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Operation & Maintenance Manual

SEM 919&921 Motor Grader

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2 Caterpillar: Confidential Green
Important Safety Information
Most accidents occurred during the operation, repair and maintenance are due to the
inobservance of basic safety rules or that no preventive measures are taken. If
potential dangers are aware before the accidents, usually they can be avoided. The
operators must be warned about all the potential dangers. Besides the operators also
need to take necessary training to master basic skills and correctly operate the
machine.
Improperly performing the operation, lubrication, repair and maintenance to the
product is dangerous, as it may cause injuries or even death.
The above works shall be performed when the operator have read all the instructions
about product operation, lubrication, repair and maintenance.
There are safety precautions and warnings on the Manual and the machine. If
ignoring the warnings, it may cause injuries or death to you and others.
Note the potential dangers when you see “safety warning signs” and “warning labels”,
such as “Danger”, “Warning “ or “Caution”. The “Warning” sign is shown below:

The warning sign means: Warning, be alert! Your safety is involved!


The danger conditions are explained under the word “Warning”, some are stated with
words, and some with graphs.
For those operations which can cause product damage, “Caution” signs are attached on
the machine and they are also explained in the manual.
Caterpillar (Qingzhou) Ltd.can not predict every condition of potential danger, thus
not all the conditions are included in the warning signs of the manual and the
machine. If the tools, operation procedures, work methods, or operation
technologies that you have utilized are not specially recommended by CQL, you
should guarantee the safety of yourself and others, and that what you have used
can not damage the machine or cause any danger.
The data, technical range, and graphs in the manual are compiled according to what are
available at the compile date. And the technical standards, torque, pressure, measured
value, adjustment value, graphs and other items are subject to change at any time, which
can affect product repair. So you must get the latest manual before each operation. If you
have any question, please contact SEM or the nearest agent.

CQL recommends the original genuine parts or parts with the same technical
parameters when the parts need to be replaced.
Ignoring the warning may cause accident, product damage, injuries or death.
Contents
Foreword................................................................................................................................... 1
Machine Overview ............................................................................................................. 3
Product and Parts Plate....................................................................................................... 8
Instruments ....................................................................................................................... 12
Safety Information .......................................................................................................... 15
Safety Signs and Explanations ......................................................................................... 15
General Safety Information .............................................................................................. 20
Operation Information.................................................................................................... 29
Operation Regulations ...................................................................................................... 32
Operator’s Control Devices.............................................................................................. 35
Operation Technology ...................................................................................................... 48
Parking ............................................................................................................................. 66
Machine Transportation................................................................................................. 68
Service & Maintenance .................................................................................................. 74
Scheduled Maintenance List ............................................................................................ 75
Storage............................................................................................................................. 105
Trouble Shooting........................................................................................................... 108
Technical Parameters....................................................................................................... 114

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transportation, traction, etc.
Foreword The photos and illustrations are very
intuitional for operators to check, start,
operate, and stop the machine according
Manual Information to normal procedures.
This manual introduces basic operation
The operation manual should be placed of the machine. The operators will
in the file folder or in the file repository improve their skills with further
behind the driving seat inside the cab. understanding of the machine and its
performance.
Please read carefully and understand the
manual before the operation, repair and
maintenance. Maintenance
The manual includes safety notes,
operating instructions, and information This part is a guide for operators to
about transport, maintenance, and perform maintenance. The periodic
storage, as well as machine overview, maintenance chart lists the maintenance
technical parameters, and so on. items to be performed in the stipulated
period. Each periodic maintenance chart
Some illustrations in the manual clearly is followed with detailed operating
show the details or working devices procedures of the listed maintenance
which are different from your machines. items, which facilitates operators
To explain the illustrations more clearly, understanding and performing the
the external cover may be removed. scheduled maintenance work.
The modifications of the machine, which The maintenance items with no regular
is due to the improvements and maintenance interval are listed under the
upgrades of product design, may not be column “When Necessary”.
included in the manual. Please read it
carefully and keep it in the machine. Maintenance Period
If the manual is lost, broken, or can not Maintenance period can be set by
be read easily, please change it in time. timesheet or calendar meter. No matter if
the timesheet or the calendar meter is
If you have any question about the
used, the maintenance should be
manual, please consult with SEM agent.
performed according to the maintenance
period which comes first.
Machine Overview
Under extremely tough, dusty, and moist
This part mainly introduces each system
working conditions, it may be necessary
and the main parts of the machine, and
to make more frequent lubrication and
the basic safety precautions. In addition,
maintenance than what is stipulated in
there is also explanation about various
the periodic maintenance chart.
signs and labels attached on the
machine, including their locations. When performing maintenance operation,
Before the operation, repair and the items with shorter maintenance
maintenance, please read the manual interval should also be included in e.g.
carefully and understand the basic safety when performing the 250 hour
precautions. maintenance, the 50 hour maintenance
item and 10 hour maintenance item
Operation should also be included in.
This part can be used as a reference for Engine Maintenance
inexperienced new operators and as the
revision materials for experienced To keep the engine and machine
operators, which covers information systems running normally, correct
about various switches and controls, maintenance and inspection are

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important. The owner of the heavy duty
off–road diesel engine is responsible to
maintain in accordance with the
requirements in the manual and the
maintenance items in the engine manual.
During the repair and maintenance
process of the engine and machine, it’s
prohibited for anyone to remove or
modify the emission devices or elements
of the engine and the machine or make
them out of action at any time. As some
machine parts and engine parts may be
related to the emission, such as exhaust
system, fuel system, electrical system,
air intake system, and cooking system,
none modification is allowed without the
approval of SEM.

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Machine Overview
Introduction
The SEM 919 & 921 motor grader has multiple features: the spacious cab has wide view,
and it is quiet and comfortable to operate; internationally advanced blade mobility and
work range; various kinds of optional working tools can be applicable to all kinds of work
conditions, meet different customer needs, and maximize customer profits.
SEM 919 & 921 motor grader is a kind of multifunctional earthmoving machinery which

features high speed, high efficiency and high precision. The blade is mounted between

the front and rear axle, which makes it possible to flatten the ground and pave materials

according to various grade requirements. The machine is mainly used for flattening large

sites, the reshaping of road base, finishing side slope, trenching, and the paving and

mixing of road materials in road project. And it can also perform various operations like

ripping, bulldozing, and snow removal, etc. when equipped with scarifier, moldboard and

snow plow.

The scraper of the machine can achieve degrees of freedom, i.e. moving and

rotating along the space coordinate axes x, y, z. And each motion can be

finished independently or in combination with others.

The machine can provide good strength and stability for the road base. In the road

base construction, the machine mainly performs grading, slope cutting, and filling

embankment operation.

The machine consists of diesel engine, hydraulic system, drive system, brake system,

electrical system, structural parts, sheet parts, and cab. See the diagram below.

The machine has wider blade location range provided by the 7-hole blade rod,
standard 7 locating holes, blade connecting device, longer and higher main frame,
which also contributes to the following advantages:

• The work performance is improved in the slope range of 1.5: 1~2: 1.

• The productivity is improved due to prolonged reach distance of moldboard


and wider cutting angle, which is achieved through the longer blade lift and the
central shifting cylinder.

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1. Structural parts 4. Sheet parts 7. Hydraulic system

2. Cab 5. Transmission 8. Drive system

3. Engine system 6. Cooling system 9. Electrical system

System Diagram

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Diesel Engine much lower oil consumption and good

economy.
The machine adopts Shangchai SC9D
When the machine works, the fuel in the
(6114) engine which is a kind of
fuel tank is pumped through the fuel filter
6-cylinder, 4-stroke, water cooled,
into fuel injection pump, and the fuel
turbocharging, and air-air intercooling
pressure is increased inside the pump,
engine. The engine has gained the
which ensures that different amount of
non-road diesel engine certicification of
fuel is supplied to the fuel injector
national Ⅱ emission standard(China).
according to work conditions. This is the
The engine features good cold start,
process that the fuel does work. The
plateau performance, low fuel
surplus fuel from the high pressure fuel
consumption, low noise, low emission,
pump returns to the suction pipeline
high reliability and durability.
through the fuel injector and the oil
The key parts of the machine are
return pipelines. There is a hand pump
optimized on the basis of SC8D (6114)
at the feed pump, which can be used to
diesel engine, inheriting the
release the air in the fuel pipelines. The
advantages of SC8D(6114), which
throttle handle controls engine speed
makes it more powerful.
through the flexible shaft.
High Reliability

The engine is designed of 400hp, and Hydraulic System


the actual power is 260~350hp, which The hydraulic system consists of 2

has large safety margin and ensures parts, one is for the working devices

the reliability. and the other is for the steering

Good Economy system.

The lowest oil consumption is 195 The hydraulic system for working
g/kwh. Besides, it adopts piston oil devices is used to control various
cooling technology and alloy bainite working devices (blade, ripper, scarifier,
cylinder liner, which contributes to moldboard, etc.), including the lifting

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and lowering of both sides of the blade, and the gear-shifting is electronically
controlled. The forward and reverse
the slewing of blade, the sideshift of
movement and different speed can be
blade relative to the turning cycle, or achieved through the control of gear
sideshift with the slewing ring, the shift lever.

change of blade cutting angle, the turn Drive axle: The drive axle of motor
of the slewing ring, and the release and grader is the key parts of chassis drive
system. Its main function is amplifying
withdrawal of the ripper, scarifier and
the torque from the engine and
moldboard, etc.
delivering it to the left and right drive
The machine adopts full hydraulic wheel, and make the wheels at the two

steering system, i.e. the steering wheel sides has differential function.

directly drives the hydraulic steering At the same time, the drive axle also
bears various kinds of acting force
gear to make power steering.
from the ground and the frame. Power
The machine also adopts advanced from the engine is delivered to
hydraulic drive fan technology. When transmission through torque converter.

the coolant is in a low temperature, the And then it is delivered to the rear drive
axle through the drive shaft, which
fan runs slow. And the fan speed will
directly drives the rear wheels and
be relatively improved when the
make the grader move.
coolant temperature rises. The
Brake system
hydraulic drive technology reduces
The brake system is composed of
engine power loss and improves the
service brake, parking brake and
work efficiency of the machine.
emergency brake.
Drive System
The service brake system adopts dual
The drive system is composed of the
circuit drum brake structure. When the
power shift transmission and rear axle,
brake pedal is pressed down, the
etc.
compressed air in air reservoir goes
Transmission:the transmission is fixed through air dryer and brake valve and
axle, straight tooth, constant engaged
enters the assistor and then the brake,
power shift transmission mounted on
and thus make the machine stop.
the front of rear frame. It has 6 gears
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The parking brake is also drum type wheels, etc. The front and rear frames

brake and it is mounted at the power are connected through the articulated

output end of the transmission. It bracket.

achieves brake effect through the


Cab
control of brake lever.
The cab consists of two kinds of cab
The emergency brake system is used at
structure and control system,
emergency situations by pulling out
respectively the roll over protection cab
the parking brake lever.
and the normal cab. Among which, the
Electrical system roll over protection and falling objects

There are two 12V batteries connected protection structure can effectively

in series in the electrical system, and protect the driver when there are falling

the rated voltage is 24V. The system objects or roll over accident. Through

includes start system, generating the modal analysis and experiments,

system, control system, lighting system, the vibration absorption system can

instruments and signal system, etc. greatly reduce cab vibration and noise

The engine drives the generator to level, improve comfortability and

work through ribbed belts. The operator’s work efficiency. The cab is

generator can feed the power supply equipped with glass doors and

unit and charge the batteries under windows which are optimally designed

normal conditions. Each control switch so that the operator can have a good

controls different electrical equipment. view when operating the machine. In

addition to the basic configuration,


Structural parts
there are optional high standard seat,
The structural parts consists of front
luxurious seat, rear wiper, radio, air
frame and rear frame. The front frame
conditioner, heater, etc. The operation
is mounted with working devices,
system is ergonomically collocated,
control console and cab, etc. The rear
which is convenient and comfortable.
frame is the key grader parts, which is
Sheet parts
mounted with travel drive devices, rear

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Sheet parts include engine hood, oil

tank, fuel tank, etc.

The plate is located at the timing gear

housing of engine. The content mainly

includes rated engine power, rated


Product and Parts Plate revs, serial number, manufacture date,
The product and parts plate are used for net weight, and manufacturer
users to understand the basic
information of the machine and parts, information, etc.
and provide elementary repair and
maintenance service support for the
Transmission Plate
agents.

Product Plate

The plate is located at the lower right of

transmission housing. The content

includes transmission model, torque


The plate is located at the left beam of
converter model, product code,
front frame. The content mainly
manufacture date, and manufacturer
includes machine model, working
name.
weight, engine model, rated engine
Drive Axle Plate
power, dimension, serial number,

manufacture date, and manufacturer

name.

Engine Plate

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and manufacturer name.

The plate is located at the left balance

box of drive axle. The content includes

axle model, axle code, serial number,

Roll Over Protection Cab


Optional Equipment
(ROPS)
Engine

Name
Seat
Option

Shangchai D9
Common Seat

Perkins Engine Functions


Suspension vibration absorber,
Common Seat

weight adjustable
Armrests are available for the
Transmission operator to rest his/her arms
( Large Seat

Name The backrest can be folded


forward and stepless adjusted for
Option

Hangchi Transmission 28°


Height adjustable

ZF Transmission Headrest available


Seatbelt available

High Configuration Seat


Cab
Functions
Name Suspension vibration absorber,
Configurati
High

weight adjustable
nal
Optio

Standard Cab
Armrests are available for the
operator to rest his/her arms

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The backrest can be folded Rotary warning light with switch
forward and stepless adjusted for Electrical device for snow
28° removal
Height adjustable Electrical device of front top
A file packet is available for you to light
keep documents and manual Machine tracking device
Seatbelt available
Headrest available Blade Assembly
Name

Optional blade
Air Conditioning System Blade assembly(12 ft)

Air Optional for high ambient


Blade assembly(13 ft)
Conditioner temperature condition
Warm air Optional for low ambient Blade assembly(14 ft)
temperature condition
Structural Parts
Electrical System Name
Rear ripper
Options

Cab Electrical Equipment


Rear ripper + front moldboard
Name
Rear ripper + front moldboard +
Warm air/ air conditioner
middle scarifier
switch
Snow push plate(only provide
Rear wiper assembly
Option the installation and hydraulic
(with switch)
valve)
Rear washer assembly
(with switch) Tyre
Name

Startup Assembly
Options

Common Tyre
Name
Tubeless Tyre
Option Normal temperature start
system

Low temperature start


device
Polar region start device

Other Options
Electrical Equipment
Cold start switch
t
O

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Instruments

1 Working hour meter 12 Cylinder location indicator


2 Speed meter 13 High beam indicator
3 Left pressure gauge 14 Right direction indicator
4 2nd, 3rd level warning indicator 15 Hydraulic oil filter indicator
5 Transmission oil filter indicator 16 Charging
6 Low brake pressure 17 Mute
7 Left direction indicator 18 Transmission oil filter indicator
8 Oil pressure indicator 19 Right pressure gauge
9 Parking brake indicator 20 Oil gauge
10 Water temp gauge 21 Tachometer
11 Oil temp gauge

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No. Name Symbol Function
When the engine stops, the hour meter
Working hour shows the overall working hour; when the
1
meter engine runs, the hour meter begins
timekeeping.

It indicates the travel speed within 0~50


2 Speed meter
Km/h.

Left pressure
3 It indicates the left pressure within 0~1 MPa.
gauge

2nd, 3rd level


When there is 2nd or 3rd level warning occur
4 warning
in the machine, the light is on.
indicator

If the light is on, it indicates that the working


Transmission oil
5 oil of hydraulic clutch is too low. You should
filter indicator
immediately stop the machine and check.
If the light is on, it indicates that the brake
Low brake pressure is too low and the brake system
6
pressure works abnormally. You should immediately
stop the machine and check.

Left direction When the steering switch is pressed forward,


7
indicator the light flashes.

If the light is on, it indicates that the engine oil


Oil pressure
8 pressure is too low. You should immediately
indicator
stop the machine and check.

Parking brake The light is on when the parking brake is


9
indicator pulled down.

When the temperature is normal, the pointer


is in the green area. When the temperature is
Water temp
10 above 110℃, the pointer points to the red
gauge
area. When the sensor is disconnected, the
pointer points to the right end.
When the temperature is normal, the pointer
is in the green area. When the temperature is
11 Oil temp gauge
above 120℃, the pointer points to the red
area. When the sensor is disconnected, the

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pointer points to the right end.

Cylinder
When the light is on, it indicates that the
12 location
cylinder is relocating.
indicator

High beam When the high beam light is turned on, the
13
indicator indicator is illuminated.

Right direction When the steering switch is pressed


14
indicator backward, the light flashes.

When the filter element is clogged which


Hydraulic oil make the differential pressure achieve the
15
filter indicator alarm limit, the light is on. And the filter
element must be replaced.
If the light is on when the engine is running, it
Charging indicates that the generator does not work.
16
indicator You should immediately stop the machine to
check.

17 Mute indicator Press the switch to turn off the alarm sound.

When the filter element is clogged which


Transmission oil make the differential pressure achieve the
18
filter indicator alarm limit, the light is on. And the filter
element must be replaced.

Right pressure It indicates the right pressure within 0~1


19
indicator MPa.

When the oil level is normal, the pointer is in


20 Oil gauge the green area; When the oil level is less
than 1/10, the pointer points to the red area.

It indicates engine speed. The actual speed


21 Tachometer
is the value(n/min)×100.

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Safety Information

Safety Signs and Explanations

Safety Signs Location

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Oil Tank
Do not stand behind the machine
when it is reversing, otherwise it
may cause personal injury or even
death.

Hot & Pressurized Fluid


The sign is located outside the oil tank,
indicating the position of oil tank. Warning
Rotating Fan Warning

The sign is located near the pressure


cover of cooling system.

The sign is located at the left side


outside the engine hood.
Pressurized system: the hot coolant
can cause serious scalding. To open
Don’t put your hands close to the fan and the cover, you need to stop the
other rotating parts when the engine is
machine and wait until the radiator
running. It may cause personal injury or
death. is cooled down. Then loosen the
cover to release pressure.

Reverse Warning
Fuel Tank

The sign is located outside fuel tank.

The sign is located outside engine Crushing Danger


hood.

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The sign is at the side of front frame,
near the locking rod.

Danger of crushing. No one is allowed


The sign is located near the articulation
to stand here when the machine is
joint of front and rear frame.
turning. Serious injuries or death may
be caused by crushing. During the
transportation, the steering locking During the transport of the machine,
rods of front and rear frames must be the steering frame of the front and rear
locked up. frame must be locked up, i.e. the safety
lever must be kept at the lock-up
Before the machine starts to work
position.
again, restore the safety locking
rod. Jump Start

Safety Lever

The sign is located outside the battery


case

Risk of explosion! Incorrect connect


of jumper cable may cause
explosion and personal injury or
death.
The sign is attached at the safety lever.

During the transport of the machine,


24V
the safety lever must be kept at the
lock-up position.

The lock is only for the Transport.


The sign is located outside the battery
case. It means that the battery can

Safety Lever Installation provide 24V voltage.

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Parking Brake

The signs are located at the rear of the


The sign is located under the parking
machine and the side of the swing
brake lever.
frame of front frame.

The parking brake can only be used


when the engine is stopped. In Incorrect lifting and fastening may
emergency situations, it can be applied lead to load shifting and cause
together with the service brake to make personal injury or loss.
the grader stop.
Safety Distance of Rotating
Operating Instruction
Shaft

The sign is located at the right side


The sign is attached at the column of rear frame.
inside the cab.

When the machine works, the drive


Please do not operate the machine shaft rotates at high speed. Never
before you read and understand the get close to it and make inspection
Operation & Maintenance Manual. Not or repair, otherwise it may cause
complying with the warnings may cause personal injury or death.
casualties. If you need a new manual,
please contact SEM agents. The users
have responsibility to pay attention to the Engine Oil Drainage
engine.

Lifting Hook

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The sign is located at the exterior or
rear frame.

Hydraulic Oil Drainage

The sign is located at the right side of


oil tank which is mounted at the rear of
cab.

Hot oil and parts may cause


personal injury. Do not make hot oil
or parts contact your skin. Store the
oil in separate container and be
cautious of environmental
protection.

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person who send the signals. Only
General Safety Information accept the gesture signals sent by one
person.
Smoking is not allowed when repairing
the air conditioner, and also when there
is cooling agent vapor. Inhalation of the
air mixed with smoke which is generated
in the combustion of the cooling agent
may cause injuries or death. When the
vapor of air conditioner cooling agent is
breathed in with the burning cigarette, it
may also cause injuries or death.
Don’t put the maintenance fluid in glass
Before servicing and maintaining the containers. All the maintenance fluid
machine, attach a warning board should be drained into appropriate
“Operation Prohibited” or a similar one containers.
on the start switch or control lever.
Please comply with all the local laws and
Be aware of the width of working devices regulations about the disposal of various
and tools, and keep certain distance liquid wastes.
from the fences or barriers when working
near them. Be careful to use the cleansing fluid.
Report all the items need to be
Be cautious of the high voltage wires and inspected.
cables. Otherwise injuries or death may
occur if the machine touches the Any one should not get on the machine
wires/cables. without permission.
The machine maintenance can only be
performed at specific maintenance
places, unless otherwise directed. As for
the procedure of parking the machine at
the maintenance places, please refer to
the Operation and Maintenance Manual.

Compressed Air and

High-pressure Water
Please wear safety helmet, goggles and Compressed air and high-pressure water
other protective devices. may make scraps or hot water splash,
Do not wear loose clothes or jewelries, which may cause personal injury.
as they may entangle the control lever or Please wear protective suit, shoes, and
other parts of the machine. eye protectors when cleaning with
Ensure that all the guard shields are compressed air or high-pressure water.
fastened on the corresponding positions. Eye protectors include goggles and face
shield.
Do not stack sundries on the machine.
Clear all the scraps, oil, tools and other When the nozzle makes empty injection
sundries on the floor, passages and or using nozzle with valid flow deflector
stairs. and protective equipments, the
maximum air pressure for cleaning must
Properly keep the scattered objects, be declined to 205 kPa. The maximum
such as lunch-box, tools, and other water pressure for cleaning must be
objects that are not machine parts. under 275 kPa.
Get familiar with the specific gesture
signals used on the job site and the
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Remaining System Pressure Liquid
Pressure may remain in the hydraulic Be careful when inspecting, maintaining,
system. When releasing the remaining testing, adjusting, and repairing the
pressure, the machine or optional parts machine. Make sure to hold the
overflowing liquid properly. Before
may move suddenly. Be careful when
opening any chambers or dismantling
dismantling the hydraulic pipes or joints, any parts containing liquid, please
as the released high-pressure oil may jet prepare appropriate containers.
out and make the oil tube whip. And the Please comply with all the local laws and
fluid penetrating into the body will cause regulations about handling various liquid.
serious injury or even death. Asbestos
Oil Penetration
Even if the engine has flamed out for a
long time, the pressure may remain in
the hydraulic circuit. If the pressure is not
released correctly, it will cause the
hydraulic oil or pipe plug jetting out at
high speed.
None hydraulic parts should be
dismantled before the pressure is
released; otherwise it will cause personal
injury.
The equipment and spare parts
produced by SEM do not contain
asbestos. SEM suggests using the spare
parts produced by SEM only. When
handling any spare parts containing
asbestos or asbestos scraps, please
follow the principles below.
Please be careful. Avoid inhaling the
dust generated during handling the parts
containing asbestos fiber. Inhaling the
dust will harm your health. The parts that
When inspecting leakage, be sure to use may contain asbestos fiber include:
board or cardboard as guard. The liquid brake friction plate, brake band, gasket
spurting under pressure may penetrate material, clutch friction plate, and some
gaskets. The asbestos fiber is usually
into human tissue and cause serious soaked in the resin or sealed by using
personal injury or even death. Even the some method. Unless the asbestos dust
liquid jetting out from a pinhole may also floats in the air, the common handling
method is harmless.
cause serious personal injury. If the
liquid spurts out onto your skin, If the floating dust may contain asbestos,
please follow the rules below:
immediately seek the doctor who is
• Never use compressed air to clean.
familiar with the injuries for treatment.
• Avoid brushing materials which contain
Containing Overflowing asbestos.

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• Avoid polishing materials which contain fall down.
asbestos.
The cab must be supported well when
• Clean asbestos material with wet operating under it.
process method.
Never make any adjustment when the
• The vacuum cleaner with efficient
machine is moving or the engine is
particulate filter also can be used to
running, unless otherwise directed.
clean.
• Use exhaust ventilation device when It is not allowed to start the engine by
operating the machine for a long time. using bridging cable to connect the
• If there are no other methods to handle electromagnetic coil terminals of the start
the dust, please wear valid dust mask. motor. Otherwise it may cause
• Comply with all the rules of the working unexpected movement of the machine.
site.
If there is linkage system for operating
• Please dispose the asbestos waste
the equipment, the clearance of the
according to the environmental
linkage system will change with the
protection law.
movement of the machine. Keep away
• Keep away from the sites where there
from the area where the clearance will
may be asbestos particulates in the air.
change suddenly with the movement of
Disposing Waste the machine.
Keep away from all the rotating and
running parts.
Appropriately
Some protective covers should be
dismantled during service and
maintenance operation. Do restore them
when the operation is completed.
Keep any object away from the rotating
fan blades. The fan blades will toss the
objects or cut them.
Never use tangled or worn wirerope.
Please wear gloves when touching the
wirerope.
When knocking the lock pin, the pin may
burst out and cause injuries. When
knocking the pin, please make sure that
Inappropriate dispose of the waste will nobody else is around, and wear goggles
harm the environment. Please dispose to avoid hurting eyes.
the harmful liquid according to local laws
and regulations. When knocking objects, the scraps will
burst out. Before knocking any object,
Contain the released liquid with please make sure that nobody will be
leakproof containers. Never dump the hurt by the flying scraps.
waste to the ground, drain-pipe, or any
water sources. Scalding Prevention
Don’t touch any parts of the running
Crushing or Cutting Injury engine. Before maintaining the engine,
cool it down first. Before disconnecting
Prevention the conduits, joints, and relevant
connections, first release all the pressure
in the air system, oil system, lubricating
Operation and maintenance can be
system, fuel system, or cooling system.
performed under the machine only when
it has been well supported. If the control
lever is moved or there is cracked
Coolant
hydraulic pipes, the working devices may When the engine is running, the coolant
22 Caterpillar: Confidential Green
is hot and pressurized. There is hot liquid not access them without permission.
in the radiator and all the conduits to the Keep the oiled rags and all the
heater and engine. flammables in the protective containers.
No smoking is allowed at the sites where
Touching the hot coolant or vapor will
there are flammables.
cause serious injuries. Before draining
the cooling system, the parts of the Operating the machine close to sites with
cooling system should be cooled down naked flame is prohibited.
first.
The protective cover of the exhaust pipe
Check the coolant level only when the (if equipped) can protect the glowing
engine stops. exhaust parts, which can avoid the parts
being splashed by engine oil or fuel
Before taking down the filler cap, make
when there is rupture in the conduits,
sure that it is cooled. And it must be
hoses, or seals. The cover should be
cooled enough to be touched by bare
mounted correctly.
hand. Take down the filler cap slowly,
and release the pressure. It is prohibited to weld on the pipelines or
oil tank where there is flammable liquid,
The additive of the cooling system
or cut the pipelines or oil tank where
contains alkali which will cause personal
there is flammable liquid with fire. Before
injury. Don’t make it touch your skin, or
welding and cutting, clean them
enter into your eyes and mouth.
thoroughly with uninflammable solvent.
Oil Check all the wires every day. Before
operating the machine, repair loose or
Hot oil and parts may cause personal worn wires, and clean and tighten all the
injury. Don’t make hot oil and parts touch wire joints.
the skin.
The dust generated by repairing
Only open the filler lid of the hydraulic oil nonmetal protective covers or baffle
tank according to the standard procedure plates may be flammable or explosive.
of the manual when the engine stops and Repair these parts at draughty site which
the filler lid is cooled enough to be is far from naked flames and sparks.
touched by bare hand.
Fire and Explosion Check if all the pipelines and hoses are
worn or aged. The layout of the hoses
Prevention must be appropriate. And there must be
appropriate supports and firm pipe
clamps for pipelines and hoses. Tighten
all the joints according to the
recommended torque. Leakage will
cause fire.

All the fuel, most lubricating oil, and


some coolant mixture are flammable.
The flammable liquid leaking or
splashing on the glowing surface or the
electrical parts may cause fire, which will
cause personal injury and property loss.
Clear all the flammables on the machine,
such as fuel, lubricating oil, and other
scraps. Don’t make any flammables
accumulate on the machine.
Keep all the fuel and lubricant in the
containers with marks. Anyone should

Caterpillar: Confidential Green 23


Be careful when refueling the machine. Please consult SEM agents for the repair
No smoking is allowed. And not to add and replacement of the parts.
fuel at places near the naked flame and
Inspect the pipelines, conduits, and
sparks. Remember to flame out the
hoses carefully. Don’t inspect pipelines
engine before refueling. The refueling
with bare hands; instead use a board or
must be performed at outdoors.
cardboard. Screw up all the joints
according to the recommended torque.
Please replace the parts, if any of the
following conditions occur:
• Damaged end joints or leakage.
• Worn or cut outer layer.
• Exposed metal wires.
• Bulged outer layer
• Bent hoses
• Armored sheath inserting into the outer
layer
• Displaced joints
The gas emitted from the battery may Make sure that all the clamps,
explode. Keep naked flames and sparks protections, and heat insulation plates
away from the top of the battery. And no are installed correctly, which is helpful to
smoking is allowed at places where the prevent machine vibration and the
battery charges. friction and overheat of parts during the
operation.
It is prohibited to check the charging
condition by using bridging method to Fire Extinguisher Location
connect the terminal blocks. Using the
voltmeter or hydrometer is necessary.
Do not weld or drill on the ROPS in order
Incorrect bridge connection of cables
to install the fire extinguisher.
can cause explosion and personal injury.
Charging the frozen battery is prohibited, If the fire extinguisher needs to be
which may cause explosion. installed on the ROPS, bundle the
mounting board to the leg of ROPS. If
Fire Extinguisher the weight of the fire extinguisher is over
4.5 kg, the lower the fire extinguisher is
Make sure the fire extinguisher is installed, the better. Do not install the fire
available, and get familiar with the usage extinguisher over the 1/3 height of the
of it. Inspect and maintain the fire leg.
extinguisher regularly. And comply with
the instructions on the product plate. Tyre
Pipelines, Conduits, and The gas in the pneumatic tyre will burn
when heated, which can cause explosion.
Heat generated by welding, heated rim
Hoses parts, exterior fire, and overuse of brake
can cause explosion.
Don’t bend and knock the high-pressure
pipelines. Don’t install any bent or Tyre explosion is much fiercer than tyre
damaged pipelines. break. Explosion can push tyre, rim parts,
and axle parts 500m far from the
Repair all the loose or damaged machine, even farther. The explosive
pipelines, as leakage may cause fire. power and splashing fragments may
24 Caterpillar: Confidential Green
cause property loss and personal injury.

(A) at least 15m Ensure that the frame lock pin (1) has
(B) at least 500m been unlocked. Do take down the
Keep away from the hot tyre. As the
frame lock pin so that the articulation
diagram above shows, keep the shortest
distance and stay outside the shaded
parts can move.
area.
When inflating the tyre, stand behind it
and use self-connected inflating joint.
Repairing tyre and rim is dangerous. It
can only be performed by trained staffs
using correct tools through correct
procedures. Incorrect repair procedures
may cause tyre break under explosive
power which can cause serious injury or
death. So please strictly comply with the
Remove the bolt (2) for the tilting of
instructions of tyre agents.
front wheels, so that the front wheels
Lightning Damage can be ed.

Prevention Only start the engine when you are in the

cab. Never make short circuit to connect


When there is lightning near the machine,
never perform the following operations: the starting motor terminals or connect
• Get on the machine.
• Get off the machine. the battery. The short circuit connection
When there is lightning, do not leave the
may damage the electrical system.
cab if you are in the cab, or keep away
from the machine if you are on the Check the seatbelt and installation
ground.
parts. Replace the damaged or worn
Before Starting the Engine
parts. Change the seat belt every third

year regardless of its condition. Do not

use lengthened belt which can be

rolled-up.

When the driver leans closely against

Caterpillar: Confidential Green 25


of the machine. Understand the
the seatback, adjust the seat properly
obstacles that can easily cause danger,
for enough pedal travel. Adjust the tilt such as wires, ditches, etc.
Make sure that all the windows are clean.
lever of steering column to make the
The doors and windows should be kept
operator more comfortably operate the at the constant open or closed position.
machine. Optimally adjust the rearview mirror (if
Make sure that the lighting system meets equipped) to observe surrounding areas.
the work requirements, and all the lights Make sure that the horns, back-up alarm
work normally. (if equipped), and other alarming devices
work normally.
Before starting the engine and driving
the machine, make sure that there is Fasten the seatbelt firmly
nobody on, under, or near the machine.
Field of View
Starting the Engine
Before starting the machine, the
operator should check around the
machine and ensure there is no
danger.
When the machine is running, continue
to check the surrounding area and find
out the potential danger in time.

At some sites, the view of all the areas


surrounding the large machine can not
If there is a warning label of “Operation
Prohibited” or a similar one attached to be seen directly. Proper site
the engine starting switch or the control
device, do not start the engine or move organization is needed to reduce the
any control devices. danger caused by vision limit.
Before starting the engine, check if there
are bystanders or maintenance The site organization refers to a set of
technicians. Make sure that all the rules and procedures used to
people are far away from the machine.
Blow the horn briefly before starting the coordinate the machines and staffs
engine. working simultaneously at the same
Press down the parking brake lever.
site. Usually it includes:
Be sure to start and run the engine at
draughty places. In closed area, the • Safety instructions
exhaust gas should be released • The control mode of machine and
outward.
vehicle movement.
Before Operation
• The worker who coordinates traffic.
Keep all the people away from the
• Restricted area
machine and surrounding area.
Clear all the obstacles on the work path • Operator training

26 Caterpillar: Confidential Green


• Warning signs and labels on the are devices as follows:
machine or vehicle • Additional seat
• Additional seatbelt
• Communication system Pay attention which parts need to be
repaired when the machine is running.
• Communication between the workers Report the items need to be repaired.
and the operator before accessing the Once the machine sideslips on the
machine. slope, immediately discharge the load

The field of view may be limited if the and turn the machine to downhill

user modifies machine configuration, direction.

which should be considered seriously. Avoid any situation that may cause
machine rollover, such as operating at
hilly areas, banks, and slopes, or
Operation crossing the ditches, ridges, or other
unexpected barriers.
The machine must be operated within
Avoid the machine working crosswise on
the permitted temperature range. The
the slope. Always drive the machine
lowest ambient temperature at which the uphill or downhill.
standard machine can work safely is
-40℃~50℃(when start the engine in the Stopping the Engine
temperature Below 0 degrees, the Do not stop the engine immediately after
engine needs to be configured the working under loads, otherwise the
corresponding auxiliary starting device; if engine parts will be overheated and worn
quickly.
higher than 43 degrees in the work
After stopping the machine and applying
environment, you need to configure the the parking brake, turn off the engine
high-temperature cooling system, detail after two minutes, so that the hot engine
please contact your local dealer), and parts will be gradually cooled down.
the relative humidity is 0~100%, unless
otherwise stated. Parking
Only operate the machine when you sit Park the machine on level ground. If it
on the driving seat. And fasten the seat has to be parked on the slope, block the
belt when operating the machine. wheels.
Operate the control devices only when
Move the control lever to neutral
the engine is running.
position.
When slowly operating the machine
Apply the parking brake.
at open sites, check if all the control
Stop the engine.
systems and protective facilities work
Turn the engine starting switch to the
normally. Special attention should be OFF position, and pull off the key.
made when moving the moldboard as it Note: When parking the machine for a
can make contact with tires and/or steps long time, turn the battery cutoff switch to
on the cabin resulting in damage. the OFF position, which will avoid battery
discharging. Short circuit of battery,
electricity leakage from some parts, or
Before operating the machine, make other artificial damage can cause battery
sure that it will not cause danger to discharging.
anyone.
No passenger is allowed unless there Noise and Vibration

Caterpillar: Confidential Green 27


Noise Level recommended procedures.
When you need to work in the machine
with open operating platform for a long Other Protective Device (If
time or in noisy circumstances, you may
need hearing protection. If the cab is
maintained inappropriately, or the
Equipped)
machine works for a long time or in noisy
circumstances with doors and windows Prevent being hurt by flying or falling
open, you may need hearing protection. objects in specific sites.

Install the front shield when using tools


Cab
which may produce flying objects. Front
Any modification to the operating area protective net cover and makrolon front
should not compromise space for the shield can be used for machines with
operating area or the additional seat. open or closed cab. When there are risks
The stipulated space for operation or the of flying objects, close the windscreen
additional seat (if equipped) must be when you are on the machine with
reserved when installing radio, fire closed cab, and wear safety goggles if
extinguisher, and other equipment. you are on the machine with open cab.
Anything brought into the cab should not
If the materials extend to the top of
occupy the stipulated space for the
operating area or the additional seat (if the cab, top and front guards should be
equipped). Lunch boxes and other
installed.
scattered objects must be fastened. And
make sure these objects will not cause Note: If there is any problem, please
impacts and injuries when the machine contact the SEM agents.
travels on rugged ground or rollover
accident occurs.

Protective Device
Various types of protective devices are
used to protect the drivers. The machine
itself and its working condition determine
the type of protective device needed.

To find the bent, ruptured, or loose


structures, it is necessary to make daily
inspection on the protective devices.
Never operate the machine when these
structures are damaged.

If the machine is operated


inappropriately or unskillfully, the driver
may be in danger, even if the machine is
equipped with proper protective devices.
Please operate the machine according to

28 Caterpillar: Confidential Green


Operation Information
Overview

SEM 919/921 Motor Grader


Overall length 8709 mm

Overall width 2630 mm

Overall height 3362 mm

Basic configure Overall weight(919/921) 15100 Kg/15800 Kg

Related Operation
The basic rules must be followed when The falling objects may cause injuries
operating the machine. or death. Remove all the hanging
• To avoid injuries, no one should stay on objects and be aware of the falling
the machine or work around. Always objects.
keep control of the machine.
• Before releasing the parking brake, the Downhill Operation
service brake pedal must be pressed
down to avoid machine moving. Keep the lowest speed required under
• Drive the machine forward to achieve the downhill condition. Before going
optimal view and effective control. downhill, choose the proper gear to keep
• When turning back at narrow site or suitable speed on the slope. The throttle
travelling uphill, the engine speed should control device shall be kept at high idling
be lowered. position, and engine overspeed is not

Caterpillar: Confidential Green 29


allowed. In most cases, the speed gears handrails, and make all the necessary
are the same when climbing uphill and repairs.
going downhill.
When getting on/off the machine, face
If the machine runs over speed during
the machine and keep “3-point “contact
downhill, it may cause engine overspeed,
with the ladders and handrails.
which may damage the engine and/or
Note: “3-point “contact may be two feet
the drive train. Apply service brake or
and one hand or one foot and two hands.
engine brake to reduce the machine
speed until the lower speed gear can be It is prohibited to get on/off a moving
engaged. Continue to engage much machine. Do not jump off the machine.
lower gear and keep the throttle at high Do not bring with tools or objects when
idling position. getting on/off the machine. Use hauling
cable to pull the apparatus onto the
Change Direction and platform. Do not use the operation lever
as handrail when entering or exiting the
Gears cab.

It is not suggested to change the speed


gear and direction gear at full engine Daily Inspection
speed. In any case, when changing the
travel direction, completely stop the In order to prolong the machine life, walk
machine, and press down the main around the machine to make thorough
clutch pedal. When changing the speed inspection before starting the engine.
gear, lower the speed and press down Check all around and under the machine
the main clutch pedal. to see if there are loose or missing bolts,
accumulated garbage, fuel or coolant
leakage, and cracked or worn parts.
Before Operation
Note: Keep close watch if there is
leakage. Find out the source of leakage
and solve the problem. More frequently
Get on/off the machine check the liquid level if there are signs of
leakage.

Check the condition of equipment and


hydraulic parts.

Check the tyre. Charge the tyre if


necessary.

Check the oil level, coolant level and fuel


level.
Get on/off the machine only from where Clear all the accumulated waste and
there are ladders and/or handrails. Clean fragments. Make necessary repair
the ladders and handrails before getting before operating the machine.
on the machine. Check the ladders and
30 Caterpillar: Confidential Green
Ensure that all the covers and guard
plates are secured firmly.
The lock device of steering frame can
Adjust the rear mirror of the machine to a
proper angle. prevent the machine from swing.
Ensure that the engine filter indicator is
not in the red area.

Fill lubricant to all the lubricating points


which need daily maintenance.

Perform the following maintenance


procedures which are suitable for your
machine every day.

• "Gas tank moisture and deposit Insert the lock devices (2) into the
– Release" bracket (1) before performing any of
• “Reverse alarm – Test”
• "Indicator lights and the following works.
instruments- Test" Lift the machine.
• "Rotary table driven pinion
teeth – Lubrication" Transport the machine.
• "Top of the rotary table Work near the middle of the machine.
–Lubrication "
• " Coolant level - Check" Ensure that the lock device of steering
• "Engine air filter indicator – frame is in the lockup position and the
Check "
• "Engine air coarse filter – lock pin is secured.
Clean" Before operating the machine, first
• "Engine oil level- check"
• "Fuel system oil-water unlock the lock device (2) of steering
separator - drainage" frame, and ensure it is kept in the
• "Seat belt - check"
• "Transmission and differential bracket (1) with the lock pin.
oil level – check"
ROPS Structure
Steering Frame Lockup The Roll Over Protection system (if

equipped) is specially designed for the


No one is allowed to be here when machine, which has been tested and
the machine is steering. Otherwise proven. Any modification to the
crush injury or serious casualty may structure may weaken its function, and
occur.

Caterpillar: Confidential Green 31


put the operator under unprotected environment, work conditions and the
materials;
condition. If the machine weight --- Understand all the rules and
exceed the stated weight on the plate regulations and precautions of the work
site;
due to any modification or retrofitting, it --- Read and understand the operation
will also put the operator under manual, get familiar with all the rules and
precautions about operating the
unprotected condition. machine;
--- Wear protective devices according
The overweight may also limit the
to the safety regulations: work suit,
machine performance like brake, safety helmet, ear protection, respirator,
protective glass, fluorescent clothing,
steering and ROPS. If the
etc.
ROPS/FOPS structures have structural All the operating devices must be set

damage, their protective ability will be at “neutral” position before starting the

weakened. Rolling over and bumping engine.

will damage the structures. Check the hydraulic oil and the

Do not weld brackets for fire lubrication oil to see if they have

extinguisher, first-aid case, working deteriorated, replace the oil when

light, etc. on the ROPS structure or necessary.

boring on it. Otherwise the Get familiar with the environment of

performance of the structure may be the job site, work conditions and

weakened. materials. The operators should wear

Note: Please contact SEM Dealer if any protective devices.

problem occurs. It is prohibited for the operator to

drink alcohol, take stimulant or other

medicines before operating the machine.

Operation Regulations Understand where the fire

extinguisher, first-aid apparatus, and the


Operation Notes
emergency phone are placed.
Operator Preparation:
Check if the rear-view mirror is
--- Get trained and become qualified;
Do not drink alcohol or take stimulant. properly adjusted, so that the operator
--- Get familiar with the work can have a better view.
32 Caterpillar: Confidential Green
Check if all the designations, signs 5. Press down the service brake (2) to

and diagrams in the cab are clear. prevent the machine from moving.

The operator should guarantee that 6. Move the transmission control (lever)

there is nobody in the adjacent and no to the parking brake position.

barriers under or around the machine. 7. Move all the control lever to the

The operator shall not leave the retaining position.

machine while the engine is running. 8. Release the control (2) of service

Starting the Engine brake.

9. Turn the key of engine switch and

There are combustion products in the start the engine. Loose the key when
engine exhaust, which is harmful to
the engine is started.
human health.
Only start and run the engine in 10. Press down the throttle pedal(3)
ventilated area. Release the exhaust
until required engine speed is
outside when running in a closed
area. achieved.

11. Drive the machine forward to achieve

the optimal view and control.


Start procedures:
Caution
1. Adjust the driving seat.
The time for engine barring should not
2. Adjust the tilting of steering wheel exceed 30 seconds. Cool down the start
motor for 2 minutes before barring again.
3. Fasten the seatbelt.
Before the engine oil pressure
4. Lift all the lowered parts to pass any light/gauge indicates sufficient oil
pressure, it may damage the
barriers.
turbocharger if the engine does not run
at low speed.

Engine and Machine

Preheating
1. At lease run the engine idling for 5

minutes when cooling down the

engine.

Operate all the control devices in turn

Caterpillar: Confidential Green 33


to make hydraulic oil run through all the it when the engine runs smoothly.
When the machine stops, use
hydraulic oil tank and pipelines and insufficient or too much diethyl ether
preheat the hydraulic oil. will damage the piston and piston ring
Wait for about 2 seconds before filling
Run the engine idling. If the hydraulic again.
function is sluggish, it may need more Only use diethyl ether at cold weather.
It need to rest for 2 minutes each time
preheating time. the engine starts for 30 seconds, so
2. Release the brake. Move the that the start motor can be cooled
down before the next start.
machine several meters (yards) Before the engine oil pressure
forward and backward. Then make trial light/gauge indicates sufficient oil
pressure, it may damage the
operation for a few minutes. turbocharger if the engine does not run
To reduce the overall preheating time, at low speed.

make trial operation of the machine


Start the engine according to step
before preheating the hydraulic oil.
1~11.
3. Operate the machine under low load
Press down the diethyl ether auxiliary
until the system achieves normal work
start switch (if equipped) , and then
temperature.
release it after 2 seconds. Repeat the
4. During operating the machine, often
process until the engine starts and
check the indicators and instruments.
Use diethyl ether to assist rotates smoothly.
starting the Engine Release the engine start switch key

when the engine starts.


There are combustion products in the
engine exhaust, which is harmful to According to the step 12~13 of starting
human health.
the engine.
Only start and run the engine in
ventilated area. Release the exhaust When the temperature is below −18°C
outside when running in a closed
(0°F), the cold weather auxiliary start
area.
device is suggested. Besides, the

coolant heater, fuel heater, water jacket


Caution
Only fill the diethyl ether to assist heater, and extra-large capacity battery
engine starting at the beginning
may also be needed.
period of engine start. And stop filling
34 Caterpillar: Confidential Green
Operator’s Control Devices snow blade feather plate lift control (if

equipped) (26) snow blade feather


Note: your machine may not be
plate tilting control (if equipped) (27)
equipped with all the control devices
ripper control (if equipped) (28) blade
introduced in the section.
angle control handle (29) blade center
The operator’s control devices mainly
frame driving handle (30) wiper and
include:
washer of rear window (31) lower
(1) Engine start switch (2) Heating and
wiper and washer of front window (32)
air conditioning control (3) blade
wiper and washer of front window (33)
buffering control (4) cigarette igniter
blade lighting(34)snow blade side
(5) interior top lights switch (6)
plate lighting (35) auxiliary reverse
direction indicator and warning flasher
light (36) front defrost fan (37) rear
control (7) diethyl ether auxiliary start
defrost fan (38) warning signal light
switch (8) low beam work light (9)
(39) steering column tilting control (40)
instrument light, rear light and driving
steering wheel tilting control
light (10) head light modulator switch

(11) transmission control and parking


Engine start switch (1)

brake control (12) service brake When the engine start switch (1) is

control (13) throttle control (14) turned to ON position, it will feed

throttle speed switch (15) throttle electricity to the cab system.

mode switch (16) central frame lock Stop(OFF) - When inserting or

control (17) central frame side shift removing the engine start switch key, it

control (18) articulation turning control must be at the OFF position. To

(19) snow plow /moldboard lift control disconnect the current in the cab, turn

(if equipped) (20) moldboard angle the engine start switch to OFF position,

control (if equipped) (21) wheel and the engine will also be stopped.

tilting control (22) right end blade lift Work – To supply current to the cab,

control (23) blade side shift handle turn the engine start switch clockwise

(24) left end blade lift control (25) to ON position.

Start – To start the engine, turn the

Caterpillar: Confidential Green 35


start switch key clockwise to the medium fan speed.

START position. The key will H - The highest fan speed.

automatically return to ON position Operation of the heater and air

when it is released. conditioning system

Note: if the engine cannot be started, The heater and air conditioner have

be sure to turn the engine start switch four functions.

to OFF position before restarting the Heating – Turn the switch (2B)

engine. to L, M, or H position. Adjust the

Heater and air conditioner controller (2A) to achieve the required

temperature.
Control (2)
Air conditioning - Run the air
Temperature controller (2A)
conditioning system. Turn the switch(2B)
Temperature controller (2A) - Turn
to L, M, or H position. Adjust the
the switch from OFF position(left) to
controller (2A) to achieve the required
the MAX. position (right) to control the
temperature.
level of warm/cool air.
Pressurization - Pressurize the cab
Fan speed switch (2B)
when the air conditioner is not used to
Fan speed switch (2B) - The fan
prevent dust entering the cab. Turn the
speed switch has 3 speed gears.
controller (2A) to achieve required
Stop (OFF) – the fan will stop when the
temperature. Turn the controller (2B) to
switch is turned to OFF position.
L, M, or H position to keep dust off .
Heater - Turn the switch to the right to
Defrosting – Run the air
start the heating system.
conditioning system. Turn the switch
Air conditioner - Turn the switch to
(2B) to L, M, or H position.
the left to start the air conditioning
Eliminating the moisture in the cab with
system.
required speed. And it can avoid the
L – Low speed (39) – The lowest
moisture condensing on the
fan speed.
windscreen and the windows. Adjust
M – Medium speed (38) – the
the controller (2A) until the moisture is

36 Caterpillar: Confidential Green


reduced and there is comfortable the interior top light. Press the half

temperature in the cab. switch (5) to turn off the interior top

Blade buffering control (3) light.

The blade buffering control (if Direction indicator (6)


equipped)is located on the control Direction indicator

panel of transmission, left to the Left direction indicator – Press down

operator. Though the amount of the controller (6) to turn on the left

switches may be different, he control direction indicator. Press down the

(switch) is always located left to the controller (6), the indicator on the front

center. instrument panel will be illuminated.

Blade buffering control - Turn the The direction indicator will be kept on

switch to the upper position to run the until the controller (6) is turned to OFF

blade buffering device. And turn the position manually.

switch to the lower position to close the Stop (OFF) - Turn the the controller (6)

blade buffering device. to the middle position to turn off the

Cigarette igniter(4) direction indicator.

Right direction indicator - Push the


Cigarette igniter (4) – Push the igniter
controller (6) up to turn on the right
forward, and then release it. The
direction indicator. Push the controller
igniter will popup if it can ignite. The
(6) up, and the indicator on the front
igniter (4) can also be used as the
instrument panel will be illuminated.
24V power connection. And the power
The direction indicator will be kept on
socket can be used to feed the
until the controller (6) is turned to OFF
electrical equipment or the
position manually.
attachment. Remove the cover before

using it. Auxiliary start switch (7)

Interior top light (5) Diethyl ether auxiliary start switch (if

equipped) – The diethyl ether auxiliary


Interior top light switch (5) – Press the
start (switch) is needed when working
half switch (5) at the back to illuminate

Caterpillar: Confidential Green 37


at cold weather. When starting the light switch (9) - Press down the upper

engine, press down the bottom of the side of the switch (9), the instrument

switch (7), make the required amount light, rear light and driving light will be

of diethyl ether inject into the intake illuminated. Press the switch (9) to the

pipe. Release the switch(7), it will middle position, the instrument light,

return to the neutral position. rear light and driving light will be turned

Note: If the temperature is below 0 °C off. Press down the lower side of the

(32°F), the diethyl ether will switch (9), only the instrument light and

automatically inject into the engine. If rear lights will be illuminated.

the temperature is above 0 °C (32 °F), Head light modulator (10)


the diethyl ether will not inject into the
Head light modulator switch (10) –
engine.
Press down the switch (10) , the head
Note: When starting the engine, only the
light will be changed to high beam light.
diethyl ether is injected. Use small
Push the switch (10) up, the head light
amount of diethyl ether. Too much
will be changed to low beam light.
diethyl ether will damage the piston and
Transmission control and
piston ring. Only use diethyl ether to

start at cold weather. parking brake control (11)

Low beam work light (8) The control handle (11) controls the

transmission and parking brake at


Low beam light switch(8) (if equipped)
the same time.
– Press down the upper side of the
Transmission control
switch (8), the low beam work light is
Note: The handle (11) should be placed
illuminated. Press down the lower side
to the neutral position only when it is
of the switch (8), the low beam work
moved away from the engaged
light is turned off.
position of parking brake.
Instrument light, rear light
Forward – Turn handle (11) to the
and driving light (9) left, and then pull it back to the

Instrument light, rear light and driving required forward gear. Thus the

38 Caterpillar: Confidential Green


machine will move forward. reduce the ground speed to avoid

Neutral – Turn handle (11) to the machine damage.

neutral position in order to park the

machine. Note: When changing to a lower gear,

Reverse – Turn handle (11) to the there is the gear-down protection.

right, then pull it back to the required Suggested procedures are listed

gear. Thus the machine will move below:

backward. 10. Downshift a gear at a time. When

Change direction and speed the machine downshifts under load,

1. Turn the handle for a round to first increase the engine speed so that

check its operation function. the engine speed will be similar with

2. Ensure that the throttle control is at the original speed after downshift.

the low idling position. 11. When changing the travel direction,

3. Engage the variable speed use service brake to slow down the

adjuster. machine, engage the variable speed

4. Lift all the tools. adjuster control to stop the machine.

5. Engage the service brake. Then move the transmission control

6. Move the transmission control (handle) (15) to the required direction

(handle) (11) to the required direction and speed gear. Then release the

and speed gear. service brake and the variable speed

7. Release the speed adjustor. adjuster control (pedal).

8. Press down the throttle control Note: when there are failures in the

until the required speed is achieved. transmission solenoid valve or gear

9. Each time change to a higher gear, sensor, choose the “Limp Home”

the engine speed should be mode. Use the following procedures in

increased as required. this case.

If there is a problem with the gear

Note position sensor, it means that not all

When changing to a low gear, first the solenoid valves work normally and

Caterpillar: Confidential Green 39


only the gears can be used that the damaged if it is used as a service

solenoid valves work normally. Move brake.

the transmission control to the neutral

position, and then move it to the

Forward or Reverse position. Not all Caution

the speed gear can work. If moving the machine when the

Parking brake control parking brake is engaged, the brake

will be excessively worn or damaged.


The sudden stop of the machine may
Repair the brake before operating the
cause personal injury. If the pressure of
machine if necessary.
brake system is lower than normal

work pressure, the movement alarm


The transmission control (handle)(11)
will sound. Besides, the brake warning
is located at the right side of the
indicator on the instrument panel will
operator inside the cab.
also flash and so will the movement
The parking brake (11) is controlled by
signal light.
the handle. When the machine stops,
If the pressure continues to fall, the
engage the parking brake.
parking brake will automatically
To engage the parking brake, press
engage. Do some preparations for the
down the upper side of the handle (11)
sudden stop. Find out the reasons of
and push it to the engaged position of
pressure loss, and solve the problem.
parking brake at the same time. When
Do not move the machine under
lossening the handle(11), the parking
abnormal brake pressure.
brake will keep engaged.

To release the parking brake, press the


Caution
upper side of handle (11) and pull it
Do not engage the parking brake
back at the same time. Then the
when the machine is travelling,
handle (11) will not be at the engaged
unless the service brake fails to work.
position of parking brake. When
Under normal work conditions, the
loosening the handle(11), the parking
parking brake will be severely
40 Caterpillar: Confidential Green
brake will keep released. Restore/slow down - when the

Service brake control (12) switch(15) is not at the OFF position,

press switch(14) backward to reduce


Press down pedal (12), the service
engine by 100r/s. press switch(14)
brake will be engaged. Engage the
backward and keep it pressed to
service brake to reduce ground speed.
reduce engine speed by 700r/s. When
Apply the service brake to stop the
the switch (15) is at Automode, press
machine.
switch (14) backward to restore engine
Loosen pedal(12) to release the
speed to the original set value.
service brake.
Fixed throttle mode switch
Throttle control (13)
Press down pedal (13) to increase (15)
engine speed. When loosening pedal This is a 3-position switch (15) which

(13), the engine speed will be restored can be used to set fixed throttle modes

to the set value of throttle. Loosen including the AUTO, OFF and

pedal (13) to reduce engine speed. MANUAL modes.

Throttle speed switch (14) MANUAL mode – Press switch(15)

backwards to place the throttle control


Use the switch (14) to set throttle
at Manual mode. Use the throttle pedal
speed. Operate the switch (14) to
to achieve required engine speed.
change engine speed according to the
Press the switch (14) forward to set the
need.
throttle at the current engine speed.
Setting / Speed up – when the
Use switch(14) to change the throttle
switch(15) is not at the OFF position,
settings.
press switch(14) forward to set engine
If the throttle pedal is pressed too
speed. Press the switch (14) forward
much that it exceeds the throttle setting,
again to increase engine speed by
then the engine will speed up. When
100r/s. Press switch(14) forward and
releasing the pedal, the engine speed
keep it pressed to increase the engine
will recover to the set speed. The fixed
speed by 700 r/s.

Caterpillar: Confidential Green 41


throttle will not be released under unlocked.

below conditions: When removing the lock pin of central

· The service brake is pressed frame, the sudden move of blade may

down. cause personal injury. Therefore,

· The throttle pedal is moved. before removing the lock pin, ensure

The fixed throttle will be released that there is no people at the blade

under any of the below conditions: area; that the central frame and blade

· Move switch (15) to OFF position. are centered with the machine body;

· Turn switch key to OFF position. and that the blade has been lowered to

When the fixed throttle is released, the the ground.

restore function will not work. 1. Use the central frame control handle

Under Manual mode, if the throttle is (18) to move the traction frame to the

fixed, the fixed throttle indicator will be place which need to be graded. Move

illuminated. the lifting handles at the both sides to

OFF mode – Press the switch (15) to the floating position, and lower the

the middle position, and this will keep blade to the ground.

the throttle switch at the OFF position. 2. Move the switch (18) to the release

If the switch(15) is at the OFF position, position, and the indicator on the

the AUTO and Manual modes will not instrument panel will be illuminated.

work. Only the throttle pedal works 3. To move the connection bracket to

under OFF mode. the 1st or 2nd hole of any side outside

Central frame lock control the center, please follow the step 3.a.

To move the connection bracket to the


(16)
3rd or the 4th hole of any side outside
The central frame lock control – Move
the center, please follow the step 3.c.
switch (16) to the bottom position to
a. Ensure that the two blade lifting
lock the central frame. Press down the
handles are still at the floating position.
lock pin, and move the switch (16)
Move the central frame control handle
upward, then the central frame will be
(18) to the opposite side, which will

42 Caterpillar: Confidential Green


keep the traction frame at step 1. If the Central frame, right shift– To move

central frame cylinder moves, the the central frame to the right, move the

connection device will move freely. handle (17) backward. When handle

Besides, the linkage can move at the (17) is released, it will return to the

side surface. fixed position.

b. Continue to follow step 4. Fastening - When handle (17) is

c. Move the blade lifting handle away released, it will return to the fixed

from the floating position. position.

d. At the same time, move the central Central frame, left shift -To tilt the

frame control handle (18) forward, and central frame to the left, move handle

also move the right blade lifting handle (17) forward. When handle (17) is

(23) forward. Meanwhile pull the left released, it will return to the fixed

blade lifting handle (26) backward. position.

4. Align the lock pin of central frame Articulation control (18)


with the hole on the linkage. Use the
Articulation, right shift– To move the
indicator on the right lifting bracket to
rear of the machine to the right, pull
check the alignment.
handle (18) backward. When handle
5. Move the switch (18) to the engaged
(18) is released, it will return to the
position. When the lock pin of central
fixed position.
frame is is folded, the indicator of
Fastening - When handle (18) is
central frame lock will turn off.
released, it will return to the fixed
Note: If the indicator of central frame
position.
lock does not go out, slightly move the
Articulation, left shift - To move the
linkage to align the lock pin with the
rear of the machine to the left, pull
hole.
handle (18) forward. When handle (18)
6. Side shift the linkage to the place
is released, it will return to the fixed
that need to be graded. Use the blade
position.
lifting cylinder to adjust the work angle.
Snow plow/ moldboard lift
Central frame control (17)
Caterpillar: Confidential Green 43
control (19) (if equipped) backward. When handle (21) is

released, it will return to the fixed


Lowering - move handle (19) forward
position.
to lower the snow plow/ moldboard.
Fastening - When handle (21) is
When handle (19) is released, it will
released, it will return to the fixed
return to the fixed position.
position.
Fastening - When handle (19) is
Wheel tilting, left – To tilt the wheels
released, it will return to the fixed
to the left, move the handle (21)
position.
forward. When handle (21) is released,
Lifting - move handle (19) backward to
it will return to the fixed position.
lift the snow plow/ moldboard. When

handle (19) is released, it will return to Right end blade lift (22)
the fixed position. Blade, lifting - Move handle (22)

Moldboard angle control (20) backward to lift the right end of blade.

When handle (22) is released, it will


(if equipped)
return to the fixed position.
Right – Move handle(20) backward to
Fastening - When handle (22) is
make the moldboard turn right. When
released from the lowering or lifting
handle (20) is released, it will return to
position, it will return to the fixed
the fixed position.
position.
Fastening - When handle (20) is
Blade, lowering - Move handle (22)
released, it will return to the fixed
forward to lower the right end of blade.
position.
When handle (22) is released, it will
Left - Move handle(20) forward to
return to the fixed position.
make the moldboard turn left. When
Blade side shift handle (23)
handle (20) is released, it will return to
Blade side shift, right- Move handle
the fixed position.
(23) backward to side shift the blade to
Wheel tilting control (21)
the right. When handle (23) is released,
Wheel tilting, right - To tilt the wheels
it will return to the fixed position.
to the right, move handle (21)
44 Caterpillar: Confidential Green
Fastening - When handle (23) is When handle (25) is released, it will

released, it will return to the fixed return to the fixed position.

position. Fastening - When handle (25) is

Blade side shift, left - Move handle released, it will return to the fixed

(23) forward to side shift the blade to position.

the left. When handle (23) is released, Lowering - Move handle (25) forward

it will return to the fixed position. to lower the snow blade feather plate.

Left end blade lift (24) When handle (25) is released, it will

return to the fixed position.


Blade, lifting - Move handle (24)

backward to lift the left end of blade. Snow blade feather plate
When handle (24) is released, it will tilting control (26) (if
return to the fixed position.
equipped)
Fastening - When handle (24) is
Note: as multiple tools can be mounted
released from the lowering or lifting
on the connecting device of the
position, it will return to the fixed
machine, the controller position on
position.
your machine may be different.
Blade, lowering - Move handle (24)
Lifting - Move handle (26) backward to
forward to lower the left end of blade.
tilt the snow blade feather plate upward.
When handle (24) is released, it will
When handle (26) is released, it will
return to the fixed position.
return to the fixed position.
Snow blade feather plate lift
Fastening - When handle (26) is
control (25) (if equipped) released, it will return to the fixed

Note: as multiple tools can be mounted position.

on the connecting device of the Lowering - Move handle (26) forward

machine, the controller position on to tilt the snow blade feather plate

your machine may be different. downward. When handle (26) is

Lifting – Move handle (25) backward to released, it will return to the fixed

lift the snow blade feather plate. position.

Caterpillar: Confidential Green 45


Ripper/scarifier control (27) position.

Blade turntable handle (29)


(if equipped)
Turntable, clockwise – Move handle
Ripper/scarifier, Lifting – Move
(29) backward to make the blade rotate
handle (27) backward to lift the
clockwise. When handle (29) is
Ripper/scarifier. When handle (27) is
released, it will return to the fixed
released, it will return to the fixed
position.
position.
Fastening - When handle (29) is
Fastening - When handle (27) is
released, it will return to the fixed
released, it will return to the fixed
position.
position.
Turntable, counterclockwise - Move
Ripper/scarifier, Lowering – Move
handle (29) forward to make the blade
handle (27) forward to lower the
rotate counterclockwise. When handle
Ripper/scarifier. When handle (27) is
(29) is released, it will return to the
released, it will return to the fixed
fixed position.
position.
Window wiper/washer
Blade angle control handle
switch (30, 31,32)
(28)
Wiper and washer of rear window
Blade angle, forward – Move handle
(30) – Turn the switch(30) clockwise to
(28) forward to tilt the top of blade
activate the wiper. Turn the switch (30)
forward. When handle (28) is released,
counterclockwise to stop the wiper.
it will return to the fixed position.
Press down the switch (30) to activate
Fastening - When handle (28) is
the washer. When releasing the switch,
released, it will return to the fixed
it will restore to the original position
position.
under the spring force.
Blade angle, backward - Move handle
Lower wiper and washer of front
(28) backward to tilt the top of blade
window (31) - Turn the switch(31)
backward. When handle (28) is
clockwise to activate the wiper. Turn
released, it will return to the fixed
46 Caterpillar: Confidential Green
the switch (31) counterclockwise to Auxiliary reverse light (35) (if

stop the wiper. Press down the switch equipped) - Press the top of the switch

(31) to activate the washer. When (35), and the reverse lights will be

releasing the switch, it will restore to illuminated under Manual mode. When

the original position under the spring the switch is at the Manual mode, the

force. auxiliary reverse light will always be

Wiper and washer of front window illuminated. Press the bottom of the

(32) - Turn the switch(32) clockwise to switch (35), and the auxiliary reverse

activate the wiper. Turn the switch (32) light will work under Auto mode. The

counterclockwise to stop the wiper. auxiliary reverse light will be

Press down the switch (32) to activate illuminated when the transmission

the washer. When releasing the switch, control lever moves to any reverse

it will restore to the original position gear. Move handle (35) to the middle

under the spring force. position, and the auxiliary reverse light

Blade lighting (33) will be turned off.

Blade lighting (33) (if equipped) - Defrost fan control (36, 37)
Press the top of the switch (33) to The defrost fan adopts 3-position

illuminate the blade light. Press the switch.

bottom of the switch (33) to turn off the Front defrost fan (36) – Press the

blade light. switch (36) to the middle position, and

Snow blade feather plate the defroster fan will run at low speed.

Press the top of the switch (36), and


lighting (34)
the defroster fan will run at high speed.
Snow blade feather plate lighting (35)
Press the bottom of the switch (36), the
(if equipped) - Press the top of the
fan will be turned off.
switch (34) to illuminate the snow
Rear defrost fan (37) - Press the
plow’s feather plate. Press the bottom
switch (37) to the middle position, and
of the switch (34) to turn off the light.
the defroster fan will run at low speed.
Auxiliary reverse light (35) Press the top of the switch (37), and

Caterpillar: Confidential Green 47


the defroster fan will run at high speed.

Press the bottom of the switch (37), the

fan will be turned off.

Warning signal light (38)


Warning signal light (38) (if

equipped) - Press the top of the switch

(38) to activate the rotary warning light.

Press the bottom of the switch (38) to

turn off the warning light.

Steering column tilting

control (39)
Press the steering column tilting

control (handle) (39), move the

steering column forward/backward to


Operation Technology
adjust the angle of steering column. To avoid personal injury, ensure that

Release the handle (39), the steering there is no people on or around the

column will still be kept at the required machine, and keep control of the

position. machine at any time.

Do not operate the machine until there is


Steering wheel tilting
normal pressure in the pressure system.
control (40)
Fasten the seatbelt.
Press the tilting control (40) to adjust
The blade must be lowered to the ground
the angle of steering wheel. And move
before removing the lock pin of central
the seat to proper position at the same
frame.
time. Loosen the tilting control (40),
When going down the slope, do not
and the headrest will be kept at the
disengage the transmission. And do not
required position.
make the machine run with neutral gear.

And also do not use the transmission

48 Caterpillar: Confidential Green


adjuster when going down the slope. straight travel.

3. Continue to make grading operation.


Angled steering
Straight steering
Caution Note: If necessary, the machine can run

To avoid drive system damage, the across ditches when it is turning. Use

differential must be unlocked before small angle to drive the machine

running or steering the machine. And backward to cross the ditch.

keep the differential unlocked until 1. When the machine is to turn right

the machine makes straight travel. during forward travel, slightly adjust the

front wheels to the right side and then

Note: the articulation is easier when the turn the wheels to the steering direction.

machine is moving. When the machine is to turn left during

forward travel, slightly adjust the front

wheels to the left side and then turn the

wheels to the steering direction.

2, When the machine turns during

forward travel, the travel distance should

be as for as possible. Then stop the


1. When the machine starts to turn, turn
machine.
the steering wheel to the left and the
3. Turn the front wheels to the opposite
rear of the machine will swing to the left.
direction. Then reverse the machine.

And the reverse distance should be

sufficient to swing the machine to the

required direction. And then stop the

machine.

4. Turn the wheels to the new travel


2. After the turn, turn the steering wheel
direction, and continues to turn the
to the right, and the rear of the machine
machine.
will swing back until the machine makes
5. After the turning, turn the wheels

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straight. Continue the movement. reduce the labor work.

Exit the slope or ditch

1. Grading near obstacles.


1. Stop the machine, lift the blade and

tools.

2. Move the blade slowly off the

2. When the machine reverses slowly, obstacles and move it along the

swing the rear of the machine to road obstacles.

center. 3. Move the blade slowly into the

obstacles and move it along the edge of

obstacles.

3. When the machine reverses slowly,

swing the front wheels to the travel

direction.

4. Continue to reverse the machine until


4. Restore the blade to the original
it exits the slope or ditch.
position after crossing the obstacles.
Grading near obstacles
S- shape curve grading
Note: Try to work near the obstacles

during the grading operation, so as to


Caution
50 Caterpillar: Confidential Green
In order to avoid piercing the tyre, do right through the control lever of central

not make the blade touch tyres when frame. Then engage the central frame

the machine swings. lock.

2. Set the blade to make the cut

materials stack to the outside of right


1. Swing the machine to the left. And
wheels.
move the blade to the right.

3. Horizontally lower the blade to the


2. Move the wheels straight. And Side
required cutting depth. Tilt the front
shift the blade when necessary.
wheels to the right to offset the side shift.

3. Swing the machine to the right. And


4. Adjust the blade angle to the optimal
side shift the blade to the left.
position according to the soil property.
Left side grading First adjust the top of the blade and

1. Unlock the central frame. Move the make it 100 mm (4 inches) in front of the

traction frame 200 mm (8 inches) to the cutting edge.

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5. Under good work conditions, the

grading operation can be performed

easily from one side to the other side.

6. Pave the loose materials on the road

until the road surface is smooth.

Under normal conditions, the grading


2. Set the blade to make the cut
work should be performed with straight
materials stack to the outside of left rear
machine body. The machine body can be
wheel.
angled to offset the side shift caused by

the load generated in deep cutting. Turn

the front wheels which are tandem driven

to the rear cutting edge of the blade.

If the wheels begin to slip, turn the

tandem driven front wheels away from 3. Horizontally lower the blade to the

the rear edge of the blade. Thus the required cutting depth. Tilt the front

grading width is reduced which leads to wheels to the left to offset the side shift.

reduced machine load.

Under normal grading work, the scraped

materials are extracted to the outside of

rear wheels, which keeps the rear wheel

surface smooth.

Right side grading 4. Adjust the blade angle to the optimal

1. Unlock the central frame. Move the position according to the soil property.

traction frame 200 mm (8 inches) to the First adjust the top of the blade and

left through the control lever of central make it 100 mm (4 inches) in front of the

frame. Then engage the central frame cutting edge.

lock. 5. Under good work conditions, the

grading operation can be performed

easily from one side to the other side.


52 Caterpillar: Confidential Green
6. Pave the loose materials on the road

until the road surface is smooth. When removing the lock pin of central

Under normal conditions, the grading frame, the sudden blade movement

work should be performed with straight may cause personal injury.

machine body. The machine body can be Ensure that there are no persons

angled to offset the side shift caused by around the blade when removing the

the load generated in deep cutting. Turn lock pin. In addition, the turntable and

the front wheels which are tandem driven blade must restore to the central

to the rear cutting edge of the blade. position under the machine. Place the

If the wheels begin to slip, turn the frame straight and lower the blade to

tandem driven front wheels away from the ground.

the rear edge of the blade. Thus the

grading width is reduced which leads to 1. Set the linkage position to keep the

reduced machine load. lock pin of central frame at the central

Under normal grading work, the scraped hole. Turn the switch to lock the central

materials are extracted to the outside of frame.

rear wheels, which keeps the rear wheel

surface smooth.

Scraping left side V-shape

ditch

Caution 2. Set the blade, swing the left blade

If the machine swings, the tyre edge and make it level with the left tyre

sidewalls may press the slope and get rim of front wheels. Tilt the blade forward

damaged. At the same time, soils will and make the upper of blade slightly in

be pressed into the gap between tyre front of the cutting edge.

and rim and cause a flat tyre. 3. Lift the right side of blade to the

highest position. Adjust the blade angle

and make the materials extracted stack

Caterpillar: Confidential Green 53


to the inner side of the right rear wheel.
Scraping right side of

V-shape ditch
1. Set the linkage position to keep the

lock pin of central frame at the central

hole. Turn the switch to lock the central

frame.
4. Lower the left side of blade and place

the cutting edge to the required cutting

depth.

2. Set the blade, and make the right

blade edge level with the right tyre rim of

front wheels. Tilt the blade forward and

make the upper of blade slightly in front

5. Tilt the front wheels to the right side. of the cutting edge.

First cut a shallow layer of soil, about 3. Lift the left side of blade to the highest

50~100mm (2~4 inches). position. Adjust the blade angle and

make the materials extracted stack to the

inner side of the rear wheels.

6. Keep the left tyre of front wheels at the

bottom of the ditch. And continue to cut

the ditch until the required cutting depth 4. Lower the right side of blade and place

is achieved. the cutting edge to the required cutting

depth.
54 Caterpillar: Confidential Green
for the detailed instructions about the

central frame lock, please refer to

“Central Frame Lock”, Operation &

Maintenance Manual.

2. When scraping back slope at the right

side, the lock pin of central frame should

5. Tilt the front wheels to the left side. insert in the last hole of the left side.

First cut a shallow layer of soil, about While scraping the back slope at the left

50~100mm (2~4 inches). side, the lock pin of central frame should

insert in the last hole of the right side.

3. Use the central frame handle to move

the traction frame to the slope surface of

the ditch.

4. Lower the blade to the ground. Tilt the

blade to the middle position of the angle

6. Keep the right tyre of front wheels at range. Tilt the blade forward to make

the bottom of the ditch. And continue to deep scraping operation. Tilt the blade

cut the ditch until the required cutting backward to scrape thin soil layers.

depth is achieved. 5. Use the blade lift lever to swing the

Ditch backfill linkage to the required position.

Note: the procedure is for right side road 6. Insert the lock pin of central frame.

surface. 7. Extend the central frame cylinder to

Note: when scraping the back slope of the required extent.

ditches, the ditch and road shoulder

must be tidy and smooth. Coarse surface

may cause great effect to the front edge

of the blade.

1. Use the central frame lock controller to


8. Turn the turntable to the left.
detach the lock pin of central frame. As

Caterpillar: Confidential Green 55


the depth of the flat ditch that need to be

scraped.

Note: The road shoulder slope should be

milder than normal road shoulder slope.

And the road shoulder slope must be

made to the end of road shoulder.


9. Tilt the blade forward.
1. Tilt the blade forward.
10. While the turntable rotates, lower the
2. Locate the connection bracket, and
left blade edge.
insert the lock pin of central frame in the
11. Place the rear edge of blade in front
first hole to the left of the central hole.
of the right rear wheel.
Turn the switch to lock the central frame.
12. Lower the right side of blade to set

the slope degree.

Note: The wheels should be placed at

nearly vertical position under normal

conditions.

13. When performing deep cutting

operation, tilt the front wheels towards 3. Place the right front wheel at the

the slope side. Tilt the front wheels off bottom of V-shape ditch.

the slope side to make thin layer

scraping.

Grading flat ditches

4. Locate the blade, place the front edge

of blade at the wheelmark of the right

front tyre, and make it scrape as per the

required width at a time.


If there is no V-shape ditch, then cut one.
5. Lower the right blade edge to the
The depth of V-shape ditch is the also

56 Caterpillar: Confidential Green


required depth.

6. Lift the left edge and place it according 12. Set the linkage position to keep the

to required road shoulder slope. lock pin of central frame at the central

7. Tilt the front wheels to the left. hole position. Turn the switch to lock the

8. Cut the V-shape ditch again, and central frame.

make it slightly higher or the same depth

with the prior cut.

9. Discharge the soil to the center of road

surface.

13. First place the right front tyre at the

bottom of the prior cut V-shape ditch.

10. Lower the right blade edge to the

required depth.

11. Lower the left blade edge to the

required depth.
14. Place the right blade edge at the

bottom of back slope.


When removing the lock pin of central

frame, the sudden blade movement

may cause personal injury.

Ensure that there are no persons

around the blade when removing the

lock pin. In addition, the turntable and

blade must restore to the central


15. Lower the right blade edge and place
position under the machine. Place the
the cutting edge properly across the cut
frame straight and lower the blade to
slope.
the ground.

Caterpillar: Confidential Green 57


16. Lower the left blade edge to the

required depth. Tilt the front wheels to

the left.

4. Set the right end position of the blade

to make the scraped materials stack at

the slope between the tandem wheels of

17. Place the blade at a small angle, and both sides.

discharge the materials to the ditch 5. Slightly tilt the front wheels to the right.

slope. 6. Scrape again and pave the scraped

18. Pave the materials stock and finish soils on the slope and road shoulder.

the grading work. Pave the materials level and make the

final grading operation.


Clearing left side ditch
1. Set the linkage position to keep the Clearing right side ditch
lock pin of central frame at the central 1. Set the linkage position to keep the

hole position. Turn the switch to lock the lock pin of central frame at the central

central frame. hole position. Turn the switch to lock the

central frame.

2. Place the left side of blade at the back

of left front wheel. 2. Place the right blade edge at the back

3. Lower the left side of blade to set the of right front wheel.

cutting depth.

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3. Lower the right blade edge to set the 2. Align the left blade edge with the left

cutting depth. tyre rim. And the soils must be

discharged between the two wheels.

3. Lower the blade, keep it at level

position and required depth.

4. Slightly tilt the front wheels to the right.

Clearing right road shoulder


4. Set the left end position of the blade to 1. Set the linkage position to keep the

make the scraped materials stack at the lock pin of central frame at the central

slope between the tandem wheels of hole position. Turn the switch to move

both sides. the lock position of the central frame to

5. Slightly tilt the front wheels to the left. the engaged position.

6. Scrape again and pave the scraped

soils on the slope and road shoulder.

Pave the materials level and make the

final grading operation.

Clearing left road shoulder


1. Set the linkage position to keep the 2. Align the right blade edge with the

lock pin of central frame at the central right tyre rim. And the soils must be

hole position. Turn the switch to lock discharged between the two wheels.

the central frame. 3. Lower the blade, keep it at level

position and required depth.

4. Slightly tilt front wheels to the left.

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Building road by flat ditch
Note: the procedures below are used for

grading operation at one road side.


7. Grading the road shoulder and the
While operating at the other side, repeat
road surface for the last time.
the procedures.
Build road by V-shape ditch
Note: the procedures below are used for

grading operation at one road side.

1. Scraping the inner slope. While operating at the other side, repeat

the procedures.

2. Cut the left side ditch to the ditch

bottom according to the bottom width.


1. Cut slightly to mark the outline of the
3. Scrape clean the road shoulder. And
ditch.
pave the soils in the middle of the road.

2. Then cut deeper.


4. Scraping the slope surface of the

embankment.

3. Cut for the third time, deeper than the

second time.

5. Scraping the ditch bottom. And clear

the ditch.
4. Twist the machine to clear the road

shoulder. Bulldozing and pave the soils

to the road center.

6. Clear the inner side of the slope.

60 Caterpillar: Confidential Green


5. Twist the machine for the fourth deep 11. Cut for the last time to form the road

cutting. Scraping the road shoulder shoulder.

clean.

6. Turn the machine in line and pave the

soil pile to the road center.


12. Pave the soil pile and finish the road

building work.

Grading wet ditch


7. Cut the outer side of the ditch to form

the slope, and increase the height of side

slope surface.

8. Clear the bottom of the ditch. Twist the machine, and place the front

wheels and the blade at the ditch. Use

the front wheels to steer.

9. Cut on the ditch bottom to clear the

inner side of the slope and form the inner

side of slope.

The wet mud and loose soil in the ditch

10. Cut for the last time to finish the will make the wheels slip. Keep the rear

slope forming. wheels at the road shoulder to avoid

slipping.

Note: there may be obstacles in the old

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ditch, such as branches and stones. cut surface. To obtain the max stability,

When clearing an old ditch, avoid the twist the machine body to make balance

obstacles by these methods. compensation.

Grading on the slope of 3: 1

When working under the steep side

slope, you must know the machine’s

performance well.

Do not twist the machine too much When the blade encounters heavy load,

when operating uphill or at steep which makes the front of the machine

slope. slide away, handle the condition by


When working under steep side slope, torsional steering.
the machine may roll over and cause
Cutting right side slope
personal injury or death.

When removing the lock pin of central


Note: When working on steep slope, the
frame, the sudden move of blade may
machine must be operated at the first
cause personal injury.
gear or at reduced engine speed. And
Therefore, before removing the lock
use the accelerator to control the speed.
pin, ensure that there is no people at

the blade area. The turntable and

blade must be aligned straightly with

the center position under the machine

body. Align the frame straight and lower

the blade to the ground.

When working at steep slope, operate

the machine by torsional steering. The Note: This procedure is used for the soil

torsional steering method can keep the pile at the right side. Place the blade to

rear of the machine at the bottom of the the other side to handle the soil pile at

62 Caterpillar: Confidential Green


the left side.

6. Turn the turntable clockwise, and

lower the left blade edge at the same


1. The surface of road base must be kept
time.
at the same level.

7. Place the rear blade edge at the

bottom of the ditch. And swing it to the


2. If the soil pile is hard, tilt the slope of
position which is level with the outside of
road base slightly towards the soil pile,
the rear wheel.
so as to avoid slipping away from the soil

pile.

3. Tilt the blade forward, the tilting

distance should be 3/4 of the whole tilting

range, or just tilt the blade to the

complete tilting range.

4. Locate the linkage, insert the lock pin 8. The right rear tyre should be at the

of the central frame into the utmost right slope base of V-shape ditch.

hole. Turn the switch to lock the central 9. Lower the right end of blade and

frame. adjust the blade to the proper angle for

5. Side shift the blade to the right. the required slope.

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Before loosening the lock pin of the

central frame, ensure that there are no

people around the machine. Restore the

turntable and blade to the center under

the machine, and then lower the blade


10. Gradually move the blade into the
onto the ground.
cutting surface.
1. Locate the linkage, insert the lock pin
Note: Normally, the wheels should be
of the central frame into the utmost right
nearly vertical with the cutting surface.
hole. Turn the switch to lock the central
11. When performing deep cutting, tilt
frame.
front wheels towards the slope.
2. Side shift the moldboard to the right
12. When performing shallow cutting, tilt
end. As for the detailed instructions,
front wheels towards the opposite side of
please refer to “Moldboard”, Operation &
slope.
Maintenance Manual.
The soil is discharged from the slope to
3. Lower the blade to the required depth.
the outer side of rear wheels.
Adjust the blade angle properly. Tilt the
Moving to the side edge
blade forward to push the soil from the

side.
When removing the lock pin of central
Note: To reach the left end, insert the
frame, the sudden blade movement
lock pin of central frame to the opposite
may cause personal injury.
side, and then side shift the moldboard to
Ensure that there are no persons
the left end.
around the blade when removing the
Ripper
lock pin. In addition, the turntable and While performing ripper operation, use

blade must restore to the central the first gear speed. It is better to use

position under the machine. Place the more ripper blades than running at high

frame straight and lower the blade to speed.

the ground. Use the reducer to match the traction

64 Caterpillar: Confidential Green


force of the tools and the current traction not recommended to place the ripper

force. Use the reducer to match the on the outside socket. When necessary,

traction force and ground conditions. And place the ripper shank to the highest

also use the reducer to avoid wheels position. Operate at low speed. The

slipping. main ripper frame can not withstand

Try to lower the ripper down deeply full power operation with the single

according to the ground conditions. shank ripper at the outside.

Sometimes only part of the ripper tools The multi-shank ripper is not suitable

can rip the soil deeply. Try to rip soil for deep ripping operation. Only use it

along the natural soil layer. at designated distance.

The size of ripped soil lumps depends on Use single-shank ripper for deep

the cutting depth of the ripper and the ripping operation.

blade intervals. Solid soil, hard ground, clay, shale,

Multi-shank ripper or bonding gravel

The multi-shank ripper features high 3-shank ripper works well under this

yield production, and it can be used at kind of soil condition, which can rip the

tough conditions like firm and solid soil soil to the required lumps. It’s better to

and less stones. It is used where at use the ripper with the maximum

least two shanks of ripper blades are number of shanks. However, the

required. When the utilization ratio of number of hilts can not be so much as

central single shank ripper is less than to hinder the machine.

20% during the whole operation Rocks with multi-cracks, fault, and

process, multi-shank ripper is joints

recommended. Use 2-shank ripper to break the rocks

The multi-shank ripper is not suitable into nubs. And the machine is easily

for rocky ground condition. The central controlled during the operation. When

single shank ripper are commonly used the machine is hindered or the tyre slips,

in rocky ground condition. it can only use central single-shank

When using the single-shank ripper, it ripper.

Caterpillar: Confidential Green 65


Hard rocks, granite, rigid aggregated 3. Move all the hydraulic control lever back
and force to release the pressure in the
rocks are not easily broken hydraulic system. Then restore the
Use single-shank ripper for cracked hydraulic control lever to the fixed position.

stones or not easily broken stones. Stop the engine when

electrical failures occur


Parking
Turn the engine start switch to OFF
Stop the machine position.
Place the machine at level ground. If it has

to be placed on the slope, block the wheels

firmly.

Move the throttle lever backward to reduce

engine speed.

Engage service brake to reduce the speed.

Use the transmission adjuster control lever


If the engine can not be stopped, lift the
to stop the machine.
cover of engine stop switch (1). Pull the
Place the transmission lever at
engine stop switch (1) to the STOP
NEUTRAL position.
position.
Engage the parking brake.
Turn the battery cutoff switch to the OFF
Lower the blade onto the ground and apply
position. Do not operate the machine
downward pressure slightly.
Stop the engine. unless the failures have been solved.
Note: While the engine is running under
load, it will cause overheating and wearing
Lower the working tools
of the engine parts if the machine is
immediately stopped. Please follow the
when the engine flames out
steps below to cool down the engine and
avoid oil coking caused by the overheating When lowering the equipment, ensure
of turbocharger housing. that there are no people around the
1. Stop the engine, and run it idling for 5 machine. Otherwise, it may cause
minutes. personal injury.
2. Turn the engine start switch to OFF
Note: if the engine does not work when the
position, and pull out the key.

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tools has not been lowered to the ground, relief valve.

take any of the following methods: Leave the machine


1. Use the stairs and handrails when
No lowering valve on the
getting off the machine. Face the machine
machine
and use both of your hands.

2. Check if there is scraps in the engine

compartment. Clear the scraps to prevent

fire.

3. Clear all the inflammable scraps at the

front bottom guard through the inspection

cover. And handle the scraps properly.

Diagram 1 4. Turn the battery cutoff switch to OFF


The pressure relief valve is mounted at the position. When not operating the machine,
tools control valve under the cab.
pull out the key to avoid short circuit of the

battery and prevent the battery from being

damaged. And it can also avoid electric

leakage caused by some parts.

5. Lock all the antitheft covers and all the

compartments.

Diagram 2
Hold the pressure relief valve (1) tightly,

and then loosen the locknut (2). Turn the

hex cap nut (3) counterclockwise slightly to

loosen it until the working tools are lowered

to the ground.

Note: do not let the tools descend too fast.


When the tools have been lowered to the
ground, remove the bushing chuck of
pressure relief valve. Install a new bushing
chuck or adjust the settings of pressure

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Remove the diethyl ether tank (If

equipped) which helps to start.

When the machine is transported to

colder places, make sure that there is


Machine proper antifreeze in the cooling

Transportation system.

1. Before loading the machine, block


Load and transport the
the wheels of the trailer or the rail car.
machine 2. When anchoring the machine,

Understand the height limits on the connect the frame retaining ring to

travel line. Make sure that the machine firmly secure the front and rear frame.

has enough moving space during In addition, cover the wheel tilting

transport. This is especially important locking device to fasten the front

to the machine installed with ROPS wheels at the straight position.

structure. 3. During transport, all the tools must

Before loading the machine onto the be lowered, and move the transmission

transport vehicle, clear the ice, snow, lever to the engaged position of

or other slippery objects on the loading parking brake.

platform and the compartment of 4. Turn off the engine.

transport vehicle to prevent the 5. Turn the engine starting switch to

machine from slipping during transport. the OFF position, and remove the key

of the switch.

6. Turn the battery cutoff switch to

the OFF position, and remove the key

of the switch.

7. Lock the door and covers. Install

all the protective facilities.


Note: Observe all the transport related
regulations (height, weight, width, and 8. Put wedges under the tyres and
length). And observe all the rules about
ensure that the machine is secured.
wide cargoes.
68 Caterpillar: Confidential Green
Caution charge the tyres to proper pressure.
If the turbocharger is running while
the engine stops, it will be damaged. When charging the tyres, use
To avoid turbocharger running self-prepared tyre holder or stand
during the transport, cover the vent
hole or fasten the rain cover. behind the tyre tread.

Check around the machine, and


9. User nut cap or rain cover to
cover the vent hole, and this can avoid measure the liquid level of each tank.
the turbocharger running during the Check with related officials to gain
transport.
necessary license and approval.
Check around the machine and
Drive at medium speed and observe all
measure the liquid level of each oil
the speed limits during transport.
tank.

Drive at medium speed and observe all Lifting and Fastening


the speed limits during transport.

About the load and transport of your


Caution
machine, please consult SEM agent. Incorrect lifting and fastening may
lead to load shift and cause
Travelling on Roads
personal injury and loss.
Please consult local agent about the

recommended tyre pressure and

speed limit, before operating the

machine.

Do observe the speed limit of ton-km/h

(ton-mile/h). Consult local tyre agent

about the speed limit of tyres you are

using.

Stop the machine periodically to cool

down the tyres and other parts during As for the basic technical parameters,
long distance transport. Stop the please refer to “Technical Parameters” ,
machine for 30 minutes every 40km Operation & Maintenance Manual.
(25miles) or every 30 minutes, and

Caterpillar: Confidential Green 69


Inappropriate hitching and towing is
Lifting point- Be sure to connect the
dangerous, which can cause
lifting device to the lifting point when lifting
personal injury or death.
the machine.

Fastening point - When attaching The towing connection must be


the machine, be sure to tie the rigging
secured, and use two sets of towing
to the fastening point.
machine which are of the same size
Lift the machine with proper steel rope
with or larger than the towed machine.
and lifting tools.
If using two towing machines, connect
Properly place the crane and lifting
each one to the towed machine. If
equipment so as to lift the machine
using only one towing machine, it must
horizontally.
be larger than the towed machine.
The expander bar must be wide
Before starting to work again, the
enough to avoid the steel rope
machine being towed to the repair
scratching the machine.
plant must be well repaired and
1. Install the frame locking pins first to
adjusted.
keep rigid articulation.
The towing instruction is applicable to
2. Attach 4 ropes to the expander bar.
the condition of moving the machine
The expander bar must be in the
which can not drive, for a short
center of the machine.
distance at low speed. Towing the
3. Lift the machine to the required
machine where it can be repaired
position.
conveniently at the speed of 2km/h or
4. When the machine is in place, place
lower. This is only for emergency
wedges in front of the wheels. And
situations. If the machine needs to be
then stuff wedges at the back of the
transferred to a far place, it must be
wheels when the machine is secured.
transported.
Towing Protective plates must be installed on

the two machines to protect the

70 Caterpillar: Confidential Green


operator in case that the traction rope When towing a undrivable machine

or towbar is broken. down the slope, the towing vehicle

The operator is not allowed to stay on must have effective control and brake

the machine being towed, unless the capability. Thus a larger towing vehicle

operator is able to steer or brake the or connecting an extra machine at the

machine. back of the towed machine may be

Before towing the machine, make sure needed to prevent the machine from

that the traction rope or towbar is in out of control and roll over.

good condition and has enough All the different situations can not be

strength to tow the machine. The listed here. On level ground, only the

intensity must be no less than 1.5 minimum traction force is needed. On

times the weight of the machine being slopes or rugged ground conditions,

towed. This is especially important for much larger traction force is needed.

towing the machine which is trapped in Lifting Jack Position


a mud pit or towing it uphill.
Inappropriate lifting or wrong block
The traction rope should maintain the
minimum traction angle, no more than position may cause injury or death.
30° with the straight travel direction. When lifting the machine with a jack,
Sudden move of the machine may
keep certain distance from it. The jack
cause overload the traction rope or
must have correct rated capacity that is
towbar and make them broken.
required to lift the machine. Before
Normally, it is more efficient to move
performing any work on the machine,
the machine slowly and smoothly. In
put the blocks under it.
general, the towing vehicle should be
The front of the machine
as large as the machine being towed.
Before lifting the front of the machine,
Make sure that the towing machine has
confirm the following items:
enough braking capacity, weight, and
· The transmission control lever is at
driving force. And the towing machine
the parking brake position.
must control the two machines at the
· The wheel tilting pins are on the
slope and the overall towing distance.
front wheel axles.

Caterpillar: Confidential Green 71


· The articulated lock pins are

mounted.

· Wedges have been put under the

rear wheels.

· The jack size is proper relative to

the machine weight. As for the The rear lifting position of the machine
machine weight, please refer to is under the main frame.

“Technical Parameters”, Operation &


Fire Prevention Regulations
Maintenance Manual.
Prevent fire during the usage, service

and storage of the machine:

--- Filling oil/fuel

--- Electric welding service

--- Keep the muffler, exhaust away

from withered grass or other


The front lifting position of the machine
is under the front wheel axle. flammables.

The rear of the machine --- Machine storage

Before lifting the rear of the machine, --- Battery

confirm the following items: --- under explosive environment.


• The transmission control lever is at Take the following measures in case of
the parking brake position.
• The wheel tilting pins are on the fire:
front wheel axles. --- Move the machine far from the
• The articulated lock pins are
mounted. danger area
• Wedges have been put under the --- Stop the engine, turn the ignition
front wheels.
• The jack size is proper relative to switch to OFF position.
the machine weight. As for the --- Exit the cab
machine weight, please refer to
“Technical Parameters”, Operation & ---Turn off the power power switch
Maintenance Manual. ---Inform the fire brigade (if

necessary)

72 Caterpillar: Confidential Green


Caterpillar: Confidential Green 73
Service & Maintenance
Oil / Fuel Grade

Parts Temperature Grade Service Interval


Engine fuel

5℃ 0#

-5℃ -10#

-20#
-14℃

-29℃ -25#

Engine lubricant
SAE5W-40
-40℃ Replace the oil at the
SAE15W-40 first 50 hour, and then
-15℃~50℃
replace it every 250
SAE10W-30
-20℃~40℃ hours.
Transmission oil
Replace the oil at the
first 100 hour, and then
Mobil Delvac 1300 SAE15W-40
replace it every 1000
-40℃ hours.
Drive axle final drive
and wheel reductor
SAE85W-90 Replace the oil at the
-40℃
first 100 hour, and then
SAE85W-90 replace it every 1000
-20℃~40℃ hours.
Hydraulic oil
-26℃~40℃ L-HV46 low temp. hydr. oil 2000 hr

Brake system

-20℃ L-HV46 antiwear hydr. oil as demand


Frame articulated pin
NGLI2 grease/ lithium
Steering articulated
grease/ 0# molybdenum Each week
pin
disulfide
Rear drive axle
Cooling system
YF-2 -35℃
74 Caterpillar: Confidential Green 2000 hr
YF-2A -45℃
Turntable drive pinion – lubricate

Scheduled Maintenance List Turntable top – lubricate

Parts to be replaced immediately Brake booster oil level – check

Battery – recycle Cooling system oil level – check

Turntable clearance – adjust Engine air filter maintenance

Turntable drive oil level – check indicator – check

Disconnector – reset Engine oil level – check

Blade plate and side blade – Water and sediment in fuel tank

check/replace – drain

Traction frame ball and bracket Windscreen – clean

movement – check - adjust Maintenance every 50 working hours


Engine air filter core – clean/replace
or every week
Fan coil – clean
Articulated bearing – lubricate
Fuse – replace
Front axle oscillation bearing –
Oil filter – check
lubricate
Radiator core – clean
Cab air filter – clean/replace
Seat – check
Central frame locking lever –
Seat belt – check
clean/lubricate
Cab fresh air filter unit/circulated air
Traction frame ball and bracket –
filter unit – clean/replace
lubricate
Windscreen washer reservoir – fill
Hydraulic system oil level – check
Windscreen wiper – check/replace
Main pin bearing – lubricate
Maintenance every 10 working hours or
Scarifier cylinder bearing –
every day lubricate

Water and sediment in air manifold Scarifier lifting linkage – lubricate

– drain Tyre pressure – check

Back-up buzzer – test Front wheel tilting lever bearing –

Brake, indicator and instrument – test lubricate

Caterpillar: Confidential Green 75


Front wheel tilting bearing – lubricate Engine oil and filter-replace

Axle tilting cylinder bearing – Radiator – clean

lubricate Tandem drive oil lever – check

Drive shaft – lubricate Main reducer oil level – check

Maintenance at the first 50 working Transmission and differential oil

level – check
hours
V belt – check/adjust/replace
Engine oil and filter – replace
Front wheel bearing –
Maintenance at the first 100 working check/lubricate

hours Engine water filter element-replace

Engine water & oil separated filter


Transmission oil/oil filter – replace
(fuel primary filter) – replace
Tandem drive oil – replace
Fuel system – fill the fuel
Maintenance at the first 250 working
Fuel system filter –
hours clean/check/replace

Engine valve clearance – check Maintenance every 500 working hours


Hydraulic return oil filter element
or every 3 months
–replace
Articulated bearing – lubricate
Maintenance every 250 working hours
Engine crankcase breather – clean
or every month Fuel tank cover and strainer –

Battery electrolyte level – check clean

Blade lifting cylinder bracket – Hydraulic system oil filter – replace

lubricate Air filter – replace

Central frame cylinder bracket – Brake system – test

lubricate Pump drive shaft – lubricate

Center deflection locking Transmission and differential oil

lever-clean/lubricate filter strainer – replace/clean

Coolant-fill Transmission oil/oil filter – replace

76 Caterpillar: Confidential Green


(tough condition) replace

Fuel Box & Hydraulic oil Box add

Maintenance every 1000 working hours oil & breath filter

Hydraulic oil Box add oil & breath


or every 6 months
filter– replace
Cooling system pressure
Fuel Box add oil & breath filter–
cover-clean/replace
replace
Roll Over Protection Structure
Maintenance every 3000 working
(ROPS) – check

Transmission and differential oil – hours or every 2 years

replace worm-gear case gear oil – replace

Tandem drive oil – replace

Transmission oil/oil filter – replace

Hydraulic return oil filter element


The no-failure working hours and service
–replace
life of the grader depend on the correct

Maintenance every 2000 working hours operation and maintenance or not. The

or every year correct inspection and maintenance not

only prolong the service life of the machine,


Air conditioner – test
but also shoot and settle the trouble earlier,
Battery or battery cable –
thus reduce the servicing time and
check/replace
maintenance cost.
Turntable drive oil – replace

Condenser (refrigerant) – clean Inspection and maintenance

Engine valve clearance – check prior to the driving


Engine valve rotator – check
• Radiator water level
Evaporator coil and heater coil –
• Engine oil pan level
clean
• Oil volume in fuel tank,
In-line refrigeration dryer – replace
hydraulic oil tank and
Tandem drive oil-replace
transmission
Cooling system coolant/antifreeze –

Caterpillar: Confidential Green 77


• Sealability of each oil pipe, water • Check if there are loose rim

pipe and component bolts, drive shaft bolts and pins.

• Check if the foot brake and • When the temperature is below

handbrake are reliable. 0 ℃, drain the cooling water

• Check if each control lever is (except when there is

flexible, and place them in neutral antifreeze)

position.
• Fill grease at each filling point
• Check if the tyre pressure is
according to the schedule.
normal (2.6 Bar). Blade plate
• Check the rim bolt, axle assembly Adjust it to the right.
1. Move the blade to the right.
bolt, drive shaft connecting bolt 2. Lower the blade to the ground.
and other bolt to see if they are

loose.

Inspection and maintenance after

the driving

• Check the fuel level.


Diagram 1
• Check the engine oil pan level 3. Loosen the bolt which fixes the
and oil cleanness. If the oil level is piston rod end and blade bracket to the
position (2). Loosen the 4 bolts and 4
too high and the oil is diluted locking washers.
gradually, find the reason and 4. Withdraw the piston to the position
(1).
settle it. 5. Entirely align all the bolt holes with
• Check the oil pipe, water pipe and the substitute holes on the plate at the
position (1).
each component to see if there is 6. Install the 4 check washers. Install
leakage. 4 bolts and tighten them.
Adjust it to the left
• Check the transmission, hydraulic 1. Move the blade to the left.
oil pump, front and rear axle, to 2. Lower the blade to the ground.

see if there is loose fixing, seals

and overheating.

78 Caterpillar: Confidential Green


Turntable clearance-check/adjust

Blade turntable and traction


frame
1. Rotate the blade. Rotate the blade to

Di the position which is 90° to the frame.


agram 2 Note: Before lowering the blade to the
3. Loosen the bolt which fixes the piston ground, install the C-clamp first.

rod end and the blade bracket to the

position (1). Loosen the 4 bolts and 4

locking washers.

4. Extend the piston rod.

5. Entirely align all the bolt holes on the

bracket with the substitute holes on the

plate at the position (2).

6. Install the 4 check washers. Install the

4 bolts and tighten them.


Scarifier cutting angle
1. Lower the blade to the ground.

2. Use two C-clamp to fix the front

blade turntable (1) and traction

Di frame (2). Tighten the two


agram 1 C-clamp, till the wear plate (3)
2. Dismantle the bolt (1) of the front
bracket on both sides of the scarifier.
contacts the upper part of the
3. Loosen the bolt(2) of the rear bracket blade turntable; besides, the
on both sides of the scarifier.
4. Lift or lower the scarifier to set the wear plate (3) contacts the
angle. bottom of the traction frame.
5. Install the bracket bolt.

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3. Lower the blade to the ground

and stop the engine.

4. Measure the distance (A)

between the blade turntable top

surface and traction frame bottom

surface. If the distance is less

than 1.5mm (0.06 inch), replace 2. Use two C-clamp to fix the front

the wear plate (3). blade turntable (1) and traction

5. Check the wear plate (3) and frame (2). Tighten the two

traction frame. The wear plate (3) C-clamp, till the wear plate (3)

shall contact the blade turntable contacts the upper part of the

surface in full scope. If they are blade turntable and the bottom

not contacted in full scope, of the traction frame.

replace the wear plate (3). 3. Lower the blade to the ground

and stop the engine.


Clearance between blade turntable
Note: Check the condition of the wear
and liner plate
plate (3) around the blade turntable.
1. Rotate the blade. Rotate the blade
The wear plate (3) shall contact the
to the position which is 90℃ to the
blade turntable and traction frame in
frame.
full scope.
Note: Before lowering the blade to the
ground, install C-clamp first.

4. The liner plate installation

fasteners (4), (5) and (6) must be

tightened. Make sure the wear

plates (3) are completely seated


80 Caterpillar: Confidential Green
on the liner plate of turntable. 8. After all turntable liner plates (9)

are adjusted completely, check

if the clearance of the turntable

liner plate (9) is proper. Adjust

the turntable liner plate (9) if

necessary.

Note: When all the adjustments are

completed, the rotation of the blade

5. Measure the clearance (B) turntable (1) must be smooth.

between the bottom of the


Turntable pinion and turntable
turntable (1) and the top of the
Note: The engagement of turntable
wear plate (7) of the liner plate.
pinion and turntable gear depends on
Keep the maximum clearance of
the adjustment condition of the liner
0.5 mm (0.02 inch). Increase or
plate. Clean the turntable and pinion
decrease the gasket (8) to keep
and eliminate the dust and other
the proper clearance.
abrasive materials, thus lighten the

abrasion of the turntable pinion and


Note: With proper clearance, the blade
turntable gear. Besides, it would help
turntable could rotate freely within 360°.
improve the adjustment accuracy of
Regularly adjust the gasket (9) of the
the turntable liner plate. After the
turntable.
adjustment is finished, spread the
6. Loosen the gasket installation
clean grease on the turntable pinion
fastener (6). Remove the liner
and turntable gear.
plate installation fasteners (4) and
Rotate the blade. Rotate the blade to
(5). Mount or remove the gasket if
the position which is 90°to the frame.
necessary.
Lower the blade to the ground. Engage
7. Install the liner plate installation
the service brake when the machine
fasteners (4) and (5), and tighten
drives forward slowly. Apply slight load
them.
to the wear plate of the front turntable

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liner plate and turntable and engage the fastener and locking nut on the

parking brake. Thus the engine stops. side liner plate of the turntable if

installed.

6. Regularly adjust the liner plate

in front of the turntable. Adjust

the bolt (12) to the inside, or

adjust the bolt (12) to the

outside, and keep the

2. Measure the clearance clearance of 49.5 to 52.5 mm

between the bottom flange (10) of (1.95 to 2.07 inch). Adjust other

the pinion and inner surface (1) of front turntable liner plate.

the turntable. If the clearance is


Note: If the turntable liner plate moves
less than 49.5 to 52.5 mm (1.95
forward, the machine is needed to drive
to 2.07 inch), adjust it.
forward slowly to apply slight load to the

place between turntable, turntable liner

plate and wear plate.

Note: Adjust the front liner plate, and

make sure the liner plate in front of the

turntable has the same clearance.

3. Loosen the liner plate installation


7. If the correct clearance could not
fasteners (4) and (5) on the liner
be obtained due to the abrasion
plate in front of the turntable, and
of the wear plate (7) of the front
the liner plate installation
liner plate, replace the worn wear
fasteners (6) and (11).
plate (7) of the liner plate. And
4. Loosen the liner plate installation
then repeat the step 6.
fastener and locking nut of the
8. Tighten the liner plate installation
rear turntable liner plate.
fastener and locking nut on the
5. Loosen the liner plate installation
liner plate in front of the
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turntable. to the position which is 90°to

the frame and lower the bucket


Note: Before tightening the liner plate
to the ground.
installation fastener and locking nut, fasten
2. Operate the blade lifting cylinder
the adjusting bolt on the turntable liner
and watch the bracket. If the
plate.
bracket moves while the blade

9. Contact all turntable liner plates to does not move, the adjustment is

the turntable fully. No clearance is necessary.

allowed between the turntable

liner plate and the turntable.

10. When the clearance setting of the

pinion is finished, the front turntable

liner plate has contacted the blade

turntable. Measure the clearance


3. Dismantle the two bolts (2) of
(C) between each wear plate (7)
each cover plate (1) and remove
and the blade turntable. The
the cover plate (1).
maximum clearance shall be 0,8
4. Remove one gasket from either
mm (0,03 inch).
side to reduce the clearance.
11. Use the torsion of 475 ± 60 N·m
5. Note: if it is necessary to
(350 ± 44 lb ft) to tighten the liner
dismantle two gaskets, remove
plate installation fasteners (4) and
one gasket from each side
(5), and the fastener of all other
respectively.
liner plates.
6. Install the cover plate. Install the
12. Use the torsion of 200 ± 30 N·m
bolts and fasten them.
(150 ± 22 lb ft) to tighten all locking
7. Watch the movement of the
bolts (11).
bracket. If the bracket is moving,
Blade lifting cylinder bracket, repeat the steps from 3 to 5.
check/adjust/replace
Note: If there is no gasket, install the
1. Rotate the blade. Rotate the blade

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new gasket. Plug two gaskets from each

side respectively. Add the gasket if

necessary.

Blade lifting cylinder bracket,


lubricate

Dismantle the bolt (1) of the cover plate


Before filling the grease to the nozzle,
(2) and remove the cover plate (2).
clean all nozzles first.
Remove one gasket from either side to

reduce the clearance.

Note: if it is necessary to dismantle two

gaskets, remove one gasket from each

side respectively.

Install the cover plate and bolt, and


The machine has two blade lifting cylinders
tighten the bolt.
(1).
Watch the movement of the bracket. If
The bracket of each blade lifting cylinder
the bracket is moving, repeat the steps
has a nozzle (2). In order to fill the oil to the
from 3 to 5.
blade lifting cylinder bracket, use the
Note: If there is no gasket, install the new
grease sleeve to fill the grease into the
gasket. Plug two gaskets from each side
nozzle.
respectively. Add the gasket if necessary.
Central frame cylinder bracket,
check/adjust/replace
Central frame cylinder bracket,
Rotate the blade. Rotate the blade to the lubricate
position which is 90°to the frame and Before filling grease to the nozzle,

lower the blade to the ground. clean all nozzles first.

Operate the central frame displacement

cylinder and watch the bracket. If the

bracket moves while the traction frame

does not move, the adjustment is

necessary.
84 Caterpillar: Confidential Green
Before filling the lubricant through the

nozzle, clean the nozzle.

There is a nozzle each end of the center

moving frame. In order to fill grease to the

wheel tilt bearing, use grease sleeve

(including molybdenum disulfide of 5%) to

fill grease into the nozzle.

Center displacement locking lever,


clean/lubricate
Fill the lubricant of right amount

through the nozzle to lubricate the

towbar ball and ball bearing housing.

Towbar ball head and support


activity level, check/adjust

Check
The center displacement locking lever (1)
Rotate the blade to the position which
is under the front frame and above the
is 90 ° to the frame, and lower the
rotary disc.
blade to the ground. When the load on
Clean the sundries, oil stains and rusty
the traction frame ball and bracket is
spot in the locking frame hole on the center
light, move the machine backward
displacement locking lever.
slowly. Stop the machine and turn off
Fill the lubricant of right amount into the
the engine.
hole of the center displacement locking

lever.

Towbar ball head and ball socket,


lubricate

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the joint.

2. Remove the gasket (4) or install

the gasket (4) if necessary to

keep the shaft end clearance of

0.6 ± 0.2 mm (.02 ± .01 in).

3. Install bolt (7) and joint (6)

inside cover (3). Rotate the

cover (3) manually. The bracket

shall rotate freely around the


Measure the shaft end clearance
traction frame ball (2).
between the ball (2) and cover (3). The
4. Check the torque of the bolt
clearance shall be 0.6 ± 0.2 mm (.02
which is fixing the traction
± .01 in). Adjust it if necessary.
frame ball (2). The correct

torque is 500 ± 65 N·m (370 ±


Adjust
50 lb ft).
Place the support to the traction frame
5. Install the towbar on the frame
and rotary disc.
bolster. Tighten the bolt (1) till
Dismantle the bolt (1) which is fixing the
the torque reaches 950 ± 50
traction frame and frame bolster. Move
N·m (701 ± 37 lb ft).
the traction frame backward or move the
Battery, clean/check
machine forward.

Battery Diagram

Note: the battery on the machine is


1. Dismantle the bolt (7) which is
maintenance-free. It is not necessary to
fixing the traction frame and joint

(6) from the cover (3). Remove


86 Caterpillar: Confidential Green
check the electrolyte level of

maintenance-free battery.

Check the following items:

• Use the cleaning cloth to wipe the

battery top.
Battery
• Clean the battery terminal. Spread oil

glue on the battery terminal. 5. Disconnect the battery negative

• Tighten the fasteners of the battery. cable connected to the frame on the

battery cutoff switch.


Battery recycling Note: Do not make the disconnected
The battery must be recycled, and it is battery cable contact the cutoff switch,
other cables, or the opposite polarity
not allowed to discard the battery.
terminal of other batteries.
The used battery has to be delivered to 6. Disconnect the battery negative
one of the following departments: cable on the battery.
• Battery supplier 7. Disconnect the battery positive
• Specified battery recycling site cable on the battery.
• Recycling site 8. Remove the positive wire from the

starting motor.
Battery or battery cable, check/replace
9. Remove the connecting wire
1. Turn the starting switch of the engine between two batteries.
to OFF, and turn all switches to OFF. 10. Make the necessary repair.
2. The battery box is on the right of the Replace the cable or battery if
rear frame which is in the middle of the necessary.
machine. 11. Reconnect the battery according to
3. Open the battery box cover. the above procedure in the opposite
4. Turn the battery cutoff switch to OFF. sequence.

12. Connect the battery cable to the

battery cutoff switch.

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13. Turn the battery cutoff switch to ON shall sound at once and continue to sound

position. till the variable speed lever shifts to

14. Close the battery box cover. Neutral or Forward gear.

Note: it is suggested that the replacement


Engine air filter maintenance
of battery cable shall be performed by
indicator, check/replace
professional technicians.

Fuse, replace

Fuse–the fuse protects the circuitry to

avoid the damage caused by circuit

overload. Replace the blown fuse with new

fuse. If the new fuse is blown again, please The air filter is in the engine hold, on

check the circuit. Settle the trouble first, the left of the machine.

and then start the machine. When the machine is operated every

100-200 hours or the alarm is in red, use

compressed air of less than 490 kPa to

clean the filter core from the interior to

the outside along the fold of the filter

core.

Do not strike the filter core with other

tools when taking it down. Clean the

Central electric controller diagram inside of outlet pipe and seal surface of

the filter.
Reverse alarm
When the filter core has been cleaned
The reverse alarm is on the rear of the
for six times, or working for 1000 hours
machine, lower right of the hydraulic fan.
(high dust level)~2000 hours (low dust
Start the machine, and pull the variable speed
level), replace the filter core.
lever to Reverse gear. The reverse alarm

88 Caterpillar: Confidential Green


Check the joint, and make sure that the comes from the engine with clean filter

filter end cover fits the engine air inlet core after the engine starts, the new

and there is no leakage. primary filter core is required to install. If

the plunger is still in red area, replace the


Maintain the air filter only when the engine
secondary filter core.
is stopped, or the engine may be
Clean the primary filter core of
damaged. air filter
When the blue plunger of the engine air
filter core indicator enters the red area,
maintain the air filter core. Caution
SEM recommends using the certificated

air filter cleaning service provided by

SEM agents. The cleaning procedure of

SEM adopts the steps examined by the

practice to guarantee the consistent

quality and long service life of the filter.


1. Dismantle the end cover (1) of the air
If you want to clean the filter core by
filter housing.
yourself, please follow the following
2. Take the primary filter core (2) down
principles:
from the air filter housing.
Do not strike or hit the filter core to
3. Clean the interior of the air filter
clean the dust.
housing.
Do not wash the filter core.
4. Install the clean primary filter core of the
Clean the dust in the filter core with low
air filter, and install the end cover of the air
pressure compressed air. The air
filter.
pressure is no more than 207-kPa.
Note: refer to “clean the primary filter core
Clean the pleated paper in the primary
of the filter”.
filter core with the air flow. Be careful,
5. Reset the maintenance indicator of the
and do not damage the pleated paper.
engine air filter.
Do not use the air filter with damaged
If the blue plunger of the indicator enters
pleated paper, gasket, or seal ring. The
red area, or exhaust of black smoke still

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dirt which enters the engine would times. The compressed air is not able to

damage the parts of the engine. clean the carbon deposit and oil. Use the

filtered dry air with the maximum pressure


If the primary filter core of the filter is
of 207 kPa.
cleaned and checked properly, it could be

used repeatedly for 6 times. Check the

filter core material if it is torn after the

primary filter core of the filter is cleaned.

Replace the primary filter core of the filter

at least one time every year. No matter

how many times it is cleaned, replace it Note: Start from the clean interior to

after one year. clean the primary filter core of the filter,

Caution and flush the dirt particles to the

Do not strike or hit the filter core to clean it, or outside.

the seal may be damaged. Do not use the Aim at the direction of the hose to make

filter core with damaged pleated paper, the air flow in the filter core along the

gasket, or seal. The damaged filter core length direction of the filter, which could

would allow the dirt to pass through, which avoid the damage of the pleated paper.

may damage the engine. Do not aim at the primary filter core of

the filter with the air, or the dirt may be


Visually check the primary filter core of the
further pressed into the interior of the
filter prior to the cleaning. Check the air filter
pleated paper.
core to see if the seals, gasket and cover is
Vacuum cleaning
damaged. Discard any damaged filter core. Vacuum cleaning is another method to
The primary filter core of the filter is cleaned
clean the primary filter, which is
in two common methods:
• Compressed air necessary for daily cleaning in dry and
• Vacuum cleaning dusty environment. Compressed air

Compressed air cleaning is used in preference. The

Compressed air is used to clean the primary vacuum cleaning is not able to clean the

filter core which is cleaned no more than two carbon deposit and oil.
90 Caterpillar: Confidential Green
Check the primary filter core of the filter

Do not use the coating or waterproof

Check if the primary filter core of the filter is covers or plastic materials as the

clean and dry. Use a blue light of 60W in the protective packing for storage, otherwise,

dark room or similar facilities. Put the blue it will cause poor ventilation. In order to

light in the primary filter core of the filter. avoid the dirt and damage, use volatile

Rotate the primary filter core of the filter to corrosion inhibitor to pack the primary

see if there is damage and/or holes, and filter core.

check if there is light passing through the filter Put the primary filter core of the filter in
the box for storage. Attach a label on the
material. Compare the primary filter core of
outside of box and filter core for
the filter with the new filter core of the same recognition. The label shall include the
following information:
part number to confirm the result.
• Cleaning date
Do not use the filter core if the filter material • Cleaning times
Keep the box in dry place.
is damaged and/or there is the hole in it. Do

not use the filter core with damaged Secondary filter core of the
pleated paper, gasket or seal ring. Discard engine air filter, replace
the damaged filter core. Caution
The secondary filter core must be
Storage of the primary filter core of the
replaced. The secondary filter core is
filter
not allowed to use even if it is cleaned.
If the checked primary filter core of the filter
When the secondary filter core is
is not used, preserve it for future use. replaced, the primary filter core of the
filter shall be replaced.
If the dark smoke is still in the exhaust,
replace the secondary filter core of the
filter.

1. Open the engine hood.

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2. Read the “Primary filter core of engine

air filter -clean/replace ”in the Operation

and Maintenance Manual. Dismantle the

air filter cover on the air filter housing, and

remove the filter core from inside the air

filter housing.
The above diagram shows that there

are scraps in the filter core.

Cut through the filter core, and expand

the pleated paper to check if there is

metal or other scraps in the filter core.

The excessive scrap in the filter core

3. Take the secondary filter core of the may cause trouble.

filter down. If the metal scrap is in the filter core, use

4. Cover the air inlet. Clean the interior of a magnet to distinguish the ferrous metal

the air filter housing. and non ferrous metal.

5. Take the cover down from the air inlet. 6. Ferrous metal means that the steel and

Install a new secondary filter core of the iron parts are worn.

filter. Non ferrous metal means that the

7. Install the primary filter core of the filter. aluminum parts of the engine are worn,

8. Install the air filter cover and fasten it. 9. such as main shaft bush, connecting rod

Close the engine hood. bush, or turbocharger bearing bush.

Oil filter, check A small amount of scrap may be in the

Check if there are scraps in the used filter core. It may be produced by friction
oil filter
and normal wear. If excessive scrap is

found, please contact SEM agent and

arrange further analysis.

The usage of filter core not

recommended by SEM may damage the

engine bearing, crankshaft and other


92 Caterpillar: Confidential Green
parts seriously. It may produce larger Use engine degreaser to clean the

particles in the unfiltered oil, and these engine compartment. Keep little water

particles may enter the lubricating system around the bearing and electrical

and cause the damage. connection.

Cab fresh air filter


Engine oil and oil filter, replace
unit/circulating air filter
The engine drain hole is on the right of the
unit-clean/replace
machine, under the cab.
Clean the filter core of the filter unit

Drain hole of engine oil pan

Note: drain the oil when the oil is hot

and the pollutant is in suspension. Note: clean the cab filter more
Run the diesel engine till the water frequently in dusty environment.
temperature reaches 60℃, and then stop There are two fresh air filter units in the
the machine. Remove the oil drain plug. ventilation system of the cab. Each one
Note: Refer to Engine Maintenance is on the top of the door at both sides
Manual for other maintenances of the of the cab respectively.
engine. The circulating air filter unit is behind

Engine compartment-
compartment-clean the operator seat in the cab.

1. Dismantle the cover plate of the


Caution
Before cleaning engine compartment with filter unit.
high-pressure water, turn off the engine
2. Remove the filter core of the filter
and cool the engine down. Do not spray
the hot injection pump with water directly, unit. Blow and clean it with high
or it may cause damage.
pressure air.

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3. Blow and clean the filter core.

4. Install the filter unit and install the

cover plate of it.

Replace the filter core of filter unit

Note: Replace the air filter unit in the cab if

necessary.

1. Dismantle the filter unit cover.

2. Remove the filter core of the filter unit.

Discard the filter core correctly. Windscreen wiper

3. Install new filter core of the filter unit. Check the front and rear windshield
4. Install the filter unit cover. wiper blade. Replace the windshield

Windscreen washer reservoir, fill wiper blade if necessary.


Windscreen, clean

Use the detergent in the market to clean

the windscreen. Stand on the ground to

clean the exterior of the cab windscreen

without the handrail.

Turntable drive oil, check


If it is leaking or may be leaking, check

the worm-gear case oil level.

indscreen washer reservoir

The windscreen washer reservoir is on the

the lower right side, outside of the cab.

If the gear oil level is below 1/3 of the


If the detergent level is low, fill
sight glass, fill the gear oil.
the detergent into the reservoir.
Before filling the gear oil, wipe the
Windscreen wiper, check/replace
94 Caterpillar: Confidential Green
surface of the worm-gear case. steps if necessary.

Fill the gear oil till the oil is above 1/2 of Articulated bearing, lubricate
the sight glass. Before filling grease, wipe the surface of

Turntable drive oil-replace grease nipple.

Note: if it is necessary to watch, test, The grease filler is under the cab, on the

maintain, repair or replace the relevant liquid, left side of the machine.

prepare the proper liquid container prior to

the repair and replacement.

Oil drain plug

1. Unscrew the oil drain plug, and Blade lifting cylinder bracket,

drain the gear oil to the proper lubricate

container. Before filling grease, wipe the grease

2. After the oil is drained completely, nipple.

clean and tighten the oil drain

plug.

3. Unscrew the refuel plug, and fill

the gear oil till the 1/2 of the sight

glass.

4. Clean and tighten the refuel plug.

5. Start the machine, and run it for 5 Two blade lifting cylinders

minutes. Brake system test

6. Check the oil level through the --Service brake system brake ability test

sight glass. Repeat the refuel Warning: the sudden movement of the

machine may cause personal injury in the

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test. If the machine moves suddenly, lower the test.

the engine speed at once, and start the The test field shall be the dry and flat

parking brake system. ground.

Make sure there is no barrier and other Fasten the safety belt before the test is

irrelevant personnel on the test field prior to started.

the test. Use the following method to make sure if

The test field shall be the dry and flat ground. the parking brake system is engaged.

Fasten the safety belt before the test is This is not to test the maximum brake

started. ability of the parking brake system.

Use the following methods to check if the 1. Place the machine on the slope

service brake system is engaged. This with the tilt angle of 20°.

is not to test the brake ability of the 2. Pull up the handbrake, and

parking system. release the service brake

Start the engine, and lift the blade system, and the wheel shall not

slowly. rotate. If the wheel rotates,

1. Press down the brake pedal, and press down the brake pedal.

shift the variable speed lever to

gear 4, and increase the engine Air desiccant, replace


speed to high speed. Note: the pressure of the brake pipeline

2. Lower the gear of the variable where there is air desiccant must be equal

speed lever gradually. The to the atmospheric pressure. If the system

machine shall be stationary. pressure is not released, it may cause

3. Lower the engine speed, and pull personal injury. Release the system

up the handbrake. Lower the pressure completely prior to the

blade to the ground and stop the maintenance and service.

engine.

Parking brake system test


Make sure there is no barrier and other

irrelevant personnel on the test field prior to

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The air desiccant is on the rear left of the
Open the oil cup cover, and check the
machine, under the hydraulic fan.
brake fluid level.
If the air desiccant could not continue to
When the brake fluid level is below the
absorb the water, replace the air
lower mark, fill the brake fluid till it
desiccant.
reaches the position below the upper
Water and sediment in air manifold,
mark.
drain
Tandem drive oil level, check
The tandem drive oil drain plug is on

the front bottom of the tandem drive

box.

The air manifold is on both sides of the

rear frame, under the engine.

Pull the pull ring on the bottom of the air

manifold downward, and drain the water Prepare a proper container before

and other sediment in the air manifold. draining the oil.

Then reset it. Stop the machine on the slope with the

Brake booster oil level, check gradient of 20%. The rear wheels are

The brake fluid oil cup is in the engine on the slope.

hood, on the left of the machine. Unscrew the oil drain plug, and drain

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the oil to the container. Main reducer oil, replace
The main reducer oil drain plug is

under the main reducer.

Prepare the proper container before

draining the oil.


The plug screw next to the breather on
Unscrew the oil drain plug, and drain
the tandem drive is the filling port.
the oil to the container.
When filling the oil, keep the axle in the

horizontal position.

Keep the oil charge at the lower line of

the axle, and the spilled oil of small

amount is allowed. The oil charge of

single balance box assembly is about

23L.
The main reducer oil level hole is the
Main reducer oil level, check
filling hole.
The main reducer oil level hole is on both
When filling the oil, keep the axle in the
sides of the main reducer assembly.
horizontal position. Keep the oil charge

at the lower line of the axle, and the

spilled oil of small amount is allowed.

The oil charge of main reducer and

planetary reducer assembly is about

28L.

Transmission oil level, check


Unscrew the oil level plug and check the
The oil pointer of the transmission oil
oil level. The lower limit is 8 mm from the
level is on the rear right of the
lower line of the oil level hole.
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machine. dipstick oil level should between the
intermediate scale line and higher line;

Note: due to the influence of the


installing condition, when the engine in
parking condition, gearbox oil surface
will increase the actual.

Place the grader on the flat and dry

ground. Stop the engine and cool it off for

5 minutes, and then check the oil pointer.

Pull out the oil pointer, and check if the oil

level is above the lowest mark.

Transmission oil/oil filter, replace


The transmission oil drain plug is on the Note: Replace the transmission oil and

rear right of the machine. The oil level transmission oil filter simultaneously.

gauge is on the opposite side. The transmission oil filter is on the

upper left of the transmission.

Machine park in flat and dry ground, start


the machine, after the engine idle running
for 5-10 minutes, check gearbox oil level:
Note: after the replacement for the
when the temperature is 40 ℃, the
first 100 working hours, replace the
dipstick oil level should between the
oil and oil filter every 500 hours in
intermediate scale line and lower line;
tough condition.
when the temperature is 80 ℃, the

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Drive shaft, lubricate

The center deflection locking lever is

under the front frame, above the

slewing ring.
Two drive shafts. One is connected to the
Clean the dirt, lubricant and rust in the
engine and transmission, and the other is
center deflection locking lever.
connected to the engine and plunger
Fill the proper lubricant to the seven
pump.
holes of the center deflection locking

lever.
Central frame cylinder bracket,
Turntable drive pinion, lubricate
lubricate
The turntable drive pinion is on the
Prior to the lubrication, wipe the grease
bottom of the slewing ring.
nipple.

1. Clean the the dirt and the filled

lubricant.

2. Fill the proper lubricant.


Center deflection locking lever,
Turntable top, lubricate
clean/lubricate

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grease nipple.

Each front wheel has a front wheel

tilting bearing.

Front wheel tilting lever bearing,


lubricate
Before filling the lubricant, wipe the

grease nipple.

There is one grease nipple on the left and

right side.

Lubricating position

Main pin bearing, lubricate

Front wheel tilting cylinder


bearing, lubricate

Before filling the lubricant, wipe the

grease nipple.

Front wheel tilting bearing,


lubricate Before filling the lubricant, wipe the

nozzle

Front axle oscillation bearing,


lubricate
Before filling the lubricant, wipe the

nozzle
Before filling the lubricant, wipe the

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Dozer cylinder bearing-lubricate
Before filling the lubricant, wipe the
Scarifier lifting linkage, lubricate
nozzle
Before filling the lubricant, wipe the

nozzle.

Dozer lifting linkage, lubricate


Before filling the lubricant, wipe the

nozzle.
Safety belt, check/replace
Check the safety belt prior to the

operation. If any part is damaged,

replace it and then operate the

machine.

Scarifier cylinder, lubricate


Before filling the lubricant, wipe the nozzle.

Check 1. safety belt base, 2. safety belt

buckle 3. if the safety belt is worn or


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damaged. If it is damaged, replace it at

once.

Replace the safety belt within three years

from the installation date or within five

years from the manufacture date.

Fuel tank cover and strainer, clean After the bolt is unscrewed, drain the

water and sediment from the fuel tank.

Hydraulic system oil level, check


Stop the machine on the flat ground.

Turn off the engine, and check the

hydraulic system oil level after 5 minutes.

Open the fuel tank cover, and check if the

O-ring of the fuel tank cover is damaged.

If it is damaged, replace it with a new

one.

Remove and clean the refueling strainer,

and then install it. Lubricate the O-ring.

Water and sediment in fuel tank ,


When the oil level is very low, fill the
drain
hydraulic oil of the same brand.
The oil drain bolt is one the right of the
Hydraulic system oil level,
machine.
replace
Stop the machine on the flat ground.

Prepare a container with sufficient

capacity.

Turn off the engine. Unscrew the oil

drain plug after the oil is cooled off.

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After the oil is drained completely, which can be checked through the

level sight gauge.

Note: If it is necessary to fill the coolant

every day, check if the cooling system

is leaking.

Coolant, fill
The coolant filler on the upside of the
engine, the rear side of the engine tail
fill the hydraulic oil. pipe.

If the coolant could not be seen through


the sight glass, fill the coolant.
Cooling system coolant level, Note: with the operation temperature, the

check coolant temperature is very high. Opening

The sight glass of the cooling system the coolant cover directly may cause

coolant level is in the engine hood, on the personal injury.

right of the machine. When unscrewing the coolant cover, make

it slowly to release the pressure to avoid

the scald.

Cooling system pressure cover,


clean/replace
Note: with the operation temperature, the

coolant temperature is very high. Opening

Open the right door of the engine, and the coolant cover directly may cause

the sight glass is on the expansion water personal injury.

tank which is above the engine. When unscrewing the coolant cover, make

The coolant must be kept at proper level it slowly to release the pressure to avoid

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the scald. capacity.

Tightening the pipe connection is not allowed Stop the machine on the flat ground.

if the coolant is very hot. After the coolant is cooled off, open the

water drain valve, and drain the

coolant/antifreeze completely.

Then fill the coolant or antifreeze of the

same model to the cooling system.

The cooling system pressure cover is on

the engine hood, the rear side of the

engine tail pipe.


Storage
After the coolant cover is unscrewed, Storage Instruction
check the seal ring to see if there is Provide the information, the required
preventive measures and special tools
damage, sediment or other sundries. for the operator who prepares the
Wipe it with clean cloth. If the cover is long-term or short-term storage.
Note: short-term storage refers to the
damaged, replace it with a new cooling duration of less than 2 months;
system pressure cover. long-term storage refers to the
duration of more than 2 months.
Install the cooling system pressure cover.
Short-term storage:
Cooling system coolant/ antifreeze,
• Clean the dirt and dust on the
replace
machine, especially the engine,
The water drain valve of the cooling system is
generator, start motor, injection pump,
on the bottom of the water tank.
fuel injector, hydraulic pump and

motor as well as hydraulic pipelines

and their surface. Be sure to use dry

and soft cloth to clean these areas.

• Drain the coolant from the engine

radiator.

Prepare a container with sufficient

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• Use the kerosene to wipe the ● Start the machine once a month, and

surface of all the parts and all the run it at low speed for half an hour to

lubricating holes, and fill the oil wax. lubricate all the systems of the grader.

• During the short-term storage, the Fill grease to all the grease nozzles.

machine shall be ready to start at any ● Inspect the exterior, protective surface

time. and preserver of the machine regularly;

The inspection interval for long-term


Long-term Storage
storage:
Storage Site In warm environment, check the
machine once every 6 months;
● The machine is generally stored in dry
In tropical zone, cold climate in
and ventilated storehouse. If the machine temperate zone, cold zone and coastal
areas, check the machine once every 3
is stored in open air, it should be parked on
months.
the concrete ground which has good water

drainage. Cover the machine with canvas


After Long-term Storage

or canopy and fasten it. The machine Remove the cover.

should be stored on the site where it can Clear the preservers coated on the

not be damaged by natural disaster and exposed surfaces.

there is no corrosive and harmful Charge, install and connect the

substance or gas. battery.

Storage Drain the oil from the engine

● Place the machine on the support to crankcase, wheel reducer and drive axle,

avoid distortion of the machine body and and clean them. Fill new oil according to

tyre deformation. The distance between the requirements.

each wheel and the support surface should Drain the sundries and water from

be no less than 8cm. hydraulic oil tank and fuel tank.

● The battery should be cutoff. If the Fill grease at all the articulated

machine is stored for more than one month, points.

remove the battery from the machine and Check and adjust the tyre pressure.

keep it at a special place.

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When inspecting the machine prior to

the operation, refer to the inspection rules

in Operation.
Recommended preserver cleaning methods:
Protection
Cleaning method
method
Remove the protection
Coat the
paper, and blow it with hot
surface with
and dry air, or wash it with
preserver
soda soap solution.
Coat the Clean it with hot water or
surface with detergent solution, or wipe
oil or it with organic solvent first,
painting and then clean it with hot
water or detergent solution.
Coat the Cut the polymer film apart
surface with at proper position and
protective remove it.
polymer
Coat the
rubber
surface with
Clean it with detergent.
light
resistance
compound

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Trouble Shooting

During operation of the grader, various kinds of troubles may occur due to natural

abrasion, improper operation, maintenance or assembly. Check and diagnose the

troubles according to the instructions in this chapter. The common grader troubles and

solutions listed in this chapter is only for reference.

Regarding the engine trouble diagnosis and solutions, please refer to the

engine operation manual delivered with the machine.

Transmission

Troubles Reasons Solutions


1. The clutch is adjusted improperly, and
Adjust it.
Difficult gear the detaching is not complete.
shifting 2. The operating mechanism is adjusted
Check and adjust it.
improperly.
1. The lubricating oil is too dirty. Replace it.
2. Insufficient lubricant and the lubricating
Abnormal oil could not meet the quality Check and replace it.
damage of requirement.
bearing 3. The transmission body and each part
Clean them in assembly.
are not well cleaned.
4. The bearing used is of low quality. Replace it.
1. The oil seal is worn, harden or loses
Replace the oil seal.
elasticity.
2. The transmission shaft neck matching Repair and weld the
the oil seal is worn. transmission shaft.
Oil leakage of
Replace the transmission
transmission 3. The transmission housing is cracked.
housing.
4. The bush is broken or the joint is not
Replace the gasket.
close
5. The oil level is too high. Drain the redundant oil.

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Brake System

Troubles Reasons Solutions


1. The brake disc is sticky with oil stain Check and eliminate the
and the friction disc is worn overly. Thus leakage. Rivet the friction
the rivet is exposed outside. disc heavily.
2.The brake fluid is insufficient. Fill the brake fluid to the
required position.
Bad brake
3.The air booster cylinder does not return. Replace the booster cylinder
performance
component or assembly.
4. The brake oil circuit is mixed with air. Exhaust the air from the
brake system.
5. The brake disc clearance is excessive. Adjust the brake disc
clearance.
1. The brake disc of one side is sticky with Clean the brake disc.
oil stain.
Single-side 2. The brake hose or joint of one side is Clean the brake hose and
brake blocked. joint.
3. The friction disc of one side is worn Replace the friction disc.
overly.

Steering Hydraulic System


Trouble Reasons Solutions
1. The filter is blocked. Clean or replace the filter
2. The oil supply of the hydraulic pump is Check and repair the
insufficiently. hydraulic pump.
3. There is air in the steering system. Release the air in the system
and check if there is leakage
in the inlet line.
4. The steering valve and check valve fail to Check and repair the steering
Heavy
work. valve.
Steering
5. The viscosity of the hydraulic oil is too Use the oil with
large. recommended viscosity.
6 The level of the oil tank is too low. Fill the oil to the stated level.
The relief valve of steering valve block has a Adjust the relief valve
lower pressure than the working pressure, pressure or clean the relief
or it is blocked, or the spring fails, or the seal valve. Replace the spring or
ring is damaged. seals.

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Working Devices
No. Troubles Reasons Solutions
1 The working device fails to work. 1, The cylinder is 1, Replace the pump.
damaged. 2.Repair it.
2, The safety valve is
blocked or leaking.
2 The working device could not be kept at 1, The seal ring of 1, Replace the seal
the fixed position the cylinder piston is ring
damaged 2, Repair it.
2, The locking valve
is failed
3 The blade is trembling in operation. 1, The blade slide 1, Adjust or replace
clearance is the blade.
excessive. 2, Adjust it.
2, The clearance of
the swing ring
bearing is excessive.
4 The blade could not swing. 1, The drive motor or 1, Replace the
the turbine box hydraulic motor.
2, The swing bearing 2, Adjust and
slide is blocked. eliminate the
3, The hydraulic blockage.
motor joint is leaking. 3, Replace the seals.
5 The blade could not extend to the side. 1, The blade guiding 1, Clean it.
device is blocked. 2, Repair the
2, The center swing leakage.
joint is leaking.
6 The oil volume from the hydraulic pump 1, The oil in the oil 1, Fill to the stated
is too small, and the noise is too large tank is much less. level.
during operation. 2, The hydraulic 2, Replace the
pump is damaged. hydraulic pump.
7 The control lever could not return to the The return spring is Replace the return
neutral position. too soft or broken spring.

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Clutch
Trouble Reasons Solutions
1. The free stroke of the clutch pedal is too Adjust the free stroke of the
big. clutch pedal.
2. The the inner ends of the release lever Adjust the inner ends of the
The clutch are not on the same plane, and the release release lever to the same
does not lever is adjusted much lower. height, and keep certain
detach height of the release lever.
completely 3. The steel disc of the clutch is deformed. Replace the steel disc of the
clutch.
4. The friction disc is too thick. Replace or repair the friction
disc.

Drive Axle
Trouble Reason Solution
1.The parts such as gear and bearing are Replace the gear or bearing.
worn overly or damaged.
2. Poor engagement between the bevel Adjust the back lash of the
pinion and bevel gear. bevel gear pair.
Abnormal 3. Improper adjustment of the bearing Adjust the bearing clearance
sounds clearance of bevel gear and bevel pinion. of bevel gear and bevel
pinion.
4.Damaged gears or bearings. Replace the gear or bearing.
5. The lubricating oil is insufficient. Fill the lubricating oil to the
standard height.

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Air Conditioning System
No refrigeration
Condensation fan does not Compressor Check if the fan joint falls off, if the
Evaporator fan rotates

rotate works
ground connection is good, and if
the fan is damaged.
Condensation fan rotates Compressor Check if the temperature control
does not work
switch is damaged, if the relay is
actuated, and if the relay joint is
loose.
No refrigeration

Condensation fan rotate, and Check if the speed control switch is normal, if the fan
Evaporator fan

the compressor works wire is broken, and if fan grounding wire is good.
stops

Condensation fan does not Check if the fuse is fused, if the relay is normal, and
rotate, and the compressor if the wire is loose.
does not work
The evaporator fan and R-134a in the system is charged too much. Use the
compressor work
Compressor is

high and low pressure gauges to check if it fits the


normal

stated pressure value.


It is not used for a long time, R-134a is leaking, use
the high and low pressure gauges to check if there is
R-134a.
The evaporator fan and The liquid reservoir inlet is connected reversely.
refrigerating volume

Check if the expansion valve is blocked by dirt or


Compressor is

compressor work, and the ice, and replace the liquid reservoir.
Insufficient

normal

evaporator and condenser are Replace R-134a


normal
The fan works normally and Check if the condenser surface is blocked by
others are normal begrimes.

Other Trouble Solutions

No. Troubles Reasons Solutions


1 The refrigerating function of the system is The loader often Check the leakage
well at first, however the cold air is travels on the tough with leak detector, and
insufficient after the operation for some road, causing the joint tighten the loose part
time; bubbles are in the sight glass and loose, thus the carefully.
the readings of the high and low pressure leakage happens.
gauges are low.
2 The refrigerating function of the system Improper usage. The Replace the
does not work, and the hot wind is from thermal bulb is worn expansion valve, and

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the air outlet. There is no temperature and leaking, thus the recharge R-134a.
difference between the expansion valve valve hole is closed.
inlet and outlet feeling by hand, and the
reading of the low pressure gauge is low.
3 The wind from the outlet is not cold, the The expansion valve R-134a Start the cold
compressor temperature increases, and is blocked by the wind system from time
indicator of the low pressure gauge sundries in the to time, and the instant
decreases rapidly, approaching 0. The system, and the blocking phenomenon
reading of the high pressure gauge is expansion valve is could be settled if it is
high. frosting or “sweating”. not serious. Dismantle
the expansion valve
and clean it with ethyl
alcohol, and exhaust
the system and
recharge it with R-134.
4 Cold volume is insufficient, the evaporator The throttle hole in the Exhaust the system,
is frosting; the readings of the high and expansion valve does replace the expansion
low pressure gauges are low. not work valve, and recharge
R-134a
5 After the system runs for some time, the The desiccant in the Exhaust the system,
refrigerating volume starts to decrease, liquid reservoir is and replace the liquid
and the reading of the high pressure saturated, and the reservoir, and
gauge is high, while the reading of low throttle hole of recharge R-134a.
pressure gauge is low. expansion valve is
blocked by ice.
6 After the cold air system is started, the The temperature Use the multimeter to
system is only blowing the wind without control switch has bad check if the
cold air, and the readings of the high and contact, or the wire of temperature control
low pressure gauges are not changed. the electromagnetic switch is damaged;
clutch on the replace the
compressor is electromagnetic clutch
damaged on the compressor
7 The electromagnetic clutch on the The opening of the Check the
compressor acts frequently, short temperature control temperature control
contacting time, and the cab is not cold, switch is small, and switch, and turn it to
and the readings of the high and low the compressor is the coldest position.
pressure gauges are normal. forced to stop
automatically, causing
insufficient
refrigerating volume.

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Technical Parameters
Items Unit MT190 / SEM919 MT210 / SEM921
Traction kN 78 84

Forward I gear km/h 5.4 5.4

Forward II gear km/h 9.5 9.5

Forward III gear km/h 12.4 12.4

Forward IV gear km/h 21.2 21.2

Forward V gear km/h 26.2 26.2

Forward VI gear km/h 43.8 43.8

Reverse I gear km/h 5.4 5.4

Reverse II gear km/h 12.4 12.4

Reverse III gear km/h 26.2 26.2

Max. gradeability ° 30 30

Min. turning radius mm 7374 7374

Blade width mm 3669(12ft) 4279(14ft)

Wheel base mm 6138 6138

Wheel track mm 2185 2185

Min. clearance mm 413 413

Operation weight kg 15100 15900

Diesel engine model SC9D190G2 SC9D220G2

Diesel engine rated power kw 140 154

Diesel engine rated rev r/min 2200 2200

Diesel engine max. torque n.m 720 855


Diesel engine fuel
consumption under
specific work conditions g/kw.h ≤220 ≤220

Transmission gear shifting 6F/3R 6F/3R


Variable speed pump (gear
pump) working pressure Mpa 1.3-1.7 1.3-1.7

Tyre pressure (front axle) Mpa 250 250

Tyre pressure (rear axle) Mpa 250 250

Service brake type Gas cap oil drum brake Gas cap oil drum brake

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