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605-8864
i i 2019
Sep.

Operation and
Maintenance
J
M
2
Manual J
M
2
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SEM
_ 822D Track-Type Tractor _
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S8T (822D
m Stage II/StageⅢ) m
2 2
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i Important Safety Information i
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Most accidents involving product operation, maintenance and repair are caused by failure to observe basicisafety
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. 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 have read and
understood the operation, lubrication, maintenance and repair information.
Saf ety precautions and warnings are provided in the manual and on the machine. If these hazard warnings are not
heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”,
“WARNING” or “CAUTION”. The Saf ety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Notice! Become Alert! Your Safety is Involved.!
J The message that appears under the warning explains the hazard and can beJeither written or pictorially
M presented. M
Operations that may cause product damage are identified by NOTICE labels on the product and in this manual.
2 2
Caterpillar (Qingzhou) Ltd. cannot anticipate every possible circumstance that might involve a potential
8 hazard. The warnings in this manual and on the product are, therefore, not all inclusive.
8 If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar (Qingzhou) Ltd. is
_ _
used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the
j will not be damaged or made unsafe by the operation, lubrication, maintenancej or repair
product
procedures you choose.
m m
The information, specifications, and illustrations in this manual are on the basis of information that was available at
2 manual was written. The specifications, torques, pressures, measurements, adjustments,
the time the 2 illustrations,
and other items can change at any time. These changes can affect the service that is given to the product .
8 the complete and most current information before starting any work. If you have any8questions,
Theref ore, Obtain
please contact Caterpillar (Qingzhou) Ltd. or consult the nearest dealer.
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When replacement parts are required for this
product Caterpillar (Qingzhou) Ltd. recommends
using Caterpillar (Qingzhou) Ltd. replacement
parts or parts with equivalent specifications.
Failure to heed this warning can lead to
premature failures, product damage, personal
injury or death.
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i To the User i
Dear User: i i
It is our honor to have the chance to provide premium service for you, and it is our persistent pursuit to provide you
with equipment that can bring you considerable economic benefits. Thank you very much for using SEM 822D
Track-Type Tractor Operation and Maintenance Manual. This manual contains:
• Machine Overview
• Machine Operation Information
• Operation Instructions
• Maintenance
• Storage
• Common Faults and Causes
• Specifications
This manual will help you understand basic knowledge regarding the performance, features, operation and
maintenance of the machine, and avoid failures caused by improper operation or use. Following the maintenance
guidelines will
J • reduce f ailures during on-site use and increase working efficiency J
M • increase the service life of the machine M
2 Do not attemp to operate or repair the machine until you understand the instructions2 in this manual! Caterpillar
(Qingzhou) Ltd. will not take any responsibility for the consequences resulted from failure to follow relevant
8 instructions. 8
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Table of Contents Inspection and Maintenance before Operation i 47
Inspection and Maintenance after Operation...47
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Foreword......................................................... 5 i
Lubricant Viscosities ...................................48
Maintenance support ..................................48
Machine Overview............................................ 6 Storage ....................................................70
Overview.................................................... 6 Decommissioning and Disposal ....................72
Layout of the systems of the machine............. 7 Common faults and troubleshooting ................73
Instrument Information ............................... 10
Switch Information..................................... 13 SEM822D Track-Type Tractor Specifications.....77
Safety ........................................................... 15 Regular maintenance basics ...........................80

Saf ety Messages and Additional Messages ... 15

General Hazard Information ........................ 19
Pressurized Air and Water .......................... 19
Trapped Pressure...................................... 19
Fluid Penetration....................................... 20
Containing Fluid Spillage ............................ 20
Asbestos Information ................................. 20
Dispose of Waste Properly.......................... 21
Crushing Prevention and Cutting Prevention.. 21
Burn Prevention ........................................ 21
Coolant .................................................... 21
Oils ......................................................... 22
J Batteries .................................................. 22
J
M Fire Prevention and Explosion Prevention ..... 22 M
Fire Extinguisher ....................................... 23
2 Lines, Tubes, and Hoses ............................ 23 2
Fire Extinguisher Location .......................... 23
8 Four-roller-one-track Information.................. 23 8
_ Lightning Damage Prevention ..................... 23 _
Before Starting Engine ............................... 23
jEngine Starting ......................................... 23 j
Restricted Visibility .................................... 24
m Operation....................................... 24
Before m
Visibility Information................................... 24
2 ................................................. 25
Operation 2
Engine Stopping........................................
8 25 8
Parking .................................................... 25
Sound Level i Information........................... 25 i
Vibration Information.................................. 26
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Cab ......................................................... 26 i
Guards .................................................... 26
Other Guards (If Equipped)......................... 26
Machine Operation Information....................... 27
Related Operation Information..................... 27
Downhill Operation .................................... 27
Before Operation....................................... 27
Machine Operation .................................... 28
Operator Controls ...................................... 30
Operation Section...................................... 37
Parking .................................................... 40
Operation techniques ................................. 40
Transport Information................................. 44
Lif ting and Tying Down the Machine ............. 44
Towing Information .................................... 45
Maintenance Interval Schedule ....................... 46
Operational Inspection and Maintenance......... 47
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Foreword Maintenance Intervals i
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Use the service hour meter or calendar intervals
Literature Information determine servicing intervals. No matter which way is
used, recommended service should always be
This manual should be stored in the operator’s perf ormed at the interval that occurs first.
compartment in the literature holder or seat back
Under extremely severe, dusty or wet operating
literature storage area.
conditions, more frequent lubrication or service than
Please always read carefully and understand the is specified in the maintenance intervals chart might
content of this manual before operating, maintaining be necessary.
and repairing the machine.
Perf orm service on items at multiples of the original
This manual contains safety information, operation requirement. For example, at every 250 service
instructions, transportation information, maintenance hours, also service those items listed under every 50
inf ormation, storage information, machine overview service hours and every 10 service hours.
and specifications.
Engine Maintenance
Continuing improvement and advancement of
product design might have caused changes to your Proper maintenance and repair is essential to keep
machine which are not included in this manual. Read, the engine and machine systems operating correctly.
study and keep this manual with the machine. As the heavy duty off-road diesel engine owner, you
are responsible for the performance of the required
If the manual is lost, damaged or becomes illegible, maintenance listed in this manual.
please replace the manual timely.
J Whenever a question arises regarding this manual,
J any person to remove, alter, or
It is prohibited for
render inoperative any emission related device or
M please consult your Caterpillar (Qingzhou) Ltd. dealer element installed on Mor in the engine or machine at
f or the latest available information. any time during the repairing and servicing of the
2 2 elements of the machine
engine or machine. Certain
Machine Overview
8 8 system, fuel system,
and engine such as the exhaust
electrical system, intake air system and cooling
The machine overview section mainly contains the
_
introduction to each of the systems of the machine system may be emission related _ and should not be
and main components, as well as basic safety altered unless approved by Caterpillar (Qingzhou)
j
precautions. In addition, this section identifies the text Ltd. j
and locations
m of warning signs and labels used on the m
machine. Read and understand these basic Special Tips
2 before operating or performing
precautions 2
maintenance and repair on this machine. Due to the continous improvement and advancement
8 of the product design and the number of 8 product
Operation Section varieties, some photographs or illustrations and
i i texts
in this manual may show details that are different
The operation section is a reference for new
i resher for experienced ones. This
operators and a ref f rom your machine; i
section includes a discussion of switches, machine Please read this manual carefully and strictly follow
controls, transportation and towing information. the operation and maintenance instructions specified
Photographs and illustrations guide the operator in the manual. Caterpillar (Qingzhou) Ltd. will not
through correct procedures of checking, starting, take any responsibility for the personal injuries or
operating and stopping the machine. machine damages resulted from failure to follow
operation instructions;
Operating techniques outlined in this manual are
basic. Skill and techniques develop as the operator Whenever a question arises regarding the machine
gains knowledge of the machine and its capabilities. or this manual, please contact the service engineer at
Caterpillar (Qingzhou) Ltd.;
The company reserves the right to revise the
contents of the operation and maintenance manual
due to technical improvements without further
notif ications. The safety alert symbols used in this
manual are explained below:
Be aware of moderate risks, which, if not avoided,
can lead to potentially hazardous situations that can

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cause serious injury. i
perf orm power steering and pivot steering, which
enables the machine to adapt to the needs of various
Watch f or minor risks, which, if not avoided, can lead
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to potential hazards that may lead to minor or
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operations. It not only has the advantages of high
power density, convenient layout, strong overload
moderate injuries.
protection and flexible control.
Indicates that this operation does not comply with
The machine consists of diesel engine, working
saf ety regulations and is prohibited or subject to
hydraulic system, drive train, undercarriage, electrical
accident.
system, structure, sheet metal, work tools and
operator station.

Machine Overview
Overview
The tractor features simple structure, flexible
operation and high production efficiency. It is the
most commonly used machine in the mechanization
of roadbed construction. It can excavate and move
hard soils, weathered rock formations, blast rock and
other rock and soil materials. The tractor is a type of
self -propelled dozing and transport machinery, with
track-type or tire-type tractor specific chassis as the
J base machine, and equipped with suspended blade J
(some also with scarifier). When the tractor is working,
M the blade cuts into the soil, and the forward driving M
2 power is provided by the drive train to complete the 2
cutting and dozing, and sometimes it can also be
8 used f or filling, leveling, scarifying and the like. The 8
use of tractors can relieve heavy physical labor,
_ up construction progress and ensure
speed _
construction quality. Therefore, it is a general
j
construction machine that is widely used in j
construction,
m road building, mining, agriculture, m
f orestry, and defense construction.
The drive2 train of the SEM822D hydrostatic tractor 2
mainly consists8 of a hydraulic pump and a hydraulic 8
motor. Therefore, the transmission is light in weight
and small in size,i which facilitates the overall layout i
of the machine. Furthermore, with different
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combinations of pumps and motors, it is possible to i
make the machine get different traction
characteristics; Stepless speed regulation and
f retting running of the machine can be easily
achieved, so that the machine can be softly started,
and the speed can be changed quickly and the
driving direction can be changed without impact. The
engine has good load characteristics at low speeds,
that is, the machine can exert its maximum traction at
low engine speeds, which is particularly important for
traction machines such as tractors. It is easy to
integrate machinery, hydraulics, and electronics
together and realize automatic control, which is the
basis for intelligent machine realization. The
operation is simple and labor-saving. With a single
joystick, the forward and reverse movement and
steering of the machine can be completed. The
hydraulic drive can achieve the independent drive of
the lef t and right track of the machine, which can
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Layout ofi the systems of the machine i
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1. Blade 4. Engine System 7. Drive Train
8 2. Working hydraulics 5. Cab 8
8. Undercarriage
3. Sheets 6. Ripper 9. Cooling
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j tools
Work Diesel Engines j
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The work tools mainly consists of blade, push arm,
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This machine is equipped with engine with Stage III
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and ripper. and Stage II emission certification. The 2engine has
good cold start performance, high altitude
The SEM822D tractor has the following types of
blades:
8 8 low
perf ormance, low fuel consumption, low noise,
emission, high reliability and durability.
i for most conditions
• S blade - suitable i fully
The diesel engine of the construction machinery
considers the special requirements of the
i for pushing coal or other loose
• U blade - suitable i
construction machinery, and is fully equipped with a
materials more beautiful appearance, with higher reliability and
better matching adaptability.
• SU blade - suitable for large earthwork conditions
When the machine is working, the fuel supply pump
transfers the fuel in the fuel tank through the fuel filter
to the f uel feed pump, where the fuel is pressurized
and supplied to the injectors according to different
working conditions to complete the power process.
Excessive fuel supplied by the fuel pump returns to
the suction line through injector and fuel pump fuel
drain lines. There is a manual f uel pump on the
primary f uel filter, which can be used to vent the air in
the f uel lines. The throttle is controlled by the
electronic hand throttle and the deceleration/brake
pedal.

Caterpillar: Confidential Green 7

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Implementi Hydraulic System
i system includes two parts:
The working hydraulic
implement hydraulic system and pilot hydraulic
system.
The implement hydraulic system is used to control
the movement of the various work tools (rippers,
blades, etc.) of the tractor. The pilot hydraulic system
makes the operation simple and convenient,
consisting of proportional pilot valves, pilot
accumulators and pipes.
Undercarriage
The undercarriage consists of four-roller-one-track,
tensioning mechanism, and track roller frames.
The f our-roller-one-track mainly receives various
f orces from the road and the frame, guiding the
machine f orward and supporting the track.
The main f unction of the tensioner is to provide
sufficient tension for the track and reduce the jumping
or shedding of the track during traveling.
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Drive Train
M machine with glassM windows and doors that are
The drive train is mainly composed of the hydrostatic
2 system, the final drive, the brake system and
couplings.
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The machine is driven by a hydrostatic system. Each
_ is driven by a closed circuit consisting of a
track
two-way swashplate variable displacement pump and
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a variable motor. The drive train is greatly simplified.
The drive
m pump is connected to the coupling and the
traveling motor is directly connected to the final drive.
2 system of the tractor is directly driven
The hydrostatic
by a traveling motor to realize power steering and
8 hydrostatic system composed of a
driving (a closed
variable displacement piston pump and a variable
i motor, a control element, and
displacement piston
i
other necessary hydraulic components, used to
implement driving and steering of the machine).
The main f unction of the final drive system is to
increase the torque transmitted by the traveling motor,
distribute the torque to the left and right sprockets,
and drive the track to move the tractor.
This machine adopts the wet brake system. The
f riction plate is assembled in the brake housing of the
f inal drive. The brake is achieved through the
pressure charging (brake released) and pressure
release (brake applied) of the hydraulic oil.
Electrical Systems
The electrical system of the machine is powered by
two 12 V batteries in series, rated at 24 V. It contains
starting system, charging system, control system,
lighting system, instrument and indicator system, etc.;
The alternator is driven by the engine through a belt.
8
Under normal conditions, the alternator can isupply
power to the electrical equipments and charge the
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batteries. Each control switch controls individual
appliance.
ECM checks and analyzes the received signal and
outputs the corresponding signal to the actuating
devices. EDT software is used to diagnose machine
f aults.
Structural Parts
The structure of the machine includes the pivot shaft
of the tractor, the main case, the equalizer bar, and
the radiator guard etc.
Cab
The operator station consists of a cab and the
operator controls. The cab effectively protects the
operator's safety. Modal analysis and test verification
show that the damping system can greatly reduce the
vibration and noise levels of the cab, and improve the
comfort of the cab and the operator's work efficiency.
In order to give the operator a good view when
operating the machine, our designers equip the
optimized in design. The operator controls is
ergonomically arranged2for convenient and
comfortable operation.
Sheets
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Sheet metal include engine hood, fender, bottom
j oil tank,
guard plate, oil filter box, hydraulic
hydrostatic transmission oil tank, diesel
m tank and so
on.
2
Air Conditioning System 8
The tractor can be optionally equipped with an i air
conditioning system in the cab. The air conditioning
system is a dual-purpose cooling and heating isystem.
The cooling source is the refrigerating system
included in the system. The heat source is the waste
heat of the circulating cooling water in the engine
radiator. The air conditioner is an air conditioning
device specifically for construction machines. It
consists of the compressor, condenser, liquid storage
dryer, evaporator, piping, and electrical system.
Non-professionals are prohibited from disassembling
the air-conditioning system.
Fresh air filter and deodorizing device
The f resh air f ilter and deodorizing device is mainly
used for tractors and is optional for other models. The
product is mainly applicable to the severe working
conditions with heavy dust and dirt and pollution.
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i Component Dataplate
Product and i
The dataplates ofi the product and components are i
mainly for the users of the machine to understand the
basic information of the machine and components, as
well as to provide preliminary service support for the
dealers during repair and maintenance.

Machine Product Dataplate

The dataplate is on the left side of the front guard.
The dataplate mainly contains information about the
model of the machine, the machine mass, the engine
model, the engine rated power, the external
dimensions, the factory number, the manufacture
date, and the name of the manufacturer.

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Model(A)____________________________
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Machine Mass(B)_____________________
8 Product Identification Number(C)_________ 8
_ Power(D)_____________________
Engine _
j acture Date(E)__________________
Manuf j
Localm regulation may require documentation of the m
Month and/or Year of manufacture in the Opeation
2
and Maintenance Manual. Enter on line (E) above if 2
required.
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Engine Dataplate i i
This dataplate is located on the oil cooler cover on
the lef t side of thei engine. i
The dataplate mainly contains information about the
engine's rated power, rated speed, factory number,
date of manufacture, net weight, emission stage,
name and address of manufacturer, etc.
.

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i Information
Instrument i
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J Symbol Description J Function

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The pointer should be in the green area during
normal operation. When the pointer reaches over
Engine Coolant Temperature Gauge
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100℃, it enters the red alarm area.

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When the fuel level is less than 17%, the
Fuel Level Gauge
pointer enters the red alarm zone
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The pointer in the yellow area indicates an engine
i Engine Speed Tachometer
speed between 2400 RPM and 2600 RPM, and the i
pointer in the red area indicates an engine speed
greater than 2600 RPM.

Preset forward gear and speed

Location: Top left
Preset reverse gear and speed
Location: Top right
Storage icon for preset and saved speed
This icon appears when the system has saved the
previously set gear and speed.
Location: Top middle
LCD Display Transmission oil temperature (celsius)
Location: Middle left
Battery voltage display (Volts)
Location: Middle right
Service hour meter, showing the total working hours
when the engine is not working, and the current
engine speed (RPM) when the engine is working
Location: Bottom line

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Symbol Description Function i
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This light turns on when there is a fault in the drive
Electronic control unit warning light control system.

When the machine enters the parking brake state

Parking Brake Indicator and the parking brake is engaged, this light turns
on.

When the filter element is obstructed so that the

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

When the transmission oil temperature is greater

Transmission Oil Temperature Indicator than 93°C, this light turns on

J Preheat Indicator J
This lamp turns on when the preheating system is
working.
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This light turns on to indicate low engine oil
Engine Oil Pressure Indicator
pressure
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Level Two or Three Warning Indicator When a level two or three warning occurs on the
j Lamp machine, this light flashes j
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2 Fuel Level Indicator 2
When the fuel level is less than or equal to 10%, this
light turns on
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This light turns on when the pilot hydraulic lock is in
i Hydraulic Lock Indicator Lamp
effect i

If it is illuminated when the engine is working, it

Battery Indicator means that the alternator is not working and needs
to be checked.

This light turns on when the right pedal mode switch

Deceleration Pedal Mode Indicator
（for stage Ⅲ）
is depressed. At this time, the pedal controls the
machine speed but not the engine speed. When this
light is off, the pedal controls both the machine
speed and the engine speed.

Engine Economy Mode Indicator This light is on when the engine is operating in
（for stage Ⅲ） economy mode

Engine Heavy Duty Mode Indicator This light is on when the engine is in heavy duty
（for stage Ⅲ） mode

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Symbol Description Function i
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Rear defrost indicator This light is on when the defrost function is running

This light is on when the engine is working

FAULT INDICATOR
abnormally.

This light is on when there is water in the fuel. This

Water in Fuel Indicator
light is a reserved indicator

This light is on when the air filter is restricted. This

Air filter restriction indicators
light is a reserved indicator

This light turns on when the steering mode switch

Steering Mode Indicator on the right is pressed. The steering rate will
become slow.
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Switch Information i
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1. Parking brake switch 5. Instrument light switch 9. Front wiper switch
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2. Headlight switch 6. Implement lockout switch _
10. Washer switch
3. Rear light switch 7. Steering mode selection switch 11. Rear wiper switch
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4. Blade light switch 8. Deceleration pedal mode selection switch
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12. Rear defroster switch
13. Reverse Switch of Hydraulic Fan
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Number i Name Symbol Function i
i 1. When the operator presses the switch once and the machine is parked, the
parking brake light on the instrument panel lights up.
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1 Parking brake switch
2. When the operator presses the switch twice, the machine parking is
released and the parking brake signal on the instrument panel is off.

2 Headlight Switch When the switch is pressed the headlights turn on

3 Rear light Switch When the switch is pressed the rear lights turn on

4 Blade Light Switch When the switch is pressed the blade light turns on

5 Instrument light switch The operator presses the switch once and the instrument panel light turns on

Open the lockout on the switch and press the switch,

6 Implement lockout switch
the hydraulic implement locks up and the instrument panel light turns on

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Steering mode selection
switch
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When the switch is pressed, the steering rate becomes slow and the indica tor
on the instrument panel turns on
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Deceleration pedal mode
selection switch
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When the switch is pressed, the pedal will control the vehicle speed but not the
engine speed, and the indicator on the instrument panel turns on
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j9 Front wiper switch When the switch is pressed, the front wiper works j
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10 2 Washer switch
the switch is pressed and held downward, the rear washer works 2
When the switch is pressed and held upward, the front washer works. When

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Rear wiper switch When the switch is pressed, the rear wiper works i
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Rear defroster switch
12. When the switch is pressed, the Rear defroster works

Each time push, fan will reverse for 30 seconds.

Reverse Switch of
13. Hydraulic Fan If hold the switch, fan will continue reverse.

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Safety i i
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Safety Messages and Additional Messages

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Locations of Safety Messages on the Machine _
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i Oil (Hydraulic Oil) Tank
Lubricating No Entry When Reversing i
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This message is located outside the lubricating oil

(hydraulic oil) tank of the machine. It indicates the
location of the lubricating oil (hydraulic oil) tank.
This message is located at the rear of the machine.
No Insertion When Rotating

Do not stay behind the machine when it is

J reversing. ThisJ may cause personal injury or
death.
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High Temperature High Pressure
8 Fluid Spillage 8
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8 is located outside the engine hood on
This message 8
the lef t. i i
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Keep the hands away from fan when the engine is
running. This may cause personal injury or death.

This message is located near the pressure cap of the

cooling system

Pressurized system! Hot coolant can cause

serious burns. To open the cap, stop the engine
and wait until the radiator is cool. Then loosen
the cap to relieve the pressure.

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Hot Surfaces Antifreeze i
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This message is located on the top of the engine

hood. It indicates the filling location of engine coolant.

This message is located on the left and right side of Jump Start
the engine hood in the middle.

J Avoid getting burned by the hot machine. J

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2 Diesel Fuel Tank 2
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_ _ the battery box.
This message is located inside
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m Explosion Hazard! Improper jumper cable
m
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connections can cause an explosion
serious injury or death.
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This message is located outside of the diesel fuel
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tank of the machine. It indicates the location of the
diesel f uel tank.

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24 V i Lifting Hook i
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This message is located outside of the battery box. It

indicates that the battery provides 24 V power supply.

Do Not Operate

This message is located on the side of the machine

f rame.

Improper lifting or tie-down can cause the load to

shift and lead to the personal injury and damage.
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Hydraulic Oil Drain
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8 This message is located on the inside pillar of the 8
_
cab. _
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Do not operate this machine unless you have
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read and2 understand the instructions and 2
warnings in the Operation and Maintenance
8 to follow the instructions or heed
Manual. Failure 8
the warnings could result in injury or death.
i
Contact any Caterpillar (Qingzhou) Ltd dealer for i
replacement manuals.
i Proper care is your i
The message is located on the right side of the
responsibility. hydraulic oil tank.

Hot oil and components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin. Use a separate container for oil
storage when draining and pay attention to
environmental protection.

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General Hazard Information Know the appropriate work site hand signalsi and the
personnel that are authorized to give the hand
i signals. Accept hand signals from one personionly.
Do not smoke when you service an air conditioner.
Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released f rom a flame that
contacts air conditioner ref rigerant can cause bodily
harm or death. Inhaling gas from air conditioner
ref rigerant through a lighted cigarette can cause
bodily harm or death.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.

Attach a "Do Not Operate" warning tag or a similar Obey all local regulations for the disposal of liquids.
warning tag to the start switch or to the controls Use all cleaning solutions with care. Report all
bef ore you service the equipment or before you necessary repairs.
repair the equipment.
Do not allow unauthorized personnel on the
Know the width of your work tools in order to maintain equipment.
proper clearance when you operate the machine
near f ences or near boundary obstacles. Unless you are instructed otherwise, perform
maintenance with the machine in the servicing
Be aware of high voltage power lines and power position. Refer to Operation and Maintenance
J cables that are buried. If the machine comes in J
Manual f or the procedure for placing the machine in
contact with these hazards, serious injury or death the servicing position.
M may occur f rom electrocution. M
2 Pressurized Air2and Water
8 Pressurized air and/or water
8 can cause debris and/or
hot water to be blown out. This could result in
_ personal injury. _
j When pressurized air and/or pressurized
j water is
used for cleaning, wear protective clothing, protective
m m
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
2 2
The maximum air pressure for cleaning purposes
8 8 is dead
must be reduced to 205 kPa when the nozzle
headed and the nozzle is used with an effective chip
i protective glasses, and other
Wear a hard hat, def lector and personal protective equipment.i The
protective equipment, as required. maximum water pressure for cleaning purposes must
i be below 275 kPa. i
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment. Trapped Pressure
Make sure that all protective guards and all covers Pressure can be trapped in a hydraulic system.
are secured in place on the equipment. Releasing trapped pressure can cause sudden
Keep the machine free from foreign material. machine movement or attachment movement. Use
Remove debris, oil, tools, and other items from the caution if you disconnect hydraulic lines or fittings.
deck, from walkways, and from steps of the machine. High pressure oil that is released can cause a hose to
whip. High-pressure oil that is released can cause oil
Secure all loose items such as lunch boxes, tools, to spray. Fluid penetration can cause serious injury
and other items that are not a part of the equipment. and possible death.

19
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i
Fluid Penetration
Pressure can be itrapped in the hydraulic circuit long
af ter the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur.
Always use a board or cardboard when you check for
J a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
M serious injury and possible death. A pin hole leak can
2 cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
8 f rom a doctor that is familiar with this type of injury.
_
Containing Fluid Spillage
Carej must be taken in order to ensure that fluids are
contained during performance of inspection,
m
maintenance, testing, adjusting and repair of the
equipment. Prepare to collect the fluid with suitable
2
containers before opening any compartment or
8 any component that contains fluids.
disassembling
Obey all local regulations for the disposal of liquids.
i i
i • Avoid brushing materials that contain asbestos.
20
Asbestos Information i
i
Caterpillar (Qingzhou) Ltd. equipment and
replacement parts that are shipped from Caterpillar
(Qingzhou) Ltd. are asbestos free. Caterpillar
(Qingzhou) Ltd. recommends the use of only genuine
Caterpillar (Qingzhou) Ltd. replacement parts. Use
the f ollowing guidelines when you handle any
replacement partsJ that contain asbestos or when you
handle asbestos debris.
M
Use caution. Avoid inhaling dust that might be
2 components that contain
generated when you handle
asbestos fibers. Inhaling this dust can be hazardous
8
to your health. The components that may contain
_ brake bands, lining
asbestos fibers are brake pads,
material, clutch plates, and some gaskets.
j
The asbestos that is used in these components is
usually bound in a resin or sealedm
in some way.
Normal handling is not hazardous unless airborne
2
dust that contains asbestos is generated.
8 there
If dust that may contain asbestos is present,
are several guidelines that should be followed:
• Never use compressed air for cleaning.
i
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
ef f iciency particulate air filter can also be used.
• Use exhaust ventilation on permanent machining
jobs.
 j j
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8 8
i respirator if there is no other
• Wear an approved i the
Whenever there are equipment control linkages
way to control the dust. clearance in the linkage area will change with the
i movement of the equipment or the machine. Stayi
• Comply with applicable rules and regulations for clear of areas that may have a sudden change in
the work place. clearance with machine movement or equipment
movement.
• Obey environmental regulations for the disposal of
asbestos. Stay clear of all rotating and moving parts.

• Stay away f rom areas that might have asbestos
particles in the air.
Dispose of Waste Properly
J J can fly off an object when you
M M
2 2
8 Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
_
disposed of according to local regulations.
Always
j use leakproof containers when you drain
f luids. Do not pour waste onto the ground, down a
drain,m or into any source of water.
2 Coolant
Crushing Prevention and Cutting
8
Prevention
i engine coolant is hot. The coolant is also under
Support the equipment properly before you perform
i
any work or maintenance beneath that equipment.
Unit can f all if a control is moved, or if hydraulic lines
break.
Do not work beneath the cab of the machine unless
the cab is properly supported.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while the
engine is running.
Never jump across the starter solenoid terminals in
order to start the engine. Unexpected machine
movement could result.
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the
maintenance is performed.
Keep objects away from moving fan blades. The f an
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can f ly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. In order to avoid injury
to your eyes, Wear protective glasses when you
strike a retainer pin.
Chips or other debris
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
Burn Prevention
8
Do not touch any part of an operating engine. Allow
the engine to cool before any_maintenance is
perf ormed on the engine. Relieve all pressure in the
j lubrication system,
air system, in the oil system, in the
in the f uel system, or in the cooling system before
m disconnected.
any lines, f ittings or related items are
2
8 the
When the engine is at operating temperature,
i
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. i
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.
Ensure that the f iller cap is cool before removing the
f iller cap. The f iller cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.

21
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Oils i Do not weld on lines or on tanks that containi
f lammable fluids. Do not flame cut lines or tanks that
i
Hot oil and hot components can cause personal injury. contain flammable fluid. Clean any such linesior
Do not allow hot oil to contact the skin. Also, do not tanks thoroughly with a nonflammable solvent prior to
allow hot components to contact the skin. welding or flame cutting.
Remove the hydraulic tank filler cap only after the Check all electrical wires daily. Repair any wires that
engine has been stopped. The f iller cap must be cool are loose or frayed before you operate the machine.
enough to touch with a bare hand.。Follow the Clean all electrical connections and tighten all
standard procedure in this manual in order to remove electrical connections.
the hydraulic tank filler cap.
Dust that is generated from repairing nonmetallic
Batteries hoods or f enders may be flammable and/or explosive.
Repair such components in a well ventilated area
Electrolyte is an acid. Electrolyte can cause personal away f rom open flames or sparks.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for Inspect all lines and hoses for wear or for
servicing batteries. Wash hands after touching the deterioration. The hoses must be properly routed.
The lines and the hoses must have adequate support
batteries and connectors. Use of gloves is
recommended. and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Fire Prevention and Explosion
Prevention
J J
M M
2 2
8 8
_ _
j
All f uels, most lubricants, and some coolant mixtures
j
m
are f lammable. m
Flammable fluids that are leaking or spilled onto hot
2
surf aces or onto electrical components can cause a
2
f ire. Fire may8cause personal injury and property 8
damage.
i
Remove all flammable materials such as fuel, oil, and
Use caution when you are fueling a machine. i Do not
smoke while you are f ueling a machine. Do not fuel a
i
debris f rom the machine. Do not allow any f lammable machine near open flames or sparks. Always stop i the
materials to accumulate on the machine. engine before ref ueling. Fill the fuel tank outdoors.
Store f uels and lubricants in properly marked
containers away from unauthorized personnel. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not operate the machine near any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil spray or fuel spray in case of a
break in a line, in a hose, or in a seal. Exhaust shields
must be installed correctly.

22
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i
Gases f rom a battery can explode. Keep any open
f lames or sparks away from the top of a battery. Do
i charging areas.
not smoke in battery
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.
Improper jumper cable connections can cause an
explosion that can result in injury.
Do not charge a frozen battery. This may cause an
explosion.
Fire Extinguisher
Make sure that a f ire extinguisher is available. Be
f amiliar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Follow the recommendations
on the instruction plate.
Lines, Tubes, and Hoses
Do not bend high pressure lines. Do not strike high
J pressure lines. Do not install any lines that are bent
or damaged.
M • Dismount the machine.
Repair any lines that are loose or damaged. Leaks
2 can cause f ires. Consult your Caterpillar (Qingzhou)
Ltd. dealer for repair or for replacement parts.
8 Check lines, tubes and hoses carefully. Do not use
_ bare hand to check for leaks. Use a board or
your
cardboard to check for leaks. Tighten all connections
j recommended torque.
to the
m the parts if any of the following conditions
Replace
are present:
2
• End f ittings are damaged or leaking.
8
• Outer coverings are chafed or cut.
i
• Wires are exposed.
i damaged parts and any worn parts. Regardless
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End f ittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
Fire Extinguisher Location
Do not weld the ROPS in order to install the fire
extinguisher. Also, do not drill holes in the ROPS in
order to mount the fire extinguisher on the ROPS.
If the fire extinguisher is mounted on the ROPS, strap
the mounting plate to a leg of the ROPS. If the weight
i the
of the fire extinguisher is more than 4.5 kg, mount
f ire extinguisher as low as possible on one leg. Do
i
not mount the fire extinguisher at the upper one-third
area of the ROPS leg.
Four-roller-one-track Information
There must not be lots of dirt and debris at the
f our-roller-one-track during the operation of the
machine. The dirt and debris, if any, must be
removed timely to avoid the wear or affect the power
output. Use cleaning tools and wear protective
clothing, protective shoes, and eye protection during
cleaning. Eye protection includes goggles or a
protective face shield. Stop the machine to avoid
personal injury. Strictly follow the track specific
instructions.
Lightning Damage Prevention
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
f ollowing procedures:
• Mount the machine.
J
M
If you are in the operator’s station during an electrical
2 station. If you are on the
storm, stay in the operator’s
ground during an electrical8storm, stay away from the
vicinity of the machine.
_
Before Starting Engine
j
Start the engine only from the operator's
compartment. Never short acrossm the starter
terminals or across the batteries. Shorting could
2 Shorting
bypass the engine neutral start system.
could also damage the electrical system.
8
Inspect the condition of the seat belt and the
condition of the mounting hardware. Replace i any
i of
appearance, replace the seat belt after three years of
use. Do not use a seat belt extension on a retractable
seat belt.
Adjust the seat so that full pedal travel can be
achieved when the operator's back is against the
back of the seat. Adjust the steering column tilt bar so
that it is comfortable for the operator to control the
machine on the seat.
Make sure that the machine is equipped with a
lighting system that is adequate for the job conditio ns.
Make sure that all lights are working properly.
Bef ore you start the engine or before you move the
machine, make sure that no one is on the machine,
underneath the machine, or around the machine.
Ensure that there are no personnel in the area.
Engine Starting
23
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i NOTE: The shaded areas indicate i the
approximate location of areas with significant
i restricted visibility. i
Before Operation
Clear all personnel from the machine and from the
area.
Clear all obstacles that are in the path of the machine.
Beware of hazards such as wires, etc.
Keep the windows clean. Secure the doors and the
windows in the open position or in the closed
position.
Do not start the engine or move any of the controls if
there is a "Do Not Operate" warning tag or similar Adjust the inside mirror (if equipped) to obtain the
warning tag attached to the start switch or to the optimal visibility of the machine and its around area.
controls. Make sure that the machine horn, the backup alarm
Bef ore you start the engine, check for the presence (if equipped) and all other warning devices are
of bystanders or maintenance personnel. Ensure that working properly.
all personnel are clear of the machine. Briefly sound Fasten the seat belt securely.
the horn bef ore you start the engine.
Always start the engine and operate the engine in a Visibility Information
J well ventilated area. In an enclosed area, vent the Bef ore you startJ
the machine, the operator shall
exhaust to the outside. perf orm a walk-around inspection in order to ensure
M M around the machine.
that there are no hazards
2 Restricted Visibility While the machine is in2operation, constantly survey
the area around the machine in order to identify
8 The size and the configuration of this machine may 8
potential hazards as hazards become visible around
result in areas that cannot be seen when the operator
is_seated. The illustration provides an approximate the machine. _
visual indication of areas of significant restricted It may not be possible to provide direct visibility on
j The illustration indicates restricted visibility
visibility. j
large machines to all areas around the machine.
areasm at ground level inside a radius of 12 m (40 ft) Appropriate job site organization ismrequired in order
f rom the operator on a machine without the use of to minimize hazards that are caused by restricted
2 aids. This illustration does not provide
optional visual visibility. 2
areas of restricted visibility for distances outside a
radius of 12 8m (40 f t). 8 and
Job site organization is a collection of rules
procedures that coordinates machines and people
i that work together in the same area. Examples i of job
site organization include the following:
i i
• Saf ety instructions
• Controlled patterns of machine movement and
vehicle movement
• Workers that direct traffic to move when it is safe
• Restricted areas
• Operator training
• Warning symbols or warning signs on machines or
on vehicles
• Communication system
• Communication between workers and operators
prior to approaching the machine
Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
24
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evaluated. i i
Operation i
Machine Operating Temperature Range. The
machine must work in the approved temperature
range. The minimum requirements for the safe
operation of the machine are: −20°C to 40°C f or
temperatures and 0-100% relative humidity, unless
otherwise specified in features and specifications
when sold.
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
area, check for proper operation of all controls and all
protective devices.
Make sure that no personnel will be endangered
bef ore you move the machine.
Do not allow riders on the machine unless the
J machine has the f ollowing equipment:
M • Additional seat
2 • Additional seat belt
8 Note any needed repairs during machine operation.
Report any needed repairs.
If_the machine begins to sideslip on a downgrade,
immediately remove the load and turn the machine
j
downhill.
Avoidm
any conditions that can lead to tipping the
machine. The machine can tip when you work on hills,
2
on banks and on slopes. Also, the machine can tip
8 ditches, ridges or other unexpected
when you cross
obstructions.
i
Avoid operating the machine across the slope. When
possible, operateithe machine up the slopes and
down the slopes.
Engine Stopping
Do not stop the engine immediately after the machine
has been operated under load.
This can cause overheating and accelerated wear of
engine components.
Af ter the machine is stopped, allow the engine to run
f or f ive minutes before shutdown. This allows hot
areas of the engine to cool gradually.
Parking
Park on a level surface. If you must park on a grade,
chock the machine to prevent it from sliding.
Move the propel control lever to the NEUTRAL
position.
i
Stop the engine.
Turn the engine start switch to the OFF position and
remove the engine start switch key.
Note: This will prevent drainage of the battery. A
battery short circuit, any current draw f rom certain
components, and vandalism can cause drainage of
the battery.
Sound Level Information
Ref er to the machine Operation and Maintenance
Manual f or the specific sound levels for your
machine. “ISO 6396:2008” is used to measure the
value f or an enclosed cab.The value was
88dB(A) .The measurement was conducted at the
maximum engine cooling fan speed. The sound
level may vary at different engine cooling fan
speeds. The measurement was conducted with the
cab doors and the cab windows closed.
J Operation and Maintenance
Ref er to the machine
Manual f or the specific sound levels for your
machine. The valueM is 111 measured according to
the dynamic test procedures
2 and the conditions that
are specified in “ISO 6395:2008”. The measurement
8 engine cooling fan
was conducted at the maximum
speed. The sound level may vary at different engine
cooling fan speeds. _
When sound levels are specified using either
j the declared
“ISO6395:2008” or “ISO 6396:2008”,
mmaximum sound
level is a maximum sound level. The
level includes both measurement uncertainty and
uncertainty due to production variation.2
Hearing protection may be also needed when the
8
machine is operated with an open operator station
i
for extended periods or in a noisy environment.
Hearing protection may be also needed when the
i
machine is operated with a cab that is not properly
maintained, or when the doors and windows are
open for extended periods or in a noisy
environment.
25
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Vibrationi Information
i
Information Concerning Seat Vibration
The suspension seat meets the criteria of "ISO 7096".
This represents vertical vibration level under severe
operating conditions. This seat is tested with the input
"spectral class EM3". The seat has a transmissibility
f actor of “SEAT<1.0”.
Guidelines for Reducing Vibration Levels
on Earthmoving Equipment
Vibration levels are influenced by many different
parameters, such as: operator training, operator
behaviour, operator mode and stress, job site
organization, job site preparation, job site
environment, job site weather, job site material,
machine type, quality of the seat, quality of the
suspension system, attachments, and condition of
the equipment.
Properly adjust machines. Properly maintain
J machines. Operate machines smoothly. Maintain the
conditions of the terrain. The f ollowing guidelines can
M help reduce the whole-body vibration level:
2 1. Use the right type and size of machine, equipment
and attachments.
8 2. Maintain machines according to the manufacturers
recommendations: tire pressures and brake and
_
steering systems, controls, hydraulic system, and
linkages.
j
3. Keep the terrain in good condition by performing
m items: remove any large rocks or
the f ollowing
obstacles, fill any ditches and holes and provide
machines2and schedule time to maintain the
conditions of the terrain.
8 maintained and adjusted by doing
4. Keep the seat
the f ollowing: adjust
i the seat and suspension for the
weight and the size of the operator and inspect and
maintain the seatisuspension and adjustment
mechanisms.
5. Perf orm the following operations smoothly: steer,
brake, accelerate, and shift the gears.
6. Move the attachments smoothly.
7. Adjust the machine speed and the route to
minimize the vibration level by doing the following:
drive around obstacles and rough terrain and slow
down when necessary to go over rough terrain.
8. Minimize vibrations for a long work cycle or a long
travel distance by doing the following: use machines
that are equipped with suspension systems, if no ride
control system is available, reduce speed to prevent
bounce and haul the machines between workplaces.
9. Less operator comfort may be caused by other risk
f actors. The f ollowing guidelines can be effective to
provide better operator comfort: adjust the seat and
adjust the controls to achieve good posture,
adjust the mirrors to minimize twisted posture,
26
i avoid
provide breaks to reduce long periods of sitting,
jumping from the cab, minimize repeated handling of
i
loads and lifting of loads and minimize any shocks
and impacts during sports and leisure activities.
Consult your local SEM dealer for more information
about machine features that minimize vibration levels.
Consult your local SEM dealer about safe machine
operation.
Cab
Any modifications to the inside of the operator station
should not project into the operator space or the
additional seat space. The addition of a radio, fire
extinguisher, and other equipment must be installed
so that the defined operator space or additional seat
(if equipped) space is maintained. Any item that is
brought into the cab should not project into the
defined operator space or additional seat (if equipped)
space. A lunch box or other loose items must be
secured. Objects must not pose an impact hazard in
rough terrain or in the event of a rollover.
J
Guards
M
There are different types of guards that are used to
2 machine and the machine
protect the operator. The
application determines the type of guard that should
be used. 8
_ is required in order to
A daily inspection of the guards
check f or structures that are bent, cracked or loose.
Never operate a machine with ajdamaged structure.
The operator becomes exposed tom a hazardous
situation if the machine is used improperly or if poor
2
operating techniques are used. This situation can
occur even though a machine is equipped
8 an
with
appropriate protective guard. Follow the established
operating procedures that are recommendedi for your
machine.
i
Other Guards (If Equipped)
Protection from flying objects and/or falling
objects is required for special applications.
A f ront guard needs to be installed when a work tool
that creates flying objects is used. Mesh front guards
or polycarbonate front guards are available for
machines with a cab or an open canopy. On
machines that are equipped with cabs, the windshield
should also be closed. Safety glasses are
recommended when flying hazards exist for
machines with cabs and machines with open
canopies.
If the work material extends above the cab, top
guards and front guards should be used.
Note: In case of any problems, contact your
Caterpillar (Qingzhou) Ltd. dealer.
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Machinei Operation i Make
handholds. Inspect the steps and handholds.
all necessary repairs.
i
Information Face the machine whenever you get on the machine
i
and whenever you get off the machine. Maintain a
Related Operation Information three-point contact with the step and with handholds.
Note: Three-point contact can be two feet and one
Follow these basic instructions whenever you are hand. Three-point contact can also be one foot and
operating the machine:
two hands.
• In order to prevent injury, make sure that no one is Do not mount a moving machine. Do not dismount a
working on the machine or near the machine. moving machine. Never jump off the machine. Do not
Always maintain control of the machine. carry tools or supplies when mounting or dismounting
• Reduce the engine speed when you maneuver in the machine. Use a hand line to pull equipment onto
tight quarters and when you are going over a hill. the platform.
Do not use any controls as handholds when you
• When working in tight quarters, the engine hood enter the operator compartment or when you exit the
must not be opened to prevent accidents.
operator compartment.

Daily checks
For maximum service life of the machine, perform a
Falling objects could cause personal injury or thorough walk-around inspection before you mount
death. the machine and before you start the engine.
J Remove all overhangs and be ware of falling
J
Inspect the area around the machine and under the
M objects. M bolts, trash buildup, oil,
machine. Look for loose
coolant leakage, broken parts, or worn parts.
2 Downhill Operation 2
Note: Watch closely for leaks. If you observe a
8 Maintain a ground speed that is slow enough for the 8 leak and correct the
leak, find the source of the
conditions. Before you operate the machine down a leak. If you suspect a leak or you observe a leak,
_ select the proper gear before you start down the
hill, check the fluid levels more_ frequently.
grade.j The throttle control should be at high idle and
the engine should not overspeed. In most situations,
j
Inspect the condition of the equipment and of the
hydraulic components.
m gear will be the same gear that is required
the proper m
to drive up the grade. Check the condition of the four-roller-one-track. If
2 necessary, adjust the tensioner. 2
If the machine builds up excessive speed, the engine
8 This can result in damage to the
can overspeed. Check all lubricant level, all coolant level 8
and all fuel
engine and/or damage to the power train system. level.
Use the servicei brake or engine brake to reduce the Remove any trash buildup and debris. Make all
i
speed of the machine until a suitable speed can be
selected.
i i
necessary repairs before you operate the machine.
Make sure all covers and guards are securely
Before Operation attached.
Mounting and Dismounting Make sure the equalizer bar pin, frame pin and push
arm pin are f irmlr fixed.
Adjust the mirrors for the correct rear view of the
machine.
Make sure that the engine air filter service indicator is
not in the red zone.
Grease all of the fittings that need to be serviced on a
daily basis.
Daily, perform the procedures that are applicable to
your machine:
Mount the machine and dismount the machine only at
locations that have steps and/or handholds. Before
• Backup Alarm - Test
you mount the machine, clean the steps and the • "Indicators and Gauges - Test"
27
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• "Bulldozer Hinge
i Pin - Grease" Lengthening the Seat Belt i
• "Cooling System
i Level - Check" i
• "Engine Oil Level - Check"
• "Fuel-Water Separator of the Fuel System - Drain"
• “Water and Deposits in Fuel Tank - Drain"
• "Hydraulic System Level - Check"
• “Seat Belts - Inspect"
• "Track Idler - Inspect"
• "Fuel Level - Inspect" 1. Unf asten the seat belt
• "Leaks in Each System - Check"
• "Engine Fan and Drive Belt - Inspect"
• "Battery Connection - Inspect"
• "Engine Filter Element - Check"
• "Fuel System Filter Element - Check"
J J
• "Radiator Core - Clean and Inspect”
M M
• "Radiator Pressure Cap - Inspect"
2 2
• "Cutting Edge - Inspect" 2. To remove the slack in outer loop (1), rotate
8 8 the seat belt to move
buckle (2). This permits
• "Work tools - Inspect" through the buckle.
_
Refer to the maintenance schedule for
_
3. Remove the slack from the outer belt loop by
j
maintenance. pulling on the buckle. j
m
Machine Operation m belt in the same
4. Loosen the other half of the seat
manner. If the seat belt does not fit snugly with
Alternate2 Exits 2 seat belt.
the buckle in the center, readjust the
Machine cabs8 have alternate exits. If one door is Shortening the Seat Belt 8
broken, the other
i door can be used as alternate exit. i
Release the latch to open the door.

Seat Belt
i i
Notice: This machine was equipped with a seat
belt when the machine was shipped from
Caterpillar (Qingzhou) Ltd. At the time of
installation, the seat belt and the instructions for
installation of the seat belt meet the installation
standards. See your Caterpillar (Qingzhou) Ltd.
dealer for all replacement parts.
Always check the condition of the seat belt and the 1. Fasten the seat belt. Pull out on the outer belt
condition of the mounting hardware before you loop in order to tighten the seat belt.
operate the machine.
2. Adjust the other half of the belt in the same
Seat Belt Adjustment for manner.
Non-Retractable Seat Belts 3. If the seat belt does not fit snugly with the buckle
Adjust both ends of the seat belt. The seat belt in the center, readjust the seat belt.
should be snug but comfortable. Fastening the Seat Belt
28
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i i
i i

Push the release button on the buckle in order to

Fasten the seat belt catch (3) into the buckle (2). release the seat belt. The seat belt will automatically
retract into the retractor.
Make sure that the seat belt is placed low across the
lap of the operator. Extension of the Seat Belt
Releasing the Seat Belt

When using retractable seat belts, do not use

seat belt extensions, or personal injury or death
can result.
The retractor system may or may not lock up
depending on the length of the extension and the
J J If the retractor does not lock
size of the person.
up, the seat belt will not retain the person.
M M
2 Pull up on the release lever. This will release the seat 2 please consult Caterpillar
If you have any questions,
belt. (Qingzhou) Ltd. dealers to obtain seat belt
8 inf ormation. 8
Adjustment for Retractable Seat
_
Belts
_
j j
Fastening the Seat Belt
m m
2 2
8 8
i i
i i

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

motion.
Fasten seat belt catch (3) into buckle (2). Make sure
that the seat belt is placed low across the lap of the
operator.
The retractor will adjust the belt length and the
retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.
Releasing the Seat Belt

29
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Operator iControls i
i i

J J
M M
2 2
8 8
_ _
j j
m m
2 2
1. Cup holder 8 7. Pedal 13. Lock-out handle 8
2. Tool box 8. Radio 14. Switch panel
3. Armrest i 9. Instrument panel 15. Bulldozer control lever i
4. Multiple state switch 10. Engine Start Switch 16. Ripper control lever (optional)
5. Hand throttle i 11. Inside mirror 17. Seat i
6. Steering and traveling control lever 12. Deceleration brake pedal 18. 12 V Power converter

30
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Adjustablei armrest Three Gear Temperature i
Switch Lamp Control Switch
i i

Grab handles
(2A) Fan control knob
(2B) Air conditioning temperature control knob

Warm air control

If necessary, use the following procedure to adjust Fan speed switch (2A) - This knob
the lef t and right armrests (1). controls the four f an speeds.

1. Loosen the bolt on the armrest (indicated in the

picture). Off (O) - Move the knob to this position to stop
J the fan. J
2. Move the armrest (1) to the desired height.
M Low (L) - Move theM
knob to this position for the
3. Tighten the bolt. lowest fan speed.
2 4. Push the armrest to tilt it forward or backward.
2
Middle (M) - Move the knob to this position for the
8 fan medium speed. 8
_ conditioner warm air
Air High (H) - Move the knob to _
this position for the high
f an speed.
j
control device j
Air Conditioner Switch
m m
Air Conditioning - Turn switch (2B) to
2 2 Turn
switch on the air conditioner.
clockwise to change temperature from
8 high to low. 8
i i
Heating and Air Conditioning System
i Operation i
The heating and air conditioning system can perform
f our functions:
Heating - Turn the knob (2A) to the desired speed
(low, medium, maximum). Adjust the knob to get the
2A 2B temperature you need.
Cooling - Push the switch (2B) to turn on the air
conditioner. Turn the knob clockwise to change the
temperature from high to low. Adjust the knob to get
the temperature you need.
Defrosting - Push the switch (2B) to turn on the air
conditioner. Turn the knob (2A) to the desired fan
speed (low, medium, or maximum). Adjust the knob
to get the temperature you need.
Defogging - Push the switch (2B) to turn on the air
conditioner. Turn the knob (2A) to the desired speed
(low, medium, or maximum). Adjust until the water
31
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i and side windows drops and the
content at the front Forward Right (3E) — Move the lever to the i right to
moisture is removed. turn the machine to the right. The turning radius of
i the machine is proportional to the movement of i the
lever. To make the machine turn slightly to the right,
Steering and Traveling move the lever slightly to the right. To increase the
bend, move the lever farther to the right. To turn the
Controls machine in place, move the lever to the lowest
position on the right side. When the machine turns in
Note: In order to use the steering and traveling place, the track on the left turns forward and the track
control device, make sure that the parking brake on the right turns reverse.
switch is in the disengaged state.
Reverse left (3F) - Move the lever to the left to turn
the machine to the left. The turning radius of the
machine is proportional to the movement of the lever.
To make the machine turn slightly to the left, move
the lever slightly to the left. To increase the bend,
move the lever farther to the left. To turn the machine
in place, move the lever to the lowest position on the
lef t side. When the machine turns in place, the track
on the right turns reverse and the track on the left
turns f orward.
Reverse right (3G) - Move the lever to the right to
turn the machine to the right. The turning radius of
J J
the machine is proportional to the movement of the
lever. To make the machine turn slightly to the right,
M M to the right. To increase the
move the lever slightly
2 2 to the right. To turn the
bend, move the lever farther
machine in place, move the lever to the lowest
8 8 the machine turns in
position on the right side. When
place, the track on the left turns reverse and the track
_ on the right turns forward. _
j To change the traveling directionj of the machine, first
move the lever to the neutral position, and then move
m the lever to the opposite direction.m
2 Notice: In order to steer the machine,2the lever must
be moved to one of the forward or reverse positions.
8 8
Speed (3H)
i i
Low - Turn the runner (3H) reverse to get a desired
i low speed. i
Forward (3A) - Move the operating lever
to this position to move the machine
forward. High - Turn the runner (3H) f orward to get a desired
high speed.
Neutral (3B) - Move the lever to this
position to put the machine in neutral.
The f actory settings of this machine are as follows:
Reverse (3C) - Move the lever to this position to
reverse the machine. • The maximum forward speed is 10 km/h (6.2 Miles)
Forward Left (3D) - Move the lever to the left to turn • The maximum reverse speed is 10 km/h (6.2 Miles)
the machine to the left. The turning radius of the
machine is proportional to the movement of the lever. Notice: The maximum forward or reverse speed of
To make the machine turn slightly to the left, move the machine is 10 km/h (6.2 miles). To change the
the lever slightly to the left. To increase the bend, speed setting, consult your Caterpillar (Qingzhou) Ltd.
move the lever farther to the left. To turn the machine dealer.
in place, move the lever to the lowest position on the Horn (3J)
lef t side. When the machine turns in place, the track
on the right turns forward and the track on the left
turns reverse.
32
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Horn -i Press the black horn button (3J) to i
pedal to increase the engine speed and machine
activate the horn. speed.
i Using the deceleration brake pedal prevents
i
Speed memory button excessive speed downhill. The deceleration brake
pedal is also particularly required when turning on
The yellow speed signal button (3K) allows you to high slopes.
preset a f orward or reverse speed.
Work tool control lever
1. Ensure the parking brake.
2. Move the steering and traveling lever to the
f orward position.
3. When the steering and traveling lever commands
f orward, turn the runner to get the desired speed.
4. Move the steering and traveling lever to the
reverse position.
5. When the steering and traveling lever commands
reverse, turn the runner to get the desired speed.
Bulldozer control lever
6. Move the steering and traveling lever to the
neutral position. Press and hold the speed
memory button for 3 seconds.
J 7. Push the speed memory button (3K). This J
machine will move forward in response to the
M preset speed. Push the speed recall button (3K).
M
2 This machine will move reverse in response to 2
the preset speed.
8 8
Gauges and indicators
_
See the Operation and Maintenance Manual for more
_
j
inf ormation. j
m Engine Start Switch m
Off - Turn the engine switch key to the off
2
position and pull out the engine key. These 2
do not form a
8 closed circuit. 8
Turn the key to the off position is to stop the
i
engine. i
i the engine switch key clockwise
On - Turn i
to the ON position in order to activate all Float - Push the control lever all the way forward to
circuits. the f loat position, and the blade will be in a f loating
Start-up - Turn the engine switch key state. The blade moves up and down with the ground
clockwise to the start position in order to contour.
start the engine. Release the switch key When released, the control lever will return to the
while the engine is started to return the key hold position.
to the ON position.
Lower - Push the control lever forward to lower the
Notice: If the engine f ails to start, the start blade. When released, the control lever will return to
key must be returned to the off position in the hold position.
order to attempt a restart.
Hold - When released, the control lever will return to
Deceleration brake pedal the hold position and the moving blade will stop.
Depress the deceleration brake pedal to Raise - Pull the control lever backward to raise the
reduce the engine speed and machine blade. When released, the control lever will return to
speed. In emergency, depress the pedal the hold position.
completely and the speed drops to stop. Release the

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i - Pull the control lever left to lower
Left tilt i
the lef t side of the blade. The control lever
i to the HOLD position when
will return i
released.
Right tilt - Pull the control lever to the right
to lower the right side of the blade. The
control lever will return to the HOLD
position when released.

Hand throttle

Hand throttle

J J
M M
2 The engine hand throttle controls the engine speed
2
8 electronically through the change of signal. 8
_ Low idle - The engine is at low idle when _
the hand throttle is turned to the leftmost.
j j
m High idle - The engine is at high idle when m
2the hand throttle is turned to the rightmost. 2
8 8
i i
i i

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i switch
Multiple state Ripper Control (Optional) i
i i

Multi-Status
Switch

Raise (10A) - Turn the control lever to

the left to raise the ripper, and release
the lever to return to the hold position.

Hold (10B) - Release the lever to return

it to the hold position, at which point
the ripper stops moving.
J J
M M - Turn the control lever to
Lower (10C)
the right to lower the ripper, and release
2 2
the lever to return to the hold position.
8 Economy Mode: This mode is 8
recommended for the light duty
_ conditions such as bulldozing downhill _
and leveling etc. where big power is not
j
required, so that energy can be saved. Mirror j
m Standard Mode: To be used under m
general conditions.
2 2
Adjust all mirrors as specified in the Operation
8 Duty Mode: This mode is
Heavy
and Maintenance Manual. Failure to8heed this
warning can lead to personal injury or death.
i
recommended for the heavy duty
conditions such as bulldozing uphill,
i
Mirrors provide additional visibility around your
i big power output is required
wet land etc. where machine. Make sure that the mirrors are intacti and
to increase the work efficiency. clean. Adjust all mirrors at the beginning of each work
period and adjust the mirrors when you change
operators.
Proper workplaces can also reduce the danger
caused by visibility.
Modified Machines or machines that have additional
equipment or attachments may influence your
visibility.

35
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i
Mirror Adjustment Winch Controls (If Equipped) i
• Park the machine
i on a level surface i
• Put the work tool on the ground
• Move the hydraulic lock so that it is locked and the
engine is off.
• Adjust the inside rear view mirror in order to provide
visibility behind the machine at a maximum
distance of 30 m.
Notice: Hand tools may be needed in order to adjust
the mirrors to a certain position.

Inside mirror
1. Winch Control Lever

J J
M M
2 2
8 The rear view mirror inside the machine allows the 8
REEL OUT(C) - Move the lever to this position in
_
operator to see the rear during reversing _ The winch cable
order to reel out the winch cable.
reels out under power. Speed for the winch cable is
j j
proportional to the lever position. Release the lever.
Backup alarm
m The Lever will return to the HOLDm position.
HOLD(B) - Move the lever into this position in order
The backup alarm is located on the rear of the
machine. 2 to maintain the current position of the 2 winch cable.
The winch brake is applied at this time.
8 REEL IN (A) - Move the lever to the left8in order to
reel in the winch cable. The winch cable should move
i i
toward the winch under power. Speed for the winch
i i
cable is proportional to the lever position. Release
the lever. The Lever will return to the HOLD position.

Personal injury or death can result from

Backup alarm - used to alert any personnel that is
behind the machine.
unexpected movement of objects. Be sure all
persons are clear of cable and objects before a
machine is winched or moved. A safe distance
of at least one and a half times the working
length of the cable should be maintained. The
tail end of a moving object can throw debris at
bystanders. It is required that the back pull
generated by the load is not greater than the
pulling force for the winch specified for towing.

Notice: If at all possible, always line up the rear

end of the machine with the logs, so that the
logs can be winched in a straight path. This

36
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i
avoids unnecessary strain and wear on the Idle start check i
side rollers. It also helps to wind the cable onto
the winch drumiin level layers. Bef ore every operation of the machine or afteri every
10 operation hours the following must be checked
In winter, when the temperature is lower than according to the maintenance schedule.
-30°C, before using the winch, the oil pump • Check the backup alarm.
should be started first to run with no load for
10 to 15 minutes, and then the winch can be • Check the brake
started. • Check the gauges and indicators
2. Free Spool Switch • Inspect the filter element
• Clean and replace the filter element
• Check the cooling system
• Check the oil level
• Check the f uel-water separator and drain
• Check the hydraulic oil level
• Discharge the water and sediment in the fuel tank

J • Check the seatJbelt

M • Check the transmission

M oil
2 • Walk around 2
Push this switch in order to release the winch cable.
8 No machine or hydraulic assistance is needed. The 8
winch will remain in the FREE SPOOL position until
_ press the switch again or until you activate any
you
Operation Section
_
other f unction for the winch. To prevent injury, make sure that no personnel is
j j
around the machine when it is working and that the
m machine can be controlled normally.
m
When the machine is moving uphill, the speed of the
2 gloves when handling the winch
Wear leather machine should be reduced. When the 2machine is
cable.
8 8
moving downhill, select the appropriate speed.
During the operation of the winch, it is 1. Adjust the seat
absolutely noti allowed to release the switch i
and the anti-detachment baffle should block 2. Fasten the seat belt
i
the handle to prevent the clutch from coming
i
3. Raise the work tools
off while the winch is in normal operation.
4. Depress the pedal to prevent moving forward
5. Put the brake switch to the neutral position
6. Set the engine throttle to a position where the
desired speed can be achieved
7. Release the pedal
8. Operate the steering and traveling lever to adjust
the traveling direction
9. Use the runner to control the speed of the
machine
10. A good control vision must be available before
operation

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Principles ofi the Hydrostatic Drive i
System
General Safe Operation Skills
i The seat belt must always be fastened.
i
The hydrostatic system is the power conversion from
the engine to the track. The hydrostatic drive system For a momentary stop, depress the brake pedal
eliminates the conventional form of transmission and urgently and move the operating lever to neutral. This
does not utilize helical gears and transmission shafts, will stop the machine immediately.
eliminating steering clutches and braking devices.
On a level or slope surface, move the control lever to
Simply put, the hydrostatic system includes the the lef t to turn left, and move the lever to the right to
f ollowing components: Hydraulic oil pump with turn right.
control system, hydraulic components between
hydraulic motor and high pressure oil circuit. Conditions for Braking:
Hydraulic pumps convert mechanical energy into • Depress the parking pedal
hydraulic energy.
In order to enable the machine to forward, reverse
• Parking switch ON
and steer, the pump is designed to provide different • Turn off the engine
f low rates to achieve the forward and reverse of the
motor.
Tracks can drive either forward or reverse at different
speeds. Battery Disconnect Switch
As there are two f inal drives, there are two hydraulic
J pumps, two sets of high pressure lines, and two J
hydraulic motors.
M M
For the f orward or reverse mode of the machine, the
2 pump and the motor work with each other, and the 2
8 hydraulic oil flow generated by the pumps drives the
motor forward or reverse. Changes in the flow of the
8
_ can cause the machine to turn or change its
pump _
speed continuously. For the steering of the machine,
j pump can independently reduce the flow. The
each j
independent liquid flow can reduce the speed to The battery disconnect switch is located inside the
m the steering of the machine.
achieve the right side console of the cab..
m
2
The deceleration or stop of the machine is achieved 2
On - Turn the switch in a clockwise
by reducing or stopping the hydraulic flow of the drive direction to activate the electrical
8 of the machine is a hydraulic brake.
motor. The brake 8
system. The switch must be in the ON
i is located on the final drive group.
The parking brake i
position in order to start the engine.
The parking brake is engaged through the release of Off - Turn the key counterclockwise
i spring to compress the f riction
the pressured butterfly deactivate the electrical system.
i to
plate, which is realized through the disconnection of
the hydraulic oil, and the engine will be turned off to
brake the machine. The electrical system should be shut off when you
leave the machine for an extended period of time.
Notice: When the engine is running, the circuit must
not be disconnected, otherwise serious damage to
the circuit system will occur.

38
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Check the ibattery disconnect Adjust i
switch i Ripper i
To check the battery disconnect switch, perform the
f ollowing steps:
1. When the switch is in the ON position, check the
electrical components in the cab, and verify the
display information of the hour meter.
2. Turn off the battery disconnect switch
3. If the operator station electrical components, hour
meter, and the engine crank are still running
when the switch is off, contact Caterpillar
(Qingzhou) Ltd. dealers.

Bef ore the tip (2) mounted on the shank is worn out,
Engine idle start the pin (1) must be removed to change the tip.
1. Turn on the start power Cutting edge
2. Lower the work tool down, and put the control
lever to the hold position.
3. Put the steering and traveling control lever to the
J neutral position.
J
M 4. Turn the engine start switch ON M
2 5. Release the start switch immediately after the 2
engine starts
8 8
6. Allow the engine to warm up at idle speed before
_ proceeding. _
j j
Engine
m and Machine Warm-Up m
Notice: Keep the engine speed low until the engine
2 light goes out. If the light does not go out
oil indicator 2
Replace or rotate the cutting edges on the basis of
within ten seconds,
8 stop the engine and investigate 8
edge wear.
the cause before starting again. Failure to do so can
i
cause engine damage. i
• Engine Warm-up
i at Idle i
• Check the indicators and gauges frequently during
the operation
Observe the following recommendations during the
warm-up period for the engine and the machine:
• In temperatures above 0°C (32°F), the warm-up
period is about 5 minutes.
• In temperatures below 0°C (32°F), the warm-up
period is about 20 minutes.
• In temperatures below −18°C, more time is
required if the hydraulic controls are sluggish.

39
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Parking i i
1. Turn the hydraulic lock switch to the unlock
position.
i
Stopping the machine i
2. Turn the engine switch key to the start position.
Notice: Park the machine on a level surface. If it is
necessary to park on a grade, secure the machine 3. Keep the key in the start position.
with chocks. 4. Slowly move the control lever to lower the dozer
1. To stop the machine, first move the steering and to the ground.
traveling control lever to the neutral position. • No hydraulic accumulator pressure
2. Depress the brake to keep the machine still. Start the engine
3. Put the brake switch to the active position. 1. Turn the hydraulic lock switch to the unlock
4. Release the brake pedal. position.
5. Lower all work tools so that all work tools are in 2. Turn the engine start key until the engine starts.
normal contact with the ground. 3. Keep the key in the start position.
6. Put all operating devices in the neutral position. 4. Slowly move the control lever to lower the dozer
Stopping the Engine to the ground.

Notice: Stopping the engine while the machine is

under load may cause the engine to overheat and
accelerate the wear of parts.
J 1. OperationalJdata
1. Idle the engine at low speed for 5 minutes with no
M load.
2 This will cool the hot engine down gradually and
increase the lif e of the engine.
8 2. Turn the engine start key to the off position.
_ Repeatedly operate the control lever of the
3.
jhydraulic
pressure.
system to release the hydraulic
m all control levers to the hold position.
4. Operate
2 2 filling,
Lower the 8 work tools and stop the
engine
i i
i and good economic effect can be achieved when
Lowering the dozer can cause personal injury or
death. Stay away from the machine when the
dozer is being lowered.
Lowering the dozer
If hydraulic energy is lost, perform the following
procedure to lower the dozer:
• Hydraulic accumulator booster
Operation techniques
Msure no person is on or around
To avoid injury, make
the machine. To avoid injury, make sure the machine
2
is under control at all times.
To prevent door damage or 8even personal injury, it is
necessary to ensure that the doors on both sides are
closed during the operation of_the machine. Fasten
the seat belt securely. j
2. Operating range and applicable conditions of
the tractor
m
The tractor is mainly used for embankment
cutting excavation, site leveling, backfilling of
8
pipelines and ditches, and other ancillary operations
in road construction projects. The moving distance is
generally not more than 100 m while high efficiency
i the
distance is within 30-50 m. Too big and too small
distances will reduce productivity. When the earth
moving distance exceeds 75 m, its production
ef f iciency is significantly reduced. In addition, the
working soil is grade I-II, and pre-scarifying is needed
f or grade III or above. If there is a small amount of
solitary rock in the soil, it should be broken first
bef ore carrying out operations. If there are too many
rocks, it would be not appropriate to use the tractor.
Otherwise, severe vibration and wear to the machine
will result, which will greatly shorten the service life of
the machine.
In addition, the tractor can be used to cut trees,
remove rocks and dig roots during construction
preparations. In the auxiliary operation, it can be
used to push the scraper as an assistant dozer.

40
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3. Cutting i • Straight cutting i
• Wave-cutting i During the straight cutting operation, the bladei is held
in a f ree state and pushed forward while a certain
depth of cutting is maintained. In the actual
About
1.5m
About
1.5m
About
1.5m construction, the straight cutting is often combined
with slot dozing. This method can maintain the
leveling of the cutting roads and the delivery courses,
and f acilitate the bulldozer to increase smooth speed
1/2 High 2/3 High
on the returning trip.
Fig. 8-1 Wave-cutting

4. Dozing
Figure 1 • Downhill dozing

About About About

1.5m 1.5m 1.5m

1/2 High 2/3 High

J Figure 2 J
Downhill dozing illustration
M When the tractor begins to cut soil, the blade should M
be cut into the soil as much as possible. When the In the cut-and-fill construction areas where the
2 engine is slightly overloaded, the blade should be earth-moving distance 2 is relatively short, the terrain
shall be used as far as possible so that the cutting
8 lif ted slowly until the engine resumes normal 8
area and the soil-delivery road will have a downward
operation. Then the blade is lowered again to cut the
_ The blade should not leave the ground when
soil. _
slope or gradually create a favorable terrain for
lif ting. Repeat this cycle for several times until the dozing downhill during construction, as shown in the
enoughj soil is accumulated in front of the blade, as j maximum amount
figure. This will not only ensure the
shownm in the above f igure. The advantage of this kind of soil per blade but also increase the dozing speed
of cutting soil is that the engine power can be fully of the bulldozer. The slope shouldm not be too steep.
utilized and 2 the time and distance of cutting can be Too steep slopes will affect efficiency. 2
shortened. The disadvantage is that the tractor will • Step dozing
bump on the8uneven course on the returning trip. 8
i
• Cross-cutting i
i 1st Cycle i
Blade

2nd Cycle

The cross-cutting is also called overlapping or Step dozing illustration

line-type cutting , as shown in the figure below. Cut
the soil at an interval of 2/3 of the width of the blade
and cut the ridges left during the second cycle.
Repeat the cycles. This kind of cutting is suitable for
solid soils, as the cutting area is reduced during the
second operation cycle, so that the bulldozer has
enough power to cut the soil and improve the work
ef f iciency.
See illustration. Cut the blade of the bulldozer into the
soil as deep as possible from the beginning, and then
raise the blade slightly from the soil while moving the
bulldozer f orward for 1 to 1.5 m before cutting the
blade deep into the soil again. Repeat several times
to gather a large amount of soil in f ront of the blade. If
this method is used to push the soil on a downhill, the
engine power can be fully utilized and a higher
productivity can be achieved.

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i
• Slot dozing (making use of slot or ridge to move • Side-by-side dozing (parallel dozing) i
soil)
i i
The Hard

Not more
than 0.5 m

Not more than 1m

Width
Blade Length
+30~40cm

Slot dozing

Side-by-side dozing illustration

J J
M M
2 Slot dozing illustration
8 Slot dozing makes use of the ridges to block the earth
on
_ both sides of the blade to reduce leakage and
increase the amount of earth moving. There are two
ways j to form slots: One is to purposely keep the soil
ridge f ormed as a result of the leakage from both
ends m of the blade during the first several times of
earth moving, and work in the same slot to prevent
2leakage. The other is to push the soil on
f urther soil
the same line
8f or several times in a row to create a
shallow slot on the ground, which can also reduce the
i But the ridge should not be too
loss during dozing.
high and the slot should not be too deep, generally
not exceeding 1 m. i The width of the ridge is about
0.40.5 m, and the width of the deep slot itself can be
0.3 to 0.4 m wider than the blade.
2
8
_
j
Side-by-side dozing illustration
m
Side-by-side dozing, as shown in the figure, two or
more bulldozers of the same type are 2 arranged
side-by-side and push forward at the same time to
8
reduce loss during dozing. The blade spacing for
side-by-side operations should not be too smalli or too
large, generally being 0.30.5 m。This type of dozing
i of
has high requirements for the operation techniques
the operators. Attention needs to be paid to the
speed and direction during the operation to avoid
collision. In general, when dozing ahead, the first
bulldozer on the left or right shall be used as a
benchmark, and the speed of the bulldozers shall be
basically the same through the accelerator pedal
control, and the direction shall be flexibly controlled
so as not to avoid collision. When reversing, the
bulldozer on the left or on the right should reverse
f irst and keep a suitable distance from the next one.
Reverse back to the cutting point one by one.

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The use of two ior more bulldozers in parallel to move • Segment dozing i
the earth can reduce soil leakage. But attention must
i
be paid to the following points: i
(1) The distance between the bulldozer blades is
generally 15 to 20 cm. It is advisable to use a
bulldozer with a large force in the middle position,
and the type of bulldozers used for side-by-side
dozing should be similar.
(2) The operator should keep an eye on the end of A
the blade of the adjacent bulldozer to control the B
Subgra
de or
distance between the machines. When the machine C spoil
pile
speed is inconsistent, the throttle can be adjusted to D
make the speed consistent. The throttle should not
be too much at the beginning. Cooperate with each
other to avoid waiting. Segment dozing

(3) The bulldozers on both sides should pay attention In segment dozing, the dozing distance is divided into
to the scope of the cutting area, and keep a slightly several sections, successively stacking the soil, and
higher speed so that the fleet moves forward in the accumulating a few piles on the earth-moving line,
shape of a sector. and pushing it to the filling site once, as shown in the
(4) When dozing, the bulldozers can push and cut the right f igure. When dozing in a slot, first push the back
soil independently and pile the soil into heaps on the soil of 1 to the embankment. When pushing 2, the
J way of transport. When transporting, all bulldozers J
f ront soil of 2 is pushed to the back of 1 first, then the
shall push together. When the bulldozers on both bulldozer retreats to push the back soil of 2 forward,
M sides push the soil to about 1 m f rom the unloading
M
together with the previously pushed soil, onto the
embankment, and so on. This method can reduce the
2 area, they can return to the cutting area to push the
resistance at the bottom 2of the blade when cutting
soil f irst, leaving one bulldozer in the middle to
8 remove the residual soil from the dumping area and soil, reduce soil leakage and 8 waste in bulldozing,
the transport road. maintain f ull load of soil in front of the blade, and be
_ _
more ef fective when dozing downhill.
6) Blades with baffles
j • Relay Earthmoving j
m m
2 2
8 8
i i
i i
Blade rib Wing

Blades with baffles illustration

In the case of loose sandy soil or sand and the depth
of dozing is too shallow to use slot dozing, two baffles
can be added on both sides of the bulldozer blade (as
shown in the f igure) to increase the earth-moving
capacity of the blade. The lower edge of the baffle
should be about 10 to 15 cm away from the cutting
edge, and the size of the baffle should be about 40
cm wide on the bottom, 20-30 cm wide on the top,
and 60-70 cm in height. Bolt-on or weld-on fastening
method can be used.
Relay Earthmovin Illustration
See illustration. Use two or three bulldozers to work
together during construction. When the distance
exceeds 30 m, the distance can be divided into two or
three sections, and two or three bulldozers can be
used to transport the earth. Each bulldozer delivers
the soil to the one before it and the first bulldozer
pushs the soil to the unloading site. Each bulldozer
also, within its section, make one cut to increase the
amount of soil in front of the blade. If the
earth-moving route is not an cutting area, the first two
bulldozers must be given a longer distance. This will
43
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i in the back to deliver a volume of
allow the bulldozer 6. Turn the battery disconnect switch to thei OFF
two cuts to ensure that the first two bulldozers are position. Remove the disconnect switch key.
i
f ully loaded with earth. i
7. Lock the door and the access covers. Attach any
vandalism protection.
Transport Information 8. Place the wedge into the track. Make sure the
machine is choked.
Shipping the Machine
Notice
Investigate the travel route for overpass clearances.
Make sure that there is adequate clearance for the If the engine stops and the turbocharger runs, the
machine that is being transported. This is especially turbocharger can be damaged. Cover the vent
important for machines equipped with Rollover hole or close the rain cover to avoid idling the
Protective Structure (ROPS) and cab. turbocharger during transportation.
Remove ice, snow, or other slippery material f rom the 9. Cover the vent with a cap or cover to avoid idling
loading dock and from the truck bed before you load the turbocharger during transportation.
the machine onto the transport machine. This will
help to prevent the machine from slipping in transit. Perf orm a walk-around inspection and measure the
f luid levels in the various compartments.
Drive at moderate speed. Observe all speed limits
when driving the machine.
Consult your Caterpillar (Qingzhou) Ltd. dealer for
J J for your machine.
shipping instructions
M M
2 Lifting and Tying
2 Down the
Machine
8 8
Notice: Obey all laws that govern the Notice
_
characteristics of a load (height, weight, width, and
_
Improper lifting or tie-down can cause the load to
j Observe all regulations that govern wide
length). shift and lead to the personal jinjury and damage.
loads.
m
Remove the ether tank used to assist start, if
m
equipped.2 2
When you move8 the machine to a colder climate, 8
make sure that the cooling system has the proper
antif reeze. i i
1. Bef ore you load
i the machine, chock the trailer i
wheels or the rail car wheels.
2. When the machine is parked, connect the rack
f ixing ring. This will firmly fix the front and rear
racks. In addition, put the wheel tilt lock on. This
will f ix the front wheel in a straight position. For the basic specifications of the machine, refer to
the Operation and Maintenance Manual,
3. All working equipment must be lowered down to "Specifications".
the ground on machines in transit. Move the lever
of the transmission to the parking brake engage Lifting Point - In order to lift the machine,
position. attach the lifting devices to the lifting points.
4. Stop the engine.
5. Turn the start switch key to the OFF position. Tie Down Point - In order to tie down the
Remove the engine start switch key. machine, attach the tie-downs to the tie
down points.

44
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Use properly ratedi cables and properly rated slings in
order to lift the machine.
i
Position the crane or the lifting device in order to lift
the machine in a level position.
The width of the spreader bar must be sufficient to
prevent the lifting cables or the lifting straps from
contacting the machine.
1. Connect the four lifting cables to a spreader bar.
The spreader bar must be centered over the
machine.
2. Lif t the machine. Move the machine to the
desired position.
3. When the machine is positioned, place blocks in
f ront of and behind the track.
Towing Information
Towing the Machine
J J controls of the machine must
M Improper hookup and towing are dangerous and
2 could result in injury or death to yourself or
others.
8 8
These towing instructions are for moving a disabled
_
machine f or a short distance at low speed. Move the
machine at a speed of 2 km/h or less to a convenient
j for repair. These instructions are only for
location
emergencies.
m Always haul the machine if long
distance moving is required.
Shielding2 must be provided on both machines. This
will protect the
8 operator if the tow line or the tow bar
breaks.
i
Do not allow an operator to be on the machine that is
i the operator can control the
being towed unless
steering and/or the braking.
Bef ore towing, make sure that the tow line or the tow
bar is in good condition. Make sure that the tow line
or the tow bar has enough strength for the towing
procedure that is involved. The strength of the towing
line or of the tow bar should be at least 1.5 times of
the gross weight of the towing vehicle. This is true for
a disabled machine that is stuck in the mud and for
towing on a grade.
Keep the tow line angle to a minimum. Do not exceed
a 30 degree angle from the straight ahead position.
Quick machine movement could overload the tow line
or the tow bar. This could cause the tow line or the
tow bar to break. Gradual, steady machine
movement will be more effective.
i as
Normally, the towing machine should be as large
the disabled machine. Make sure that the towing
machine has enough brake capacity, enough iweight,
and enough power. The towing machine must be able
to control both machines for the grade that is involved
and f or the distance that is involved.
You must provide sufficient control and sufficient
braking when you are moving a disabled machine
downhill. This may require a larger towing machine or
additional machines that are connected to the rear.
This will prevent the machine from rolling away out of
control.
All situation requirements cannot be listed. Minimal
towing machine capacity is required on smooth, level
surf aces. On inclines in poor condition or on surfaces
in poor condition, maximum towing machine capacity
is required. Attach the towing device and the machine
bef ore you release the brakes.
Engine Running
If the engine is running, the machine can be pulled for
a short distance under certain conditions and the
driveline and operator
be operational. ForM example: The machine is stuck in
mud or on a slope.
2
Fire safety procedures
Fire prevention during equipment use, maintenance
and storage _
• Fire prevention during refueling
j process;
• Fire protection during welding orm
cutting repair;
• Muf fler, exhaust gas, etc. shall not be
2 close to
withered grass, flammable materials;
8 and
• Fire prevention during equipment parking
storage; i
• Fire protection for battery; i
• Fire protection when working in explosive
atmospheres
Measures to be taken in case of fire;
• Move the machine away f rom the dangerous areas;
• STOP THE ENGINE AND TURN THE IGNITION
SWITCH TO "OFF” POSITION;
• Exit the cab;
• Turn off the power shut-off switch;
• Inf orm the fire brigade (if necessary).
45
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i
Maintenance Interval Schedule i
Every 250 Service Hours or Monthly
i • Battery Posts - Clean i
Replace the parts as required or daily
• Battery Post Vaseline - Apply
• Engine Oil Level - Check
• Engine Cylinder Head - Clean
• Coolant Level - Check
• Radiator Set - Clean
• Hydraulic Oil Level - Check
• Diesel Tank Filler Filter - Clean
• Fuel level - Check
• Hydraulic Oil Tank Filler Filter - Clean
• Water and Impurities in Fuel Prefilter - Drain
• Check the loading welding and mounting bolts of
• Lighting and Instrumentation - Inspect the work tool, frame, and track roller frame for
cracks and looseness - Check
• Backup alarm operation - Inspect
• Final Drive Lubrication Oil Level - Check
• Lubrication at each Lubrication points - Inspect/Fill
• Engine intake system - Inspect
• Abnormality or leakage in each system - Inspect
• Tension and damage of the engine fan belt, air
• Visual inspection of engine fans, air conditioning conditioning compressor belt - Inspect
and drive belts - Inspect
• Service/Parking brake capacity - Test
• Battery and battery cable - Inspect
J J
• Primary Fuel Filter Element – Replace (Stage II)
• Engine f ilter element - Inspect
M M Oil Filter Element – Replace
• Engine Oil and Engine
• Fuel system filter element - Inspect
2 (Stage II) 2
• Radiator core - Check/Clean • Secondary Fuel Filter Element
8 8 – Replace (Stage II)
• Radiator pressure cap - Inspect • Air Filter Element – Replace
_ _(Stage II)
• Cutting edge -Inspect • Water-Fuel Separator Filter Element – Replace
j j
• Seat belts - Inspect (Stage II)
m m
• Work tools - Inspect
2 First 100 Service Hours 2
• Idler position - Inspect
8 • Engine Oil - Check/Change (Stage III) 8
• Track tension - Check
i • Oil Filter - Check/Change (Stage III) i
i Hours
First 50 Service Every 500 Service Hours or 3 Months i
• Engine Oil - Check/Change (Stage II) • Track Tensioner - Adjust
• Oil Filter - Check/Change(Stage II) • The f ixing bolt of equalizer bar pin - Check
• Primary Fuel Filter Element – Replace (Stage III)
Every 50 Service Hours
• Engine Oil and Engine Oil Filter Element – Replace
• Check f or leaks on both sides of the pivot cap (Stage III)
• Secondary Fuel Filter Element – Replace (Stage
III)
• Air Filter Element – Replace (Stage III)
• Water-Fuel Separator Filter Element – Replace
(Stage III)

46
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i Hours or Half a Year
Every 1000 Service i
Operational Inspection and
• Engine valve clearance
i - Adjust Maintenance i
• Tensioner bearing and fan shaft housings of the
The trouble-free working time and the service life of
engine - Inspect
the bulldozer depend largely on whether the machine
• All battery mounting bolts - Tighten is properly used and serviced. Proper inspection and
maintenance can not only prolong the service life of
• Battery top - Clean the machine, but also identify the fault as early as
possible, and deal with it early, to reduce the
• Diesel Tank - Clean maintenance time and save the maintenance cost.
• Hydraulic oil tank suction filter element - Replace Inspection and Maintenance before
• Hydraulic oil tank drain filter element - Replace Operation
• Pilot hydraulic system filter element - Replace • Coolant level in the radiator.
• Rollover Protective Structure (ROPS/FOPS) - • Engine oil pan oil level.
Inspect
• Fuel tank oil level, hydrostatic oil tank level.
• Final Drive System Lubricants - Replace
• Leak tightness of all oil pipes, water pipes and
• Final Drive Oil - Change accessories.
• Hydrostatic Filter Element - Replace • Braking operation reliability.
J J
• Whether the control levers are flexible and put in
M Every 2000 Service Hours or 1 Year M
the neutral position.
2 • Engine vibration damper - Inspect 2 coupling bolts and other
• Whether the f inal drive
8 • Wear of the f riction disc of the service brake system bolts are loose. 8
_- Inspect • Check if the dirt in the four-roller-one-track
_ system
is cleaned. Check if the tension of the track is
• Service brake system lines - Replace
j appropriate. j
• Steering system flexibility - Inspect Inspection and Maintenance
m mafter
• Leak tightness of hydraulic cylinder and hydraulic Operation
system2 - Inspect 2
• Check the f uel level.
8 tank breather - Replace
• Hydraulic oil 8
• Check the oil level and cleanliness of the engine oil
i - Replace
• Fuel tank breather pan. If the oil level is found to be too high iand the
oil is gradually thinning, identify the cause and fix it.
• Cooling systemi - Clean i
• Check the oil pipes, water pipes, and accessories
• Hydraulic oil - Replace f or leaks.
• Hydraulic oil tank - Clean • Check the hydraulic oil pump, hydraulic motor, and
f inal drive for secure mounting and sealing, and
• Suction pipe - Inspect
overheating.
• Clearance between idler and track roller frame -
Check/Adjust
• Check the tension of the track.

• Hydraulic System Oil - Replace • The coolant should be discharged if the

temperature is lower than 0 degrees Celsius
• Alternator, starting motor, clean and check (except that the antifreeze is available).
turbocharger - Inspect
• Grease each grease point according to the
schedule.

47
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i
Lubricant Viscosities 3. Place the ground cable clamp as close as i
possible to the weld. Make sure that the electrical
i information
Lubricant basic i
circuit f rom the ground cable to the component
does not go through any bearing. Use this
When the ambient temperature is below -20°C (-4°F),
the relevant publications of Caterpillar (Qingzhou) Ltd. procedure in order to reduce the possibility of
should be observed. The publications can be viewed damage to the following components:
at the dealers of Caterpillar (Qingzhou) Ltd. The drive • Bearings of drive train
hydrostatic oil is SAE-10W at room temperature.
• Hydraulic components
Selection of viscosity • Electrical components
The proper lubricant viscosity grade is determined by • Other components of the machine
the minimum outside temperature when the machine
is started. The temperature should be measured 4. Protect any wiring harnesses from the splatter
bef ore starting and operating the machine. Select the which is created from welding.
appropriate viscosity for the ambient temperature. 5. Use standard welding procedures in order to weld
High-viscosity lubricating oils should be used for the materials together.
continuous operation of the final drive, and Access doors - Entrance and
high-viscosity lubricating oils can maintain a high oil
f ilm thickness. If necessary, consult your Caterpillar covers
(Qingzhou) Ltd. dealer.
J J
M Maintenance support M
2 Maintenance support - Welding 2
8 Do not weld any protective structures by yourself. If it 8
is_necessary to repair the protective structure, _
contact your Caterpillar (Qingzhou) Ltd. dealer.
j welding process must be used if welding is
Suitable j
m so that damage to the electronic control
necessary,
system, bearings and structures can be avoided. Open the access door (as shown m
in picture) to see
2 the parts, try to remove the parts to be
When welding the f ollowing components: 2
welded f rom the machine or engine before welding • Batteries
them. If you 8
have to weld near the electric control, 8
hydraulic or engine, the electric control should be • Battery Disconnect Switch
i
temporarily removed to prevent it from being
i
damaged by heat. i Follow these steps: i
1. Turn off the engine and turn its engine start
switch to the off position.
2. Turn the battery switch to the off position and
disconnect the battery negative cable if there is
no battery switch.
Notice: Do not use electrical components or
electronic component grounding points for grounding
the welder.

48
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Open the access i door (as shown in picture) to see Open the access door (as shown in picture)ito see
the f ollowing components: the f ollowing components:
• Circuit breaker
i • Radiator Pressure Cap
i

Open the access door (as shown in picture) to see Open the access door (as shown in picture) to see
the f ollowing components: the f ollowing components:
• Air conditioning compressor belt, fan drive, water • Fan Drive, Alternator, Water Pump
pump
• Engine oil filter
• Common rail pump, common rail line
• Engine oil dipstick
• Electronic control unit
J J
• Primary Fuel Filter
M M- Test
Backup alarm
• Secondary Fuel Filter
2 2
• Air f ilter
8 8
_ _
j j
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2 2
8 8
i i
Turn the engine start switch to the ON position in
Open the accessidoor (as shown in picture) to see order to test the backup alarm. i
the f ollowing components:
• Engine f an
• Radiator

49
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i pedal, disengage the parking
Depress the brake Battery or Battery Cable - i
brake switch, and put the control lever to the reverse
i alarm should start to sound
position. The backup Inspect/Replace i
immediately to inform people behind the machine 1. Turn the engine start switch to the OFF position.
that the machine is reversing. The backup alarm will Turn all switches to the OFF position.
continue to sound until the control lever is moved to
the NEUTRAL position or to the FORWARD position. 2. Turn the battery disconnect switch to the OFF
position and remove the key.
3. Remove the negative battery cable from the
disconnect switch.
Notice: It is not allowed to disconnect the battery
cable before disconnecting the battery disconnect
switch.
4. Remove the negative cable from the battery.
5. Remove the positive cable from the battery.
6. Check the battery clamps for corrosion and cable
f or wear and damage.
The backup alarm is at the rear of the machine. The
sound of the alarm has been set to an appropriate 7. Perf orm the necessary repairs. Replace the
loudness before leaving the factory, and then is not cables or the batteries, as needed.
adjustable.
J 8. Connect theJ
positive cable at the battery.
9. Connect the negative cable at the battery.
M M
10. Connect the disconnect switch and battery
2 Battery - Check negative cable. 2
8 Tighten
hours.
the battery retainers at least once every 1000 11. Insert the key and turn8the battery disconnect
switch to the ON position.
_
1. Open the battery box cover.
_
2. jClean the top of the batteries with a clean cloth. j
Clean the battery terminals. Coat the battery Belts -Inspect/Replace
m
terminals with vaseline jelly.
m
The engine is equipped with the belt, the alternator
3. Close2the battery box cover. and the a/c compressor. 2
8 Belt - Inspect 8
i
Battery - Recycle 1. Stop the machine on the level ground, loweri the
blade, turn the control lever to the neutral position
Always recycle aibattery. Never discard a battery. and engage the brake. Turn off the engine. i
Always return used batteries to one of the following 2. Open the lef t engine access door.
locations:
• A battery supplier
• An authorized battery collection facility
• Recycling facility

50
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i Braking System - Test i
i i
If the machine moves during the test, the engine
speed should be reduced immediately and the
parking brake should be performed.
If the machine moves while checking the brake,
consult Caterpillar (Qingzhou) Ltd. dealers for
inspection and repair. The machine can only be
operated after the damaged brake is repaired.

Make sure there are no people around the machine

3. Inspect the condition of the belt (1). and remove obstructions.

Notice: The machine is equipped with a belt
tensioner (2) which automatically adjusts the belt's
correct position.
4. Close the left access door.
Belt - Replace
The braking test must be on a dry flat surface.
The seat belt must be tightened before testing the
brakes.
1. Start the engine.
2. Raise all work tools and their attachments.

J Notice: When the condition of the belt is not good, it 3. Use the special
J ET service tool to test the drive
must be replaced with a new belt . stop. For more information on your machine, see
M The belt (1) can drive the fan, the water pump, the M manual.
the test adjustment

2 alternator and the air conditioner. 4. Reduce the engine2 speed, making it idle at low
speed. Depress the brake pedal, put the work
8 1. Open the right door of the engine hood. 8 and finally stop the
tool down to the ground,
2. The belt should be replaced if any of the following engine.
_ conditions occur: _
5. Make necessary maintenance before operating
j• Crack the machine. j
•mWear m -
Blade and push arm hinge
2
• Damage Lubricate 2
8 the battery disconnect switch (OF).
3. Disconnect 8
4. Loosen theibelt and use the tool to pry the belt i
counter-clockwise at the tensioner.
i
5. Remove the belt from the pulley.
i
6. Install a new belt around the pulley.
7. When you loosen the belt tensioner, it will
automatically adjust the belt position and restore
the tension.
8. Turn on the battery disconnect switch (ON).
9. Close the engine hood left door.
Notice: If a new belt is replaced, the belt should be
checked and adjusted after 30 minutes of machine Blade and push arm: Push arm hinge lubrication (1),
operation. tilt cylinder hinge (2), bucket lift cylinder hinge (3),
bucket lift cylinder hinge (4), adjustment support
hinge (5), push arm adapter (6), push arm center
hinge lubrication (7), lubrication point at the central
hinge (8) of the push arm.

51
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i
Notice: If it is difficult to grease at the push arm joint Intermediate Cutting Edge - i
(2), please turn on the machine to raise the blade to
i Operate the tilt cylinder 2 to 3
an appropriate height. Inspect/Replace i
times to the maximum tilt, then level the blade to the
ground, and then add grease. . The maximum
lubrication interval for the lubrication points of the
work tool is 50 hours.

Circuit Breakers - Reset

The circuit breaker is located behind the ECM
mounting plate to the right of the seat.

1. Raise and block the blade; When removing the

intermediate cutting edge, keep the blade higher
than the minimum removal height.
J J
2. Remove the bolts.
M Main breaker - 105A breaker button M
3. Remove the intermediate cutting edge.
2 Alternator breaker - 105A breaker button 2 surface.
4. Thoroughly clean the
8 5. Check the screw hole 8 of the blade at the position
Condenser
_ - Clean of intermediate cutting edge,
_ and replace the
intermediate cutting edge if there is no damage at
Notice: If the condenser is too dirty, use a brush to
clean j it. To prevent damage or bending of the fin, do the hole. j
not use ma hard brush. If a defect is found, repair the 6. Install all bolts and tighten them
bolts to the
f in. specified torque.
1. Open2
the condenser cover. 2 and lower
7. Raise the blade to remove the block
8 condenser for chips and clean the the blade to the ground. 8
2. Check the
condenser if necessary. 8. Check the bolts for proper torque after a f ew
i hours of operation. i
3. Clean the dust and dirt on the condenser with
water. i i
4. Install the condenser cover. Engine air filter - Clean/Replace
The air f ilter is in the engine hood.
Cooling system coolant - When the alarm appears red, use compressed air of
Add/Check less than 205 kPa, along the direction of the pleats, to
The coolant should be added once every 500 hours clean the f ilter element from inside out.
and replaced at least once every two years as Do not use other tools to knock the filter element
specified. Please control the interval by yourself if when removing the filter element. Clean the inner
you have special reasons. wall of the filter outlet pipe and the sealing surface.
Cooling system inspection: Replace the f ilter element after 6 times of cleaning or
1. Open the lef t access door. 250 (high dust) - 500 (low dust) working hours.

2. Make sure that there is enough coolant, and add

if necessary. Check the system for leaks.
3. Close the access door.

52
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i
Check the connections to ensure that the filter cap Notice i
matches the engine intake and is airtight.
i
The air filter can only be serviced when the
Caterpillar (Qingzhou) Ltd. recommends thei use
of a certified air cleaner cleaning service
engine is shut down. Otherwise, the engine may provided by an authorized Caterpillar (Qingzhou)
be damaged as a result. Ltd. dealer. The cleaning process of Caterpillar
Service the air cleaner filter element when the (Qingzhou) Ltd. employs proven procedures that
blue plunger on the engine air filter service ensure consistent quality and long cleaner life.
indicator enters the red zone. Observe the following guidelines if you attempt
to clean the filter element:
Do not tap or strike the filter element in order to
Cleaning the air filter primary element remove the dust.
Do not wash the filter element.
Use the low pressure compressed air to remove
the dust from the filter element. The air pressure
must not exceed 207 kPa. Direct the air flow up
the pleats and down the pleats from the inside of
the filter element. Take extreme care in order to
avoid damage to the pleats.

J Do not use theJ air filters with damaged pleats,

M cause damage to Mengine components.
2 The PRIMARY element
8 1. Loosen all clips connecting the rear cover to the
housing, remove the rear cover, and remove any
_ dust on the rear cover. Caution: When stopping
the machine to check, the dust can be removed
jby dust valve in time. Replace the dust valve
immediately when it is damaged or missing.
m m
2. Counterclockwise rotate the seal cover and
2 and then the external element can be
remove,
seen. 8
3. Catch the clamps of external element rear cover
and pull theiexternal element out of the air
cleaner cavity.i
4. Maintain the external element according to the
maintenance instructions of air filter.
5. Bef ore installing back the external element, clean
the inside of the cleaner and remove the dust
accumulating on the internal threads with a bristle
brush or a rag to make sure that the thread is
smooth, and prevent dust f rom entering the inside
of the element.
6. Install back all parts in the opposite order of
removal and make sure that they are installed
correctly to ensure a correct sealing. Do not omit
any part.
gaskets, or seals. Dirt entering the engine will
2can be used up to 6 times
if the element is properly8cleaned inspected. After
the primary filter element is cleaned, inspect the
filter element for tears. The_primary filter element
should be replaced at least once every year. This
replacement must be performed j regardless of the
number of cleanings.
Notice
2
Do not clean the filter elements by striking or
tapping. This will damage the seals. 8Do not use
the filter element with damaged pleats, gaskets or
i
seals. The damaged filter element will allow dirt
to pass through. The engine may be damaged i as
a result.
Visually inspect the primary air filter elements before
cleaning. Inspect the air filter element for damage to
the seal, the gaskets, and the outer cover. Discard
any damaged air cleaner elements.
Two general methods can be used to clean the
primary f ilter element:
• Compressed Air
• Vacuum Cleaning

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i
Compressed Air Check if the primary filter element is clean and i dry.
Use a 60 watt blue light in a dark room or in a similar
Pressurized air can be used to clean elements that
i
have not been cleaned more than two times.
i
f acility. Place the blue light in the primary element.
Rotate the primary filter element. Inspect the primary
Pressurized air will not remove deposits of carbon
element f or tears and/or holes. Inspect the primary
and oil. Use f iltered, dry air with a maximum pressure
element f or light that may show through the filter
of 207 kPa. material. To confirm the result, the primary element
must be compared with a new f ilter element with the
same part number.
Do not use a primary air filter element that has any
tears and/or holes in the filter material. Do not use an
air cleaner element with damaged pleats, gaskets or
seals. Discard damaged air cleaner elements.

Storing the Primary Filter Element

If a primary element that passes inspection will not be
used immediately, store the element for future use.
Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside) in
order to force dirt particles toward the dirty side
(outside).
J Aim the hose so that the air flows inside the element
J
M along the length of the filter in order to prevent M
damage to the pleats. Do not aim the stream of air
2 directly at the primary air cleaner element. Dirt could 2
be f orced further into the pleats.
8 8
Vacuum Cleaning
_ _
Vacuum cleaning is another method for cleaning a
j air f ilter element which requires daily
primary j
Do not use paints, waterproof covers, or plastics as
cleaning because of a dry, dusty environment.
m with pressurized air is recommended prior
Cleaning
protective packaging when storingm to prevent air
circulation from being blocked. To protect against dirt
to vacuum2cleaning. Vacuum cleaning will not remove 2elements in
deposits of carbon and oil. and damage, wrap the primary air filter
Volatile Corrosion Inhibited (VCI) paper.
Inspect the 8
primary element. 8
Place the primary element into a cardboard box for
i storage. For identification, mark the outside iof the
box and mark the air filter element. Include the
i f ollowing information: i
• Date of the cleaning
• Number of cleanings
Store the box in a dry location.

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i
Engine Secondary Air Filter Element - i
Notice: Fill the crankcase to full or spill, otherwise it
Replacement will damage the engine.
i 1. Open the lef t access door of the machine.
i
Notice
2. Stop the engine to check the oil dipstick and keep
Always replace the secondary element. Never the oil level between the low mark and the full
attempt to reuse the secondary filter element by mark.
cleaning the element.
Notice: The oil level must reach the full mark on the
When the secondary filter element is replaced, oil dipstick when working on the severe slope.
the primary filter element should also be
replaced. 3. Take of f the oil filler cap. Add some oil if
necessary.
The secondary filter element should also be
replaced if the exhaust smoke is still black. 4. Clean and install the oil filler cap.

1. Open the engine hood. 5. Close the access door.

2. See Operation and Maintenance Manual, Notice: It is best to stop the engine for more than two
"Engine Air Filter Primary Element - hours and wait until all the oil has returned to the
Clean/Replace". Remove the air cleaner cover crankcase before checking the level.
f rom the air cleaner housing. Remove the primary
f ilter element from the air cleaner housing.
Engine Oil Sample - Obtain
J J
M M
2 2
8 8
_ _
j j
3. Remove the secondary filter element.
m m
4. Cover the air inlet opening. Clean the inside of
the air2cleaner housing. 2
5. Remove8
the cover from the air inlet opening. 8
6. Install the new
i secondary filter element. i
7. Install the primary filter element.
i i
8. Install the air cleaner cover and tighten it.
9. Close the engine hood.

Engine Oil Level - Check

1. Open the lef t access door of the machine.

Hot oil and components can cause personal
injury. Do not allow hot oil and components to 2. Obtain the oil sample regularly.(at the oil
contact the skin. sampling valve)
3. Close the access door.

55
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Engine OiliFilter - Check
i filter for debris
Check the used oil
The element is shown with debris.
Use a f ilter cutter to cut the filter element open.
Spread apart the pleats and inspect the element for
metal and f or other debris. An excessive amount of
debris in the filter element can indicate a possible
f ailure.
If metals are found in the f ilter element, a magnet can
J be used to differentiate between ferrous metals and
M nonf errous metals.
Ferrous metals may indicate wear on the steel and
2 cast iron parts.
8 Nonf errous metals may indicate wear on the
aluminum
_ parts of the engine, such as main bearing,
connecting rod or turbocharger bearings.
j amounts of debris may be found in the filter
Small
element.
m This could be caused by friction and the
normal wear. If excessive debris are found, contact
2 (Qingzhou) Ltd. dealer for further
the Caterpillar
analysis.
8 8 and
Using the lubrication oil filter element which is
not recommended i by Caterpillar (Qingzhou) Ltd.
can cause serious damage to the engine bearings,
i
crankshafts and other parts. This may generate
the larger particles in the unfiltered lubricating oil.
These particles could enter the lubricating
system and cause damage.
56
i
Engine Oil and Filter - Replace
i
Hot oil and components can cause personal
injury. Do not allow hot oil and components to
contact the skin.
Notice: The engine oil can be changed at a 500
hours interval if the machine is properly operated and
the recommended oil is used. Change the oil at a 250
hours interval if the requirements are not met.
Changing the engine oil and oil filter
1. Open the lef t access door of the machine.
2. Remove the crankcase drain case cover.
3. Open the crankcase drain valve and drain the oil
to a suitable container.
4. Remove the oil filter element and discard the
used element. Make sure to remove the seal on
the used f ilter element.
J
5. Clean the new seal with oil. Install the filter
Melement seal has been installed
element af ter the
on the element.
2
6. Fasten the f ilter according to instructions and use
8
the instructions as a guide.
Notice: You may need special _ tools from Caterpillar
(Qingzhou) Ltd. during installation. To ensure that the
j special tools
f ilter element is not damaged, use
whenever possible.
m
7. Close the crankcase drain valve.
2
8. Remove the oil filter cap and add new oil to the
crankcase. Clean dirt from the filter cap
install the f ilter cap.
i
9. To ensure correct amount of oil is added, please
use the oil dipstick to measure the oil leveli
f requently.
10. Use the indication on the oil dipstick to keep the
oil level between the low mark and the full mark.
11. Close the left access door of the engine.
Note: The engine oil should be drained when the oil
is hot and the contaminants are in suspension.
The diesel engine should be stopped when the water
temperature reaches 60 degrees Celsius. Remove
the oil drain plug.
Note: For other engines, please refer to Engine
Maintenance Instructions.
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i
Engine Compartment– Cleaning i
Braking Capacity Test of Parking
i Notice
Brake System i
The engine should be shut off and cooled down Make sure there are no obstacles and other irrelevant
before spraying the high pressure water against people on the test site before testing.
the engine compartment. Do not spray the water Select a dry, level surface as the test site.
directly to the hot fuel injection pump, otherwise
damage may occur. Bef ore starting the test, fasten the seat belts.
Use the f ollowing test methods to determine if the
Use a commercially available engine degreaser to
parking brake system is functioning.
clean the engine compartment. Take care to keep the
water around the bearings and electrical connections 1. Start the engine.
as little as possible.
2. Open the brake switch and release the service
brake pedal. The machine should not move
Engine Valve Lash - Check f orward. If it moves forward, depress the brake
pedal.
Check with the correct procedure. Consult your
dealer or ref er to the Engine Service Manual. Note: If necessary, remove and inspect the wear of
the f riction plates. Check and replace the brake lines.
Notice: Special tools and training are required to
perf orm a qualified adjustment of the engine valve.
Equalizer bar pin - Lubricate
J Service Brake - Check/Replace J Notice
M Braking capability test of the service brake system A hand grease M gun can be used for the
lubrication. The use of pressure lubrication
2 2 the seal.
equipment will damage
8 Lubricate the center pin of8the equalizer bar with the
Sudden movement of the machine during testing
_ cause personal injury. If the machine moves
can oil cup, which is located in the_engine access door
below the crankcase.
suddenly, reduce the engine speed immediately
andj activate the parking brake system. j
m
Make sure there are no obstacles and other irrelevant
m
people on2the test site before testing. 2
Select a dry,8level surface as the test site. 8
Bef ore starting the test, fasten the seat belts.
i i
Use the f ollowing test method to determine if the
i is functioning. This test is not
service brake system i
intended to test the braking capacity of the service
brake system.
1. Turn on the engine and lift the blade and the
ripper slowly.
1. Remove the cover.
2. Depress the brake pedal and move the steering
2. Lubricate the oil cup.
and traveling lever to the forward position to
increase the engine speed to high speed. 3. Install the cover and repeat the above procedure
on the other side.
3. Gradually reduce the speed. The machine should
remain stationary.
4. Reduce the engine speed. Lower the blade and
ripper to the ground. Stop the engine
Note: If necessary, remove and inspect the wear of
the f riction plates. Check and replace the brake lines.

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Final Drivei Lubrication Oil - Final Drive Oil Level - Check i
Change i i
1. Park the machine in a level location for oil change,
i.e. the drive arrow points to the right and is
parallel to the ground.
2. Remove the fill plug (2) to check the oil level.
3. The oil should reach the lower thread of the fill
plug (2). If the oil is insufficient, fill it to the
specified position.
4. Clean or replace the plug.
5. The above procedure also applies to the other
side.

Idler position - Check/Adjust

Figure 1--Draining the oil

1. Move the machine so that the drain plug (1) is at

the bottom of the final drive.
2. Loosen the fill plug (2) f irst, and then loose the
J drain plug (1) to allow the oil to flow into a suitable J
container (Figure 1).
M 3. Clean the drain plug (1) and replace it with a new M
2 drain plug if it cannot be used. 2
8 4. Move the machine so that the arrow on the final
drive points to the down.
8
_ Loose the fill plug (2), and fill the oil to the plug
5. _
location.
j j surface. Be sure
1. Stop the machine on a dry, flat
6. Clean the f ill plug (2) and replace it if it cannot be to keep the tensioned grouser on a vertical line
m
used. with the idler shaft.(As shown m
in Figure)
2 procedure also applies to the other
7. The above 2 the track is
2. Fill the filling valve with grease so that
side. f ully tensioned. Then slowly loosen the filling
8 8 the
valve to release part of the grease, retract
i idler by about 10 mm, and control the amount
i of
subsidence between the four grousers to be
i about 25 mm. i
Note: Filling valve tightening torque (58 to 88) N.m.
If you have any questions, please contact Caterpillar
(Qingzhou) Ltd. dealer.

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i
Fuel Tank Filter/Breather - Replacing Fuses i
Replace/Clean
i Notice i
1. Remove the fuel tank cap (breather). Replace the fuse with fuse of the same type and
2. Disassemble the fuel tank cap. capacity, otherwise damage to the electrical
system will result.
3. Check the f uel tank cap seal for damage.
Replace the seal if it is damaged. Lubricate the
seal on the f uel tank cap. Notice
4. Check the shield sleeve for damage. Replace if If the fuse is replaced frequently, there may be a
damaged. problem with the electrical system.
5. Replace the f ilter element on the fuel tank cap or Please consult Caterpillar (Qingzhou) Ltd. dealer.
clean the f ilter element.
1. If it blows, replace it with a new f use.
Note: Af ter cleaning the filter element, dry it before
installation. 2. If the f use in an electrical circuit is replaced
f requently, check this circuit.
3. If necessary, repair the circuit.
Fuel Tank Water and Sediment -
Drain Fuse module
Power lock 10A
J J
Ceiling light/Horn 15A

M Personal injury or death may result from failure to M

Controller/Dashboard/GPS 20A
follow these steps.
Air Conditioner 30A
2 Leakage or spillage of fuel into hot objects or
2
Washer 15A
8 electrical components may cause fire. Headlight
8 20A
_ up any leaked or spilled fuel. Do not smoke
Clean Rear lights/Instrument _ 20A
near the fuel system. Lights/Relays
j Front wiper/Fan
j 20A
Disconnect the power switch when replacing the
m
fuel filter. Rear wiper/Backup alarm m 20A

2 the pressure, please slowly remove

1. To release
Solenoids 2 10A
the f uel tank
8 breather cap. Cigarette lighter 10A
8
2. Loosen the drain valve core to drain the fuel. Preheating 30A
i Left door wiper 15A
i
3. Use a tool to open the drain flange and clean the
dirt inside theifuel tank. Right door wiper/Washer 15A i
4. Install the drain f lange and drain valve core. Shut down 30A

Spare 10A/15A/20A/30A

Fuses and Circuit Breakers -

Replace/Reset
Main Breaker - 105A
Removing the fuse cover
The f use block is located on the right rear side of the
seat.
1. Loosen the bolts on the fuse box cover.
2. Remove the fuse box cover.

59
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i - Replace
Hydraulic oil i
i hydraulic oil every 2000 working
Notice: Change the i
hours or once a year.
To preheat the hydraulic oil, run the machine with no
load f or several minutes.
Stop the machine on a flat surface. Lower the work
tool to the ground. Turn the parking brake switch to
the use position, and stop the engine.

8. Keep the oil level above the mark. If not, add oil.
Notice: Avoid air bubbles in the oil. If there are air
bubbles in the oil or in the hydraulic system, check
the suction tube and tubing clamp.
9. Stop the engine.
J 1. Open the cab left cover.
10. If necessary,Jtighten the loose clips and links and
M 2. Remove the hydraulic tank filler cap. M hoses.
replace the damaged

2 Hydraulic Oil Filter

2 - Replace
8 8
_ _
j j
m m
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8 8
i i
i i
3. Loosen the oil drain plug (circled in the figure) 1. The hydrostatic oil filter is located on the left side
and drain the oil into a suitable container through of the machine. Open the cover plate assembly.
a drain tube.
4. Tighten the oil drain plug.
5. Fill to the right place.
6. Install the hydraulic tank cap.
7. Start the engine and run for a f ew minutes.

2. Remove the filter with special tools.

3. Clean the f ilter base and remove all gaskets from
the base.

60
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4. Replace thei gaskets of the new filter element. Hydraulic Oil Level i
5. Install a new f ilter element. When the gasket
i
contacts the filter base, tighten the filter element
i
f or an additional 3/4 turn to increase the strength.
6. Install the cover assembly.

1. Park the machine on a flat surface before

checking the hydraulic oil level.
J 2. Observe theJoil level of the hydraulic oil.
M Mopen the oil tank filler cap.
3. If need to add oil,

2 4. Clean and install the

2filler cap.
8 8
Hydraulic Oil Sample -

_ _
j j
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i i
Obtain
i i
Obtain the sample from the pressure measuring port
at the hydraulic oil filter at the rear of the machine
with a special tool.

61
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i
Working Hydraulic Oil Tank i Oil
Track Roller Frame Pivot Shaft
Strainer - Replace
i Level i
1. Loosen the hydraulic oil tank cap (breather)
located at the left rear of the machine.
2. Clean and inspect the breather and strainer for Hot oil and components can cause personal
damage and replace if damaged. injury. Do not allow hot oil and components to
contact the skin.
3. Install the strainer and the breather.
Notice: Do not get burned by the hot hydraulic oil.
Note: Af ter cleaning the strainer, dry it before
installation.

Hydraulic Oil Return Filter -

Check/Replace

Lubrication Plug
J J
M M
2 2 frame pivot lubrication
1. Loosen the track roller
8 1. Clean the dirt at the f ilter flange. plug on one side of the8machine.
2. Check the pivot oil level. The oil level should be
_ Remove the filter flange and gasket. Remove the
2. _ hole.
at the bottom of the threaded
jspring and return filter. j should reach the
3. If need to add oil, the oil level
3. check the gasket and return filter element for bottom of the threaded hole.
m
damage. m
4. Repeat the above process for the other side.
4. Clean2 the gasket and the oil return filter. Replace 2
if damaged.
8 Radiator Set - Clean 8
5. Install the f ilter element, spring, gasket and filter
f lange. i 1. Open the grille in front of the hood. i
i the strainer, dry it before
Note: Af ter cleaning i
2. Compressed air, high pressure water, or steam
installation. can be used to remove dust and other debris
f rom the radiator. It is recommended to use
compressed air preferentially.
Hydraulic oil tank - Clean
1. Slowly loose the breather.
2. Open the bottom flange and drain the oil into a
suitable container.
3. Clean and dry the oil tank. Check the suction pipe
connection for leaks.
4. Install the f lange. Add appropriate hydraulic oil
and install the breather.

62
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i
Radiator Filler Cap - Clean/Replace Shank i
i i

When the shank is worn or damaged, replace the

shank.
1. Slowly loosen the radiator cap to reduce the
system pressure. 1. Raise the ripper. Put a block under it, and put the
ripper on the block. The ripper should be high
2. Check the radiator filler cap for damage,
enough so that the shank can be removed. But it
sediment, and impurities. Remove the dirt with a
must not be too high.
clean cloth and replace it with a new one if
damaged. 2. If the shank is worn or damaged, remove the
cotter (3) and the pin (4) and remove the shank.
3. Install the f iller cap.
J 3. Replace withJthe new shank and pin.
M Ripper - Inspect/Replace 4. Raise the ripperMand remove the block.
2 Tip
5. Lower the ripper to2
the ground.
8 8
Cylinder Natural Subsidence -
_ _
Measure
j j
Raise the blade to the highest position and then turn
m m the initial
of f the engine. After 5 minutes, measure
height of the blade tip from the ground. Measure the
2 height of the blade tip from the ground2again after 15
minutes. A difference between the two
8 8
measurements equal to or less than 150 mm is
i acceptable. If greater than 150 mm it shouldi be
considered a problem with the hydraulic system.
i ripper is worn or becomes blunt
When the tip of the i
Including: Cylinder, valve, connection, pump, tubing
and cannot cut into the soil, the tip should be and a series of hydraulic components.
replaced promptly.
1. Raise the ripper. Put a block underneath, and
place the ripper on the block. The ripper should
be high enough to allow the ripper to be removed.
But it must not be too high.
2. If the ripper is worn, remove the pin (1) and
retainer, then remove the ripper.
3. Clean the pin and retainer.
4. Install the new ripper tip.
5. Raise the ripper to remove the block.
6. Lower the ripper to the ground.

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i
Ripper Connections and Cylinder Seat Belt - Inspect/Replace i
Bearings - Lubricate
i i be
Bef ore operating the machine, the seat belt must
inspected. If there are any damaged parts, they must
be replaced before operating the machine.

Check: 1. the seat belt mounting hardware, 2.the

buckle, 3. and the seat belt for wear or damage.
Replace immediately if it is damaged.
Within three years of the date of installation or within
f ive years of the date of manufacture, replace the
J seat belt. J
1. Lubricate the eight connecting pins (1).
M M
2. Lubricate the two cylinder mounting pins (2) and Track - Inspect/Adjust
2 lubricate the cylinder top bearing (3). 2
8 Check the adjustment trajectory
8 of the track and the
accumulation of wear and dirt.
Rollover
_ Protective Structure - _ it will accelerate
If the track is too tight or too loose,
Inspect the wear of the track assembly. j
j
Check the bolts of the rollover protective structure for Regarding the repair of bulldozer track, it is required
m and damage. If there is a problem, replace
looseness that: m
the damaged and missing bolts.
2 2
1. Any damaged parts must be replaced;
Do not reinforce or repair the rollover protective
structure. 8 8 be
2. The main pin shaft of the crawler should
replaced once removed to ensure product quality.
i
If there is a breakage or other missing in the rollover i
protective structure, please contact Caterpillar 3. The pins removed during each repair must be
i
(Qingzhou) Ltd. dealers. i track
replaced. It is recommended to replace one
link assembly and two pins at both ends when
servicing. The replacement of pin sets and track
links should be done in the workshop
If the track is too tight or too loose, follow the
steps below to adjust.

64
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i
Track Adjustment i with
shoe is worn through, and replace the track shoe
a new one. Recommended to be measured every
i 500 working hours. i

Move the machine forward for twice the length of the

tractor on a dry, f lat surface. Slowly reduce the speed
to zero with the control lever, and turn off the engine. Note:
(1)The plane position rather than bending position
Measure the size A and size B and make them meet
should be measured for standard track shoe, as
the requirements in the table below. shown below:
822D 822DLGP
Size A 10-20 mm 15-25 mm
Size B 10-20 mm 15-25 mm
J J
1. Standard track shoe grouse
M M
2 2
8 8
_ (2)The diatance f rom the highest
_ position of LGP
track shoe to track link shoud be measured,as shown
j below: j
m m
2 2
Recommended to measure at the position as shown
in the figure.8The initial height of the track shoe is 8
72mm. Replaced when the measured height is
H=21mm, i. ie. when the wear is 51mm. i
Recommended toi be measured every 500 working i
hours.
2. LGP track shoe (3) The data of three measurements (three track
shoes) should be recorded.
Measurement of track link
1. Track link thickness

Recommended to measure at the position as shown

in the figure. The initial height of the track shoe is
123mm. When the measured height is H=113mm, i. e.
the wear is 10mm，recommended to weld a plate with
10mm height and 10mm width on the top of the track
shoe and continue to use until the surface of the track
Recommended to measure at the position as shown
65
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i initial thickness of track link is
in the figure. The 3.Four sections track link length i
129mm. Replaced when the measured thickness is
H=120mm, i. ie. when the wear is 9mm. i
Recommended to be measured every 500 working
hours.
Note:
(1)The caliper shoud be in close contact with track
link and the ruler shoud keep vertical to the track
Recommended to measure at the position as shown
shoe. in the figure. The initial value of E is 866mm.
(2)The plane position(green mark) shoud be Removed one track link and continue to use when
measured rather than the bending position(red mark). the measured value is 890mm. Recommended to be
measured every 500 working hours.
Note:
(1)The length should be measured at the position
closed to the bottom surface.
(2) Measured three times for a total of seven sections
track link, which should not include the mater pin.
(3) If the position of the mater pin need to be adjusted
by walking the machine , should use the forward gear,
not the backward gear;
J (4) The data of J three measurements should be
M (3)The green mark position as shown below shoud recorded. M
be measured for LGP track shoe. 4. Track link bushing
2 2
8 8
_ _
j data of three measurements (three track links)
(4) The j
should be recorded.
m of idle guide on walk frame
2. Distance m
2 2
8 8
i i
i i

Recommended to measure at the position as shown

in the figure. The initial value is 146mm.Removed
one track link and continue to use when the
measured distance is 0mm, i. e. the end surface of
the idle guide is f lush with the end surf ace of the
f rame. Recommended to be measured every 500
working hours.
66
Recommended to measure at the position as shown
in the figure. The f irst picture is the initial
measurement, the initial value is 74.3mm.The second
picture is the measurement after wear, replaced
when the measured value is 71.3mm, i. e. when the
wear is 3mm.Recommended to be measured every
500 working hours.
Note:
(1) Calipers that are over-tightened can be spread
like a spring, providing a measurement that is too
 j j
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small. i i
Measurement of Idler wheel tread
i i

(2) Calipers that are set at an angle to the

bushing will give an oversize measurement. Recommended to measure at the position as shown
in the figure. The initial depth of the idler wheel tread
is 22mm. Replaced when the measured depth is
H=26 mm, i. e. when the wear is 4mm.
Recommended to be measured every 500 working
hours.
Note: The data of three measurements should be
recorded.
(3) Calipers that are not passed back and forth over
the diameter of the bushing position being measured Measurement of track roller tread
J will give an undersize reading. J
M M
2 2
8 8
_ _
j
(4) If the bushing surface is not clean
j
Recommended to measure at the position as shown
m
the measurement taken will be oversized. mIdler wheel tread
in the figure. The initial depth of the
2 is 17.5 mm. Replaced when the measured
H=23.5mm, i. e. when the wear is 6mm.
2 depth is
8 Recommended to be measured every 500 8 working
hours.
i Note: The data of three measurements should be
i
i recorded. i
Measurement of carrier roller tread

(5) If the caliper is located inboard

or outboard of the minimum diameter along its length
the measurement will be undersized.

Recommended to measure at the position as shown

in the f igure. The initial depth of the carrier roller tread
is 16mm. Replaced when the measured depth is
H=22mm, i. e. when the wear is 6mm.
Recommended to be measured every 500 working
hours.
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Note: The three i measurements data of f ront roller i
and rear roller should be recorded.
i i
Measurement of Sprocket segment

Recommended to measure at the position as shown

in the f igure. The initial distance of the sprocket
segment is 234.6mm. Replaced when the measured Window Washer Reservoir
distance is L=220.6mm, i. e. when the wear of each
side is 7mm. Recommended to be measured every The window washer reservoir is located on the lower
500 working hours. right side outside the cab.
Note:
If the washer fluid level is low, refill the reservoir.
(1) It is required to measure the distance between the
three teeth of the same sprocket segment. The
J position is selected and then measured. It is J - Inspect/Replace
Window Wiper
necessary to ensure that each measurement position
M is the same fposition. For the measurement position,
M
2 please refer to the above figure,21.2mm measured 2
f rom the top of the middle tooth.
8 (2) The data of three measurements (three sprocket 8
_
segments )should be recorded. _
(3) Due to the hinder of the protective components, it
mayj be necessary to start the machine and slightly j
rotatem the sprocket segment before each m
measurement.
2 2
Windows 8 - Clean 8
Inspect the front windshield wiper blade and the rear
Use commercially available window cleaning
i the windows. Clean the outside of
solutions to clean
windshield wiper blade. If necessary, replacei the
windshield wiper blades.
the cab windows ifrom the ground unless handholds i
are available. Steering
Window Washer Reservoir - Fill

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(3D) - Move thei control lever to the left to turn the Winch Drum Bearing – Lubricate
i
machine to the left. Move the control lever slightly to Apply lubricant to the f ittings for the winch drum
i machine turn slightly to the left. If
the lef t to make the i
you want to increase your turn, move the control
lever f arther to the left. Move the control lever to the
lowest position on the left to steer the machine in
place to heck the flexibility of the machine's steering.
Check Forward Right (3E) — Move the control lever
to the right to turn the machine to the right. Move the
control lever slightly to the right so that the machine
turns slightly to the right. If you want to increase your
turn, move the control lever farther to the right. Move
the control lever to the lowest position on the right to
steer the machine in place to check the flexibility of
the machine's steering.
(3F) - Move the control lever to the left to turn the
machine to the left. Move the control lever slightly to
the lef t to make the machine turn slightly to the left. If
you want to increase your turn, move the control
Winch Oil Level – Check
lever f arther to the left. Move the control lever to the
lowest position on the left to steer the machine in
place to heck the flexibility of the machine's steering.
J J
Reverse right (3G) - Move the lever to the right to
M turn the machine to the right. Move the control M
lever slightly to the right so that the machine turns
2 slightly to the right. If you want to increase your turn, 2
8 move the control lever farther to the right. Move the
control lever to the lowest position on the right to
8
_ the machine in place to check the flexibility of
steer _
the machine's steering.
j
Notice: The engine maintenance is not mentioned
j
mPlease refer to the attached engine
above.
1. Position the machine on a f lat,m
level surface.
maintenance manual
2 2. Inspect the winch for leaks. Repair2any leaks.
Winch Cable - Inspect 3. Check the oil level by the gauge. The8oil must be
8
visible in the sight gauge.
i SPOOL switch.
1. Press the FREE i
4. Fill the winch case with oil until the oil is at the
2. Unreel the winch cable by manually pulling the
i proper level. i
winch cable.
3. Inspect the entire cable for fraying or kinking. If
Winch Oil – Change
f raying or kinking is present, replace the winch The gear oil should be replaced every year or after
cable. 100 hours of running with the winch. When replacing
the oil, drain the used oil, inject the new lubricating oil
according to the specifications for charge of
lubricating oil of the retarder indicated on the product
label of the selected winch.
Oil Specification
User Instructions Item Description
-15°C-49°C GL-5 85W-90
-25°C-49°C GL-5 80W-90
-45°C-10°C GL-5 75W-90

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i i
i i

1. Park the machine on level ground.

2. Remove drain plug and allow the oil to drain in a
suitable container.

Note: To help drain the oil, remove oil filler plug .

3. Install plug after all of the oil has been drained.

4. Ref ill the winch to the proper level. The oil
1. Heating: Open the warm water valve installed on
J volume is about 5L. J
the engine. Meanwhile turn off the cooling switch
M (cooling indicator
M off).
Winch Vent Plug – Clean If the warm air will not be used for a long time
2 (such as the entire 2 summer), turn off the warm
8 water valve. 8
2. For def rost, after opening the warm air, only
_ _
keeping the defrost air opening open, can
j increase the defrost speed. j
3. Air conditioning air inlet filter needs regular
m cleaning or replacement (3 months
m
2 recommended) 2
8 4. When air-conditioning cooling is not used
8 for a
long time (such as in winter), it is recommended
i that it be turned on at least once a monthi (for 5
minutes).
i plug.
1. Remove the vent i
2. Clean the vent plug in a suitable solvent.
3. Install the vent plug.
Storage
Storage instructions
Note: Do not replace the vent plug with a solid
plug. Damage to the winch will occur. Inf ormation for operators who are prepared for
long-term storage or short-term storage, precautions
to be taken and special tools.
Air conditioner warm air Note: Short term storage is less than 2 months;
control device Long-terms defines the storage period of 3 to 12
months.
Short Time Storage:
• Clean the dirt and dust on the machine, paying
particular attention to the cleaning of the engine,
alternator, starting motor, fuel injection pumps, fuel
injectors, hydraulic pumps and motors, as well as
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i and outer surfaces. These areas
hydraulic piping i
must be wiped with a dry, soft rag.
i
• Drain the coolant in the radiator and engine coolant
i
tank
• Scrub the outer surface of all parts and all
lubrication holes with the kerosene and fill with oil
wax.
• The machine should be kept ready to start at any
time during short-term storage.

Long-Term Storage
Storage site
• Usually in a ventilated and dry warehouse; If the
equipment is stored in the open air, it should be
parked on a concrete floor that is easy to drain,
covered with a canvas or hood and secured. The
site will not be affected by natural disasters and
shall be without corrosive and harmful substances
and gases.
J J
M M
2 2
8 8
_ _
j j
m m
2 2
8 8
i i
i i

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Storage i Decommissioning and i
• The stored machine
i should be positioned Disposal i
horizontally on the support to prevent from the
distortion of the body and deformation of the tire. When the product is removed from service, local
The distance between each wheel and each regulations for the product decommissioning will vary.
bearing surface shall not be less than 8 cm. Disposal of the product will vary with local
regulations.
• Batteries shall be disconnected. If the machine is to
be stored for more than one month, remove the Improperly disposing of waste can threaten the
batteries from the machine and store in a special environment. Obey all local regulations for the
place. decommissioning and disposal of materials.Utilize
appropriate personal protective equipment when
• Start once a month and run at low speed for half an decommissioning and disposing product.
hour to lubricate all the bulldozer systems, while
buttering all grease nipples. Consult the nearest SEM dealer for additional
inf ormation. Including information for component
• Regularly check the appearance quality, protective remanuf acturing and recycling options.
surf aces, and antiseptics of the equipment;
• Inspection interval of long-term storage:
In a warm climate, check every 6 months;
In the tropics, cold times of temperate and frigid
J zones, and coastal areas, check every 3 months. J
M M
After long-term storage
2 2
• Remove the covering;
8 8
• Remove the preserves applied to exposed parts;
_ _
• Charge the battery. Install and connect the battery
j j
• Drain the crankcase of the engine and the final
mclean and change new oil as required
drive, m
2
• Drain inclusions and water f rom the hydraulic oil 2
tank and f uel tank.
8 8
• Grease all the hinges.
i i
• Check and adjust the tension of track.
i i
Specified Storage Period
The specified storage period of this machine is 1 year.
Af ter this specified storage period has expired,
consult your SEM Dealer for inspect, repair, rebuild,
install remanufactured, install new components, and
disposal options and to establish a new specified
storage period. If a decision is made to remove this
machine f rom service, see the Decommissioning and
Disposal section of this Operations and Maintenance
Manual.

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Common i faults and i
i
troubleshooting i
During the use of the bulldozer, due to natural wear,
improper use or maintenance, or poor manufacturing
and assembly, various malfunctions may occur. Fault
inspection and diagnosis can be performed according
to the contents of this chapter. The common faults
and troubleshooting of the bulldozer listed in this
chapter are f or reference only.
Refer to the attached engine user's manual for
engine failure analysis and troubleshooting.
Braking system (The service brake is a
hydrostatic system brake. The following faults
and troubleshooting apply to the parking brake.)

Fault Probable Causes Troubleshooting Method

1. Brake hose or connector plugged Clean brake hoses and fittings
Bad braking performance
J 2. Brake friction plate worn excessively J
Replace friction plate

M M
Hydraulics
2 2
Fault Probable Causes Troubleshooting Method
8 1. Filter plugging
8
Clean or replace the filter
_ 2. Insufficient oil supply from hydraulic pump _
Check and repair the hydraulic pump

jPoor operation 4. Fuel pump failure Replace the fuel pump j

5. Hydraulic oil viscosity too high Use oil with recommended viscosity
m m
6. Tank oil level too low Refill to the specified oil level
2 7. Tubing plugged Clean the inlet and outlet pipes
2
8 8
Working device i i
Number i Symptom Cause Troubleshooting Method i
1. Damaged cylinder 1. Replace pump
1 Work tool malfunction
2. Safety valve stuck, leak 2. Repair
1. The sealing ring on the cylinder
1. Replace the sealing ring
2 Work tool cannot be kept in a fixed position piston is damaged.
2. Repair
2. The lock valve failed

1. Too little oil in the tank

The oil supply of the hydraulic pump is too small and the 1. Add to the specified oil level
3 2. The hydraulic pump is
noise of the hydraulic pump is too loud 2. Replace the hydraulic pump
damaged

1. The return spring is too soft or

4 Control lever does not automatically return to neutral position 1. Replace the return spring
broken

Caterpillar: Confidential Green 73

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Final Drivei System i
Fault i Probable Causes Troubleshooting Method i
1. Excessive wear or damage of gears, bearings, etc. Replace gear or bearing

2. Poor engagement of driving and driven gears Adjust the gearing clearance of the bevel gear pair

Abnormal Adjust the bearing clearance of the driving and driven

3. Misalignment of driving and driven gear bearing clearance
sound bevel gear

4. Broken teeth or damaged bearings Replace gear or bearing

5. Lack of lubricant Add lubricating oil to standard level

Air Conditioning System

Not refrigerating
Condensing fan not Compressor working Check if the fan connector is disconnected, if the grounding is
running good, and if the fan is damaged.
Evaporation fan
running Condensing fan Compressor not Check whether the temperature control switch is damaged,
running working whether the relay is closed, and whether the relay terminal is
loose.

Condensing fan Check if the speed control switch is malfunctioning, if the fan wire is disconnected,
running, compressor and if the fan ground wire is good.
J Not
Evaporation fan
working J
refrigerating
M stopped M
The condenser fan not Check if the fuse is blown, check if the relay is normal and no wires are loose.
running and the
compressor not
2 working 2
8 Both steam fan and 8
Excessive filling of R134a in the system. Check the compliance with the required
The compressor condenser fan working gauge pressure with high and low pressure meter.
_ is normal _
R-134a leaks in the system after long time of not working. Check with high and low
pressure meters to determine whether there is R-134a.
j j
Both steam fan and The inlet and outlet of the reservoir are reversed.
m condenser fan work
properly. Evaporator
m
Check the expansion valve for ice or dirt obstruction and replace the reservoir.
Replace R-134a.
Insufficient
cooling
2 The compressor and condenser are
normal
2
is normal
capacity
8 The fan is working Check if the condenser surface is blocked by fouling. 8
properly, other things
i are normal i
i i

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i
Other troubleshooting methods i
Number i Symptom Cause Troubleshooting Method i
At the beginning, the system is refrigerating Often run on bad roads, resulting in Use a leak detector to find the leakage point
well. After a period of time, the cooling loose connections and leaks due to and carefully tighten the loose part
1 becomes insufficient. Bubbles in the vibration
sightglass; High and low pressure meter
readings are low

The system is not refrigerating. The air
coming out of the outlet is hot. No
temperature difference between the inlet and
2 outlet of the expansion valve can be felt by
hand. The reading of the low pressure meter
is very low.
Improper use. The temperature Replace the expansion valve and refill
sensing block of the expansion valve R-134a
is worn and leaks, making the valve
hole closed

The wind at the air outlet is not cold, the
temperature of the compressor rises, the
pointer of the low pressure gauge drops
3
rapidly to near the value of 0, and the high
pressure meter reading is high
Impurities are trapped in the system, Turn on the air-conditioning system
the expansion valve screen is intermittently, which can eliminate the
blocked, and a thin frost or "sweat" at instantaneous blockage if the blockage is not
the expansion valve occurs. severe. Or remove the expansion valve and
clean it with alcohol, drain the system and
refill R-134a

Insufficient cooling, evaporator frosting; Both Throttle orifice in the expansion valve Drain the system, replace the expansion
4
high and low pressure readings are low not working valve, and refill R-134a

After the system is running for a period of The desiccant in the reservoir is Drain the system, replace the reservoir, and
time, the cooling capacity gradually saturated, and the expansion valve refill R-134a
5
J decreases, the high pressure meter reading is orifice is blocked by ice.
high, and the low pressure reading is low.
J
M After the air-conditioning system is turned on, Poor connection of temperature M
Use a multimeter to check if the temperature
there is only the wind but no cold air. The control switch or damage to the control switch is damaged; Replace the
2 6 readings of high and low pressure meters not compressor solenoid clutch wire 2
compressor solenoid valve clutch
changing. harness
8 Frequent action of the compressor solenoid The temperature control switch
8
Check the temperature control switch and
valve clutch and the engagement time is opening is too small, automatically turn it to the coldest position
_ 7
short. It is not cold in the cab. The high and forcing the compressor to stop, _
low pressure meter readings are normal resulting in insufficient cooling
j j
Specifications
m of SEM822D Stage III Track-Type Tractor
m
2 Type Name Standard LGP 2
Engine 8 8
i
Emission standards (GB/T20891-2014) Stage III Stage III
i
Rated RPM 1,800 r/min 1,800 r/min

Control Type
i Electrical Electrical
i
Drive Train

Transmission Type Dual, closed, electronic-controlled hydrostatic transmission

Drive pump 2 × variable displacement piston pump

Traveling Motor 2 × variable displacement piston motor

Overflow pressure setting 48,000 kPa

Steering and Braking Hydrostatic steering, wet multi-disc brakes

Final Drive One-stage straight gear drive, one-stage planetary drive

Speed-forward/reverse CVT 0-10 km/h

Undercarriage

Type

Track shoe width-forged 560 mm [/]

Track shoe width- Self-cleaning track shoe,

[/] 910/915 mm
cast

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i
Type Name Standard LGP i
i
Number of Shoes (single side) 40 45
i
Track shoe grouser height 70 mm 107 mm

Track gauge 2000 2340

Length of Tack on Ground 2948 mm 3488 mm

Number of Track Rollers (single side) 7 8

Number of Carrier Rollers (single side) 2 2

Track pitch 215.mm 215.9 mm

Implement Hydraulic System

System features Unloaded-center, pilot control

System Pressure 19 MPa

Pump displacement 100 L/min

Implement pump type Gear Pump

Lift cylinder bore × Number 105 mm x 2

Tilt cylinder bore × Number 150 mm x 1

Ripper lifting cylinder bore × Number 160 mm x 2

Control Position
J J
Lift Cylinder Raise, hold, lower, float
M Tilt cylinder
M
Left, hold, right
2 Ripper lifting cylinder Raise, hold, lower 2
8 Standard 8 LGP

Work tools
_ _
Straight bulldozer
Blade Type Semi-U Blade LGP straight blade with tilt cylinder
j blade with tilt cylinder j
m
Blade capacity (ISO 9246) 6.4 m^3 5.8 m^3 5.5 m^3
m
Blade width (including end bit) 3,720 mm 3,750 mm 4,455 mm

Blade Height
2 1,511 mm 1,534 mm 1,345 mm
2
Blade lift height 8 1,140 mm 1,140 mm 1,165 mm 8
i
Blade maximum cutting depth 583 mm 547 mm 600 mm i
Blade maximum tilt- Last adjustment hole 560 mm 589 mm 600 mm
i i
Blade weight (excluding push arm) 1,970 kg 1,900 kg 2,100 kg

Ripper

Ripper type Parallelogram structure [/]

Ripper Tips 3 [/]

Scarifing frame width 2,080 mm [/]

Ripper maximal cut-in depth 860 mm [/]

Ripper maximum lifting height 640 mm [/]

Ripper weight 2,210 kg [/]

Service fill capacity

Fuel tank 460 L 460 L

Cooling 45 L 45 L

Engine Crankcase 24 L 24 L

Final Drive (each side) 40 L 45 L

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i
Type Name Standard LGP i
Hydraulic Oil Tank
i 160 L 160 L
i
Pivot box (each side) 0.8 L 0.8 L

Main specifications

Length of the machine excluding the blade and

4,960 mm 4,960 mm
ripper

Length of the machine- Standard, semi-U

6,010 mm [/]
blade, excluding ripper

Length of the machin e- Standard type, semi-U 7,460 mm [/]

blade, ripper

Length of the machin e-Standard type, S blade,

7,230 mm [/]
ripper
Length of the machin e- Standard type, S blade
5,910 mm [/]
without ripper

Length of the machine- LGP, LGP straight

[/] 6,260 mm
blade with tilt cylinder, excluding ripper

Overall machine width- excluding the blade 2,880 mm 3,450 mm

Overall height of the machine - Including

3,365 mm 3,400 mm
grousers, excluding ROPS/FOPS

J Overall height of the machine - Including

grousers and ROPS/FOPS
3,375 mm J 3,410 mm

M Minimum ground clearance (excluding

400 mm
M 400 mm
grousers)
2 Gradeability 30°
2 30°
8 Minimum turning radius of outer blade tip 4,075 mm 8 4,075 mm
_
Maximum Drawbar Pull 350 kN _350 kN
Applicable ambient temperature range -40°C - +50°C -40°C - +50°C
j j
Sound pressure level at operator's position
88 dB 88 dB
m
(ISO 6396) m
2 2
8 8
SEM822D i Stage II Track-Type Tractor Specifications i
Typei Name Standard LGP i
Engine

Emission standards (GB/T20891-2014) Stage II Stage II

Rated RPM 1,800 r/min 1,800 r/min

Control Type Mechanical Control Mechanical Control

Drive Train

Transmission Type Dual, closed, electronic-controlled hydrostatic transmission

Drive pump 2 × variable displacement piston pump

Traveling Motor 2 × variable displacement piston motor

Overflow pressure setting 48,000 kPa

Steering and Braking Hydrostatic steering, wet multi-disc brakes

Final Drive One-stage straight gear drive, one-stage planetary drive

Speed-forward/reverse CVT 0-10 km/h

Undercarriage

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i
Type Name Standard LGP i
Type
i i
Track shoe width-forged 560 mm [/]

Track shoe width- Self-cleaning track shoe,

[/] 910/915 mm
cast
Number of Shoes (single side) 40 45

Track shoe grouser height 70 mm 107 mm

Track gauge 2000 2340

Length of Tack on Ground 2948 mm 3488 mm

Number of Track Rollers (single side) 7 8

Number of Carrier Rollers (single side) 2 2

Track pitch 215.mm 215.9 mm

Implement Hydraulic System

System features Unloaded-center, pilot control

System Pressure 19 MPa

Pump displacement 100 L/min

Implement pump type Gear Pump

J Lift cylinder bore × Number J
105 mm x 2

M Tilt cylinder bore × Number 150 mm x 1 M

2 Ripper lifting cylinder bore × Number 160 mm x 2
2
Control Position
8 Lift Cylinder Raise, hold, lower, float
8
_ cylinder
Tilt Left, hold, right _
j lifting cylinder
Ripper Raise, hold, lower j
m Standard LGP
m
Work tools
2 Straight bulldozer
2
Blade Type Semi-U Blade LGP straight blade with tilt cylinder
8 blade with tilt cylinder
8
Blade capacity (ISO 9246) 6.4 m^3 5.8 m^3 5.5 m^3
i
Blade width (including end bit) 3,720 mm 3,750 mm 4,455 mm
i
Blade Height i 1,511 mm 1,534 mm 1,345 mm i
Blade lift height 1,140 mm 1,140 mm 1,165 mm

Blade maximum cutting depth 583 mm 547 mm 600 mm

Blade maximum tilt- Last adjustment hole 560 mm 589 mm 600 mm

Blade weight (excluding push arm) 1,970 kg 1,900 kg 2,100 kg

Ripper

Ripper type Parallelogram structure [/]

Ripper Tips 3 [/]

Scarifing frame width 2,080 mm [/]

Ripper maximal cut-in depth 860 mm [/]

Ripper maximum lifting height 640 mm [/]

Ripper weight 2,210 kg [/]

Service fill capacity

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i
Type Name Standard LGP i
Fuel tank
i 460 L 460 L
i
Cooling 45 L 45 L

Engine Crankcase 24 L 24 L

Final Drive (each side) 40 L 45 L

Hydraulic Oil Tank 160 L 160 L

Pivot box (each side) 0.8 L 0.8 L

Main specifications
Length of the machine excluding the blade and
4,960 mm 4,960 mm
ripper

Length of the machine- Standard, semi-U

6,010 mm [/]
blade, excluding ripper

Length of the machin e- Standard type, semi-U

7,460 mm [/]
blade, ripper

Length of the machin e-Standard type, S blade, 7,230 mm [/]

ripper

Length of the machin e- Standard type, S blade

5,910 mm [/]
without ripper

Length of the machine- LGP, LGP straight

J blade with tilt cylinder, excluding ripper
[/] J 6,260 mm

M Overall machine width- excluding the blade 2,880 mm M 3,450 mm

Overall height of the machine - Including

2 grousers, excluding ROPS/FOPS
3,365 mm 2 3,400 mm

8 Overall height of the machine - Including

grousers and ROPS/FOPS 3,375 mm 8 3,410 mm

_
Minimum ground clearance (excluding _
400 mm 400 mm
grousers)
j j
Gradeability 30° 30°
m
Minimum turning radius of outer blade tip 4,075 mm 4,075 mm
m
2 Pull
Maximum Drawbar 350 kN 350 kN 2
8 temperature range
Applicable ambient -40°C - +50°C -40°C - +50°C 8
i i
i i

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Regularimaintenance i
basics i i
The regular maintenance of the bulldozer includes
the f ollowing:
• Daily routine maintenance
• First maintenance of the corresponding parts
• Maintenance at every 250 working hours or one
month
• Maintenance at every 500 working hours or 3
months
• Maintenance at every 1000 working hours or 6
months
• Maintenance at every 2000 working hours or one
year
The maintenance intervals listed in this manual are
determined by using the service hour meter or the
J calendar (day, month etc.). Caterpillar (Qingzhou) Ltd. J
M requires the service should always be performed at M
the interval that occurs first among the above two
2 interval determination methods. Under extremely 2
severe, dusty or wet operating conditions, more
8 f requent lubrication than is specified in the scheduled 8
maintenance might be necessary.
_ _
During the maintenance, the daily routine
j
maintenance and first-time maintenance of the j
corresponding
m parts should be strictly followed, and m
then different regular maintenance plans should be
executed2 according to the specific working hours. 2
The implementation
8 of the maintenance plan for the 8
regular maintenance should be based on the number
i
of working hours. i
Important Notice!
i !! i
• Use only maintenance parts authorized by
Caterpillar (Qingzhou) Ltd. or designated
dealers of Caterpillar (Qingzhou) Ltd. The use
of unauthorized maintenance parts may create
safety problems that are detrimental to the
normal operation of the machine and affect the
service life.
• Genuine maintenance parts are available from
Caterpillar (Qingzhou) Ltd. or designated
dealers of Caterpillar (Qingzhou) Ltd.
Caterpillar (Qingzhou) Ltd. is not responsible
for damage, accidents and machine damage
caused by the use of unauthorized maintenance
parts. Maintenance parts are available from
Caterpillar (Qingzhou) Ltd. or designated
dealers of Caterpillar (Qingzhou) Ltd.

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SEM822Di Regular i
i
Maintenance Parts List i

(Required that users must use)

I. Maintenance Interval Schedule

A. Fluids
The list includes Caterpillar (Qingzhou) Ltd. special
oils f or the regular maintenance of SEM822D.
SEM822D Stage II

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

-25°C-40°C CH-4 SAE15W-40

First 50 24 Engine
-30°C-40°C CH-4 SAE10W-40

-35°C-40°C CH-4 SAE0W-40

-20°C-40°C CH-4 SAE15W-40

J -25°C-40°C CH-4 SAE15W-40 J
250 24 Engine
M -30°C-40°C CH-4 SAE10W-40 M
-35°C-40°C CH-4 SAE0W-40
2 2
-15°C-49°C GL-5 85W-90
8 1000 -25°C-49°C GL-5 80W-90
8
Standard 40*2 Final drive (both
LGP 45*2 sides)
_ -45°C-10°C GL-5 75W-90 _
j -5°C-50°C Cat HYDO advanced 30 j
2000 -20°C-40°C CAT HYDO ADVANCEDE 10 160
m m Hydraulic Oil Tank
-40°C-40°C CAT TDTO (0W-20)
2 2
SEM822D Stage
8 III 8
Interval (h) User Instructions Item Description Demand (L) Where used
i -20°C-40°C CH-4 SAE15W-40
i
i -25°C-40°C CH-4 SAE15W-40 i
First 100 24 Engine
-30°C-40°C CH-4 SAE10W-40

-35°C-40°C CH-4 SAE0W-40

-20°C-40°C CH-4 SAE15W-40

-25°C-40°C CH-4 SAE15W-40

500 24 Engine
-30°C-40°C CH-4 SAE10W-40

-35°C-40°C CH-4 SAE0W-40

-15°C-40°C GL-5 85W-90

-25°C-40°C GL-5 80W-90 Standard 40*2

1000 Final drive (both sides)
-30℃-40℃ GL-5 75W-90 LGP 45*2

-40°C-40°C CAT TDTO (0W-20)

-20°C-40°C CAT HYDO ADVANCEDE 10 SAE10W

2000 160 Hydraulic Oil Tank
-40°C-40°C CAT TDTO (0W-20)

81
 j j
m m
2 2
8 8
i i
B. Saf ety i i
This list includes Caterpillar (Qingzhou) Ltd. specific
oil and spare part details of SEM822D that have a
significant impact on overall safety.

Interval (h) Item Description Where used Remarks

According to actual needs Driving friction plate Final Drive

According to actual needs Driven friction plate Final Drive

Model Applicable temperature range Change Interval

Antifreeze YF-2 Above -35°C 5 years or 10000 hours

Antifreeze YF-2A Above -45°C 5 years or 10000 hours

C. Filters
The list includes the Caterpillar (Qingzhou) Ltd.
original filter elements used for the regular
maintenance of SEM822D.
J J
SEM822D Stage II Filter Element Maintenance
M M
Interval (h) Item Description Qty. Where used
2 First 50 h Filter Element-OIL 2
2 Engine
8 Filter Element-OIL 2 8 Engine

_ 250
Air filter element 1 _ Engine

Fuel primary filter 1 Engine

j j
Fuel secondary filter 2 Engine
m Drain filter Element 1
m
Hydraulic Oil Tank
1000
2 Filter element 2 2 System
Power Train Hydraulic

20008 8
Hydraulic oil tank breather (strainer) 1 Hydraulic Oil Tank

Fill Filter (breather) 1 Diesel tank

i
Note: The air f ilter needs to be cleaned when the air filter indicator gives a warning, and needs to be replaced after
i
i
6 consecutive cleanings. For all other filters, if the filter alarms indicate that they need to be replaced, replace i them
immediately (filter elements).

Material list required for the maintenance within 2000 hours (one year) (Stage II)
Demand Volume Where used
Replacement time Filter
Item Description
(h) Oil (L) element
(piece)
Diesel engine oil 24 Engine
50
FILTER ELEMENT-OIL 2 Engine

Diesel engine oil 24 Engine

FILTER ELEMENT-OIL 2 Engine

250 Air filter element 1 Engine

Fuel primary filter 1 Engine

Fuel secondary filter 2 Engine

82 Caterpillar: Confidential Green

 j j
m m
2 2
8 8
i Demand Volume Where used i
Replacement time
(h) i Item Description
Oil (L)
Filter
element
i
(piece)
Diesel engine oil 24 Engine
FILTER ELEMENT-OIL 2 Engine

500 Air filter element 1 Engine

Fuel primary filter 1 Engine

Fuel secondary filter 2 Engine

Diesel engine oil 24 Engine

FILTER ELEMENT-OIL 2 Engine

750 Air filter element 1 Engine

Fuel primary filter 1 Engine

Fuel secondary filter 2 Engine

Diesel engine oil 24 Engine

FILTER ELEMENT-OIL 2 Engine

Air filter element 1 Engine

J Fuel primary filter J1 Engine
1000
M Fuel secondary filter 2M Engine

Standard type 40*2

2 Gear Oil
LGP type 45*2 2 Final drive (both sides)

8 Drain Element 1 8 Hydraulic Oil Tank

Filter element 2 Power train hydraulic system

_ _
Diesel engine oil 24 Engine
j FILTER ELEMENT-OIL 2
j Engine
m1250 Air filter element 1 mEngine
2 Fuel primary filter 1 2
Engine

Fuel secondary filter 2 Engine

8 8
Diesel engine oil 24 Engine
i FILTER ELEMENT-OIL 2 Engine
i
1500 i Air filter element 1 Engine i
Fuel primary filter 1 Engine
Fuel secondary filter 2 Engine

Diesel engine oil 24 Engine

FILTER ELEMENT-OIL 2 Engine
1750 Air filter element 1 Engine

Fuel primary filter 1 Engine

Fuel secondary filter 2 Engine

Diesel engine oil 24 Engine

FILTER ELEMENT-OIL 2 Engine

Air filter element 1 Engine

2000
Fuel primary filter 1 Engine
Fuel secondary filter 2 Engine

Gear Oil Standard type 40*2 Final drive (both sides)

83
 j j
m m
2 2
8 8
i Demand Volume Where used i
Replacement time
(h) i Item Description
Oil (L)
Filter
element
i
(piece)
LGP type 45*2
Drain Element 1 Hydraulic Oil Tank

Filter element 2 Power train hydraulic system

Hydraulic Oil 160 Hydraulic Oil Tank

Oil filling strainer 1 Hydraulic Oil Tank

Oil filler filter 1 Diesel tank

Material list required for the maintenance within 2000 hours (one year) (Stage III)

Demand Volume Where used

Replacement time Filter
Item Description
(h) Oil (L) element
(piece)
Diesel engine oil 24 Engine
100
FILTER ELEMENT-OIL 2 Engine

Diesel engine oil 24 Engine

J J
FILTER ELEMENT-OIL 2 Engine
M Air filter element 1
M Engine
500
2 Fuel primary filter 1 2 Engine

8 Fuel secondary filter 1 8 Engine

Heated filter with electric pump 1 Engine

_ _
Diesel engine oil 24 Engine
j FILTER ELEMENT-OIL 2
j Engine
m Air filter element 1 mEngine
2 Fuel primary filter 1 2
Engine

Fuel secondary filter 1 Engine

1000 8 8
Heated filter with electric pump 1 Engine
i Standard 40*2
i
Gear Oil Final drive (both sides)
LGP 45*2
i i
Drain filter Element 1 Hydraulic Oil Tank

Filter element 2 Power train hydraulic system

Diesel engine oil 24 Engine

FILTER ELEMENT-OIL 2 Engine

Air filter element 1 Engine

1500
Fuel primary filter 1 Engine

Fuel secondary filter 1 Engine

Heated filter with electric pump 1 Engine

Diesel engine oil 24 Engine

FILTER ELEMENT-OIL 2 Engine

2000 Air filter element 1 Engine

Fuel primary filter 1 Engine

Fuel secondary filter 1 Engine

84
 j j
m m
2 2
8 8
i Demand Volume Where used i
Replacement time
(h) i Item Description
Oil (L)
Filter
element
i
(piece)
Heated filter with electric pump 1 Engine
Standard type 40*2
Gear Oil Final drive (both sides)
LGP type 45*2

Drain Element 1 Hydraulic Oil Tank

Filter element 2 Power train hydraulic system

Hydraulic Oil 160 Hydraulic Oil Tank

Oil filling strainer 1 Hydraulic Oil Tank

Oil filler filter 1 Diesel tank

J J
M M
2 2
8 8
_ _
j j
m m
2 2
8 8
i i
i i

85