be started.
3. Position the machine on a level surface, put the
variable speed joystick to the neutral position,
pull the park brake button and install the frame
locking lever to prevent the machine from moving
and rotating.Engine is at idle.

77
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3 3
I
4. Start the engine and run it about 5 5. Use a magnet to remove the iron scurf sticking to I
minutes.Inspect if the transmission oil level is the oil drain plug and remove the iron scurf on
O
near the middle position of the dipstick.If the oil the inner wall of transmission. O
level is high, drain some transmission oil by
6. Install the oil drain plugs under the transmission
loosening the oil drain plug at the bottom of the
and torque converter oil cooler and the related
transmission. If the oil level is low, add some
seals.
transmission oil.
7. Install the oil drain plug under the torque
Attention converter and the related seals.
Over high or low level can cause damage to the 8. Open the transmission oil filler cap and add
transmission. Maintain the transmission oil level clean transmission oil through the filler tube. The
at a correct position. transmission oil level should be at the highest
While checking the transmission oil level and level that the oil level allows.
changing transmission oil, unique care must be 9. Start the engine and run it about 5
taken not to allow the contaminants to enter the minutes.Inspect if the transmission oil level is
transmission system which can cause damage to near the middle position of the dipstick.If the oil
the transmission. level is high, drain some transmission oil by
loosening the oil drain plug at the bottom of the
transmission. If the oil level is low, add some
Changing the Transmission Oil transmission oil.
The transmission oil is not only the working medium 10. Tighten the oil filler cap clockwise.
K of hydraulic torque converter - transmission hydraulic K
system, it is also used to cool down and lubricate the
M torque converter - transmission parts, therefore, the M
Replacing the transmission oil pan
selection of transmission oil should meet the suction element
2 requirements and change the transmission oil
2
1. Drain the oil in the same way of changing
F
according to the specified change interval, or else, transmission oil. F
the service life of transmission will be shortened.
_
Change the transmission oil as follows:
_
2. Loosen the transmission oil pan suction bolts
and remove the oil pan.Take out the transmission
K
1. Start the engine to operate the machine for K
suction screen and clean or replace it.
several hours to make the contaminants, metal
3 3
3. Clean the transmission bottom.Install a new
debris and sediments suspend in the oil. suction screen and tighten the oil pan bolts.
1
2. Position the machine on a level surface, put the 1
4. Add oil in the same way of changing
3
variable speed joystick to the neutral position,
pull the park brake button and install the frame
transmission oil. 3
I
locking lever to prevent the machine from moving I
and rotating.
O
3. Turn off the engine and loosen the oil drain plug
Attention O
Before changing transmission oil, cover the park
under the transmission and collect it with a
brake so that the friction plate of the park brake
container.
will not be contaminated by oil which can cause
4. Loosen the oil drain plug under the torque reduction of braking performance.
converter and collect it with a container.

The transmission oil is still hot at this point,

therefore wear protective devices and use care to
avoid personal injury.

78
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Replacing theI drive oil filter element
Maintenance of Drive Axle I
O
1. Clean the area near the drive oil filter head.
Check the oil level and replace the drive axle oil
O
2. Remove the drive oil filter housing with a strap according to the requirements in the Regular
wrench and remove the element. Maintenance.
Check the drive axle oil level:
There are respectively three oil drain plugs and oil fill
plugs for front and rear drive axles, located at the
middle of axle housing and both sides of curb. The
oil fill plug can also be used to observe the oil level.
Checking the drive axle oil
1. Drive the machine to a flat surface and slowly
move the machine to make the arrow on the front
drive axle curb end cover point vertically
downward. Pull the park brake button to prevent
3. Clean the gasket surface on the head with a the machine from moving and stop for 15
clean cloth and install a new element. minutes (the front and rear drive axle oil level
needs to be checked twice).
2. Clean the area near the oil level plugs at both
sides of drive axle curb and remove the oil level
K K
plug to check if the oil level in the drive axle is 8
M mm below the lower edge of the oil drain. Small
M
amount of spillage is allowable.If the oil level is
2 2
much lower than the lower edge of the oil drain,
add drive axle oil.Observe for about 5 minutes
F F
after adding oil until the oil level is stable (any oil
level plug can be used to check the oil level).
_ _
4. Install the drive oil filter housing. 3. Tighten the oil level plug.
K K
4. Check the rear drive axle oil level by using the
3 Attention
same steps above. 3
1
The drive oil filter is directional.During 1
installation, the direction of the arrow should
3 Replacing Drive Axle Oil 3
face away from the drive pump.
1. Drive the machine for a period of time to allow all
I sediments in the axle housing to suspend.Then I
O drive the machine to a flat surface and slowly O
move the machine to set the oil drain plug at the
drive axle curb end face at the lowest
position.The front and rear drive axle oil needs to
be drained several times because the oil drain
plugs at the left and right and front and rear drive
axle curb end face can not be at the lowest
position simultaneously.
2. Turn off the engine, put the variable speed
joystick to the neutral position and pull the park
brake button to prevent the machine from moving.
3. Remove the oil drain plugs at the drive axle curb
end faces and the middle of the axle housing to
drain oil and collect with a container.

79
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I I
Replacing the hydraulic oil tank drain
element
O O
The drive axle oil may be still hot at this point, 1. Raise the boom and put the bucket at retract
therefore wear protective devices and use care to position. Support the boom with a bracket to
avoid personal injury. prevent the work tool from falling.Put the work
tool lever at neutral position.Apply the park brake
4. Install all the oil drain plugs at the drive axle. and turn off the engine.
5. Slowly move the machine to make the arrow on 2. Remove the mounting bolts on the oil filter cover
the either side of the curb end cover point at the side of the tank and remove the cover.The
vertically downward. cover can bounce due to the force of spring, so
6. Add clean drive axle oil through the oil level plug press the cover while removing the bolts.
or oil drain plug at the axle curb end face until 3. Remove the spring and element.
the oil level reaches the lower edge of the oil
level plug of the front axle curb end face.Observe 4. Install new element, spring and cover.
for about 5 minutes after adding oil until the oil 5. Press the cover while installing the bolts and
level is stable (see the Operation and tighten the bolts evenly.
Maintenance manual for the amount of oil added).
6. Check the oil level and add oil to the specified
7. Install the plugs at the drive axle curb ends. level.
8. Change the other drive axle oil in the same 7. Check the assembly joint at the oil filter cover for
manner above. leaks.
K K
M Maintenance of Hydraulic M
Regular Replacement of Hydraulic Oil
2 System 2
Change the hydraulic oil every 2000 service hours or
every year.The method is as follows:
FCheck the oil level and replace the hydraulic oil F
1. Remove any debris in the bucket. put the
according
_ to the requirements in the Regular _
variable speed joystick to the neutral position
Maintenance.
and pull the park brake button and install the
K
Check the hydraulic oil level
K
frame locking lever.Start the engine and idle it for
10 minutes during which repeat the actions of
3 oil tank is on the right of the cab and
The hydraulic 3
lifting boom, lowering boom, tilting bucket
there is an 1
oil level gauge at the front end of the tank. 1
forward and tilting bucket backward several
To check the hydraulic oil level, position the machine times.
3 and put the bucket on the ground
on a level surface 3
2. Finally, raise the boom the highest position, tilt
I
horizontally. Meantime, the front and rear frame
should be straightened, leaving no angle between
the bucket to the maximum position and turn off I
the engine.
O Now the hydraulic oil level
the front and rear frame.
3. Push the bucket joystick of the work valve
O
should be at 1/2-2/3 of the oil level gauge.
forward to allow the bucket to tilt forward with its
own weight to drain the fluid in the bucket
cylinder;After the bucket tilts to the desired
position, push the of the work valve boom lever
forward to allow the boom to descend with its
own weight to drain the fluid in the boom cylinder.
4. Clean the opening of the oil drain tube under the
hydraulic oil tank and remove the oil drain plug to
drain the hydraulic oil and collect with a
container.Meantime, open the oil filler cap to
accelerate the oil draining.

80
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1 1
3 3
I
5. Remove the oil inlet tube of the hydraulic oil Replace the work oil filter element I
cooler to completely drain the oil residue in the
radiator. O 1. Clean the area near the work oil filter. O
2. Open the work oil filter housing with a wrench
6. Remove the oil drain element from the hydraulic
and remove the element.
oil tank and replace with a new one.Open the oil
filler cap and remove the oil filler screen for 3. Clean the gasket surface on the head with a
cleaning. clean cloth (replace if the ring seal is damaged)
and install a new element.
7. Remove the tank clean-out flange disc under the
oil filler and flush the bottom and walls of the 4. Assemble the work oil filter.
hydraulic oil tank and wipe with a clean cloth.
Replacing the seriously contaminated
8. Install the oil drain plug of the hydraulic oil tank, hydraulic oil
oil drain filter and top cover, oil filler screen, tank
clean-out flange mouth and the oil inlet tube of If the work environment is poor, or the hydraulic oil is
the hydraulic oil cooler. deteriorated due to serious contamination, such as
darkening color or bubbles, replace the hydraulic oil
9. Add clean hydraulic oil through the oil filler of
in time.
hydraulic oil tank. The hydraulic oil can only enter
from the underside of the barrel structure due to 1. Remove any debris in the bucket. put the
the right side oil filler built in the barrel structure, variable speed joystick to the neutral position
and there is an air vent plug at the middle of the and pull the park brake button and install the
flange at the top of the barrel.When releasing frame locking lever.Start the engine and idle it for
hydraulic oil is required during repair, open the 10 minutes during which repeat the actions of
K air vent plug to release a small amount of K
lifting boom, lowering boom, tilting bucket
M hydraulic oil.To change with new hydraulic oil,
open the air vent plug before adding the new oil.
M
forward and tilting bucket backward several
times.
2 The level after added should be at the top of the 2
2. Finally, raise the boom the highest position, tilt
dipstick. Tighten the air vent plug after filling.After
F idling for 5 minutes, operate the work valve F
the bucket to the maximum position and turn off
the engine.
joystick to raise and lower the boom, tilt the
_
bucket forward and backward and steer left and
_
3. Push the bucket joystick of the work valve
K
right to the largest angle for 2-3 times, to fill the K
forward to allow the bucket to tilt forward with its
cylinder and lines with hydraulic oil. own weight to drain the fluid in the bucket
3
10. Turn off the engine, open the oil filler cap of the
3
cylinder;After the bucket tilts to the desired
position, push the of the work valve boom lever
1
hydraulic oil tank, and add clean hydraulic oil to 1
forward to allow the boom to descend with its
the appropriate position of the oil level gauge in
own weight to drain the fluid in the boom cylinder.
3
hydraulic oil tank. 3
4. Clean the oil drain under the hydraulic oil tank
Note: I and remove the oil drain plug to drain the I
1. To repair the hydraulic system, such as pump,
O hydraulic oil and collect with a O
hydraulic oil line, etc., the air vent plug must container.Meantime, open the oil filler cap to
be opened to reduce the hydraulic oil drain accelerate the oil draining.
flow in the hydraulic oil tank, or else, the
hydraulic oil in the tank will be completely 5. Open one end of all the tubes to drain the oil
drained. residue in the steering cylinder, hydraulic oil
cooler and any tube.
2. The air vent plug must be opened to add
hydraulic oil. The level should be at the top of 6. After the oil draining finishes, install the oil drain
the dipstick after filling. The air vent plug plug under the hydraulic oil tank and all opened
must be closed after filling and before tubes.
starting the machine, or else air will be drawn 7. Open the oil filler cap of hydraulic oil tank and
into the hydraulic system, causing serious add clean hydraulic oil to the lower mark of the
damage to the machine. oil level gauge.
8. Perform oil change one more time according to
the procedure in the Regular Replacement of
Hydraulic Oil, replace the oil drain element, and
clean the filler screen and hydraulic oil tank.

81
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3 3
KnowledgeI of Tire Checking park brake performance I
O and Inflation
Maintenance 1. The park brake performance should be checked O
frequently to ensure park safety and the braking
The maintenance, removal, repair and installation of capability in case of emergency barking.
the tire and rim require special equipment and 2. Adjust the tire pressure of the machine to the
techniques, therefore ask a tire repair shop or a specified value and level the bucket about 300
specially trained person to do the job and obey all mm above the ground.Verify the machine has
related regulations. good service brake performance.
It is recommended to use dry nitrogen (N2) to inflate 3. Start the engine and make the machine face a
the tire.If there is air remaining in the tire, it is 20%-grade slope which should be flat and dry.
recommended to use nitrogen that can be mixed with
air to regulate the tire pressure. The tire inflated with 4. Depress the service brake pedal to stop the
nitrogen can reduce the possibility of explosion machine.Put the variable speed joystick to the
because nitrogen is nonflammable.Nitrogen can also neutral position and turn off the engine.
prevent oxidation, deterioration of rubber and 5. Pull the park brake button and slowly release the
corrosion to the rim components. service brake pedal to check if the machine is
Wait for the tires to cool down sufficiently before still at the original position.
checking and adjusting the tire inflation pressure.The
tire inflation pressure of using nitrogen is same with
that of using with air.Caterpillar (Qingzhou) Ltd. Checking service brake
recommends to determine the tire inflation pressure
K based on the operating condition of the machine. performance K
M Attention M brake system is operational
Make sure that the park
before checking the service brake performance to
2 If the machine travels at high speed for an 2
apply the park brake at emergency.
extended period of time, stop the machine for 30
F
minutes every 45 km, to cool down the tires. Drive the machine at 20 km/h F on a flat, straight and
day on a cement pavement and depress the service
_ brake pedal. After the machine_stops, push the
variable speed joystick to the neutral position, pull
K
Bucket Kickout Adjustment K
the park brake button, and then release the service
3 has a bucket self-leveling function.
This machine
brake pedal.Check the machine's brake 3 distance
which should not exceed 9 meters.
Rational use of this function during operation can
1
improve the work efficiency significantly.
1
Drive the machine at 32 km/h and slightly apply the
3 service brake, the machine should be stopped 3
instantly without deflecting.
Adjust the bucket I self-leveling device I
1. Position the machine on a level surface and put
O
the variable speed joystick to the neutral
O
position.Operate the work valve joystick to level
the bucket on the ground, pull the park brake
button, and turn off the engine;Install the frame
locking lever.
2. Loosen the arrow bolt on the caliper, move the
arrow to the middle position of the tilting cylinder
small chamber connector body and tighten the
arrow bolt.
3. After completion, remove the frame locking lever,
start the engine, and check for proper adjustment.

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Checking Ipark brake friction I
Grease fill device:

plate O O
The 3 longitudinal gutters on the caliper friction plate
are marks for grinding, it needs to replace with new
plate if the gutters on it are smooth.
Maintenance of Pin Shaft and Drive Shaft
To reduce the difficulty in adding grease, improve the
maintenance for the entire machine and the service
life and reliability of the machine, we recommend all
users to operate according to the following The use of SEM grease gun equipped on the
instructions. machine is preferred as shown that has been tested
on site and been proved to meet the machine grease
fill requirement.
Reference point for articulation pin
shaft grease fill position:
Grease Gun Use Considerations
Clean the grease nozzle before filling to make sure
that no contaminants obstructs the grease nozzle or
passage.
K K
Check the device for good condition, especially the
M M
connection between the hose/tube connector and
grease nozzle for tightness before it is used.Remove
2 2
the air inside the grease gun before adding grease to
make sure that the filling pressure is achieved.
F F
Connect one end of the hose/tube to the grease
_
There are 21 articulation pin shaft grease fill _
nozzle and adding grease by operating the handle.
positions. Please add grease according to the Increasing restriction will be felt during filling and
K
positions outlined in the table below during each K
stop filling when the grease spills from the pin shaft
maintenance event and make sure that each joint is grease passage.
3
properly lubricated:
3
1Fill position Quantity Grease fill interval:
1
Bucket and boom3 joint 2 3
Fill every 10 service hours or daily during work time
I
Bucket and drawbar joint 1 (This interval must be performed stringently); fill
every 500 service hours or three months for the drive
I
Drawbar and rocker lever joint 1
O
Rocker lever and boom joint 1
shafts. O
Grease fill considerations:
Raising cylinder and boom joint 2
The lower main articulation pin shaft can only be
Tilting cylinder and rocker lever joint 1 filled after steering;
Boom and front frame joint 2
The joint between raising cylinder and front frame
Tilting cylinder and front frame joint 1 can only be filled after the raising cylinder is raised.
Raising cylinder and front frame joint 2 Filling the swing frame requires climbing to the
Steering cylinder and front frame joint 2 underside of the machine and the grease must be
Steering cylinder and rear frame joint 2
filled after the engine is shut down.

Swing frame and rear frame joint 2

Front and rear frame joint 2
Follow-up of Grease Fill
Remove the excessive grease at the grease nozzle
after fill so that the grease will not adsorb
contaminants during operation clogging the nozzle or
allowing the contaminants to enter the grease
passage at next fill.

83
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I
Welding Operation Check the battery appearance before charging I
1. The battery with a broken case or acid leakage
O
When welding on the machine, perform as specified
can not be charged. Replace the battery after
O
below, to avoid machine damage or accidents.
identifying the reason.
1. Read and understand the related safety
regulations on welding on the machine before 2. The battery with a broken post can not be
welding. charged. Replace the battery after identifying the
reason.
2. The engine start switch must be turned off and
the power negative switch must be disconnected 3. Clean the post and remove the oxide coating on
before welding. the surface before charging.

3. The dashboard connectors must be removed

before welding to avoid dashboard damage.Or Charging Precautions
disconnect the cab harness (at the lower right of 1. Wear safety glasses.
cab and near the frame articulation;) from the
machine harness. 2. Keep the area well-ventilated while charging and
charge at normal temperature.
4. Do not use voltage greater than 200 V constantly.
3. Never smoke while charging.
5. Weld area is within 1 meter from the ground
cable. 4. Connect the positive cable first after
charging;Disconnect the negative cable before
6. The ring seal and bearing should be not located charging.
between the weld area and ground cable.
K K
Battery Charging Regulations
7. Never weld or cut any pipe or container filled with
M fuel, oil and hydraulic oil. M
1. Confirm that the battery post is clean and the
charging return circuit is well connected.
2 8. Never weld or cut any sealed or poorly-ventilated 2
2. The charger positive connects the battery
container.
F F
positive and the charger negative connects the
battery negative.Never charge the battery in
_
Maintenance-free Battery Charging series (24 V). _
K
Regulations K
3. It is recommended to use constant voltage 16.0
volts (do not exceed 16.2 volts, or else the water
3
This machine uses maintenance-free battery. The 3
will be electrolyzed and the level will drop,
following regulations must be obeyed during use. causing battery failure). The maximum current is
1 1
25 amperes. Charge the battery with a charger
Reason for Battery Discharge
3
1. Abnormal use, for example, the electric
3
until the electrolyte indicator is green.Turning
green means the electricity is sufficient.
I
appliances on the vehicle are on for an extended
4. For the battery with a battery voltage less than
I
period of time before the vehicle is started.
O
2. Long time of vehicle stopping, excessive current
11.0 volts, the battery may not be able to receive O
the electricity at initial phase.The reason is that
leakage, or installation of additional appliances. the sulfur ratio in a badly discharged battery is
close to pure water. The battery inner resistance
3. Frequent start of the vehicle.
is very high.This can be resolved by reducing the
4. Malfunctioning charging system (for example, charging current or changing for an alternator
failed alternator and electronic elements, over with a larger power. As the charging is going on,
low charging voltage setting of the alternator the sulfur ratio in the battery increases and the
governor, loose engine drive belts) made the charging current will restore to a normal level
battery charged improperly, causing battery gradually.
discharge. The electrolyte indicator is black, and
5. If a large amount of acid spills from the vent hole
the machine even can not be started.
of the battery while charging, stop charging
5. The unused battery is stored for more than 6 immediately and find the reason.
months.
6. When the battery temperature is above 45
The discharged battery due to the reasons above degrees centigrade while charging, stop charging.
can be corrected by charging timely and properly. When the battery temperature drops to the room
temperature, cut the charging current in half and
continue charging.

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Oil Use Regulations I
O
Use the specifications and types specified in the O
table below when adding or changing various oils in
this machine, to ensure normal machine operation.

Use Position Ambient Temperature Lubricating Oil Specification Note

-20°C-40°C API CH-4 SAE15W-40

-25°C-40°C API CH-4 SAE10W-40

Engine
-30°C-40°C API CH-4 SAE5W-40

-35°C-40°C API CH-4 SAE0W-40

-25°C～40°C 8# Drive Oil

Transmission
-35°C～40°C SAE0W-40

-15°C～49°C GL-5 85W-90

Drive -25°C～49°C GL-5 80W-90

-45°C～10°C GL-5 75W-90 Recommended Oils:

Contact the local office and dealer to
-5°C-40°C L-HM 46 use designated oils by Caterpillar
(Qingzhou) Ltd.
K Hydraulics -26°C-40°C L-HV 46 K
M -35°C-40°C SAE0W-40
M
DOT4 or DOT3 brake oil that meets
2 Air booster pump
SAEJ703 standard 2
F Generic grease NGLI2 F
_
Anti-freeze YF-2 or YF-2A
_
K Above 5°C 0# K
Fuel tank3 Above -14°C -20# 3
1 Above -29°C -35#
1
Considerations
3 3
I
1. Do not mix the oils with the same I
specifications but from different brands. If
O O
the oil from another brand must be used for
some reason, flush the system clean first.
2. If the machine operates at a frigid zone a long
period of time, the hydraulic oil should be
HV46 or HS46 low temperature anti-wear
hydraulic oil.
3. Various oils should be changed timely even
the oil is still clean.The oil can also
deteriorate if stored for an excessive period
of time.
4. The fuel should be chosen based on the local
record low air temperature.

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Fault Reason and Troubleshooting I
O O

K K
M M
2 2
F F
_ _
K K
3 3
1
The following section describes the common 1
fault causes and troubleshooting methods for
3 3
this machine for the user's reference.
I I
O O

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Engine System I
O
For the fault reasons and troubleshooting methods O
for engine system, see the supplied engine
instructions.

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

2. Low speed change pressure at one shift position

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

K 3. High oil temperature in torque converter K

1. Low transmission oil level 1. Fill to the specified level
M 2. High transmission oil level 2. Drain to the specified level
M
2 3. Clogged oil cooler 3. Clean or replace the cooler 2
4. Slipping clutch 4. AccessCalibrate the variable speed pressure
F 5. Excessive time of constant high-duty work 5. Stop or idle the engine for cooling F
_
4. The machine can not travel after started _
K
1. Not into gear K
1. Put into gear or adjust the shift lever into place

3
2. The speed change valve can not go back after shut off
3
2. Disassemble and check the variable speed valveTroubleshooting
faults
1
3. Low torque converter pressure 3. Adjust torque converter overflow method 1
4. Low speed change pressure 4. See 1. 2.
3 3
5. Insufficient drive power
I I
1. Low speed change pressure 1. See 1. 2.
2. O
High oil temperature in torque converter 2. See 3 O
3. Damaged torque converter impeller 3. Remove and check the torque converter and replace the impeller
4. Poor engine output power 4. Access the engine
5. Unreleased service brake or park brake 5. Access the brake system
Brake System
1. Poor service brake capability
1. Brake oil leak 1. Replace seal
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 a new plate

2. Unable to shift into gear after braking

1. Brake valve can not return to its original position 1. Remove, check and repair
2. Stuck speed change valve air valve lever 2. Remove, check and repair

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I
3. Poor air pressure at the rear cavity of speed change shutoff
valve lever
3. Access line system I
O O
3. Brake unable to be released normally
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
K 1. Unequal brake torque for front and rear wheels K
1. Check the air compressor operation
2. Unequal air pressure for front and rear wheel 2. Inflate at specified pressure
M M
7. Insufficient park brake capability
2 2
1. Excessive gap between brake drum and brake disc 1. Readjust as specified
F 2. Oil on the brake disc 2. Clean the brake disc F
_ _
Work Tool and Hydraulic System
K
1. Lift arm rotates bucket slowly or does not move
K
3
1. Damaged cylinder seal 1. Replace the oil seal
3
1
2. Oil leak in pipeline system 2. Check and repair 1
3. Serious oil leak in working pump 3. Replace with a new pump
3
4. Improper adjustment of dump valve and low system pressure 4. Adjust the system operating pressure to specified value 3
5. Air in the working pump suction tube or clogged oil filter 5. Clean the oil filter or replace the suction tube
I
6. Excessive fit clearance at hydraulic control valve 6. Access or replace the hydraulic control valve
I
O
2. Oil pump drawing oil or bubbles in oil
O
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

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4. Failed return I I
O
1. Deformation of work valve return spring
2. Contaminants present between work valve press lever and
1. Replace with new parts
2. Parts washed
O
mating hole
3. Deformation of multi-way valve return spring 3. Replace with new parts
4. Contaminants present between multi-way valve levers 4. Parts washed

5. Unreliable seating of work valve

1. Insufficient magnetic draw 1. Replace with new parts
2. Contaminant on the mating face between magnet and spring 2. Parts washed
seat
3. Clearance between rocker and press lever not adjusted as 3. Adjust as specified
specified

6. Poor control of work valve

1. Stuck or unsmooth metering valve core 1. Check the cleanliness of fluid.Clean the valve cartridge 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

K Steering System K
1. Hard Steering
M M
A. Hard steering with fast or slow action
2 2
1. Insufficient oil supply from oil pump 1. Repair or replace the oil pump
F 2. Inflexible movement of priority valve core F
2. Correct the cause of inflexible movement of priority valve core, or
replace the priority valve
_
3. Low control pressure of priority valve _
3. Adjust the control pressure of priority valve

K
4. Air in oil control circuit between priority valve and steering device
K
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
3 3
1
B. Bubbles in the oil with irregular noise, and oil cylinder operating intermittently when rotating the steering
wheel
1
3
Air in the steering system
3
Check the oil level and add oil if necessary Check for air leak in the
I suction line and troubleshootVent air in the system
I
O
C. Smooth under no load but heavy under load O
1. Pressure setting 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

2. No Stop Limit
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 not less
mounted on the steering gear oil inlet surface lower than the than 1.25 times of steering relief valve pressure setting
pressure setting of steering relief valve
2. Steering device valve bodyValve envelopeSerious wear between 2. Replace the damaged part or steering device
valve cartridges or rotor and stator, causing excessive clearance

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3. Steering Failure I I
A. Steering wheel not being able to return to neutral positronPressure runout increase at middle position
O O
Broken spring disc Replace the damaged spring disc

B. Pressure runout increasing significantly, and rotating is impossible

Broken or deformed cotter or coupled axle opening Replace the cotter or coupled axle

6. 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

2. Battery Not Being Charged or with Low Current

1. Damaged voltage regulator 1. Access or replace

K 2. Poorly connected wires or open circuit

K
2. Check the circuit between alternator and battery

M 3. Big Spark Between Alternator Brush and Commutator M

2 Seriously worn commutator
2
Clean the commutator and remove the contaminants between the
cells
F4. Overheated Alternator F
_
1. High voltage regulation by voltage regulator 1. Adjust the regulator voltage
_
K worn or insufficiently lubricated
2. Bearing 2. Replace the bearing or add lubricating oil K
3. Short circuit in commutator or armature coil 3. Repair or replace
3 3
5. Hard Engine Start
1 1
1. Low voltage or battery damage 1. Charge or replace with a battery
2. Damaged start 3 switch 2. Access or replace 3
I
3. Poorly connected wires or open circuit
4. Air in engine oil inlet line
3. Check and repair
4. Vent air in the line
I
O O
7. 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
3. Compressor not rotating, belt slipping on the pulley 3. Remove the compressor for repair or replacement
4. Compressor not operating, with little change of high and low 4. Repair or replace the compressor valve disc
pressure values while engine speed changing
5. Broken refrigerant system lines, or refrigerant leaking to none, 5. Repair the lines, check for system leaks, draw out vacuum and
high and low pressure value being zero add fluorine
6. Clogged reservoir dryer or expansion valve 6. Remove for repair or replacement

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2. Insufficient Cool AirI I
O
1. Air leak in air passage connection 1. Clean or replace the air screen, remove the restriction in air
passage, reconnect the air passage
O
2. Abnormal operation of blower motor 2. Repair or replace the blower motor
3. Slipping compressor magnetic clutch 3. Repair or replace the magnetic clutch
4. Low efficiency of compressor 4. Repair or replace the compressor
5. Air in refrigerant system, too high reading on high pressure 5. Vent air, draw out vacuum and add fluorine
gauge, fog in sight glass
6. Insufficient refrigerant, air bubbles in sight glass, too high 6. Add refrigerant until the bubble is gone
reading on high pressure gauge
7. Insufficient air flow around the condenser, too high reading 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. Idle controllerTemperature control is maladjusted 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

4. Louder Noise
1. Loose or overworn drive belt 1. Tension or replace the belt
K 2. Loose compressor mounting brace K
2. Tighten the brace mounting capscrew
3. Loose or worn blower motor 3. Repair or replace the motor
M 4. Slippery magnetic clutch causing noise
M
4. Remove for repair or replacement
2 5. Worn internal compressor parts 2
5. Repair or replace the compressor

F F
_ _
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1 1
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I I
O O

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SEM653DI Regular I
O Parts List
Maintenance O

I. Maintenance Interval Schedule

A. Fluids (with different applicable temperatures, the
customer should choose oil based on the local
condition)
This list contains SEM653D special oil used for
regular maintenance.For detailed change operation,
see the Operation and Maintenance Manual

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

-25°C-40°C API CH-4 SAE10W-40

Engine 21 50 250
-30°C-40°C API CH-4 SAE5W-40

-35°C-40°C API CH-4 SAE0W-40

K Number 8 hydraulic drive
K
-25°C～40°C
M Transmission fluid 53 M 500 1000
-35°C-40°C SAE0W-40
2 -15°C～49°C GL-5 85W-90
2
F Drive -25°C～49°C GL-5 80W-90 36 * 2 500
F 1000
_ -45°C～10°C GL-5 75W-90 _
K -5°C-40°C L-HM 46 K
3
Oil tank -26°C-40°C L-HV 46 166
3 2000

-35°C-40°C SAE0W-40
1 1
B. Safety Items 3 3
Interval (h)I Item Description Demand (L) Where used Remarks I
According to actual needs Brake oil DOT3 3 Air booter pump
O O
According to actual needs Brake discs 2 per caliper Calipers

–35～50 YF-2 5 years or 10,000 service

Engine Cooling
hours
–45～50 YF-2A

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C. Filter Elements I I
This list contains SEM653D genuine element used
O
for regular maintenance. For detailed change
O
operation, see the Operation and Maintenance
Manual.
NOTE:The air filter needs to be cleaned when the air
filter indicator gives a warning, and needs to be
replaced after 6 consecutive cleanings.For all other
filters, if the filter alarms indicate that they need to be
replaced, replace them immediately (filter elements).

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

Air filter element 1

Engine Diesel fuel filter 2 250

Heated filter with electric pump 1

Drive hydraulic Element 1 100 1000

Oil tank Drain Element 1 250 1000

K K
M M year)
II.Material list required for the maintenance within 2000 hours (one
2 Replacement
Demand Volume 2
F time:
(h)
Item Description
Oil (L)
Filter
element
F Where used

_ (piece) _
Diesel engine oil 21
K 50 K Engine
Oil filter element 2 Engine
3
100 Element 1
3
Drive hydraulic
1 Drain Element 1 1
Oil tank

3 Diesel engine oil 21 Engine

3
Oil filter element 2 Engine
250 I Air filter element 1 Engine
I
O Diesel fuel filter 2 Engine O
Heated filter with electric pump 1 Engine
Diesel engine oil 21 Engine

Oil filter element 2 Engine

Air filter element 1 Engine

500 Diesel fuel filter 2 Engine

Heated filter with electric pump 1 Engine

Gear Oil 36*2 Drive

Hydraulic drive fluid 53 Transmission

Diesel engine oil 21 Engine

Oil filter element 2 Engine

750
Air filter element 1 Engine
Diesel fuel filter 2 Engine

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I Demand Volume I
Replacement
time: O Item Description
Oil (L)
Filter
element
Where used O
(h)
(piece)
Heated filter with electric pump 1 Engine

Element 1 Drive hydraulic

Drain Element 1 Oil tank

Diesel engine oil 21 Engine

1000 Oil filter element 2 Engine

Air filter element 1 Engine

Diesel fuel filter 2 Engine

Heated filter with electric pump 1 Engine

Diesel engine oil 21 Engine

Oil filter element 2 Engine

1250 Air filter element 1 Engine

Diesel fuel filter 2 Engine

Heated filter with electric pump 1 Engine

K Diesel engine oil 21 K Engine

M Oil filter element M

2 Engine

Air filter element 1 Engine

2 2
1500 Diesel fuel filter 2 Engine
F Heated filter with electric pump 1
F Engine
_ Gear Oil 36*2 _ Drive

K Hydraulic drive fluid 53

KTransmission
Diesel engine oil 21 Engine
3 Oil filter element 2
3
Engine

17501 Air filter element 1 1

Engine

3 Diesel fuel filter 2 Engine 3

I Heated filter with electric pump 1 Engine

I
Anti-wear hydraulic oil 166 Oil tank
O Element 1 Drive hydraulic
O
Drain Element 1 Oil tank
Diesel engine oil 21 Engine
2000
Oil filter element 2 Engine

Air filter element 1 Engine

Diesel fuel filter 2 Engine

Heated filter with electric pump 1 Engine

94