572-5318

2019-05

Operation and Maintenance

Manual
SEM636D Wheel Loader
3D3 (636D Stage Ⅱ Engine)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions.An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs.A person must be alert to potential hazards, including human factors that can affect
safety.This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify that you
are authorized to perform this work, and have read and understood the operation, lubrication,
maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product.If these hazard warnings are not
heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”,
“WARNING” or “CAUTION”.The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product, Caterpillar (Qingzhou) Ltd.
recommends using SEM replacement parts.
Failure to follow this warning may lead to
premature failures, product damage, personal
injury or death.
 Month and Year of Manufacture .............................. 22
Table of Contents
PREFACE ................................................................. 4
Operation Section................................... 27
Control devices and monitoring system .................. 28
Safety Section .......................................... 6
Operating Precautions ............................................ 35
Description and location of the safety messages ..... 6
I. Before Starting the Engine .................................. 35
General Precaution ................................................... 9
II. When Starting the Engine ................................... 36
Safety Requirements ................................................ 9
III. After starting the engine ..................................... 36
Safety Devices .......................................................... 9
Ⅳ. Storage of the Machine ..................................... 39
Clothing and Personal Protective Equipment ......... 10
V. Shipping of the Machine .................................... 40
Pressurized Air and Water ...................................... 10
Trapped Pressure ................................................... 10 Ⅵ. Battery Use and Maintenance Considerations............ 42

Fluid Penetration ..................................................... 10 Ⅶ. Towing................................................................ 43

Containing Fluid Spillage ........................................ 10 Machine Operation .................................................. 45

Dispose of Waste Properly ..................................... 11 Decommissioning and Disposal .............................. 48

Crushing Prevention and Cutting Prevention ......... 11 Maintenance Section .............................. 49

Burn Prevention ...................................................... 12 Maintenance Considerations ....................................... 52
Batteries .................................................................. 12 Important Maintenance Procedure .......................... 57
Fire Prevention and Explosion Prevention ............. 12 Engine Coolant Maintenance .................................. 57
Batteries and battery cables ................................... 13 Maintenance of Engine Air Cleaner ........................ 59
Fire Extinguisher and First Aid Kit .......................... 15 Use and Maintenance of Diesel .............................. 61
Fire Safety .............................................................. 15 Maintenance of Engine Oil ...................................... 62
Fire Extinguisher Location ...................................... 15 Maintenance of Air Conditioning Heater System .... 62
Tire Information ....................................................... 16 Maintenance of Transmission ................................. 63
Lightning Damage Prevention ................................ 16 Maintenance of Drive Axle ...................................... 64
Before Starting Engine................................................ 16 Maintenance of Hydraulic System .............................. 65
Visibility Information .................................................... 17 Knowledge of Tire Maintenance and Inflation ......... 66
Restricted Visibility .................................................. 17 Bucket Kickout Adjustment ...................................... 66
Slope Operation ...................................................... 17 Checking service brake performance ......................... 67
Work Tools .............................................................. 18 Checking park brake friction plate ........................... 67
Equipment Lowering with Engine Stopped ............. 19 Fault Reason and Troubleshooting ......................... 71
Sound Information ................................................... 19 SEM636D Regular Maintenance Parts List ............ 77
Vibration Information ............................................... 19
Information Concerning Seat Vibration ................... 19
Cab ......................................................................... 20

Product Information .............................. 20

General Information ................................................ 20
3
PREFACE Maintenance
The maintenance section is a guide to the equipment
Literature Information care.The Maintenance Interval Schedule (MIS) lists
This manual contains safety information, operation the items to be maintained at a specific service
instructions, driving information, lubrication interval.Items without specific intervals are listed
information and maintenance information. under the “When Required” service interval.The
Maintenance Interval Schedule also lists the page
This operation manual details the important aspects number for the step-by-step instructions required to
of safety, operation, maintenance, inspection, etc., accomplish the scheduled maintenance.Use the
and should be kept available and read regularly.If Maintenance Interval Schedule as an index or "one
this manual is missing or dirty and not legible, you safe source (spare parts, tools and fluids manuals)"
should re-purchase it at the dealer.When you sell the for all maintenance procedures.
machine, please ensure that the manual is also
forwarded to the new user. Maintenance Intervals
The technical parameters, specifications and The maintenance section of this manual is a
illustrations in this manual are on the basis of guideline for routine maintenance of the machine
information that was available at the time that the and is organized by maintenance intervals.The
manual was written.Continuing modification of maintenance intervals listed in this manual are
product design may affect the maintenance and determined by using the service hour meter.Calendar
repair of the machine which are not included in this intervals shown (daily, weekly, monthly, etc.) can be
manual.Whenever a question arises regarding your used instead of service hour meter intervals if they
machine, or this manual, please consult with the provide more convenient servicing schedules and
manufacturer or your dealer for the latest available approximate the indicated service hour meter
information. reading.Caterpillar (Qingzhou) Ltd. recommends
service should always be performed at the interval
SECURITY that occurs first.Under extremely severe, dusty or
Caterpillar (Qingzhou) Ltd. cannot anticipate every wet operating conditions, more frequent lubrication
working circumstance that might involve a hazard. than is specified in the scheduled maintenance might
The warnings in this manual and on the product are, be necessary.Perform service on items at multiples
therefore, not all inclusive.If a tool, procedure, work of the original requirement.For example, at every 500
method or operating technique that is not specifically service hours or 3 months, also service those items
recommended by Caterpillar (Qingzhou) Ltd. is listed under every 250 service hours or monthly,
used, you must satisfy yourself that it is safe for you every 50 service hours or weekly and every 10
and for others.You should also ensure that the service hours or daily.
machine will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair
Engine Maintenance
procedures that you intend to use. Proper maintenance and repair is essential to keep
the engine and machine systems operating
Operation correctly.As the heavy duty off-road diesel engine
The operation section is a reference for new owner, you are responsible for the performance of
operators and a refresher for experienced ones.This the required maintenance listed in the Operation and
section includes a discussion of gauges, switches, Maintenance Manual.It is prohibited for any person
machine controls, attachment controls, transportation engaged in the business of repairing, servicing,
and towing information. selling, leasing, or trading engines or machines to
remove, alter, or render inoperative any emission
Photographs and illustrations guide the operator related device or element of design installed on or in
through correct procedures of checking, starting, an engine or machine that is in compliance with the
operating and stopping the machine. regulations.Certain elements of the machine and
Operating techniques outlined in this publication are engine such as the exhaust system, fuel system,
basic.Skill and techniques develop as the operator electrical system, intake air system and cooling
gains knowledge of the machine and the capabilities system may be emission related and should not be
of the machine. altered unless approved by Caterpillar (Qingzhou)
Ltd.

4
Machine Capacity
Each loader has its own design capability. Additional
attachments or modifications may exceed loader
design capacity which can adversely affect
performance characteristics. Included would be
operational stability, brakes and steering.Please
contact your dealer for updated information.As
shown below:

SEM Product Identification Number

1. World Manufacturing Code

2. Machine Description Section
3. Verification Symbol
4. Machine Indicator Section

5
Safety Section

missing.If a safety message is attached to a part of

the machine that is replaced, install a safety
message on the replacement part.Any Cat dealer
Please read and become familiar with all safety
can provide new safety messages.
instructions. Failure to do so could result in
serious injury or death.
This Safety Section also includes precautions for
optional attachments.

Description and location of the

safety messages
There are several specific safety messages on this
machine.The exact location of the hazards and the
description of the hazards are reviewed in this
section.Please become familiar with all safety
messages.
Make sure that all of the safety messages are
legible.Clean the safety messages or replace the
safety messages if you cannot read the
words.Replace the illustrations if the illustrations are
not legible.When you clean the safety messages,
use a cloth, water and soap.Do not use solvent,
gasoline, or other harsh chemicals to clean the
safety messages.Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures
the warning sign.Loose adhesive will allow the
warning sign to fall.
Replace any safety message that is damaged or

6
7
Do Not Operate
This safety message is located in the cab.
Do not get close to the machine until the engine
stops.

Message for No Standing Under the

Boom
The message is located on the outside of the boom.

Do not operate this machine unless you have

read and understand the instructions and
warnings in the Operation and Maintenance
Manual.Failure to do so may result in personal
injury or death.Contact any Caterpillar dealer for
replacement manuals.Proper care is your Lift Point Indicator
responsibility. The message is located on the inside of the
machine.

Warn labels for Hands Hurt by Fan

The message is located at the rear of the hood.

This message indicates the position of lifting the

whole machine.

No Entry when Working

The message is located in the articulation position at
the middle of the machine.
Please do not put your hands near the running
fan. Do not touch the machine in operation.

No Entry when Reversing message

The message is located on the rear of the machine.

Articulation Lockout Sign

The message is located in the articulation position at
the middle of the machine.

8
 Fuel Tank Sign
This message is located by the fuel tank.

Alternate Exits
The message is located in the cab on the right post
by the window latch.

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

If the primary exit becomes blocked, the window

on the right side can be used as an alternate
exit.Pull the latch backward, then push it outward
to open the window to the partial open
position.Remove pin from the latch.Push the
window open and exit the machine through the
window.
General Precaution
Parking Brake sign Safety Requirements
The message is located inside the cab. ⚫ Only trained and appropriately qualified
personnel could operate and maintain the
machine.
⚫ Observe all safety rules, precautions and
instructions when operating and maintaining the
machine.
⚫ Do not operate the machine if you do not feel
well, feel dizzy after taking medication or after
drinking.In this case, it will lead to the wrong
judgment and potential accident.
Engage the parking brake while the machine is ⚫ When working with another operator or traffic
parking. commander on site, you must ensure that all
personnel understand the hand signals being
used.
Hydraulic Oil
⚫ Observe all rules concerning safety.
The message indicates the hydraulic oil and is
located next to the hydraulic oil tank. Safety Devices
⚫ Make sure that all protective devices and hoods
are secured in the right place. Repair timely if
9
 they are damaged. protective shoes.The maximum air pressure for
cleaning purposes must be below 205 kPa.The
⚫ Use safety devices properly, such as lever
maximum water pressure for cleaning purposes
locking devices and safety belts.
must be below 275 kPa.
⚫ Never remove the safety device. Always keep it
⚫ Avoid direct spraying of water on electrical
in good working condition.
connectors, connections, and
⚫ Improper use of safety devices can result in components.When using air for cleaning, allow
serious injury or death. the machine to cool to reduce the possibility of
fine debris igniting when re-deposited on hot
⚫ Lock the safety devices when you exit the
surfaces.
operator seat.
⚫ Engage the parking brake switch before you Trapped Pressure
exit the seat.If the control lever is accidentally
touched, the work tools may suddenly move, Pressure can be trapped in a hydraulic
causing serious injury. system.Releasing trapped pressure can cause
sudden machine movement or attachment
⚫ When you leave the loader, lower the work tool movement.Use caution if you disconnect hydraulic
completely to the ground, engage the parking lines or fittings.High-pressure oil that is released can
brake switch, shut off the engine, lock all cause a hose to whip.High-pressure oil that is
devices with the key, and take the key with you. released can cause oil to spray.Fluid penetration can
⚫ If the right window is closed, make sure that the cause serious injury and possible death.
hooks are fully secured to prevent loosening.
Fluid Penetration
⚫ If the window is locked, be sure to tighten the
lock seat to prevent collision between the loose Pressure can be trapped in the hydraulic circuit long
glass and the lock seat. after the engine has been stopped.The pressure can
cause hydraulic fluid or items such as pipe plugs to
Clothing and Personal escape rapidly if the pressure is not relieved
correctly.
Protective Equipment
Do not remove any hydraulic components or parts
⚫ Do not wear loose clothing or jewelry. Do not until pressure has been relieved or personal injury
keep long hair.They may snap into or get caught may occur.Do not disassemble any hydraulic
in the controls or moving parts, causing serious components or parts until pressure has been
injury or death. relieved or personal injury may occur.
⚫ Do not wear greasy clothing to prevent burning.
⚫ When you operate or maintain the machine,
wear a hard hat, protective glasses, protective
shoes, protective masks and gloves.Wear
protective goggles, hard hat, and heavy gloves
when throwing metal chips and tiny debris,
especially when hammering pins and removing
air filter contaminants with compressed air.Also
check to make sure no one is near the machine.
Always use a board or cardboard when you check
for a leak.Leaking fluid that is under pressure can
penetrate body tissue.Fluid penetration can cause
serious injury and possible death.A pin hole leak can
cause severe injury.If fluid is injected into your skin,
you must get treatment immediately.Seek treatment
from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Pressurized Air and Water
Care must be taken in order to ensure that fluids are
⚫ Pressurized air can cause personal injury.When contained during performance of inspection,
pressurized air is used for cleaning, wear maintenance, testing, adjusting, and repair of the
protective masks, protective clothing and
10
equipment.Prepare to collect the fluid with suitable used.
containers before opening any compartment or
Use exhaust ventilation on permanent machining
disassembling any component that contains fluids.
jobs.
Refer to Special Publication SEM Dealer Service
Wear an approved respirator if there is no other way
Tools Catalog for the following items:
to control the dust.
Tools that are suitable for collecting fluids and
Comply with applicable rules and regulations for the
equipment that is suitable for collecting fluids
work place.
Tools that are suitable for containing fluids and
Use the requirements found in the “Ordinance on
equipment that is suitable for containing fluids
Prevention of Health Impairment due to Asbestos” in
Obey all local regulations for the disposal of liquids. addition to the requirements of the Industrial Safety
and Health Act.
Inhalation
Obey environmental regulations for the disposal of
asbestos.
Stay away from areas that might have asbestos
particles in the air.

Dispose of Waste Properly

Exhaust
Use caution.Exhaust fumes can be hazardous to
your health.If you operate the machine in an
enclosed area, adequate ventilation is necessary.
Asbestos Materials
SEM equipment and replacement parts shipped from
Caterpillar (Qingzhou) Ltd. are asbestos Improperly disposing of waste can threaten the
free.Caterpillar (Qingzhou) Ltd., recommends the environment.Potentially harmful fluids should be
use of only genuine SEM replacement parts.Use the disposed of according to local regulations.
following guidelines when you handle any Always use leakproof containers when you drain
replacement parts that contain asbestos or when you fluids. Do not pour waste onto the ground, down a
handle asbestos debris.Use caution.Avoid inhaling drain, or into any source of water.
dust that might be generated when you handle
components that contain asbestos fibers.Inhaling this
dust can be hazardous to your health.The Crushing Prevention and
components that may contain asbestos fibers are
brake pads, brake bands, lining material, clutch
Cutting Prevention
plates, and some gaskets.The asbestos that is used Support the equipment properly before you perform
in these components is bound in a resin or sealed in any work or maintenance beneath that equipment.Do
some way.Normal handling is not hazardous unless not depend on the hydraulic cylinders to hold up the
airborne dust that contains asbestos is generated. equipment.Unit can fall if a control is moved, or if
hydraulic lines break.
If dust that may contain asbestos is present, there Do not work beneath the cab of the machine unless
are several guidelines that should be followed: the cab is properly supported.
Unless you are instructed otherwise, never attempt
Never use compressed air for cleaning.
adjustments while the machine is moving or while
Avoid brushing materials that contain asbestos. the engine is running.
Never jump across the starter solenoid terminals in
Avoid grinding materials that contain asbestos.
order to start the engine.Unexpected machine
Use a wet method in order to clean up asbestos movement could result.
materials. Whenever there are equipment control linkages the
clearance in the linkage area will change with the
A vacuum cleaner that is equipped with a high
movement of the equipment or the machine.Stay
efficiency particulate air filter (HEPA) can also be
clear of areas that may have a sudden change in
11
clearance with machine movement or equipment Do not smoke while checking the battery electrolyte
movement. levels.Batteries give off flammable fumes which can
Stay clear of all rotating and moving parts. explode.
If it is necessary to remove guards in order to
perform maintenance, always install the guards back Fire Prevention and Explosion
after the maintenance is completed.Keep objects
away from moving fan blades.The fan blade will Prevention
throw objects or cut objects.

Burn Prevention
Do not touch any part of an operating engine.Allow
the engine to cool before any maintenance is
performed on the engine.Relieve all pressure in the
air system, in the oil system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings, or related items are
disconnected. All fuels, most lubricants, and some coolant mixtures
are flammable.
To minimize the risk of fire or explosion, Caterpillar
Coolant (Qingzhou) Ltd. recommends the following actions.
When the engine is at operating temperatures, the
Always perform a Walk-Around Inspection, which
engine coolant is hot and under pressure.The
may help you identify a fire hazard.Do not operate a
radiator and all lines to the heaters or to the engine
machine when a fire hazard exists.Consult your SEM
contain hot coolant.
dealer for details.
Any contact with hot coolant or with steam can cause
Understand the use of the primary exit and
severe burns.Allow cooling system components to
alternative exit on the machine.Refer to “Alternative
cool before the cooling system is drained.
Exit” in the Operation and Maintenance Manual.
Check the coolant level only after the engine has
Do not operate a machine with a fluid leak.Repair
been stopped.
leaks and clean up fluids before resuming machine
Ensure that the filler cap is cool before removing the operation.Fluids that are leaking or spilled onto hot
filler cap.The filler cap must be cool enough to touch surfaces or onto electrical components can cause a
with a bare hand.Remove the filler cap slowly in fire.A fire may cause personal injury or death.
order to relieve the pressure.
Remove flammable material such as leaves, twigs,
Cooling system conditioner contains alkali.Alkali can papers, trash, and so on.These items may
cause personal injury. accumulate in the engine compartment or around
other hot areas and hot parts on the machine.
Do not allow the alkali to contact the skin, the eyes,
or the mouth. Keep the access doors to major machine
compartments closed and access doors in working
condition in order to permit the use of fire
Oil suppression equipment, in case a fire should
Hot oil and hot components can cause personal occur.Clean all accumulations of flammable
injury.Do not allow hot oil to contact the skin.Also, do materials such as fuel, oil, and debris from the
not allow hot components to contact the skin. machine.

Remove the hydraulic tank filler cap only after the Do not operate the machine near any flame.
engine has been stopped.The filler cap must be cool Keep shields in place.Exhaust shields (if equipped)
enough to touch with a bare hand.Follow the protect hot exhaust components from oil spray or
standard procedure in this manual in order to remove fuel spray in case of a break in a line, in a hose, or in
the hydraulic tank filler cap. a seal.Exhaust shields must be installed correctly.Do
not weld or flame cut on tanks or lines that contain
Batteries flammable fluids or flammable material.Empty and
purge the lines and tanks.Then clean the lines and
The liquid in a battery is an electrolyte.Electrolyte is tanks with a nonflammable solvent prior to welding or
an acid that can cause personal injury.Do not allow flame cutting.Ensure that the components are
electrolyte to contact the skin or the eyes. properly grounded in order to avoid unwanted arcs.

12
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
explosive.Repair such components in a well
ventilated area away from open flames or
sparks.Use suitable Personal Protection Equipment
(PPE).
Inspect all lines and hoses for wear or
deterioration.Replace damaged lines and hoses.The
lines and the hoses should have adequate support
and secure clamps.Tighten all connections to the
recommended torque.Damage to the protective
cover or insulation may provide fuel for fires.
Caterpillar (Qingzhou) Ltd. recommends the
Store fuels and lubricants in properly marked following in order to minimize the risk of fire or an
containers away from unauthorized personnel.Store explosion related to the battery.
oily rags and flammable materials in protective
containers.Do not smoke in areas that are used for Do not operate a machine if battery cables or related
storing flammable materials. parts show signs of wear or damage.Consult your
SEM dealer for details.
Follow safe procedures for engine starting with jump-
start cables.Improper jumper cable connections can
cause an explosion that can result in injury.Refer to
“Engine Starting with Jump Start Cables” in the
Operation and Maintenance Manual for specific
instructions.
Do not charge a frozen battery.This may cause an
explosion.
Gases from a battery can explode.Keep any open
flames or sparks away from the top of a battery.Do
not smoke in battery charging areas.Do not use cell
phones or other electronic devices in battery
charging areas.
Use caution when you are fueling a machine.Do not
smoke while you are fueling a machine.Do not fuel a Never check the battery charge by placing a metal
machine near open flames or sparks.Do not use cell object across the terminal posts.Use a voltmeter in
phones or other electronic devices while you are order to check the battery charge.
refueling.Always stop the engine before refueling.Fill Daily inspect battery cables that are in areas that are
the fuel tank outdoors.Properly clean areas of visible.Inspect cables, clips, straps, and other
spillage. restraints for damage.Replace all damaged
Avoid static electricity risk when fueling.Ultra low parts.Check for signs of the following, which can
sulfur diesel (ULSD) poses a greater static ignition occur over time due to use and environmental
hazard than earlier diesel formulations with a higher factors:
sulfur content.Avoid death or serious injury from fire Fraying
or explosion.Consult with your fuel or fuel system
supplier to ensure that the delivery system is in Abrasion
compliance with fueling standards for proper
Cracking
grounding and bonding practices.
Discoloration
Never store flammable fluids in the operator
compartment of the machine. Cuts on the insulation of the cable
Fouling
Batteries and battery cables
Corroded terminals, damaged terminals, and loose
terminals

13
Replace damaged battery cables and replace any
related parts.Eliminate any fouling, which may have
caused insulation failure or related component
damage or wear.Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surface.A battery cable
short produces heat from the battery current, which
may be a fire hazard.
Check lines, tubes, and hoses carefully.Wear
An exposed wire on the ground cable between the Personal Protection Equipment (PPE) to check for
battery and the disconnect switch may cause the leaks.Always use a board or cardboard when you
disconnect switch to be bypassed if the exposed check for a leak.Leaking fluid that is under pressure
area comes into contact with a grounded can penetrate body tissue.Fluid penetration can
surface.This may result in an unsafe condition for cause serious injury and possible death.Even a
servicing the machine.Repair components or replace pinhole size leak can also
components before servicing the machine.
lead to serious personal injury.If fluid is injected into
your skin, you must get treatment immediately.Seek
treatment from a doctor that is familiar with this type
Fire on a machine could result in personal injury of injury.
or death.Exposed battery cables that come into Replace the affected parts if any of the following
contact with a grounded connection could result conditions are present:
in fires.
End fittings are damaged or leaking.
Check electrical wires daily.If any of the following Outer coverings are chafed or cut.
conditions exist, replace parts before you operate the
machine. Wires are exposed.

Fraying Outer coverings are swelling or ballooning.

Signs of abrasion or wear Flexible parts of the hoses are kinked.

Cracking Outer covers have exposed embedded armoring.

Discoloration End fittings are displaced.

Cuts on insulation Make sure that all clamps, guards, and heat shields
are installed correctly.During machine operation, this
Other damage will help to prevent vibration, rubbing against other
Make sure that all clamps, guards, clips, and straps parts, excessive heat, and failure of lines, tubes, and
are reinstalled correctly.This will help to prevent hoses.
vibration, rubbing against other parts, and excessive Do not operate a machine when a fire hazard
heat during machine operation. exists.Repair any lines that are corroded, loose, or
Attaching electrical wiring to hoses and tubes that damaged.Leaks
contain flammable fluids or combustible fluids should may provide fuel for fires.Consult your SEM dealer
be avoided. for repair or replacement parts.Use genuine SEM
Consult your SEM dealer for repair or replacement parts or the equivalent, for capabilities of both the
parts.Keep wiring and electrical connections free of pressure limit and temperature limit.
debris. Ether
Lines, Tubes, and Hoses Ether (if equipped) is commonly used in cold-
Do not bend high-pressure lines.Do not strike high- weather applications.Ether is flammable and
pressure lines.Do not install any lines that are bent poisonous.
or damaged.Use the appropriate backup wrenches Only use approved ether cylinders for the ether
to tighten all connections to the recommended dispensing system fitted to your machine. Do not
torque. spray ether manually into an engine. Follow the
correct cold engine starting procedures.
Use ether in ventilated areas.Do not smoke while
14
you are replacing an ether cylinder.Do not store Notify emergency personnel of the fire and your
ether cylinders in living areas or in the operator location.If your machine is equipped with a fire
compartment of a machine.Do not store ether suppression system, follow the manufacturer’s
cylinders in direct sunlight or in temperatures above procedure to activate the system.
49°C (120.2°F).Keep ether cylinders away from open
Note: Fire suppression systems need to be
flames or sparks.Dispose of used ether cylinders
regularly inspected by qualified personnel.You must
properly.Do not puncture an ether cylinder.Keep
be trained to operate the fire suppression system.
ether cylinders away from unauthorized personnel.
Use the on-board fire extinguisher and use the
Fire Extinguisher and First Aid following procedure:
Kit 1. Pull the pin.

In the event of injury or fire, take actions according to 2. Aim the extinguisher or nozzle at the base of the
the following precautions. fire.

Keep a fire extinguisher on the machine. Read the 3. Squeeze the handle and release the
instructions carefully and make sure to know how to extinguishing agent.
use. 4. Sweep the extinguisher from side to side across
Always have a first aid kit at the work site.Check the base of the fire until the fire is put out.
regularly and, if necessary, supplement some Remember, if you are unable to do anything else,
medicines. shut off the machine before exiting.By shutting off
Know what to do in case of a fire or injury. the machine, fuels will not continue to be pumped
into the fire.
Make available the phone numbers of some people
(such as doctors, emergency centers, fire stations, If the fire grows out of control, be aware of the
etc.) to contact in case of emergency.Put these following risks:
contact numbers in the specified places and make Tires on wheeled machines pose a risk of explosion
sure all people know the numbers and the correct as tires burn. Hot shrapnel and debris can be thrown
method of contact. great distances in an explosion.

Fire Safety Tanks, accumulators, hoses, and fittings can rupture

in a fire, spraying fuels and shrapnel over a large
Note:Locate secondary exits and how to use the area.
secondary exits before you operate the machine. Remember that nearly all of the fluids on the
Note: Locate fire extinguishers and how to use a fire machine are flammable, including coolant and oils.
extinguisher before you operate the machine. Additionally, plastics, rubbers, fabrics, and resins in
fiberglass panels are also flammable.
If you find that you are involved in a machine fire,
your safety and that of others on site is the top
priority.The following actions should only be Unauthorized Modification
performed if the actions do not present a danger or
risk to you and any nearby people. At all times you Any modifications not approved by Caterpillar
should assess the risk of personal injury and move (Qingzhou) Ltd. may result in danger.Before
away to a safe distance as soon as you feel unsafe. modifying the machine, consult your dealer
designated by Caterpillar (Qingzhou) Ltd.Caterpillar
Move the machine away from flammables, such as (Qingzhou) Ltd. assumes no liability for any
gas stations, buildings, garbage dumps, coverings damages resulting from unauthorized modifications.
and wood.Lower any implements and turn off the
engine as soon as possible.If you leave the engine Fire Extinguisher Location
running, the engine will continue to feed a fire. Any Make sure that a fire extinguisher is available on the
damaged hoses that are connected to the engine or machine.Be familiar with the operation of the fire
pump can cause a fire. extinguisher.Inspect the fire extinguisher and service
Turn the battery disconnect switch to the OFF the fire extinguisher on a regular basis. Obey the
position, if possible.Disconnecting the battery will recommendations on the instruction plate.
eliminate the ignition source in the event of a short Mount the fire extinguisher in the cab.
circuit.Disconnecting the battery will eliminate a Strap the mounting plate to a leg of the ROPS in
second ignition source if electrical wiring is damaged order to mount the fire extinguisher, as needed.If the
by the fire, resulting in a short circuit. weight of the fire extinguisher is more than 4.5 kg (10
lb), mount the fire extinguisher as low as possible on
15
one leg.Do not mount the fire extinguisher at the and/or rim failure.
upper one-third area of the ROPS leg.
Note:Do not weld the ROPS structure in order to Dry nitrogen gas is recommended for inflation of
install the fire extinguisher.Also, do not drill holes in tires.If the tires were originally inflated with air,
the ROPS structure in order to mount the fire nitrogen is still preferred for adjusting the
extinguisher on the ROPS. pressure.Nitrogen mixes properly with air.

Tire Information Nitrogen inflated tires reduce the potential of a tire

explosion because nitrogen does not aid
Explosions of pneumatic tires have resulted from
combustion.Nitrogen helps to prevent oxidation of
heat-induced gas combustion inside the
the rubber, deterioration of rubber, and corrosion of
tires.Explosions can be caused by heat that is
rim components.
generated by welding, by heating rim components,
by external fire, or by excessive use of brakes. To avoid overinflation, proper nitrogen inflation
A tire explosion is much more violent than a equipment and training in the usage of the
blowout.The explosion can propel the tire, the rim equipment are necessary.A tire blowout or a rim
components, and the axle components from the failure can result from improper equipment or from
machine.Stay outside the area with flying misused equipment.
objects.Both the force of the explosion and the flying
When you inflate a tire, stand behind the tread and
debris can cause property damage, personal injury,
use a self-attaching chuck.
or death.
Typical example of tire is shown below. Servicing tires and rims can be dangerous.Only
trained personnel that use proper tools and proper
procedures should perform this maintenance.
If correct procedures are not used for servicing tires
and rims, the assemblies could burst with explosive
force.This explosive force can cause serious
personal injury or death.Carefully obey the specific
instructions from your tire dealer.

Lightning Damage Prevention

When lightning is striking in the vicinity of the
machine, the operator should never attempt the
Do not approach a warm or an apparently damaged following operations:
tire.
Mount the machine.
Caterpillar (Qingzhou) Ltd. recommends against
using water or calcium as a ballast for the tires Dismount the machine.
except in machines designed for this additional If you are in the operator’s station during an electrical
mass.For those applicable machines, the storm, stay in the operator’s station.If you are on the
maintenance section will contain instructions on the ground during an electrical storm, stay away from the
correct tire inflation and filling procedures.Ballast, vicinity of the machine.
such as fluid in the tires, increases overall machine
weight and may affect braking, steering, power train Before Starting Engine
components, or the certification of the protective The steering frame lock must be in the unlocked position in
structure such as the ROPS.The use of tire/rim rust order to steer the machine.
preventatives or other liquid additives is not required.
Start the engine only from the operator
compartment.Never short across the starter
terminals or across the batteries.Shorting could
To avoid overinflation, proper nitrogen inflation bypass the engine neutral start system.Shorting
equipment and training in the usage of the could also damage the electrical system.
equipment are necessary.A tire blowout or a rim Inspect the condition of the seat belt and the
failure can result from improper equipment or condition of the mounting hardware.Replace any
from misused equipment, which could result in damaged parts or worn parts.Regardless of
personal injury or death.Due to the high pressure appearance, replace the seat belt after three years of
of approximately 15,000 kPa (2,200 psi) in the use.
nitrogen tank, when fully filled, improper use of
the inflation equipment can result in tire blowout Do not use a seat belt extension on a retractable
seat
16
belt.Adjust the seat so that full pedal travel can be and that the visual aids are clean.Adjust the visual
achieved when the operator's back is against the aids using the procedures that are located in this
back of the seat. Operation and Maintenance Manual.It may not be
possible to provide direct visibility on large machines
Make sure that the machine is equipped with a
to all areas around the machine.Appropriate job site
lighting system that is adequate for the job
organization is required in order to minimize hazards
conditions.Make sure that all lights are working
that are caused by restricted visibility.Job site
properly.
organization is a collection of rules and procedures
Before you start the engine or before you move the that coordinates machines and people that work
machine, make sure that no one is on the machine, together in the same area.Examples of job site
underneath the machine, or around the organization include the following:
machine.Ensure that there are no personnel in the
Safety instructions
area.
Controlled patterns of machine movement and
Visibility Information vehicle movement
Before you start the machine, perform a walk-around Workers that direct traffic to move when it is safe
inspection in order to ensure that there are no
hazards around the machine. Restricted areas
While the machine is in operation, constantly survey Operator training
the area around the machine in order to identify Warning symbols or warning signs on machines or
potential hazards as hazards become visible around
the machine.Before operating the machine, ensure
that the visual aids are in proper working condition
on vehicles
Communication system
Communication between workers and operators prior
to approaching the machine
Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
evaluated.

Restricted Visibility
The size and the configuration of this machine may
result in areas that cannot be seen when the
operator is seated.The illustration provides an
approximate visual indication of areas of significant
restricted visibility.The illustration indicates restricted
visibility areas at ground level inside a radius of 12 m
(40 ft) from the operator on a machine without the
use of optional visual aids.This illustration does not Note:The shaded areas indicate the approximate
provide areas of restricted visibility for distances location of areas with significant restricted
outside a radius of 12 m (40 ft). visibility.

Slope Operation
The safe machine operation in various applications
depends on the following conditions:Machine model,
configuration, machine maintenance, operating
speed of the machine, conditions of the terrain, fluid
levels, and tire inflation pressures.The most
important criteria are the skill and judgment of the
operator.
A well trained operator that follows the instructions in
the Operation and Maintenance Manual has the
greatest impact on stability.Operator training
provides a person with the following abilities:

17
Observation of working and environmental Nature of surface – Ground that has been newly
conditions, knowledge of machine performance, filled with earth may collapse from the weight of the
identification of potential hazards, and operating the machine.
machine safely by making appropriate decisions.
Surface material – Rocks and moisture of the
When you work on side hills and when you work on surface material may drastically affect the machine's
slopes, consider the following important points: traction and machine's stability.Rocky surfaces may
Travel Speed - The inertia will reduce the stability of promote side slipping of the machine.
the machine at high speed.
Slippage due to excessive loads – This may
Roughness of ground or surface – The machine cause downhill tracks or downhill tires to dig into
may be less stable on uneven ground. the ground, which will increase the angle of the
Direction of travel – Avoid operating the machine machine.
across the slope.When possible, operate the
machine up the slopes and down the slopes.Place Width of tracks or tires – Narrower tracks or
the heaviest end of the machine uphill when you are narrower tires further increase the digging into the
working on an incline. ground which causes the machine to be less stable.
Mounted equipment - Balance of the machine may Implements attached to the drawbar – This may
be impeded by the following items: Equipment decrease the weight on the uphill tracks.This may
mounted on the machine, machine configuration, also decrease the weight on the uphill tires.The
weight, and counterweights. decreased weight will cause the machine to be less
stable. specifications under special circumstances.In these
cases, customers must be aware that such choices
Height of the working load of the machine –
can reduce the machine performance and can affect
When the working loads are in higher positions, the
their warranty claims when they detect premature
stability of the machine is reduced.
failures on the machine.
Operated equipment – Be aware of features of
Work tools and work tool control systems that are
the equipment in operation and the effects on
compatible with SEM machine must be used for safe
machine stability.
machine operations and/or reliability. For any
Operating techniques – Keep all attachments or questions on the compatibility of a particular work
pulled loads low to the ground for optimum stability. tool with your machine, consult your SEM
dealer.Make sure that all protective guards are
Machine systems have limitations on slopes – secured in place on the machine and on the work
Slopes can affect the proper function and tools.
operation of the various machine systems.These
machine systems are needed for machine control. Secure all windows and doors of the machine in the
shut position.A polycarbonate guard needs to be
Note: Safe operation on steep slopes may require
installed when the machine is not equipped with
special machine maintenance.Excellent skill of the windows and when a work tool that creates flying
operator and proper equipment for specific objects is used.
applications are also required. Consult the Operation
and Maintenance Manual sections for the proper Do not exceed the maximum operating weight as
fluid level requirements and intended machine use. specified.
If your machine is equipped with an extendable stick,
Work Tools install the driver pin when you are using the following
Only work tools recommended by Caterpillar work tools:When working with the hydraulic
(Qingzhou) Ltd. can be used on SEM machines.Any hammers, augers and compactors, always wear the
use of work tools including buckets that are not goggles.Always wear the protective equipment that
recommended by Caterpillar (Qingzhou) Ltd. or is recommended in the operation manual for the
whose weight, size, flow rate, pressure, etc. exceed work tool.Wear other protective equipment that is
the specified specifications may result in diminished required for working condition.
performance of the machine, including but not limited To avoid injury caused by flying objects, ensure that
to, reduced production, stability, reliability, and all personnel are out of the work area.
component durability.Caterpillar (Qingzhou) Ltd.
recommends the use of While you are performing any maintenance, any
testing, or any adjustments to the work tool, stay
suitable implements on our machine so that the clear of the following areas:Cutting edges, pinching
customer can obtain maximum value out of our surfaces, and crushing surfaces.
products.Caterpillar (Qingzhou) Ltd. understands
that customers may use work tools that exceed our Never use the work tool as a work platform.

18
Equipment Lowering with Vibration Information
Engine Stopped Information Concerning Seat Vibration
Before lowering any equipment with the engine The suspension seat meets the criteria of "ISO 7096".
stopped, clear the area around the equipment of all This represents vertical vibration level under severe
personnel.The procedure to use will vary with the operating conditions. This seat is tested with the
type of equipment to be lowered.Keep in mind that input "spectral class EM3". The seat has a
Most systems use high-pressure fluid or air to raise transmissibility factor of “SEAT<1.0”.
or lower the equipment.The procedure will cause
high-pressure air, hydraulic oil, or some other media Guidelines for Reducing Vibration Levels
to be released in order to lower the equipment.Wear
appropriate personal protective equipment and follow
on Earthmoving Equipment
the established procedure in the Operation and Vibration levels are influenced by many different
Maintenance Manual, “Equipment Lowering with parameters, such as: operator training, operator
Engine Stopped” in the Operation Section of the behaviour, operator mode and stress, job site
manual. organization, job site preparation, job site
environment, job site weather, job site material,
Sound Level Information machine type, quality of the seat, quality of the
suspension system, attachments, and condition of
Refer to the machine Operation and Maintenance
Manual for the specific sound levels for your the equipment.
machine. “ISO 6396:2008” is used to measure the Properly adjust machines. Properly maintain
value for an enclosed cab.The value is machines. Operate machines smoothly. Maintain the
77dB(A) .The measurement was conducted at the conditions of the terrain. The following guidelines can
maximum engine cooling fan speed. The sound help reduce the whole-body vibration level:
1. Use the right type and size of machine, equipment
level may vary at different engine cooling fan and attachments.
speeds. The measurement was conducted with the 2. Maintain machines according to the manufacturers
cab doors and the cab windows closed. recommendations: tire pressures and brake and
Refer to the machine Operation and Maintenance steering systems, controls, hydraulic system, and
Manual for the specific sound levels for your linkages.
machine. The value is measured according to the 3. Keep the terrain in good condition by performing
dynamic test procedures and the conditions that are the following items: remove any large rocks or
specified in “ISO 6395:2008”. The value is obstacles, fill any ditches and holes and provide
112dB(A)The measurement was conducted at the machines and schedule time to maintain the
maximum engine cooling fan speed. The sound level conditions of the terrain.
may vary at different engine cooling fan speeds. 4. Keep the seat maintained and adjusted by doing
When sound levels are specified using either the following: adjust the seat and suspension for the
“ISO6395:2008” or “ISO 6396:2008”, the declared weight and the size of the operator and inspect and
level is a maximum sound level. The maximum sound maintain the seat suspension and adjustment
level includes both measurement uncertainty and mechanisms.
uncertainty due to production variation. 5. Perform the following operations smoothly: steer,
brake, accelerate, and shift the gears.
Hearing protection may be also needed when the
6. Move the attachments smoothly.
machine is operated with an open operator station
7. Adjust the machine speed and the route to
for extended periods or in a noisy environment.
minimize the vibration level by doing the following:
Hearing protection may be also needed when the
drive around obstacles and rough terrain and slow
machine is operated with a cab that is not
down when necessary to go over rough terrain.
properly maintained, or when the doors and
8. Minimize vibrations for a long work cycle or a long
windows are open for extended periods or in a
travel distance by doing the following: use machines
noisy environment.
that are equipped with suspension systems, if no ride
control system is available, reduce speed to prevent
bounce and haul the machines between workplaces.
9. Less operator comfort may be caused by other
risk factors. The following guidelines can be effective
to provide better operator comfort: adjust the seat
and adjust the controls to achieve good posture,
adjust the mirrors to minimize twisted posture,

19
provide breaks to reduce long periods of sitting,
avoid jumping from the cab, minimize repeated
handling of loads and lifting of loads and minimize
any shocks and impacts during sports and leisure
activities.
Consult your local SEM dealer for more information
about machine features that minimize vibration levels.
Consult your local SEM dealer about safe machine
operation.

Cab
Any modifications to the inside of the operator station
should not project into the operator space or into the
space for the companion seat (if equipped).The
defined operator and companion seat space (if
equipped) will be maintained.if the addition of a
radio, fire extinguisher, and other equipment must be
installed.Any item that is brought into the cab should
not project into the defined operator space or the
space for the companion seat (if equipped).Loose
items must be secured.Objects must not pose an
impact hazard in rough terrain or in the event of a
rollover.

Product Information
General Information
The main mechanisms on SEM636D machine are
equipped with the following features and advanced
technologies:
It uses engine that meets China StageⅡoff-road
emission regulation requirements and has been
optimized to match the conventional system more
reasonably for a higher efficiency.
An articulated vehicle frame is used to achieve a
small turning radius, mobility and flexibility. Easy to
operate in narrow areas.
The hydraulic mechanical transmission can
automatically change the speed continuously
according to the external resistance, making full use
of the engine power, improving the mobility of the
whole machine, simplifying the operation of the
loader, while protecting the engine and driveline
components.
Load-sensing full hydraulic steering, working and
steering combination for better energy-saving. Fixed
shaft power shifting transmission with optimized
technology by Cat, and reliable working device pilot
hydraulic control make the operation of the machine
easy and flexible, the movement stable and reliable.
Equipped with service braking system, emergency
and parking braking system to provide safe and
reliable braking performance, fully meeting the
requirements of GB/T21152.

20
Component Names of the Machine

1. Rocker Lever 5. Engine Hood 9. Boom

2. Bucket Cylinder 6. Rear Wheel 10. Bucket
3. Cab 7. Ladders
4. Engine 8. Front Wheel

21
Diesel Engines Cab
This machine is equipped with the six-cylinder, four- The standard cab is a fresh air featured cab. The cab
stroke, water-cooled, turbocharged, ATAAC engine. is equipped with vibration reducing system and can
This engine provides the good cold start greatly reduce the vibration and noise levels inside
performance, high altitude performance, low fuel the cab, and improve the comfort of the cab and the
consumption, low noise, reduced pollution operator's work efficiency through modal analysis
emissions, high reliability and durability. and test verification.In order to give the operator a
good view when operating the machine, our
designers equip the machine with glass windows and
Hydraulic System doors that are optimized in design.
Hydraulic system is composed of pilot hydraulic
system, work hydraulic system, steering hydraulic
Month and Year of
system, drive hydraulic system and cooling hydraulic Manufacture
system.
Product dataplate contains machine weight,
The work hydraulic system and steering hydraulic maximum vehicle speed, engine model, engine
system use bivariate junction technology in which the horsepower, machine size, month and year of
steering takes priority.
Manufacture, manufacture information,product
identification number, etc.
Drive System
The drive system includes torque converter, drive
shaft, transmission and drive axle.
The transmission is a fixed shaft type, with four
forward gears and two reverse gears.
The drive axle adopts first stage gear reducer and
first stage planetary gear reducer.

Cooling System Brand(A)____________________________

Machine Mass(B)_____________________
Radiator includes engine coolant radiator, hydraulic
oil radiator, drive oil radiator and intake air Engine Model(C)_____________________
aftercooled radiator. Dimension(D)________________________
Ensure an optimized heat balance between water Product Identification Number(E)_________
and oil temperature and an optimized working
temperature for each component and maintain the Model(F)____________________________
fluid quality within the lifecycle of the components.
Max Nominal Speed(G)________________
Engine Power(H)_____________________
Brake System
Manufacture Date(I)___________________
The braking system consists of the service brake Local regulation may require documentation of the
and parking brake.The service braking system is a Month and/or Year of manufacture in the Opeation
double-circuit caliper disc type. When the brake and Maintenance Manual. Enter on line (I) above if
pedal is depressed, the compressed air from the air required.
cylinder enters the air booster pump through the
braking valve, and the braking oil enters the brake to
stop the machine;The parking brake is a drum type
brake, installed on the transmission output shaft
flange. The parking brake is engaged by operating
the parking brake button.

22
Purpose Restricted Operation
This loader is a large construction machine mainly
used for handling of bulk material.Mainly used
for:digging, levelling, bulldozing, loading and 1. Used with overload.
dumping, towing operation. 2. Lift heavy objects with lifting sling hanging
directly on the bucket tip.
Working environment requirements
3. Lift the bucket and excavate above the machine.
1. Altitude: ≤3000m
2. Ambient Temperature:－15℃+43℃( If not Attention
equipped with high ambient radiator or pre- The precautions regarding the operation,
heater.) maintenance and safety regulations provided in
3. Fording Depth:≤630mm this manual are only applicable to the machine
used for specified purposes.Caterpillar
This loader is a general construction machine and is (Qingzhou) Ltd. will not take any safety liabilities
not applicable to flammable, explosive, high dust or if the user uses this machine outside the scope
toxic gas environment. of use specified in this manual. The use will take
the safety liabilities in such operations.Under no
circumstances, the operations forbidden in this
manual shall be taken.

23
Main specifications
Technical Specifications of SEM636D Loader
Main Parameters
Rated load kg 3000
Operating weight kg 10133
Standard bucket capacity m3 1.66
Full load bucket capacity (110% fill factor) m3 1.83
Maximum gradability ° 26.6
Dimensions
Machine Length mm 7422
Bucket Width mm 2354
Machine Height mm 3182
Operational Parameters
Maximum Breakout Force kN 113
Maximum Dumping Height mm 2989
Dump Reach mm 1112
Maximum Height of B Pin mm 3916
Minimum Turning Radius (over tire) mm 2949

Minimum Turning Radius (over bucket) mm 5795

Digging Depth mm 25
Overall Dimensions
Wheel Base mm 2740
Overall Height (Maximum lift of bucket with no load) mm 4933
Overall Height Engine Hood mm 2241
Minimum Ground Clearance mm 377

Engine1

Emissions Stage Ⅱ

Diesel Ratings kw 92
Rated diesel engine speed r/min 2200
Bore x Stroke mm 105×130
Displacement L 6.75
Maximum diesel engine torque @ rpm N.m/rpm 515/1400
Diesel engine fan diameter (blower) mm 660
Transmission
Transmission Type Fixed shaft power shifting
Transmission gears F4/R2
Torque converter type Single-stage three element centripetal
Torque converter conversion factor 3.0±0.05
Operating Speed
Forward gear I speed km/h 7.9±0.5

24
 Technical Specifications of SEM636D Loader
Forward gear II speed km/h 14±0.5
Forward gear III speed km/h 25±0.5
Forward gear IV speed km/h 39±1
Reverse I speed km/h 9.7±0.5
Reverse II speed km/h 31±0.5

Working Hydraulic System

Implement pump model Gear
Implement distribution valve model Pilot control
Number of boom cylinders-inside diameter X stroke mm 2-Φ110×780
Number of bucket tilt cylinders-inside diameter X stroke mm 1-Φ150×499
Hydraulic Cycle Times
Boom raise time s 4.65±0.5
Dump s 0.91±0.5
Lower s 2.78±0.5
Sum of three implement actions s 8.34±0.5
Brake System
Service brake type Air to oil Caliper Brake
Parking brake type Shoe/drum
Steering System
Steering Hydraulic System type Co-axial flow-amplified steering
Number of steering cylinders-inside diameter X stroke mm 2-Φ70×294
Steering pump type Gear
Steering Angle ° 36

Drive axle
Main drive type Single stage spiral deceleration
Hub reducer type Single stage planetary reducer
Gear Ratio 20.52
Main drive reduction ratio 5.286
Hub Reduction Ratio 3.882

Tires
Size of tire 17.5-25
Tire Model L-3
Ply 12
Tire Air Pressure Mpa F:0.35 R:0.30

Fuel refill capacity L 162

Hydraulic oil refill capacity L 95
Coolant L 35
Crankcase refill capacity L 17

25
 Technical Specifications of SEM636D Loader
Transmission system refill capacity L 45
Differential and final drive
Front axle refill capacity L 10
Rear axle refill capacity L 10

Electrical System Voltage v 24

Battery model 6-QW-120B
Bulb voltage v 24
Diesel engine starting type Electric Start
Working medium of air conditioning system R134a
Heating capacity of air conditioning system kilowatt 5
Cooling capacity of air conditioning system kilowatt 4.5
Voltage of air conditioning system v 24

26
Operation Section

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

27
Control devices and
monitoring system
Layout of the In-Cab Control Devices and Monitoring
System of SEM636D

Symbol Description Capability

Engine coolant temperatures in the green area are normal

Coolant Temperature Warning Lamp
and those in the red area are high.

Transmission Oil Temperature Warning

Turns on when the transmission oil temperature is too high.
Lamp

Display work hours/display the engine fault code through

LED Multi-purpose Display fault code request switch/display the shift position/engine
speed

Steering Left Indicates the machine is turning left

Steering Right Indicates the machine is turning right

The indicator light illuminates when the diesel engine is

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

Illuminates when the oil pressure is above 0.78Mpa or below

Engine Oil Pressure Indicator
0.16Mpa

Lamp turning on indicates abnormal transmission oil

Transmission Oil Pressure Indicator
pressure

28
Symbol Description Capability

Braking Air Pressure Indicator Braking air pressure is too low or too high

Low Beam Lights Low beam lights are on

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

Preheat Indicator Preheating indicator before engine start

High Beam Lights High beam lights are on

Water in fuel indicator (applicable to

Indicates the primary filter needs to be drained
China Stage III models)

Lamp turns on when the water temperature is higher than the

Coolant Temperature Indicator safe temperature or before it goes below the safe
temperature

The indicator light flashes when damage to the component

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

Engine's Fault Indicator Lamp turns on when the engine fails

Economic mode (applicable to China

The power switch is in economic mode
Stage III models)

Heavy duty mode (applicable to China

The power switch is in heavy duty mode
Stage III models)

29
1. Front Work Lights 4. Front Wiper 7. Hazard Switch
2. Rear Work Lights 5. Cover Plate
3. Alert Lamp 6. Troubleshooting Switch

1. Steering Wheel 5. Start Switch 9. Shut-down Control Lever

2. Shifting Control Lever 6. Parking Brake Button 10. High/Low Speed Control Lever
3. Combination Switch 7. Pilot Control Handle
4. Horn Switch 8. Switch Valve

30
Shut-down Control Lever Attention
The shut-down control lever is located on the control The switch key can only be inserted or removed
console. The engine will shut down 3-6 seconds after in the OFF position.
the lever is pulled up.
ON - The first position the start switch key reaches
when turned clockwise after it is inserted.In this
Parking Brake Button position, the electrical system of the whole machine
is powered on and functions normally.
The parking brake button is located on the control
START - The second position the start switch key
console.When the button is pulled up, the parking
reaches when turned clockwise after it is
brake is engaged and braking is applied;When it is
inserted.Start the machine at this position. The
pushed down, the parking brake is released and the
starting motor is powered on and starts the engine.
braking is removed.
Please release the starting switch key immediately
The parking brake also serves as the emergency after the engine is started successfully. As this
brake.In case of emergency during the operation of position can not be held automatically, the starting
the machine, manually pull up the parking brake switch key will turn back to the ON position of the
button to apply emergency brake. starting switch after it is released.
When the service brake is malfunctioning and the air Attention
pressure in the service brake circuit is below 0.4Mpa,
the parking brake will automatically apply.The loader Please make sure the negative switch is in the
will take emergency stop to ensure safe operation. ON position and the speed control lever is in the
neutral position before starting the engine.

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

31
Switch Valve During loading operation, make full use of the boom float
device and bucket auto-levelling device to effectively reduce
the work load of controlling the work tools and increase the
comfortability of operation.

Before the operation of the boom and bucket, it must

be confirmed that there is no obstacles or personnel
around, over and below the machine, otherwise
damage to the equipment or personal injury may
occur, whatever state the machine is in!！！

Horn switch
The horn switch is in the middle of the steering wheel. Push
the horn switch and the horn will sound.
Located on the control console. During normal
operation, the switch valve button is in the ON
position, and the transmission power will be cut off Shifting control lever
during braking to avoid the slipping of the
The shifting control lever is installed under the steering
transmission clutch and increase the service life of
wheel.Moving the lever forward or backward, in
the transmission. During slope operation, the switch
combination with the high/low speed control lever, can
valve button is in the OFF position, and the
operate the machine in forward gear I, gear III, gear II and
transmission power will not be cut off during braking
gear IV;Reverse gear I, II and neutral position.
to prevent the danger caused by sudden failure of
the service braking and ensure safe operation.
Combination Switch
High/Low Speed Control Lever It can control the left and right steering lights. Turning
clockwise will turn on clearance light, low beam, high beam
Push forward to get high speed and pull backward to in sequence. The top button is for the horn.
get low speed. The middle position is neutral.
Steering Wheel
Pilot Control Handle The machine uses articulated coaxial flow
amplification steering with the steering wheel
The pilot control handle is installed on the control installed in the cab. The steering wheel is
console.It is used to control the working device. connected with the coaxial flow amplification
Move the handle backward to raise the boom; push steering gear.During normal operation, turning the steering
forward to lower the boom; move left to rollback the wheel clockwise will cause the machine to turn right; and
bucket; and move right to dump the bucket.The turning the steering wheel counterclockwise will cause the
original position of the handle is at the HOLD machine to turn left.
(Neutral) position.
The coaxial flow amplification steering has the following
Push the pilot control handle forward to the foremost features:
position to put the boom in the float state. Pull the 1. The angle the steering wheel turns is not equal to the
pilot control handle back to the middle position to angle the machine turns. Turn the steering wheel
remove the boom float state. continuously will increase the turning angle of the
When lowering the boom, the pilot control handle machine until it reaches the desired steering position.
can be pushed to the float position, and the boom 2. The faster the turning speed of the steering wheel, the
will drop under the action of gravity.At this time, the faster the machine turns.
right hand of the operator can perform other 3. The steering wheel will not restore to the original
operations (e.g. levelling the bucket) to increase position automatically after it is turned and the
work efficiency. machine will hold the turning angle.Therefore,
During scraping or loading operation, push the pilot when the steering of the machine is completed,
control handle to the float position to allow the bucket the steering wheel should be turned in the
to follow the ground contours and avoid damage to opposite direction so that the machine can drive
the ground surface. in a straight direction.

32
Brake Pedal
The service brake pedal is located in front of the
When the whole machine is shut down and
operator's seat on the left.When the service brake
during flushing of the machine, the negative
pedal is depressed, the frond and rear drive axle
switch needs to be put in the OFF position.
wheel brakes will engage to brake.The braking light
switch will be turned on at the same time to Do not turn off the battery negative switch when
illuminate the braking light.Release the service brake the engine is still running. Otherwise damage to
pedal will disengage the service brakes. the electrical system of the whole machine can
In case of braking system malfunction, the repair occur!！！
should be performed in a timely manner to ensure
enough braking capability of the machine. Lighting of the whole machine
The lighting of the whole machine consists of the
front combination lights (one piece on each side),
Battery negative switch rear combination lights (one piece on each side),
The battery negative switch in installed in the battery indoor light, fog-proof light (one on each side), rear
case on the right side of the loader and can be seen working light (one on each side) and the beacon.
once the battery case cover is opened. Of which, the front combination lights include the
headlights, front small lights, and front turning lights,
and the rear combination lights include the rear small
lights, rear turning lights, braking light and backup
light.
Air conditioning system switch
The air conditioning system of the machine has three
functions, including cooling, heating and natural
wind.
Air conditioning control panel
The air conditioning control panel is located in the
bottom of the seat on the left of the evaporator.As
shown in the figure below.
OFF status of the negative switch:
To cut off the power supply for the electrical system
of the whole machine, it is necessary to turn the
negative switch handle counterclockwise to the OFF
position.
When the negative switch is in OFF status, the
handle of the switch points to the right bottom
direction of the negative switch mounting plate.
ON status of the negative switch:
Before starting the machine, the negative switch Turn the air volume switch clockwise to increase the
handle must be turned clockwise to the ON air volume and counterclockwise to reduce the air
position.When the negative switch is in ON status, volume. There are three air volume positions, i.e.
the handle of the switch points to the left bottom high, medium and low. Turn the switch to the OFF
direction of the negative switch mounting plate. position to turn off the fan.
The negative switch is different from the starting The selection switch has two positions, natural wind
switch.Turning off the negative switch will turn off the (O position) and cooling (AC position).
electrical system of the whole machine.However,
when the starting switch is turned off, the battery is
still connected to the electrical system of the whole
machine and some electrical components can still
function.

33
The specific functions and operation instructions Run-in of new machine
are as follows:
The run-in of new machine is of great importance for
Cooling: increasing the service life of the machine, eliminating
1. Move the air volume switch to a suitable air potential failure trouble, and avoiding severe
volume position after starting the engine. failures.After buying the machine, the user must
perform the operation and maintenance of the
2. Turn the selection switch clockwise to the cooling machine according to the new machine run-in
position. procedures specified in this manual before normal
The refrigerating system will start to work and cold use of the machine.
air will flow out of the air outlet. Run-in requirements of the new machine
Heating: 1. The run-in period of the new machine is 10
1. Move the air volume switch to a suitable air hours.
volume position after the engine has been 2. Idle the machine for 5 minutes after starting.
started for a period of time.
3. During the run-in period, each of the forward I, II,
2. Turn the selection switch counterclockwise to the III, IV and reverse I, II, III, IV gears should be
natural wind position (O position). The heating used evenly for run-in.
system will start to work and hot air will flow out
of the air outlet continuously. 4. The machine should start with low speed and
small throttle, and accelerate gradually.Sudden
Natural wind: starting, accelerating, turning and braking should
The air conditioning system of the machine is be avoided unless in case of emergency.
equipped with internal and external circulation 5. During the run-in period, it is preferably to load
devices. In cool seasons like spring and autumn, some loose material and the operation must not
when you only need the natural wind and use it to be too hard and too quick.During the run-in
adjust the air flow in the cab, turn the air volume period, the loading weight must not exceed 70%
switch to a suitable position and turn the selection of the rated load and the travelling speed must
switch to the natural wind position. not exceed 70% of the rated maximum machine
speed.
6. Pay attention to the lubrication of the machine.
Replace or add lubricating oil or grease as per
the specified time interval.
When the ambient temperature is below 0°C and the
engine is not working, if antifreeze is not added to 7. Frequent attentions must be paid to the
the engine coolant, the engine water tank should be temperatures of the transmission, torque
emptied, and the hot water valve and converter, front and rear axle, wheel hub, parking
electromagnetic water valve should be opened to brake, central supporting shaft, hydraulic oil,
drain the coolant in the evaporator. Otherwise the engine coolant and engine lubricating oil. If
radiator plumbing can be frozen and cracked due to overheating is found, identify the cause and
the low temperature. repair as necessary.
8. Check the bolts and nuts of all components for
Backup automatic alarm system tightness
The backup alarm is mounted on the rear sealing Perform the following after eight hours of run-in
plate. When the steering and shifting lever is of the new machine:
operated to reverse the machine, the backup alarm
will sound automatically. 1. Completely check the bolts and nuts of all
components for tightness, especially the diesel
engine cylinder head bolts, exhaust pipe bolts,
front and rear axle mounting bolts, rim nuts,
The backup alarm is close to the radiator. When driving shaft connecting bolts, diesel engine
adjusting the sound volume of the backup alarm, mounting bolts, transmission mounting bolts,
the engine must be shut down and protection front and rear frame articulation bolts etc. should
against high temperature must be used to avoid be checked completely once.
burning. 2. Check the tension of the fan belt, engine belt and
air conditioning compressor belt.

34
3. Check the oil level of transmission oil, drive axle Check the terrain and ground condition of the job site
oil and diesel engine oil. and determine the best and safest work method.
4. Check the hydraulic system and braking system Before the work, prepare the ground as solid and
for leak tightness. level as possible.If there is heavy dust at the job site,
water should be sprayed before work.
5. Check all the control levers and acceleration
lever for secure connection. If the job is to be completed on the street, there must
be a special person to direct the traffic, or a fence
6. Check the temperature and connection of
should be set up with the "Do not enter" sign to
components in the electrical system, check the
protect the pedestrians and vehicles.
power supply of the alternator, and check the
lamps and turning signal lights etc. for normal For sites with buried facilities underneath, such as
operation. water pipe, gas pipe, high voltage cable pipe, the
relevant authority should be contacted to locate the
Attention buried facilities.Meanwhile use care not to damage
When checking the oil levels, the appropriate these facilities during work.
operation specifications should be followed. When working in water or passing sand bank, check
the surface condition, water depth and water flow
Perform the following after the run-in period is
velocity first.The allowed fording depth must not be
over:
exceeded.When working in puddle or swamp site,
1. Completely check the bolts and nuts of all the water depth must not exceed the bottom of the
components for tightness, especially the diesel axle housing.Clean and check the lubrication check
engine cylinder head bolts, exhaust pipe bolts, points after the operation is complete.
front and rear axle mounting bolts, rim nuts,
driving shaft connecting bolts, diesel engine
mounting bolts, transmission mounting bolts, Axle Case
front and rear frame articulation bolts etc. should
be checked completely once.
2. Check the tension of the fan belt, engine belt and
air conditioning compressor belt.
3. Check the hydraulic system and braking system
for leak tightness.
4. Inspect/clean/change the transmission drive oil Checks before starting the engine
and drive axle lubricating oil. Perform the following checks everyday before
5. Inspect/clean/change the elements of the starting the engine.Failure to perform these checks
transmission oil filter, diesel engine oil filter and may lead to serious injury or damage.
diesel fuel filter. Check the area around the engine and battery for
6. Inspect/clean the oil drain element of the buildup of flammable material, check for fuel,
hydraulic oil tank. lubricating oil and hydraulic oil for leaks, and check
the mirrors, hand rails and steps for contamination
Attention by fuel.
When changing the transmission oil, drive axle Do not leave parts and tools around the operator's
lubricating oil and diesel engine oil, the seat.Due to the vibration during travelling and
appropriate operation specifications should be operating, these objects may fall down and cause
followed. damage to the control levers or switches, or cause
the control levers to move to start the work tools,
which will result in accidents.
Operating Precautions Before mounting the machine, remove the dirt and
fine sands attached to the shoes, as they will
I. Before Starting the Engine accumulate at the supporting points of the
acceleration pedal and brake pedal, preventing the
pedals returning to the original positions.If there is
Job Site Safety
dirt and sand accumulation at these points, remove
Before the work, check the area around the machine immediately.
carefully for any abnormal conditions that may cause
Check the coolant level, fuel level and the oil level in
danger.
35
the engine oil pan. Check the air filter for plugging started again.
and the wiring for damage. The engine should run at idle speed to warm-up after
Adjust the operator seat to a position where easy starting(at least 5 minutes recommended)
operation can be performed. Check the seat belt and Listen to check if the engine operates properly while
the mounting hardware for damage.The seat belt it is running at low speed, and check the
must be replaced after three years of use.Check all transmission of abnormal noise.
the instruments for normal operation. Check if the Check all the instrumentation for proper operation,
control levers are in the correct position. and check the lighting devices, indicators, horn,
Remove any dirt on the window glass and lights to wipers, braking lights for proper operation.
ensure good visibility. Attention
Adjust the position of the mirrors so that best views Special attention should be paid to the
can be achieved from the operator's seat.Wipe clean instrumentation panel for engine malfunction
the surface of the mirrors.Replace the glass of the indicator lamps.
mirror with new one if damaged.
In freezing seasons, preheating of the hydraulic oil
Check the headlights and working lights for proper
should be performed.Pull back the pilot valve bucket
illumination.Repair if any abnormal results are found.
control lever and hold it in position for 4-5 minutes.
A fire extinguisher must be available and its use Meantime, increase the throttle to keep the stop
method must be mastered. block of the bucket against the boom and make the
hydraulic oil to overflow, which will increase the
Do not place the machine close to open fire. hydraulic oil temperature rapidly.
Check the service brake and parking brake system
for proper operation.
II. When Starting the Engine If there is no obstacles around the machine, turn the
Before mounting the machine, perform another walk- steering wheel slowly to see if the machine turns
around inspection of your machine and check for any accordingly.
personnel or objects on, below or near the machine.
Check if there is any person in the working area.
If a "Do not operate" warning label is attached to the III. After starting the engine
control lever, the engine must not be started. Checks after starting the engine
Sound the horn when starting the engine to give an
Failure to perform the appropriate checks after
alert.
starting the engine will delay the discovery of the
The engine can only be started and operated with abnormal phenomena.And this can result in serious
the operator sitting in the operator's seat. injury or machine damage.
No person other than the operator should stay in the When conducting the checks, it should be performed
cab.No one is allowed to sit on the machine body. in an open area without obstacles.No one should get
The engine can only be started within the cab. Never close to the machine.
start the engine by short-circuit the starting motor, Check the operation of the instrumentation and
which will lead to damage to the electrical system of equipment. Check the operation of the bucket, boom,
the machine by starting the system with bypass braking system, driving system and steering system.
circuit.In addition, this operation is very dangerous.
Check the machine for unusual noise, vibration,
Make sure the backup alarm, if equipped, functions heating, smell or instrumentation operation. Check
properly. for hydraulic oil, lubricating oil, air or fuel leaks.
Attention If any abnormality is found, repair immediately.If the
One starting attempt should not be longer than machine is operated under unsuitable conditions,
15 seconds (the time that the starting motor serious injury or machine damage may occur.
works continuously should not exceed 15 Before traveling or starting the work, the lockout
seconds). If the starter does not start the engine lever should be locked in the RELEASE position
after 15 seconds, the starting switch should be securely.
released immediately. Wait at least 30 seconds When starting travelling
before another starting attempt.This is jointly
determined by the features of the starting motor Before starting traveling, check around the machine
and the battery. If the engine fails to start after again to make sure there is no people and obstacles.
three consecutive attempts, it should be When starting traveling, sound the horn to give an
checked. After the malfunction is corrected, and alert.
at least three minutes later, the engine can be The machine can only be operated with the operator
36
sitting in the operator's seat. enough to support the weight of the machine.When
Seat belt must be fastened. driving on public roads, the rules of the appropriate
No person other than the operator should stay in the authorities must be met and appropriate regulations
cab.No one is allowed to sit on the machine body. must be followed.
Check the backup alarm, if equipped, for normal Traffic rules should be followed when driving on
operation. public roads.The driving speed of the machine is
lower than the normal speed of automobiles. Drive
Considerations During Traveling on the side of the road to leave the center of the road
The key in the start switch must not be turned to the to other vehicles.
OFF position while the machine is traveling.It is very If the machine runs at a high speed continuously for
dangerous if the engine dies during traveling, a long period of time, the tires will overheat and the
because the steering will be heavy.If the engine dies, internal pressure will become extremely high.This
the brakes should be applied immediately to stop the may lead to the blowout of the tire.If the tire blows
machine. out, extreme destructive force will be generated,
which may result in severe injury or accident.
The operator must concentrate on the work during
operation. If you plan to drive the machine continuously, please
consult the authorized dealer of Caterpillar
Driving too fast, sudden braking, sudden stopping, (Qingzhou) Ltd.
sharp turns or zigzagging are all dangerous.
Checks when changing the direction
If any abnormality (noise, vibration, smell, incorrect To avoid injury or death, the following rules must be
display of instrumentation, air leak, oil leak etc.) is followed before moving the machine or the work tool,
found during the operation, the machine should be even if the machine is equipped with backup alarm
moved to a safe place and find the causes. and mirrors:
Adjust the height of the work tool to the position Sound the horn to alert the personnel on the site.
where the lowest point of the bucket is 300-400 mm Check around the machine. There should be no
above the ground, and travel on a flat surface. person.Check especially the area behind the
machine as it is not visible from the operator seat.
Where there is a danger or the visibility is poor, one
person should be designated to direct the traffic.
Persons without approval must not enter areas in the
turning direction or traveling direction.
The traveling direction must not be changed when
the machine is at high speed.
Do not operate the pilot control lever of the working
device during travelling.If the operation of the pilot Forbidden operation
control lever of the work tool is required, the machine The load of the machine must be kept within the
should be stopped first before the operation of the specified maximum load to avoid fall-over of the
pilot control lever. machine and damage to the work tool due to
overloading.The specified capacity of the machine
Do not operate the steering wheel suddenly.If doing
must not be exceeded during the use of the
so, the work tool may touch the ground surface and
machine.
the machine may lose balance, or damage to the
machines or structures around may occur. Caterpillar (Qingzhou) Ltd. will not be responsible
for any injury, accident or damage to the machine
When traveling on the uneven surface, keep the resulting from overloading of the machine.
speed low and avoid sudden steering.
Travelling on slope
Try to avoid driving over obstacles.If it is necessary
for the machine to drive over an obstacle, try to keep Traveling on slope may cause the machine to fall
the bucket close to the ground. over or slide to one side. Be especially cautious.

A distance should be kept from other machines or When traveling on the slope, the lowest position of
structures during traveling or work to avoid collision. the bucket should be kept 200-300 mm above the
ground.In case of emergency, lower the bucket to the
If working in water, the allowed water depth must not ground quickly to help stop the machine.
be exceeded.The water depth must not exceed the
bottom of the axle housing.
When driving on bridges or structures on private
properties, first check the strength to see if it is
37
 To prevent accidents, please take the following
Incorrect Correct precautions:
1. If there is a potential risk of the machine touching
power cables on the working site, consult with
the power company before starting the operation,
and check and determine the feasibility of the
operation according to the current relevant
regulations.
Do not turn or travel transversely on a slope.Drive
the machine down to a level surface to complete 2. Wear rubber boots and rubber gloves.Place a
these operations. rubber pad on the operator's seat, and pay
attention not to allow any exposed part of the
When traveling downhill, never shift gears or put the body contact the metal chassis.
transmission in the neutral position.Put the
transmission in the low speed gear before starting 3. Specify a signalman who will give warning
driving downhill. signals when the machine gets too close to the
power cable.
Keep speed low when driving downhill.If necessary,
use the brake pedal to control the speed. 4. If the work tool makes contact with the cable, the
operator must not leave the cab.
Do not drive at high speed on grassland, fallen
leaves or wet steel plate.If operating this way, even a 5. When working in the vicinity of high-voltage
very small slope can cause the machine to slide to cables, do not allow any person to get close to
one side, and the driving speed, therefore, should be the machine.
kept low.When driving on a slope, drive straight 6. Consult the power company for the voltage of the
upward and downward. cable before starting operation.
When travelling on a slope, if the engine dies, the Precautions During Operation
brake pedal should be depressed fully immediately
to apply the brake and the bucket should be lowered
to the ground before applying the parking brake to
secure the machine in position.
If the bucket is loaded when driving up or down a
slope, the bucket should always point to the uphill
direction (i.e., facing front when going up, and facing
back when going down).When driving on a slope
with a loaded bucket, keep the bucket toward the Do not get too close to the edge of a cliff.During dike-
downhill direction will cause the danger of machine building or earth-filling, or dumping into a cliff, pile the earth
fall-over. into a dump, and push the dump through another dump.
When pushing the earth down a cliff or to the top of a slope,
Do not get close to high-voltage cables the load of the machine can become light suddenly.In such
Do not allow the machine to touch the overhead cases, it can be dangerous as the driving speed will
cables.Even just getting close to the cable can increase suddenly. Therefore, the speed must be kept low.
cause electric shock.The safe distance as When the bucket is fully loaded, the machine must not start,
specified in the following table should be kept turn or stop suddenly.
between the machine and the cable. When moving unstable load, e.g. round or cylindrical object,
Voltage (V) Minimum safe distance
layered sheet, raising the work tool can cause the danger of
the load falling on the top of the cab, resulting in serious
100-200 2m 7ft injury or damage.When moving unstable load, pay attention
Low Voltage
6,600 2m 7ft not to raise the work tool too high or tilt the bucket backward
too much.
22,000 3m 10ft
Incorrect Incorrect

66,000 4m 14ft
154,000 5m 17ft
High Voltage
187,000 6m 20ft Incorrect Incorrect

275,000 7m 23ft
500,000 11m 36ft

38
If the work tool falls or stops suddenly, the reacting force chain should be used.
can cause the machine to fall over.Especially when the When driving on snow-covered slopes, never apply
machine is loaded, extreme attention must be paid to the the brake suddenly.To decelerate, depress the brake
operation of the work tool. pedal intermittently for several times.If necessary,
Do not use the bucket or boom for lifting purpose. lower the bucket onto the ground to stop the
The machine can only undertake specified work. Other machine.
operation beyond the use scope of the machine can The traction of the ground varies greatly with the
damage the machine.See "Usage and Main Technical influence of the snow. Therefore the load needs to
Features and Parameters" for specified work. be adjusted accordingly to avoid skidding of the
Pay attention to the following aspects to ensure good machine during travelling.
visibility: Do not work on soft and loose ground
1. When working in dark places, turn on the working light Do not operate the machine on a soft and loose
and the headlights, and install lighting device at the ground.As the machine tends to get stuck into such
working site if necessary. ground and it can be difficult to get out.
2. Do not work in a foggy, hazy, snowy, heavy rainy day or
Do not let the machine get too close to the edge of a
other circumstances with poor visibility.Wait until it is
cliff, or the suspended location and deep trench.If
clear and bright and there is enough visibility before
these places collapse due to the weight or vibration
starting the work.
of the machine, the machine can drop or fall over,
Pay attention to the following points to prevent resulting in serious injury or death.Remember, the
the work tool from colliding with other objects: ground will become soft after heavy rain, explosion
1. When working in the tunnel, under the bridge, or earthquake.
under the cable or in other places where the
height is limited, special attention should be paid Piles of earth on the ground and near the trench are
not to allow the bucket hit any objects. soft and loose.It can collapse due to the weight or
2. When loading a dump truck, check to make sure vibration of the machine, causing the machine to fall
there is no person around the machine. Pay over.
attention not to allow the bucket to touch the cab If there is a danger of falling stone at the work site,
of the dump truck. the falling object protective structure (FOPS) should
3. To avoid accidents resulting from collision with be installed.
other objects, the machine should work at a
If there is a danger of falling stone or rollover at the
speed of safe operation, especially in limited
working site, the rollover protective structure (ROPS)
space, indoor or places with other vehicles.
should be installed and the seat belt should be
Using method of the brakes fastened.
Do not put your foot on the brake pedal unless really
necessary.
Do not depress the pedal repeatedly unless really Ⅳ. Storage of the Machine
necessary.
When driving downhill, use the engine as a brake Park the machine on a level surface and lower the
and never shift gears or put the transmission in the work tool to the ground.The location should be free
neutral position. of falling stone or landslip.If in low-lying area, there
also should be free of the danger of flood.
Use caution in snowy days
When working on roads with snow or ice, even a If it is necessary to park the machine on a slope,
small slope can cause the machine to slide away. chock the wheels to prevent the machine
Therefore, the speed must be kept low and sudden frommoving.Then lower the work tool to the ground.
start, stop or turn must be avoided.There will be a When parking on the roads, a fence, signal, flag or
danger of slippery, especially when going up or down warning light should be set up and other necessary
a slope. signals should be placed to make sure the machine
On frozen roads, the ground will become soft as the can be clearly seen by the passing vehicles.In
temperature rises and the traveling conditions will addition, the machine, fence, or flag must not
become unstable.Under such circumstances, special hamper the traffic.
cautions must be used during driving.
When leaving the machine, lower the bucket
The road shoulder and roadside items will be completely to the ground, and lock the control levers
covered and become unclear after heavy snow. with the locking device to hold it in the braking
Therefore the snow must be cleaned carefully. position.Lock all the devices with a key.Remove the
When driving on snow-covered roads, antiskit tire key and take it with you.
39
Perform the following operations as required if the machine Disposal section of this Operations and Maintenance
needs to be stored for a long period: Manual.
Before Storage Precautions for cold areas
Clean each part of the vehicle and dry in the air. Store the
After completion of the work, remove all the water,
machine in a dry warehouse.If the machine can only be
snow or sludge attached to the wiring, wire
stored outdoors, it should be parked on a concrete surface
connectors, switches or sensors as well as the
that drains easily and covered by canvas.
covering parts of these parts.If these are not
Before storage, fill up the fuel tank, grease each moving pin removed, the water contained in them will freeze and
shafts and drive shafts, and change the hydraulic oil. cause the machine to fail during the next usage, and
Move the joystick to the NEUTRAL position. may result in unexpected malfunctions.
Pull the park brake button to apply the park brake. Remove the frozen clot of the work tool and driving
Level the bucket on the ground and put the pilot control system before starting.
lever in the neutral position.
Warm up completely.If the machine is not warmed up
Put all switches in neutral or OFF position.Lock all doors. completely before operating the control levers, the
Apply a thin film of grease on the exposed part of the response of the machine can be slow, which can
hydraulic oil cylinders. lead to unexpected accidents.
Remove the battery from the vehicle and store separately.
If the ambient temperature can possibly goes below 0°C,
add antifreeze in the engine and make sure the antifreeze
reaches the engine body and the evaporator of the air 650

conditioning system.Or drain the cooling system

completely. Also drain the air conditioning system.
Secure the front and rear vehicle frames with the frame
lockout lever.
During Storage
Start the machine once every month. Run each system
and grease each moving pin shafts and drive shafts so that
the moving components get lubricated and the battery gets V. Shipping of the Machine
charged.
Investigate the travel route for overpass height, width
Before starting the vehicle, wipe off the grease on the piston
and the allowable load before shipping. The total
rod of the hydraulic oil cylinders.Apply a thin film of grease
height, width and weight etc. with the machine
again after the operation is complete.
loaded on a shipping vehicle must not exceed the
Apply anti-rust oil to rust-prone areas. relevant regulations. In case of over-height or over-
Attention width, please consult Caterpillar (Qingzhou) Ltd. or
its dealers for solution.
If anti-rust oil is used indoors, open the doors and
windows for ventilation to remove the toxic gases. To prevent the safety accident of the machine
slipping in transit, remove ice, snow, or other slippery
After Storage material from the loading dock and from the truck
Perform the following operations when the long period bed before shipping.
storage of the machine is over:
Attention
Change the engine, transmission and drive axle lubricating
oil, as well as hydraulic oil and antifreeze. Obey all local and national laws and regulations
Grease all the moving pin shafts and drive shafts. that govern the height, width, length and weight
of a load while shipping.
Before starting the vehicle, wipe off the grease on the piston
rod of the hydraulic oil cylinders. Follow the following procedure in shipping:
Specified Storage Period 1. Before loading the machine, chock the trailer
The specified storage period of this machine is 1 wheels or the truck wheels.
year. After this specified storage period has expired, 2. When the machine is driven onto the trailer or
consult your SEM Dealer for inspect, repair, rebuild, truck, steering operation is not allowed midway. If
install remanufactured, install new components, and the steering operation is required, the machine
disposal options and to establish a new specified should return to the level ground before the
storage period. If a decision is made to remove this steering operation can be performed.
machine from service, see the Decommissioning and
40
3. Secure the front and rear vehicle frames with the
frame lockout lever after the machine is parked.
4. Level the bucket on the transport vehicle and put
the speed control lever to the neutral position.

Incorrect lifting can cause the machine to drift,

resulting in personal injury and damage.

5. During towing, all personnel should stay away

from both sides of the tow rope to avoid injury
caused by the breakage of the rope. NOTICE
6. Typically, the tractor should be the same size of Improper lifting or tie-downs can allow the shift
the machine being towed.The tractor should and cause injure or damage .Install the steering
have the sufficient braking capacity, weight and frame lock link before lifting.
power to control the uphill operation and
traveling distance of both machines. Ensure that the lift arms are in fully lowered
position before lifting the machine.
7. While the machine being towed is going downhill,
in order to obtain sufficient control and braking Check all of the laws that govern the load
capacities, there should be a larger trailer or characteristics (height, weight, width, and
another machine behind the machine being length).
towed, to prevent the machine from rolling down Reference: For shipping instructions, refer to
when the control is lost. Operation and Maintenance Manual, "Shipping
8. If the direction of the machine being towed can the Machine".
be controlled by the operator, the operator must Lifting the Machine
steer in the direction of the wire cable.
Note: Do not use handles or steps in order to lift the
machine. Do not use the work tool for a lifting point.
Shipping Considerations Note: The machine shipping weight that is listed is
the weight of the most common configuration of the
Loading and Unloading Machine machine. If attachments have been installed on your
machine, the weight of your machine and the center
of gravity of your machine may vary.
Reference: Refer to Operation and Maintenance
Improper lifting and improper tie-downs can
Manual, "Specifications" for the dimensions and
allow the load to shift or fail and cause injury or
weight of the machine
damage. Use only properly rated cables and
slings with lift and tie down points provided. The lifting points are identified by a label that shows
Follow the instructions in Operation and a hook.
Maintenance Manual, "Lifting and Tying Down
Lifting Point - In order to lift the machine, attach the
the Machine" for the proper technique for
lifting devices to the lifting points.
securing the machine. Refer to Operation and
Maintenance Manual, "Specifications" for Use properly rated cables and properly rated slings
specific weight information. to lift the machine.
Remove structures above the rear lifting points as
If lifting is required for loading and unloading the necessary in order to route lifting cables to the lifting
machine, please hoist according to the lifting points.
diagram.
Position the crane or the lifting device in order to lift
the machine in a level position.
The width of the spreader bar must be sufficient to
prevent the lifting cables or the lifting straps from
contacting the machine.
Do not allow any personnel in the area around the
machine.
41
 1. Engage the parking brake before you sling corner protection when necessary. Avoid routing
the machine and before you secure the cables over tires. Avoid contact with the work tool to
machine with tie-downs. prevent false tension.
2. Install the frame lock pin prior to lifting the
Install tie-downs at all four locations. Place wheel
machine.
chocks in front of the machine and behind the
3. Attach two lifting cables to the rear of the
machine.
machine. There is one lifting eye on each
side of the rear of the machine. Consult your SEM dealer for shipping instructions for
4. Attach two lifting cables to the front of the your machine.
machine. There is one eye on each side of
the front of the machine. Shipment
5. Connect the four lifting cables to the If the machine is transported with a tractor, obey the
spreader bars. The spreader bars must be national and local regulations on the weight, height,
centered over the machine. width and length of heavy objects.Also obey all
6. If equipped, secure any attachments. related traffic regulations.
7. Lift the machine. Move the machine to the Consider the weight, height, width and length of the
desired position. machine when determining the shipping route.
8. When the machine is positioned, place the When driving on bridges or structures on private
blocks behind the tires. properties, first check the strength to see if it is
enough to support the weight of the machine.When
Tying Down the Machine traveling on the public road, always meet and follow
the related regulations of the local authority.
Note: Do not use handles or steps in order to tie The machine may be separated into several parts
down the machine. Do not use the work tool to during shipping.Therefore, contact the designated
tie down the machine. Do not wrap chains dealers of Caterpillar (Qingzhou) Ltd. to perform
around the rear axle to tie down the machine. these work.
Avoid using the front axle as a tie down location
whenever possible.
Ⅵ. Battery Use and Maintenance
There may be more than one way to tie down the
machine. Local regulations should be used to Considerations
determine the best method. Obey all local and Precautions
regional governmental regulations. The machine uses maintenance free batteries,
without the need to add electrolyte.
Note: The machine shipping weight that is listed Battery electrolyte contains sulfuric acid and the
is the weight of the most common configuration battery can generate hydrogen.Therefore, improper
of the machine. If attachments have been handling of the batteries can lead to heavy injury or
installed on your machine, the weight of your fire.For this reason, the following considerations
machine and the center of gravity of your must be followed.Never put a lighted cigarette or
machine may vary. flame near the battery.
If the work requires making contact with the battery,
Reference: Refer to Operation and Maintenance always wear safety glasses and rubber gloves.
Manual, "Specifications" for the dimensions and
weight of the machine. If the electrolyte inside the battery splashes on the
clothes or skin, flush with plenty of clean water
Note: Use only the specified locations for tying down immediately.
the machine. Do not use any other locations in order Battery electrolyte splashing into the eyes can result
to tie down the machine. in blindness.If the electrolyte splashes into the eyes,
Tie Down Point – In order to tie down the machine, flush with plenty of clean water and see a doctor
attach the tie-downs to the tie down points. immediately.
If drinking the electrolyte accidentally, drink plenty of
Use properly rated cables and shackles for tying water, milk, raw eggs or vegetable oil and see a
down the machine. doctor or call the emergency center immediately.
Secure the machine at the tie-down positions. The Shut down the engine before performing any work
positions are identified on the machine by a label. related to the engine.
Avoid accidental contact with metal objects (e.g.
Use the front eyes and the rear eyes that are tools) which can result in a short circuit between
provided on the lower frame of your machine. Use positive (+) terminal and negative (-) terminal of the
42
battery. There should not be flame or spark above the battery
When installing the battery, connect the positive (+) pack.Do not smoke during charging.
terminal first.When removing the battery, disconnect Set the voltage of the charger to match that of the
the negative (-) terminal (ground wire side) first. battery being charged.If the voltage setting is wrong,
When installing or removing the battery, check which the charger can overheat and burn, and even
one is positive (+) terminal or negative (-) terminal explode.
first and then tighten the nut securely.
Use a cloth to clean the top surface of the
battery.Never use gasoline, solvent or any other
organic solvent or detergent.Tighten the battery top
cover securely.
If the battery electrolyte is frozen, do not charge the
battery or use other power supply to start the
engine.This is dangerous, because it can set the
battery on fire.When charging the battery or using
other power supply to start the engine, melt the
battery electrolyte and check for leaks before starting
the engine.
Remove the battery from the machine before Connect the positive (+) clip to the positive (+)
charging. terminal of the battery and negative (-) clip to
Start with Booster Cable negative (-) terminal of the battery.Make sure that
both the terminals are tightened tightly.
If there is anything wrong with the connection of
booster cable, a fire can result. Therefore, the If the charging rate of the battery is lower than 1/10,
following method must be taken. perform high-speed charging and set the value
below the battery rated capacity.If the charging
The starting operation requires two technicians to current is excessive, electrolyte can leak or
complete (one sitting on the operator's seat). evaporate, which can lead to burning or explosion.
Two machines are not allowed to make contact with
each other when starting the other machine. Ⅶ. Towing
When connecting the booster cable, turn OFF both When Towing
the START switches of the functional machine and
malfunctioned machine. If the disabled machine is towed in a wrong method,
or the selected wire cable is incorrect, injury or death
When installing the booster cable, always connect
can result. Therefore, the following considerations
the positive (+) cable first.When removing the
must be obeyed.
booster cable, always disconnect the ground wire or
negative (-) cable first. Operate according to the instructions on towing in
this Operation and Maintenance Manual.
Finally connect the ground wire to the engine
cylinder block of the malfunctioned machine.But, this Wear leather gloves while handling the wire cable.
will cause spark, so keep away from the battery as
While preparing for the towing with other technicians,
far as possible during connecting.
determine the signals to be used before performing
When removing the booster cable, be careful not to the work.
let the clips of the booster cable touch each other or
If the engine of the malfunctioned machine can not
touch the machine.
start or the braking system is malfunctioned, contact
Charging Battery the designated dealers of Caterpillar (Qingzhou) Ltd.
for repair.
Improper handling of the battery can lead to battery
explosion when charging the battery.Therefore, It is dangerous to tow a machine on a slope, so do it
perform the charging in accordance with the battery on a smooth surface.If this kind of place is
handling regulations and charging regulations in the unavailable, choose a place with minimum grade.
instructions, and obey the following considerations. If the malfunctioned machine is towed by another
Charge the battery in a well-ventilated area with the machine, the wire cable used must be capable of
top cover removed.This can spread the hydrogen carrying the weight of the malfunctioned machine.
and prevent the explosion.Gases from a battery can The wire cable used must not have broken wire
explode. strands, kinked or reduced diameter.

43
Do not stand on the wire cable. brake button immediately to apply emergency
brake.Meantime operate the pilot joystick to
While connecting to the machine to be towed, never
lower the boom to the lowest point and turn over
allow anybody to stand between the towing machine
the bucket forward to make the bucket teeth
and the towed machine.
insert into or against the ground to force the
Keep the hook of the towed machine flush with the machine to stop for safety.
trailing part and hold it in place.
6. Check the engagement of each shift
position.Drive the machine to an open and
smooth site. Engage each shift position
individually to check the shift response of the
machine.
7. Machine Steering Operation
If turning the machine is required due to the curve
ahead, operate in accordance with the related local
Machine Traveling Operation traffic laws and regulations.

1. Operate the pilot valve joystick to turn the bucket Before turning, push the turn light switch to the
to stop status and raise the boom to transport appropriate direction (pushing left is to turn left,
position (i.e. the lowest point of the bucket is pushing right is to turn right) and meanwhile the turn
about 300-400 mm away from the ground). lights on the left or right side at the front and rear of
the machine as well as the turn light on the
2. Depress the service brake pedal and meantime dashboard will illuminate to alert the adjacent
press the park brake button to release the park vehicles and pedestrians that the machine is going to
brake.Release the service brake pedal slowly turn.Then turn the steering wheel in the desired
and see if the machine is moving. direction and the steering starts.
To steer at a higher traveling speed, the accelerator
pedal must be released first and apply the service
If the machine is moving, depress the service brake as necessary to ensure travelling safety.
brake pedal immediately and pull the park brake
button to apply the park brake.Then check if the
variable speed control system of the machine is
malfunctioned.If the machine is uphill, block the Never steer at a slope. Drive the machine down
wheels to prevent the machine from moving to the smooth ground to perform these work.
before checking the machine.
8. Machine Braking Operation
3. Push the variable speed control handle forward To apply braking, release the accelerator pedal first
to I position or push it backward to reverse and then smoothly depress the service brake pedal.
position while depressing the accelerator pedal
suitably, in order that the machine can travel
forward or backward.
4. Drive the machine to an open and smooth site. If While traveling at a higher speed, do not depress
the steering performance check is not performed the brake pedal to the ground rapidly unless
during the previous operation due to narrow site, there is emergency to avoid accidents and
turn the steering wheel at this point, to check if damage to the machine.
the machine is able to counterrotate to the left or
right. Parking the Machine
5. Check the performance of the service 1. Drive the machine to a smooth area where there
brake.Drive the machine at forward shift position should be free of falling stones, landslide and
1 or 2 in an open and smooth site. Release the flood.
accelerator pedal first and then smoothly
2. Use the service brake to stop the machine.
depress the service brake pedal. The machine
should decelerate obviously and stop. 3. Move the joystick to the NEUTRAL position.

Attention 4. Pull the park brake button to apply the park

brake.
If obvious deceleration can not be felt after the
service brake pedal is depressed, pull the park 5. Operate the pilot valve joystick to lower the boom

44
 and put the bucket evenly on the ground and
then slightly push down the bucket.
6. Let the engine idle for 5 minutes to allow the
parts to cool down evenly.
7. Turn the electric key counterclockwise to OFF
position to stop the engine and cut down the
power of the machine and remove the key.
Pile
8. Move each switch to the neutral or OFF position.
9. Close the left and right doors and climb down the
ladder according to the regulations.
10. If the machine is going to be stored for a long
period of time (for example, overnight), open the
right battery case cover to move the battery Shot Rock
negative switch to OFF position.
11. If there is no antifreeze in the machine,
immediately open all engine water drain valves
and drain all coolant in the evaporators of cooling
system and air conditioning system after the
machine stops in winter climate.
12. Lock all equipment and take the key with you.

Attention
Place the machine on the smooth ground. If
parking the machine on a slope is necessary,
block the wheels to prevent the machine from
moving.
General Techniques
Common loading method
Common loading method is suitable for carrying
Machine Operation loose materials.
While the loader is approaching the loose material in
Preparation Before Operation forward shift 2 with the center of bucket targeting the pile,
Before doing the work, use this machine to level the the operator holds the steering wheel with left hand and
site, including removing the protrusion, filling the operate the pilot valve boom control lever with right hand
holes and removing the wet and slippery ground to lower the boom to 300 mm above the ground.
surface.Remove large and sharp stones from the site Do not lower the boom until the machine is about one
to avoid tire scratches. meter away from the pile, and allow the bucket to touch
the ground and shift from forward 2 to forward 1.
If using this machine to load or unload the truck or
hopper, adjust the kickout height of the boom raise Attention
kickout to allow the hopper of the loader to enter or
When the bucket touches the ground, avoid
exit from the truck or hopper safely and not to
excessive pressure from the bucket to ground which
damage the truck or hopper due to excessive
will cause unnecessary restriction and teeth
unloading height.
wear.Meantime, the front and rear frame should be
straightened, leaving no angle between the front and
rear frame.
Depress the accelerator pedal to allow the bucket to insert
into the pile completely; When the machine can not move
further, the operator toggles the pilot valve bucket joystick
backward to rotate the bucket backward and then push
the joystick back to the neutral position. Then the machine
will continue to insert into the pile. Repeat the insert and
rotation operation until the bucket is filled with material.
Combined loading method

45
Combined loading method is suitable for loading hard or
sticky material.
The operation before inserting into the material is the
same with common loading method.The operator makes
a push of the pilot valve boom joystick after the bucket
inserts into the pile and then push it back to the neutral
position to raise the bucket so that it can insert forward
further. Then the operator makes a push of the pilot valve
boom joystick backward and then push it back to the
neutral position to rotate the bucket backward so that the
bucket can continue to insert forward.Repeat the insert,
raise, insert and rotation operations until the bucket is filled
with material.
Never handle material with the bucket raised to
Exiting from the pile higher position which can cause machine
After the bucket is filled with material, the operator rollover.
operates the pilot bucket joystick to turn the bucket
backward until the bucket kickout touches the boom, and Dump
then move the bucket joystick to the neutral position.Now
1. Dump to the truck or hopper
maximum retract angle can be obtained.
Raise the boom to certain height to allow the bucket to When the loader filled with material is 15 meters
avoid the pile when the machine is moving backward.The away from the truck or hopper, release the
operator moves the joystick backward to reverse position accelerator pedal and slightly apply the service brake
with left hand to reverse the machine while holding the if necessary to slow down the machine so that the
steering wheel with right hand. machine can approach the truck or hopper at low
After exiting from the pile, the operator operates the boom speed.Meanwhile, the operator pushes the pilot
control lever to lower the bucket to the position where the valve joystick to the rearmost position and the
lowest point of the bucket is 300-400 mm above the joystick will be caught up by the electromagnet. Now
ground. the operator can release his hand and the joystick
will not bounce back to the neutral position.During
Material Handling this process, the operator should drive the machine
Self-handling can be used in the following conditions: carefully to observe the process in which the bucket
is approaching the truck or hopper and the operator
1. The truck can not be used due to soft and can move the joystick back at any time to prevent the
unleveled site. bucket from touching the truck or hopper.
2. Handling distance is within 500 meters and it is With the bucket over the truck or hopper, the operator
not economic to use the truck. depresses the brake pedal to slow down the
During handling, keep the lowest point of the bucket machine.Then move the pilot valve bucket joystick
at transport position (300-400 mm above the ground) forward to tilt the bucket forward and to pour the material
and turn the bucket backward to stop position into the truck and hopper. At this point, the drive should
(bucket kickout touches the boom) to make sure the watch for the bucket movement in order that the bucket
handling operation is smooth and safe and not will not touch the truck or hopper edge. If the material is
easily-spilling. too sticky, push the bucket joystick back and forth
repeatedly to allow the bucket kickout to hit the boom
The machine speed during handling depends on the repeatedly to remove the material sticking to the bucket.
handling distance and road condition. When the If the body length of the truck is more than twice the
machine travels over a hole or a bump, release the width of the bucket, start dumping from the front of the
accelerator pedal and slightly apply the service brake body.
as necessary to slow down the machine and reduce
the impact to the machine and the spilling when Attention
passing over the restrictions. During dumping, the bucket kickout should not hit
the boom excessively and the number of hit should
be limited in order not to damage the machine.
After dumping, the operator pushes the pilot bucket
joystick to the rearmost position until the bucket kickout
hits the boom and then move the bucket joystick back to
neutral position.Then the operator moves the variable
speed joystick to reverse position and release the brake
pedal to move the machine away from the truck or
46
hopper.When the machine is leaving the truck or hopper,
the operator should drive the machine carefully and
watch for the bucket movement in order that the bucket
will not touch the truck or hopper edge. When the bucket
completely leaves the truck or hopper, the operator can
lower the boom while driving to prepare for the next
cycle.
2. Dump at low position
When handling material between sites, dumping at low
position can be possible which means dumping with the
bucket close to the ground.In this case, rotate the bucket
backward to the horizontal position before raising the
boom.Otherwise, the boom may not be raised due to the
interference of work tool linkage. As illustrated, the loader faces the pile and the angle
Pushing operation between the truck and the traveling direction of the
loader is 60 degrees. Stop moving when it is 12-15
Place the bucket against the ground horizontally and
meters away from the pile and when the loader is
variable speed joystick at shift position 1 and depress the
filled with material, reverse the loader to where there
accelerator pedal to move the machine ahead. If
is 12-15 meters away from the pile. Drive to the truck
restrictions are found during bulldozing, slightly raise the
while steering and raising the bucket.After dumping
boom to continue. The pilot valve boom control lever
the material, reverse to the original position for next
should be operated between RAISE and LOWER
loading.
position instead of any RAISE or LOWER position, in
order to ensure smooth bulldozing operation.
Blading operation
Raise the boom and rotate the bucket forward until the
blade touches the ground and the angle between the
blade and ground should be kept at about 40 degrees.
For hard surface road, put the pilot valve boom control
lever at FLOAT position; for soft surface road, put it at
neutral position. Move the joystick to reverse shift
position and depress the accelerator pedal to reverse the
machine and blade the ground with the blade. Vertical loading
Towing Operation The loader faces the pile and travels in a straight line
A 20-ton flatbed trailer can be configured to tow the at reverse position. Then drive a truck between the
machine.The method is as follows: loader and pile.
1. Securely connect to the tow pin of the machine. This method needs less loading time which reduces
the duty cycle time efficiently.
2. Equipped with brake system of good
performance.
3. Put the bucket at transport position.
4. Moderate action is required for start and stop
and braking should be applied when going down
a slope.

Attention
When applying the brake, apply to the flatbed
trailer first and then the machine.

Operating Method
V-shaped method
Cold Weather Operation
Low Temperature Considerations
If the ambient temperature is too low, it is difficult for
47
the engine to start and the radiator may freeze.
Therefore, the following precautions must be taken:
Decommissioning and
1. All parts use low-cohesive fuel, hydraulic oil and Disposal
lubricant, and add coolant to the water.For When the product is removed from service, local
specific oil type, see the Fluids Specification in regulations for the product decommissioning will
the Operation and Maintenance Manual. vary. Disposal of the product will vary with local
2. Antifreeze Use ConsiderationsDo not mix regulations.
antifreezes of different category. Improperly disposing of waste can threaten the
Attention environment. Obey all local regulations for the
decommissioning and disposal of materials.Utilize
The antifreeze must be away from the flame and appropriate personal protective equipment when
smoking is forbidden when adding the antifreeze. decommissioning and disposing product.
3. Battery Use Considerations Consult the nearest SEM dealer for additional
information. Including information for component
When the ambient temperature reduces, the battery remanufacturing and recycling options.
capacity reduces too.If the charging rate of the
battery is low, the electrolyte may freeze, therefore
try to maintain the charging rate at 100% and keep
it warm if possible so that the engine is easily to be
started next day.
In the extreme cold area, use batteries that can
overcome extreme cold.
Considerations After Daily Work
To prevent the silt, water or snow sticking to the
machine from affecting engine start the next day, the
following measures must be taken:
1. Thoroughly remove the silt, water or snow
sticking to the machine.Prevent the silt, water or
snow from entering the seals and freezing in
them which can damage the sealing capacity.
2. Park the vehicle on a dry and hard surface.If this
is not possible, park the machine on a
board.Using a board can prevent the machine
from freezing on the ground and makes the start
the next day easier.
3. At low temperature, battery capacity will reduce
significantly as parking time grows. Cover the
battery or move it to a warmer place and install it
back the next day.
After Cold Weather
When the weather gets warm, the following work
needs to be done:
1. All components change to use semi-cohesive
fuel, hydraulic oil and lubricant.For specific oil
type, see the Fluids Specification in the
Operation and Maintenance Manual.
2. If the permanent antifreeze is not used,
completely drain and clean the cooling system
and replace with new coolant.

48
Maintenance Section

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

49
SEM636D Regular Maintenance
The maintenance intervals listed in this manual are
determined by using the service hour meter or the
calendar (day, month etc.).Caterpillar (Qingzhou)
Ltd. requires the service should always be performed
at the interval that occurs first among the above two
interval determination methods.Under extremely
severe, dusty or wet operating conditions, more
frequent lubrication than is specified in the scheduled
maintenance might be necessary.
Besides the daily maintenance, we also specify four
maintenance points: PM1:250H; PM2:500H;
PM3:1000H; PM4:2000H.
During the maintenance, the daily routine
maintenance and first-time maintenance of the
corresponding parts should be strictly followed, and
then different regular maintenance plans should be
executed according to the specific working hours.
Regular maintenance is based on working hours, or
perform the maintenance every year/2,000 working
hours.The appropriate regular maintenance plans
are:250-PM1, 500-PM2, 750-PM1, 1000-PM3, 1250-
PM1, 1500-PM2, 1750-PM1, 2000-PM4.

The specific maintenance plans can be found in

the attached chart
ANNEXES
Maintenance Items Daily PM1 PM2 PM3 PM4
Maintenance
Check the Engine Level √ √ √ √ √
Check the coolant level √ √ √ √ √
Check hydraulic oil fluid level √ √ √ √ √
Check fuel level, drain the fuel and debris in the fuel √ √ √ √ √
prefilter
Check the operation of lights and gauges √ √ √ √ √
Check the tire pressure and for damage √ √ √ √ √
Check the reverse alarm operation √ √ √ √ √
Check the transmission oil level √ √ √ √ √
Check the lubrication of each greasing point and add
grease to each greasing point as directed by machine √ √ √ √ √
maintenance chart posted on the machine.
Check the brake booster oil level √ √ √ √ √
Check the variable speed control system and adjust as
necessary √ √ √ √ √

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

Walk around the machine to visually check all systems for √ √ √ √ √
abnormal condition or leaks.
Visually check engine fans and drive belts √ √ √ √ √
Add grease to each drive shaft as directed by machine √ √ √ √ √
maintenance chart posted on the machine.
Tighten all drive shaft bolts √ √ √ √ √
Check the clearance between brake shoes and brake drum
of park brake at the first 50 working hours and adjust as √ √ √ √
necessary.

50
 Daily
Maintenance Items Maintenance PM1 PM2 PM3 PM4

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

Initial change of the engine oil and oil filter (the first 50
working hours)
Initial change of the oil in the transmission, torque
converter, radiator and drive system filter Initial Change

Initial change of the drain filter element of the hydraulic oil

tank (upper element in the oil tank) Initial Change

Initial change of the pilot hydraulic system filter element Initial Change Clean
Keep the battery post clean and apply vaseline to it to avoid √ √ √ √
post corrosion by acid mist
Sweep the engine cylinder head √ √ √ √
Sweep the radiator set √ √ √ √
Clean the fuel tank fill screen √ √ √ √
Clean the oil tank fill screen √ √ √ √
Check the torque of the transmission and engine mounting
bolts √ √ √ √

Check all the stressed welds and mounting bolts of the

work tool and the front and rear frames for cracks and √ √ √ √
looseness
Check the oil level of front and rear axles √ √ √ √
Check the engine air intake system √ √ √ √
Check the tension of engine drive belts and air conditioner
compressor belts and for damage √ √ √ √

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

Replace the engine oil and oil filter √ √ √ √
Clean the air conditioner inner filter element √ √ √ √ √
Replace the fuel prefilter √ √ √ √
Check/replace the engine water processor √ √ √ √
Check the retaining bolts of frame articulation pin for √ √ √
looseness
Tighten the bolts securing the front and rear axles to the √ √ √
frames
Clean the screen inside the air booster pump breather √ √ √
Replace the fuel filter √ √ √ √
Replace the air cleaner element √ √ √ √
Adjust the engine valve lash √ √
Check the engine tensioner bearing and fan shaft housing √ √
Tighten all battery retaining bolts and clean the top of the √ √
battery
Clean the fuel tank √ √
Clean the transmission and torque converter breather √ √
Replace the oil in the transmission torque converter and √ √
radiator
Replace the drive system filter. √ √
Replace the drain filter element of the hydraulic oil tank √ √
(upper element in the oil tank)
Replace the axle oil √ √
Replace the pilot hydraulic system filter element √ √
Check the engine vibration damper √
Check the operation of service brake system lines and park
brake system and remove to check the friction shim for √

51
 Daily
Maintenance Items Maintenance PM1 PM2 PM3 PM4

wear and replace the brake lines as necessary

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

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

Check the sealing capability of the distribution valve and

operating cylinder by measuring the natural recess of the √
cylinder
Replace the oil tank breather (fill screen) √
Replace the fuel tank breather (fill screen) √
Replace the coolant and coolant filter; clean the cooling
systemReplace the coolant at least every two years if the √
working hours do not meet the change interval
Replace the hydraulic oil, clean the oil tank and check the
suction line √

Important Notice! Access and Cleaning Before Maintenance

Do not use maintenance parts that are not approved Clean the machine before accessing and
by Caterpillar (Qingzhou) Ltd. or designated dealers of maintenance.This can ensure that dirt will not enter the
Caterpillar (Qingzhou) Ltd.The use of unauthorized machine and maintenance job can be safely done.
maintenance parts may result in safety problems that If the machine is still dirty when accessing and maintaining,
are detrimental to the normal operation of the machine it can be difficult to locate the problem and dirt or silt can
and affect the service life. spill into the eyes, and people can slip and get injured.
The following needs to be noticed when cleaning the
machine:
Maintenance Considerations 1. Wear anti-skid shoes to avoid slipping on a wet
I. Before Maintenance surface.
2. Wear protective clothes when flushing the machine
Malfunction notice with high-pressure water.This can protect you from the
If the maintenance being performed is not specified in the impact from the high-pressure water and prevent the
Operation and Maintenance Manual, unexpected dirt and silt from spilling into your eyes.
malfunctions can occur. 3. Do not spray water directly onto the electrical system
Contact the designated dealers of Caterpillar (Qingzhou) elements (e.g. sensor, wire connector).If water enters
Ltd. for repair. the electrical system, it can be failed.
If another person starts the engine or operates the lever
while the operator is maintaining the machine or adding oil, Keep the work site clean and organized
the operator can be severely injured or killed.
Do not leave any service or maintenance tool around the
Post a warning label on the lever in the cab to alert the work site.Thoroughly wipe off any grease, oil and other
other people that you are accessing the machine.Post a items that can make people slip.Always keep the work site
warning label around the machine too, if necessary. clean and organized so that the job can be safely done.
If the work site is not clean or organized, people can trip,
slip or tumble and get injured.

52
Designate a responsible person when put a wedge under the tire.
co-working with other people Lock the front and rear frames with locking lever.
Designate a responsible person who will be Take extreme care during maintenance not to be
listened to by everybody while repairing the hit or hooked by moving parts.
machine or installing/removing the work tool.
Mutual misunderstanding can cause serious
accidents when co-working with other people.
Unlock
Coolant Level in the Radiator
Locked

Support the Work Tool

While raising the bucket to perform inspection
and maintenance, support the boom with a
bracket to prevent the work tool from falling.
To check the coolant level in the radiator, shut
down the engine and wait for the engine and Place the lever at NEUTRAL position.
radiator to cool down.Do not open the radiator
top cover under normal circumstances. Suitable Tools
If there is no need to open the radiator top cover, Use only the tools suitable for the task.Using
perform as follows: damaged, poor quality, failed or temporary tools can
1. Wait the radiator to cool down before checking cause personal injury.
the coolant level.(To check if the water
temperature has reduced, put your hand close to
Lighting Use
the engine or radiator to check air Use a lighting device with anti-explosion feature
temperature.Be careful not to touch the engine or when checking the fuel, lubricating oil, battery
radiator for burn prevention). electrolyte or window glass detergent.If not,
2. When the water fill cap is cold enough that can explosion can occur.
be touched with bare hands, slowly loosen the If performing the job at a dark place without
cap to release the internal pressure. lighting, people can get injured, therefore, proper
lighting device should be installed.
Wait for the radiator to cool down and then
release the internal pressure so that the radiator Never use a lighter or flame for lighting even in a
top cover can be opened. dark place.It could cause a fire and when the
gases exiting from the battery encounters a fire,
explosion could happen.
Shut down the engine before accessing When using the machine for lighting supply,
or maintaining the machine obey the instructions in the Operation and
Place the machine on a level ground where there Maintenance Manual.
should be free of rock fall or landslide when
accessing or maintaining the machine.If the
Fire Prevention
terrain is low, there should be free of flood risk,
either.Shut the engine OFF. Fuel or gases exiting from the battery could cause a
fire during the maintenance, therefore the following
Lower the work tool to the ground after the
considerations must be obeyed while accessing or
engine is turned off.
maintaining.
Operate the work tool lever to RAISE, LOWER and
The fuel, lubricating oil and other flammable
RETRACT several times to release the retaining
materials must be stored away from the flame.
pressure inside the hydraulic oil lines.
Use nonflammable material as part detergent.Do
Pull the park brake switch to apply the brake and
not use diesel or gasoline which could cause a
53
fire. frame raised, lock the front and rear frames
with locking lever.Place the lever at NEUTRAL
Do not smoke while accessing or
position.Block the work tools and frames with
maintaining.Smoke at the designated place.
wedges.
Use a lighting device with anti-explosion feature
Before raising, block the wheel with a wedge at
when checking the fuel, lubricating oil, battery
the opposite side.After raising, put wedges under
electrolyte.Never use a lighter or flame for
the machine.
lighting.
Move all flammable material to a safe place Working on the Top of the Machine
before grinding or welding on the flame. When working on the top of the machine, make
There must be a fire extinguisher in the job site sure that the foothold is clean and free of
where accessing or maintenance will be restrictions and the following considerations
performed. must be obeyed to avoid falling.
1. There should not be spilled lubricating oil or
grease.
Ⅱ. When Performing Maintenance 2. No tools around.
WHO 3. Watch out for the step while walking.
Maintenance and service of the machine should Never jump from the machine.When getting
only be carried out by qualified technicians.Keep on/off the machine, always use the ladder and
anyone not involved in the maintenance and armrest and keep three-point (two feet and one
service away from the area.Designate a person to hand or two hands and one foot) contact any
attend the area if necessary. time.
Pay particular attention when grinding, welding Use protective devices if necessary.
or using a sledge hammer. The top of the engine hood is slippery and
dangerous so standing on it is forbidden.
Accessories The top of the tire is slippery and dangerous so
Designate a responsible person before starting standing on it is forbidden.
the removal or installation of the accessory. Stand on the fender of the front frame when
Do not allow anyone who is not involved in the cleaning the front window glass of the cab.
job to stand near the machine or accessory.
Put the accessory removed from the machine in Do not drop foreign material into the
a safe place and make sure it does not fall.Install machine
rails around the accessory with a "NO Entry" tag
on the rail to prevent the unauthorized person Take care not to drop any foreign material (e.g.
from getting close. nut, bolt, cotton yarn or tool )into the machine
when opening the access window or oil fill of the
tank.If such kind of material is dropped into the
Working under the Machine machine, machine damage, failed operation and
other malfunction can occur.
Park the machine at the hard and level ground.
Lower all work tools to the ground before If any foreign material is dropped into the
performing maintenance or repair under the machine, it must be taken out of the machine.
machine. While accessing, do not carry any unnecessary
Block the tires with wedges. tool or part in the pocket.
If the machine is only supported by the work
tools with the tires above the ground, it is very Maintenance During Engine Operation
dangerous to work under the machine.Never
work under a poorly-supported machine. Do not perform maintenance during engine operation
to avoid injury.If it is necessary to perform
maintenance during engine operation, the following
Performing Maintenance with Frame considerations must be taken:
Raised Ask a technician to sit on the operator's seat and
Before performing the job with work tool or turn off the engine at any time.All technicians

54
must be in touch with other person. Clear all flammable materials and make sure
there is a fire extinguisher at the job site.
Use extreme care when the work point is near the
rotating parts because there is the risk of getting Battery Considerations
caught in rotating parts. When repairing the electrical system or performing
Never allow any tool or any part of the body to welding on the machine, remove the negative (-) of
touch the fan blade or fan belt.Serious injury can the battery or turn off the main power switch to
be caused. prevent current flow.

When Found It Abnormal

If any abnormal condition is found during
accessing, repair it.Especially when a problem is
found in the brake system , steering system or
work tool system, serious accidents could occur.
Prevent the work tool from moving when Depending on the fault type, contact the
cleaning the interior of the radiator.Also pull the designated dealers of Caterpillar (Qingzhou) Ltd.
park brake switch to apply the park brake. for repair.
Do not touch any lever.If operating the lever is
necessary, signal the other technicians to alert
them to walk into a safe place. Regulations on Adding fuel or
Lubricating Oil
Hammer Use Considerations Fuel, lubricating oil, hydraulic oil, antifreeze, brake
Always wear safety glasses, helmet and other fluid and window glass detergent can be lit by a
protective clothes when using a hammer and put flame.The following regulations must be obeyed:
a copper stick between the hammer and the Turn off the engine when adding fuel or
object being hit on. lubricating oil.
There could be a risk of debris flying into the
No smoking.
eyes causing injury if using a hammer to hit a
hard part, For example a pin or bearing. Wipe off any spilled fuel, lubricating oil,
hydraulic oil, antifreeze, brake fluid or window
glass detergent immediately.
Welding Repair
Securely tighten all top covers of the containers
The welding must be performed by a qualified for fuel, lubricating oil, hydraulic oil, antifreeze,
technician and in a place equipped with appropriate brake fluid or window glass detergent.
equipment.Welding can generate gases and there
exists the risk of fire and electric shock, therefore The place where the fuel, lubricating oil,
never allow the unqualified technician to perform the hydraulic oil, antifreeze, brake fluid or window
welding.The qualified technician must follow the glass detergent is added or stored must be well-
following the considerations. ventilated.
Disconnect the terminals of the battery to avoid High-pressure Hose Handling
battery explosion.Remove the paint from the
position to be welded to prevent the generation If the high-pressure hose leaks, failed operation
of hazardous gas. could occur which will cause personal injury or
Welding on the hydraulic device or lines or equipment damage.If damaged hose or loosened
places very near to it can generate flammable bolt is found, stop operation and contact the
vapor and spark which can cause a fire, designated dealers of Caterpillar (Qingzhou) Ltd.
therefore, avoid to weld on such place. for repair.
If the spark generated during the welding directly Sophisticated technique is required when
falls on the rubber hose, wire or pressurized replacing the high-pressure hose and installing
piping, they can rupture and the insulation of the torque is determined by the type and size of the
wire can be damaged, therefore, cover them with hose, therefore, do not repair by yourself.
an anti-fire baffle. Contact the designated dealers of Caterpillar
Wear protective clothes during welding. (Qingzhou) Ltd. for repair.
Make sure the site where the welding is
performed is well-ventilated. High-Pressure Oil Considerations
55
When accessing or replacing the hydraulic system Never dump the used fuel or oil into the drains,
lines, check if the system pressure has been rivers, etc.
released.If there is still pressure in the lines, serious
Collect the drained oil into a container and never
injury or damage can occur. Therefore, perform as
drain the oil directly to the ground.
follows:
Dispose of the hazardous material such as
lubricating oil, fuel, coolant, solvent, filter and
battery in accordance with the related laws and
regulations.

Inspection After Access and

Maintenance
If the comprehensive access and maintenance is not
performed and the function of each maintenance
position is not checked, unexpected problems can
occur which could cause personal injury or machine
damage. Therefore, always consider the following
questions.
For details of releasing pressure, see "Turn off Inspection After Engine Shutdown
the engine before check and maintenance" in the
Maintenance Considerations.Never access or 1. Have all access and maintenance positions been
replace before the pressure is released checked?
completely. 2. Have all access and maintenance items been
Wear the safety and leather gloves. performed correctly?
If there is oil leak in the line, the line and the 3. Is there any tool or part falling into the
surrounding area will be wet, therefore, check machine?It is especially dangerous if the tool or
the tube or hose for cracks and hose for bulge.If part sticks into the linkage of the lever.
it is difficult to locate the leak, contact the 4. Have the coolant leak and oil leak been
designated dealers of Caterpillar (Qingzhou) Ltd. repaired?Have all the bolts been tightened?
for repair.
Inspection During Engine Operation
Use a plate or cardboard to check for leak See the Maintenance During Engine Operation
instead of bare hands. section of Maintenance Considerations.Consider the
If shot by the spilled high-pressure oil, see a following questions while ensuring safety:
doctor immediately. 1. Is the operation of the access and maintenance
positions normal?
Precautions for accessing at high
2. Does the hydraulic system leak oil when the
temperature or high pressure engine speed accelerates and high load is
The coolant and oil at various positions is under applied?
high temperature and high pressure just after
the operation is stopped.Opening the engine
hood, draining the oil or coolant, or replacing Ⅲ. Tires
the filter at this point can cause burns or other Tire Handling
injuries.Wait for it to cool down and access Wrong handling of the tire or rim can result in a blew
according to the procedure in the Operation or ruptured tire and the hub can be damaged and
and Maintenance Manual. scattered which could cause serious injury or death.
For other inspection items, see the Regular The following considerations must be obeyed for
Maintenance section and the related content in maintenance safety.
the Operation and Maintenance Manual. The maintenance, removal, repair and installation
of the tire and rim require special equipment and
Scrap techniques, therefore ask a tire repair shop to do
the job.
To prevent pollution, especially in the area where Only use the specified tires and inflate them to
humans or animals live, the following procedures the specified pressure.For the specified tire and
must be followed. pressure, see Usage and Main Technical
56
Features and Parameters. them with wedges so that they will not fall even if
Do not let anybody walk into the job site while touched by unauthorized person.If the tire is
inflating the tires.It is necessary to stand at the placed on its side, it will be crushed and the
side of the tire, use self-clamping collets and quality will reduce.
check the tire pressure now and then to make If the tire is going to fall, stand aside as soon as
sure that the pressure will not be too high. possible.The industrial tire is very heavy. Trying
If the rim is installed incorrectly, the rim can be to hold it can cause serious injury.
damaged or scattered after the tire is
inflated.Therefore, put protective plates around
the tire and do not work at the side of the rim.
The abnormal decrease of the inflation pressure
and the abnormal fit of the rim indicate that there
is a malfunction in the tire or rim.In this case, ask
a tire repair shop to repair the tire.
Do not adjust the inflation pressure after high-
speed traveling or high duty operation.
The fully inflated tire can explode because the air
inside the tire is heated and burnt.The heating is
caused by heating or welding the rim, external Block
flame, or air heat expansion or burn due to
frequent braking.
Tire explosion is much more forceful than
discharging the tire. Explosion can force the
tires, rims and final drive parts away from the Important Maintenance
machine more than 500 meters and the explosion
force and pieces can cause personal injury and Procedure
property damage.
It is recommended to use dry nitrogen (N 2) to Engine Coolant Maintenance
inflate the tire.If there is air remaining in the tire,
it is recommended to use nitrogen that can be Proper maintenance of engine cooling system is
mixed with air to regulate the tire pressure.The extremely important. Overheat, overcooling, pitting,
tire inflated with nitrogen can reduce the cavitation, cylinder head cracks, piston sticking and
possibility of explosion because nitrogen is radiator clogged are common faults in the cooling
nonflammable.Nitrogen can also prevent system, which not only reduce the engine's work
oxidation, deterioration of rubber and corrosion efficiency but also cause severe engine damage.
to the rim components.
Anti-freeze
Flat tire or rim damage is due to improper
inflating equipment or improper use, therefore, The main purpose of the antifreeze is to reduce the
to avoid over inflation, make sure that proper condensation point and raise the boiling point of the
equipment is used and the tire is inflated by coolant.Use antifreeze even at a common ambient
trained person. temperature, because it can raise the boiling point of
the coolant and the additives in the antifreeze can
reduce the possibility of corrosion and cracks on
machine body.
The performance of the antifreeze brands
recommended by Caterpillar (Qingzhou) Ltd. is as
follows:

Minimum Ambient Temperature Antifreeze

for Use (C) Model
Tire Storage Considerations
－50 YF-3
As a guideline, the tires must be stored in the
warehouse where unauthorized person cannot －45 YF-2A
enter.If it is necessary to store the tires outside, －40 YF-2B
set fences around the tires and put a NO ENTRY
sign on it. －35 YF-2

Put the tires uptight on a level surface and hold －25 YF-1

57
 minutes.
Change the antifreeze with a good-quality one and While adding coolant, the air must be vented
refill according to the instructions. from the engine coolant piping.
Attention 4. Start the engine with the radiator water fill cap
The antifreeze is flammable. Do not leave it close opened and run it at low idle speed for 5 minutes
to a flame. first and then run at high idle speed for 5 minutes
to make the coolant temperature above 85°C.
Coolant Level Check Method 5. Check the coolant level again and continue to
The radiator is located at the tail of the machine. add coolant if necessary until the level reaches
the high mark on the secondary water tank.
1. After the engine coolant temperature drops
below 50°C, loosen the radiator water fill cap 6. Check the seal of the radiator water fill cap and
slowly to release the pressure to prevent the replace it if damaged.
burns caused by hot vapor or hot spilled coolant.
Attention
2. Check if the coolant level is between the high
mark and low mark on the secondary water tank Do not add cold coolant to a hot engine, or else,
as shown. Add coolant to the high mark if it is the engine body can be damaged.Wait until the
below the low mark. engine temperature is below 50°C.

3. Check the seal of the radiator water fill cap and

replace it if damaged. Attention
4. Tighten the radiator water fill cap. Caterpillar (Qingzhou) Ltd. will not be
responsible for the loss caused by coolant leaks
5. If the coolant needs to be added daily, check for
and the drop of antifreeze concentration due to
leaks in the engine cooling system.If a leak is
the user's misuse.
present, correct it and add antifreeze to an
appropriate level.
Add Coolant Coolant Change or System Cleaning
Before adding coolant to a new machine or an Completely change the coolant in the cooling system
engine with a cleaned cooling system, determine the and clean the cooling system every 10,000 hours or
concentration of the antifreeze in the coolant based 5 years, whichever occurs first.
on the local record low ambient temperature (10°C Before this interval, if the coolant is contaminated,
below the record low ambient temperature is better) the engine is overheated, or there is bubbles in the
and calculate the desired antifreeze amount based radiator, clean the cooling system right now.
on the total capacity of the engine cooling system.
The steps of cleaning cooling system are as
Attention follows:
Never use water alone for coolant.Damage from 1. Turn on the negative switch of the power;Insert
corrosion can be the result of using water alone the key into the start switch and turn it to position
for coolant.We will not provide the warranty of 1 clockwise to energize the machine power;Push
the cooling system components if using water the air conditioner system toggle switch to HEAT
alone for coolant. position.
The steps of adding coolant are as follows: 2. Turn the hand valve of the engine water inlet line
to the ON position (the valve handle is in the
1. Turn on the negative switch of the power;Insert same direction of the line route at ON position).
the key into the start switch and turn it to position
1 clockwise to energize the machine power;Push 3. Start the engine and shut it down after idling it for
the air conditioner system toggle switch to HEAT 5 minutes.Turn the START switch to position 1 to
position. energize the machine power, and put the toggle
switch of the air conditioner system at HEAT
2. Turn the hand valve of the engine water inlet line position to open the magnetic water valve of the
to the ON position (the valve handle is in the air conditioner.
same direction of the line route at ON position).
3. Open the radiator water fill cap to add coolant
slowly until the level reaches the high mark on
the secondary water tank and keeps stable in 10
58
4. After the coolant temperature drops below 50C, the rear of the machine.Meanwhile remove the
loosen the radiator water fill cap slowly to release connector of rear work light.
the pressure. 2. Remove the dirt and leaves, etc. on the radiator
5. Open the water drain valve at the bottom of the fins with compressed air, vapor or water.
radiator and the drain valve of the engine oil
cooler to drain the engine coolant and collect it
with a container.
6. After all coolant is drained, close the water drain
valve at the bottom of the radiator and the drain
valve of the engine oil cooler.
7. Check all the water pipes and clamps for
damage and replace if necessary.Check the
radiator for leaks, damage and dirt accumulation.
Clean and repair if necessary.
8. Fill the engine cooling system with a cleaning
3. Also check the rubber hose.If cracks on the hose
mixture of water and sodium carbonate and the
or deterioration or hardening is found, replace
mixing ratio is 0.5 liter of sodium carbonate in
the hose with a new one.Also tighten the
every 23 liters of water.The level should reach
loosened pipe clamp.
engine operating level and keep stable within 10
minutes.
Attention Maintenance of Engine Air
While adding the cleaning solution to the cooling Cleaner
system, the air must be vented from the engine
coolant piping. Attention
During the whole cleaning process, the engine is Turn off the engine when maintaining the air
running with the radiator water fill cap removed. cleaner to prevent damage.
9. Keep the radiator water filler cap open and start
the engine. Operate the engine for another 5 Maintenance and Replacement of Engine
minutes after the coolant temperature is above
Air Filter Element
80°C.
The air filter is in the engine hood.
10. Turn off the engine and drain the cleaning
solution. When the alarm appears red, use compressed air of
less than 205 kPa, along the direction of the pleats,
11. Fill the engine cooling system with clean water to
to clean the filter element from inside out.Do not use
normal operating level and keep it stable within
other tools to knock the filter element when removing
10 minutes.Keep the radiator water filler cap
the filter element.Clean the inner wall of the filter
open and start the engine. Operate the engine
outlet pipe and the sealing surface.Replace the filter
for another 5 minutes after the coolant
element after 6 times of blowing or 250 (high dust) -
temperature is above 80°C.
500 (low dust) working hours.Check the connections
12. Turn off the engine and drain the water in the to ensure that the filter cap matches the engine
cooling system.If the water being drained is still intake and is airtight.
dirty, the system must be flushed again until the
water comes out clean.

The air filter can only be serviced when the

engine is shut down.Otherwise, the engine may
Engine coolant is toxic and undrinkable. Dispose be damaged as a result.
of it according to the local laws and regulations.
Service the air cleaner filter element when the
Cleaning Radiator Fins blue plunger on the engine air filter service
indicator enters the red zone.
If there is dirt sticking to the radiator, clean in the
following method.
1. Remove the bolts and remove the rear grid form Cleaning the air filter primary element
59
 Replacement of Safety Element
1. Open the engine hood.
2. Remove the air cleaner cover from the air
cleaner housing.Remove the primary filter
element from the air cleaner housing.
3. Remove the secondary filter element.

1. Loosen all clips connecting the rear cover to the

housing, remove the rear cover, and remove any
dust on the rear cover. Attention:When stopping
the machine to check, the dust can be removed
by dust valve in time. Replace the dust valve
immediately when it is damaged or missing.
2. Counterclockwise rotate the seal cover and
remove, and then the external element can be 4. Cover the air inlet opening.Clean the inside of
seen. the air cleaner housing.
3. Catch the clamps of external element rear cover 5. Remove the cover from the air inlet opening.
and pull the external element out of the air
cleaner cavity. 6. Install the new secondary filter element.
4. Maintain the external element according to the 7. Install the primary filter element.
maintenance instructions of air filter. 8. Install the air cleaner cover and tighten it.
5. Before installing back the external element, clean 9. Close the engine hood.
the inside of the cleaner and remove the dust
accumulating on the internal threads with a Attention
bristle brush or a rag to make sure that the
thread is smooth, and prevent dust from entering Always replace the secondary element.Never
the inside of the element. attempt to reuse the secondary filter element by
cleaning the element.When the secondary filter
6. Install back all parts in the opposite order of element is replaced, the primary filter element
removal and make sure that they are installed should also be replaced.The secondary filter
correctly to ensure a correct sealing. Do not omit element should also be replaced if the exhaust
any part. smoke is still black.
Attention Use and Maintenance Instructions for Oil-
Caterpillar (Qingzhou) Ltd. recommends the use bath Air Filter (Optional)
of a certified air cleaner and cleaning service
1. The oil-bath air filter must be pre-filled with oil to
provided by an authorized Caterpillar (Qingzhou)
the oil level mark before used (approximately4L).
Ltd. dealer.
2. Use the same oil type as the engine according to
The cleaning process of Caterpillar (Qingzhou) Ltd. the seasons.
employs proven procedures that ensure consistent
quality and long cleaner life.Observe the following 40# oil can be used throughout the year for areas
guidelines if you attempt to clean the filter element: with winter temperature higher than -10℃.
Do not tap or strike the filter element in order to For areas with winter temperature below -10℃,
remove the dust.
add 10% of 46# hydraulic oil to the oil for every air
Do not wash the filter element.Use the low pressure temperature drop of 5℃.
compressed air to remove the dust from the filter
element.The air pressure must not exceed 205 NOTE:Before adding the hydraulic oil, drain the
kPa.Direct the air flow up the pleats and down the same volume of oil from the oil tray.
pleats from the inside of the filter element.Take The oil adding method is as follows:
extreme care in order to avoid damage to the pleats.
60
1. Loosen the oil tray retaining capscrews, and 5. After the daily work, loosen the water drain plug
remove the oil tray.Take out the element at the bottom of the fuel prefilter and primary fuel
assembly and add oil to the oil tray.Install the filter to drain the water and contaminants.
upper element assembly, ring seal, lower
Do not wait to add fuel until the fuel tank is empty, or
element assembly and oil tray in sequence and
else the engine will die and there will be large
then tighten the retaining capscrews evenly to
amount of water and contaminants at the bottom of
avoid oil leak.
the fuel tank which will prevent the normal engine
2. Remove the oil tray, clean the upper and lower operation.
element assembly and oil tray, and change the
oil every 170Hrs.
Diesel Sulfur
3. Shorten the element cleaning interval if the
vehicle travels in high dust environment. The diesel sulfur percentage can affect the choice of
engine oil and oil change interval.The sulfur can
convert into sulphuric acid and sulfurous acid during
burning which will corrode the metal
Use and Maintenance of Diesel surface.Therefore, use the diesel fuel with low sulfur
content.
Diesel Tank
Some additives in the oil contain alkaline compound
The diesel fuel tank breather should be
which can neutralize the acid.Therefore, the oil
maintained as the following procedure defines:
change interval should be adjusted based on the
Typically change the breather annually, but if it is diesel sulfur:
badly contaminated, it is recommended to change it
1. If the diesel sulfur is below 0.5%, change oil
every 1,000 hours or 3 months. When slow refilling
according to the interval specified in the Regular
speed is felt, remove the breather and continue to
Maintenance in this manual.
refill. Blow out the dust etc. clogging the screen with
high-pressure air when maintaining the breather 2. If the diesel sulfur is 0.5%~1.5%, change oil at
daily. 1/2 of the interval specified in the Regular
Maintenance in this manual.
The fuel filler screen and the fuel tank should be
cleaned periodically. The fuel tank can be cleaned 3. If the diesel sulfur is above 1.5%, change oil at
with the following method: 1/4 of the interval specified in the Regular
Maintenance in this manual.
Remove the flange disc at the front end of the fuel
tank and flush the inner surface of the tank with Replacement of Fuel Filter and Fuel
clean diesel. Loosen the drain plug at the bottom of Prefilter
the tank to drain the fuel.Flush repeatedly until the
drained fuel is clean. 1. Clean the surrounding area of the filter and the
filter head first.
Removing Water and Contaminants in the Diesel
2. Remove the filter from the head with a strap
Fuel pump and injection pump are very precise wrench.
devices. If there is water or contaminants in the
diesel, the fuel pump and injection pump will not 3. Remove the gasket from the threaded connector
operate properly and will be prematurely of the head.Clean the sealing surface of the
worn.Measure should be taken to remove the water head with a lint-free cloth.
and contaminants in the diesel.The method is as
follows:
1. The diesel should be settled for 24 hours before
added to the fuel tank if possible.
2. Before refilling, open the drain plug at the bottom
of the fuel tank every week to drain the water
and contaminants.
3. Add diesel to FULL after the daily work to drain
the moisture in the fuel tank.
4. Wait 5 to 10 minutes before starting the engine 4. Install a new gasket to the threaded connector of
after the fuel tank is filled to FULL, to make the the prefilter head;Apply a film of engine oil to the
water and contaminants settle to the bottom of sealing surface of the filter;Fill the filter with clean
the tank. diesel.
61
5. Tighten the filter to the filter head with hand and 1. Clean the area near the oil filter head.
tighten another 1/2-3/4 of a turn after the filter
2. Remove the oil filter with a strap wrench.
gasket just touches the head.Do not overtighten
with mechanical method or else the filter can be
damaged.

Maintenance of Engine Oil

Check the Engine level
1. Drive the machine to a level ground, turn off the
engine and pull the park brake button.
2. Wait 10 minutes after the engine is off to allow
the engine oil to flow back to the oil pan.
3. Clean the gasket surface on the head with a
3. Open the engine hood, pull out of the dipstick, clean cloth.If the old O-ring seal sticking to the
wipe the dipstick clean, insert it back into the oil head, remove it.
filler to the end, and pull it out again to check if
the level is between the L mark and the H mark
on the dipstick.
4. If the oil level is below the L mark, add oil;If the
oil level is above the H mark, loosen the oil drain
plug at the bottom of the oil pan to drain partial
oil.

Attention
Too much or too little oil can cause damage to
the engine.
4. Install a new O-ring seal.
Changing Engine Oil 5. Install the oil filter to the filter head and tighten it
Change the engine oil when the specified oil change until the oil filter gasket surface touches the head
interval is met.Position the machine on a level with hand and then tighten it to the requirement
surface and start the engine until the water with a strap wrench.
temperature reaches 60°C. Turn off the engine. Pull
Attention
the park brake button.Remove the oil drain plug at
the bottom of the oil pan to drain the oil and collect it Excessive mechanical tightening may damage
with a container. Replace the oil filter. thread or the seal of the filter element.
Install the oil drain plug and fill with clean oil through
the oil filler to the H mark on the dipstick.Operate the
engine at idle speed to inspect for leaks at the oil Maintenance of Air
filter and the drain plug.
Conditioning Heater System
Wait 10 minutes after the engine is off to allow the
engine oil to flow back to the oil pan and check the Clean the internal and external element
engine oil level again. If the oil is not sufficient, add every 50 hours
oil to the H mark on the dipstick.
If the environment is poor, tap the element with hand
Attention or clean it with dry compressed air. Replace it in
advance if obvious insufficient air flow is felt or
There should be a reading present on the engine
broken.
oil pressure gauge after 15 seconds the engine is
started.If there is no reading, shut down the Ask the Shangong Machinery dealer to check the air
engine immediately to avoid damage and inspect conditioner every year.
for correct oil level.

Replace engine oil filter

62
 taken not to allow the contaminants to enter the
transmission system which can cause damage to
the transmission.

Changing the Transmission Oil

The transmission oil is not only the working medium
of hydraulic torque converter - transmission hydraulic
system, it is also used to cool down and lubricate the
torque converter - transmission parts, therefore, the
selection of transmission oil should meet the
requirements and change the transmission oil
according to the specified change interval, or else,
the service life of transmission will be shortened.
Change the transmission oil as follows:
Maintenance of Transmission
1. Start the engine to operate the machine for
Checking the Transmission Oil Level several hours to make the contaminants, metal
debris and sediments suspend in the oil.
The transmission oil filler is at the rear top of the left
floor. Check the transmission oil level at the specified 2. Position the machine on a level surface, put the
interval to ensure oil amount.The level can be variable speed joystick to the neutral position,
checked by observing the dipstick at the right of the pull the park brake button and install the frame
transmission body (transmission oil level should be locking lever to prevent the machine from moving
in the middle position during machine operation). and rotating.
Check the transmission oil level as follows: 3. Turn off the engine and loosen the oil drain plug
under the transmission and collect it with a
1. Check the cold oil surface before the cold container.
machine is started;The purpose is to make sure
that there is sufficient oil when the machine is 4. Loosen the oil drain plug under the torque
started.It is especially important for a loader that converter and collect it with a container.
is not used for quite a long time.
2. The oil level should be at the upper position of
the dipstick before starting the engine is started The transmission oil is still hot at this point,
which means that the engine can be started.If therefore wear protective devices and use care to
the oil level is not at the upper position of the avoid personal injury.
dipstick, add oil to the upper position so that the
engine can be started. 5. Use a magnet to remove the iron scurf sticking to
3. Position the machine on a level surface, put the the oil drain plug and remove the iron scurf on
variable speed joystick to the neutral position, the inner wall of transmission.
pull the park brake button and install the frame 6. Install the oil drain plugs under the transmission
locking lever to prevent the machine from moving and torque converter oil cooler and the related
and rotating.Engine is at idle. seals.
4. Start the engine and run it about 5 7. Install the oil drain plug under the torque
minutes.Inspect if the transmission oil level is converter and the related seals.
near the middle position of the dipstick.If the oil
level is high, drain some transmission oil by 8. Open the transmission oil filler cap and add
loosening the oil drain plug at the bottom of the clean transmission oil through the filler tube. The
transmission. If the oil level is low, add some transmission oil level should be at the highest
transmission oil. level that the oil level allows.

Attention 9. Start the engine and run it about 5

minutes.Inspect if the transmission oil level is
Over high or low level can cause damage to the near the middle position of the dipstick.If the oil
transmission. Maintain the transmission oil level level is high, drain some transmission oil by
at a correct position. loosening the oil drain plug at the bottom of the
While checking the transmission oil level and transmission. If the oil level is low, add some
changing transmission oil, unique care must be transmission oil.
10. Tighten the oil filler cap clockwise.
63
Replacing the transmission oil pan Maintenance of Drive Axle
suction element
Check the oil level and replace the drive axle oil
1. Drain the oil in the same way of changing according to the requirements in the Regular
transmission oil. Maintenance.
2. Loosen the transmission oil pan suction bolts
and remove the oil pan.Take out the transmission
Checking Drive Axle Oil Level
suction screen and clean or replace it. There are respectively three oil drain plugs and oil fill
3. Clean the transmission bottom.Install a new plugs for front and rear drive axles, located at the
suction screen and tighten the oil pan bolts. middle of axle housing and both sides of curb. The
oil fill plug can also be used to observe the oil level.
4. Add oil in the same way of changing
transmission oil. Checking Drive Axle Oil
1. Drive the machine to a flat surface and slowly
Attention
move the machine to make the arrow on the front
Before changing transmission oil, cover the park drive axle curb end cover point vertically
brake so that the friction plate of the park brake downward. Pull the park brake button to prevent
will not be contaminated by oil which can cause the machine from moving and stop for 15
reduction of braking performance. minutes (the front and rear drive axle oil level
needs to be checked twice).

Replacing the drive oil filter element 2. Clean the area near the oil level plugs at both
sides of drive axle curb and remove the oil level
1. Clean the area near the drive oil filter head. plug to check if the oil level in the drive axle is 8
2. Remove the drive oil filter housing with a strap mm below the lower edge of the oil drain. Small
wrench and remove the element. amount of spillage is allowable.If the oil level is
much lower than the lower edge of the oil drain,
add drive axle oil.Observe for about 5 minutes
after adding oil until the oil level is stable (any oil
level plug can be used to check the oil level).
3. Tighten the oil level plug.
4. Check the rear drive axle oil level by using the
same steps above.
Replacing Drive Axle Oil
1. Drive the machine for a period of time to allow all
sediments in the axle housing to suspend.Then
drive the machine to a flat surface and slowly
3. Clean the gasket surface on the head with a move the machine to set the oil drain plug at the
clean cloth and install a new element. drive axle curb end face at the lowest
position.The front and rear drive axle oil needs to
be drained several times because the oil drain
plugs at the left and right and front and rear drive
axle curb end face can not be at the lowest
position simultaneously.
2. Turn off the engine, put the variable speed
joystick to the neutral position and pull the park
brake button to prevent the machine from
moving.
3. Remove the oil drain plugs at the drive axle curb
4. Install the drive oil filter housing.
end faces and the middle of the axle housing to
Attention drain oil and collect with a container.

The drive oil filter is directional.During

installation, the direction of the arrow should
face away from the drive pump.

64
 Regular Replacement of Hydraulic Oil
Change the hydraulic oil every 2000 service hours or every
The drive axle oil may be still hot at this point, year.The method is as follows:
therefore wear protective devices and use care to 1. Remove any debris in the bucket. put the variable
avoid personal injury. speed joystick to the neutral position and pull the park
4. Install all the oil drain plugs at the drive axle. brake button and install the frame locking lever.Start the
engine and idle it for 10 minutes during which repeat
5. Slowly move the machine to make the arrow on the
the actions of lifting boom, lowering boom, tilting bucket
either side of the curb end cover point vertically
forward and tilting bucket backward several times.
downward.
6. Add clean drive axle oil through the oil level plug or 2. Finally, raise the boom the highest position, tilt the
oil drain plug at the axle curb end face until the oil bucket to the maximum position and turn off the
level reaches the lower edge of the oil level plug of engine.
the front axle curb end face.Observe for about 5 3. Push the bucket joystick of the pilot valve forward to
minutes after adding oil until the oil level is stable allow the bucket to tilt forward through its own weight to
(see the Operation and Maintenance manual for the drain the fluid in the bucket cylinder;After the bucket tilts
amount of oil added). to the desired position, push the of the pilot valve
7. Install the plugs at the drive axle curb ends. boom lever forward to allow the boom to descend
through its own weight to drain the fluid in the boom
8. Change the other drive axle oil in the same manner cylinder.
above.
4. Clean the opening of the oil drain tube under the
hydraulic oil tank and remove the oil drain plug to drain
Maintenance of Hydraulic the hydraulic oil and collect with a container.Meantime,
open the oil filler cap to accelerate the oil draining.
System 5. Remove the oil inlet tube of the hydraulic oil cooler to
Check the oil level and replace the hydraulic oil completely drain the oil residue in the radiator.
according to the requirements in the Regular 6. Remove the oil drain element from the hydraulic oil
Maintenance. tank and replace with a new one.Open the oil filler cap
Checking Hydraulic Oil Level and remove the oil filler screen for cleaning.
The hydraulic oil tank is at the rear of the cab and there 7. Remove the tank clean-out flange disc under the oil
is an oil level gauge at the front end of the tank. filler and flush the bottom and walls of the hydraulic oil
To check the hydraulic oil level, position the machine on tank and wipe with a clean cloth.
a level surface and put the bucket on the ground 8. Install the oil drain plug of the hydraulic oil tank, oil drain
horizontally. Meantime, the front and rear frame should filter and top cover, oil filler screen, tank clean-out
be straightened, leaving no angle between the front and flange mouth and the oil inlet tube of the hydraulic oil
rear frame. Now the hydraulic oil level should be at 2/3 of cooler.
the oil level gauge. 9. Add clean hydraulic oil through the oil filler of hydraulic
Replacing the hydraulic oil tank drain oil tank. The hydraulic oil can only enter from the
element underside of the barrel structure due to the right side oil
filler built in the barrel structure, and there is an air vent
1. Raise the boom and put the bucket at retract
plug at the middle of the flange at the top of the
position. Support the boom with a bracket to prevent
barrel.When releasing hydraulic oil is required during
the work tool from falling.Put the work tool lever at
repair, open the air vent plug to release a small amount
neutral position.Apply the park brake and turn off the
of hydraulic oil.To change with new hydraulic oil, open
engine.
the air vent plug before adding the new oil. The level
2. Remove the mounting bolts on the oil filter cover at after added should be at the top of the dipstick. Tighten
the side of the tank and remove the cover.The cover the air vent plug after filling.After idling for 5 minutes,
can bounce due to the force of spring, so press the operate the pilot valve joystick to raise and lower the
cover while removing the bolts. boom, tilt the bucket forward and backward and steer
3. Remove the spring and element. left and right to the largest angle for 2-3 times, to fill the
4. Install new element, spring and cover. cylinder and lines with hydraulic oil.
5. Press the cover while installing the bolts and tighten 10. Turn off the engine, open the oil filler cap of the
the bolts evenly. hydraulic oil tank, and add clean hydraulic oil to the
6. Check the oil level and add oil to the specified level. center-upper position of the oil level gauge in hydraulic
oil tank.
7. Check the assembly joint at the oil filter cover for oil
leaks.

65
Note: 5. Open one end of all the tubes to drain the oil
To repair the hydraulic system, such as pump, residue in the steering cylinder, hydraulic oil
hydraulic oil line, etc., the air vent plug must be cooler and any tube.
opened to reduce the hydraulic oil drain flow in the 6. After the oil draining finishes, install the oil drain
hydraulic oil tank, or else, the hydraulic oil in the plug under the hydraulic oil tank and all opened
tank will be completely drained. tubes.
The air vent plug must be opened to add hydraulic 7. Open the oil filler cap of hydraulic oil tank and
oil. The level should be at the top of the dipstick add clean hydraulic oil to the lower mark of the
after filling. The air vent plug must be closed after oil level gauge.
filling and before starting the machine, or else air
will be drawn into the hydraulic system, causing 8. Perform oil change one more time according to
serious damage to the machine. the procedure in the Regular Replacement of
Hydraulic Oil, replace the oil drain element, and
clean the filler screen and hydraulic oil tank.
Replacing pilot oil element
1. Clean the area near the pilot oil filter head.
Knowledge of Tire
2. Open the pilot oil filter housing with a wrench and
remove the element. Maintenance and Inflation
3. Clean the gasket surface on the head with a clean The maintenance, removal, repair and installation of
cloth (replace if the ring seal is damaged) and install the tire and rim require special equipment and
a new element. techniques, therefore ask a tire repair shop or a
4. Assemble the pilot oil filter. specially trained person to do the job and obey all
related regulations.
It is recommended to use dry nitrogen (N2) to inflate
Replacing the seriously contaminated the tire.If there is air remaining in the tire, it is
hydraulic oil recommended to use nitrogen that can be mixed with
If the work environment is poor, or the hydraulic oil is air to regulate the tire pressure. The tire inflated with
deteriorated due to serious contamination, such as nitrogen can reduce the possibility of explosion
darkening color or bubbles, replace the hydraulic oil in because nitrogen is nonflammable.Nitrogen can also
time. prevent oxidation, deterioration of rubber and
corrosion to the rim components.
1. Remove any debris in the bucket. put the variable
speed joystick to the neutral position and pull the Wait for the tires to cool down sufficiently before
park brake button and install the frame locking checking and adjusting the tire inflation pressure.The
lever.Start the engine and idle it for 10 minutes tire inflation pressure of using nitrogen is same with
during which repeat the actions of lifting boom, that of using with air.Caterpillar (Qingzhou) Ltd.
lowering boom, tilting bucket forward and tilting recommends to determine the tire inflation pressure
bucket backward several times. based on the operating condition of the machine.

2. Finally, raise the boom the highest position, tilt the Attention
bucket to the maximum position and turn off the If the machine travels at high speed for an
engine. extended period of time, stop the machine for 30
3. Push the bucket joystick of the pilot valve forward to minutes every 45 km, to cool down the tires.
allow the bucket to tilt forward through its own weight
to drain the fluid in the bucket cylinder;After the Bucket Kickout Adjustment
bucket tilts to the desired position, push the of the
pilot valve boom lever forward to allow the boom to This machine has a bucket self-leveling function.
descend through its own weight to drain the fluid in Rational use of this function during operation can
the boom cylinder. improve the work efficiency significantly.
4. Clean the oil drain under the hydraulic oil tank and Adjust the bucket self-leveling device
remove the oil drain plug to drain the hydraulic oil
1. Position the machine on a level surface and put the
and collect with a container.Meantime, open the oil
variable speed joystick to the neutral
filler cap to accelerate the oil draining.
position.Operate the pilot valve joystick to level the
bucket on the ground, pull the park brake button,
and turn off the engine;Install the frame locking lever.

66
2. Loosen the arrow bolt on the caliper, move the arrow Reference points for articulation pin
to the middle position of the tilting cylinder small shaft grease fill position:
chamber connector body and tighten the arrow bolt.
3. After completion, remove the frame locking lever,
start the engine, and check for proper adjustment.
Checking park brake performance
The park brake performance should be checked
frequently to ensure park safety and the braking
capability in case of emergency barking.
1. Adjust the tire pressure of the machine to the
specified value and level the bucket about 300 mm There are 21 articulation pin shaft grease fill
above the ground.Verify the machine has good positions. Please add grease according to the
service brake performance. positions outlined in the table below during each
2. Start the engine and make the machine face a 20%- maintenance event and make sure that each joint is
grade slope which should be flat and dry. properly lubricated:

3. Depress the service brake pedal to stop the Fill position Quantity
machine.Put the variable speed joystick to the Bucket and boom joint 2
neutral position and turn off the engine.
Bucket and drawbar joint 1
4. Pull the park brake button and slowly release the
Drawbar and rocker lever joint 1
service brake pedal to check if the machine is still at
the original position. Rocker lever and boom joint 1
Raising cylinder and boom joint 2
Tilting cylinder and rocker lever joint 1
Checking service brake
Boom and front frame joint 2
performance Tilting cylinder and front frame joint 1
Make sure that the park brake system is operational Raising cylinder and front frame joint 2
before checking the service brake performance to apply
Steering cylinder and front frame joint 2
the park brake at emergency.
Steering cylinder and rear frame joint 2
Drive the machine at 20 km/h on a flat, straight and day
on a cement pavement and depress the service brake Swing frame and rear frame joint 2
pedal. After the machine stops, push the variable speed Front and rear frame joint 2
joystick to the neutral position, pull the park brake button,
and then release the service brake pedal.Check the Grease fill device:
machine's brake distance which should not exceed 9
meters.
Drive the machine at 32 km/h and slightly apply the
service brake, the machine should be stopped instantly
without deflecting.

Checking park brake friction

plate
The 3 longitudinal gutters on the caliper friction plate
are marks for grinding, it needs to replace with new The use of SEM grease gun equipped on the
plate if the gutters on it are smooth. machine is preferred as shown that has been tested
on site and been proved to meet the machine grease
Maintenance of Pin Shaft and Drive Shaft fill requirement.
To reduce the difficulty in adding grease, improve the Grease Gun Use Considerations
maintenance for the entire machine, and improve the
service life and reliability of the machine, we Clean the grease nozzle before filling to make sure
recommend all users to operate according to the that no contaminants obstructs the grease nozzle or
following instructions. passage.

67
Check the device for good condition, especially the 8. Never weld or cut any sealed or poorly-ventilated
connection between the hose/tube connector and container.
grease nozzle for tightness before it is used.Remove
the air inside the grease gun before adding grease to
make sure that the filling pressure is achieved. Maintenance-free Battery Charging
Connect one end of the hose/tube to the grease Regulations
nozzle and adding grease by operating the handle.
Increasing restriction will be felt during filling and This machine uses maintenance-free battery. The
stop filling when the grease spills from the pin shaft following regulations must be obeyed during use.
grease passage. Reason for Battery Discharge
Grease fill interval: 1. Abnormal use, for example, the electric
Every 2 days during work time (This interval must be appliances on the vehicle are on for an extended
performed stringently) period of time before the vehicle is started.
Grease fill considerations: 2. Long time of vehicle stopping, excessive current
leakage, or installation of additional appliances.
The lower main articulation pin shaft can only be
filled after steering; 3. Frequent start of the vehicle.
The joint between raising cylinder and front frame 4. Malfunctioning charging system (for example,
can only be filled after the raising cylinder is raised. failed alternator and electronic elements, over
low charging voltage setting of the alternator
Filling the swing frame requires climbing to the governor, loose engine drive belts) made the
underside of the machine and the grease must be battery charged improperly, causing battery
filled after the engine is shut down. discharge. The electrolyte indicator is black, and
Follow-up of Grease Fill the machine even can not be started.
Remove the excessive grease at the grease nozzle 5. The unused battery is stored for more than 6
after fill so that the grease will not adsorb months.
contaminants during operation clogging the nozzle or The discharged battery due to the reasons above
allowing the contaminants to enter the grease can be corrected by charging timely and properly.
passage at next fill.
Check battery appearance before charging
Welding Operation 1. The battery with a broken case or acid leakage
When welding on the machine, perform as specified can not be charged. Replace the battery after
below, to avoid machine damage or accidents. identifying the reason.
1. Read and understand the related safety 2. The battery with a broken post can not be
regulations on welding on the machine before charged. Replace the battery after identifying the
welding. reason.

2. The engine start switch must be turned off and 3. Clean the post and remove the oxide coating on
the power negative switch must be disconnected the surface before charging.
before welding.
3. The dashboard connectors must be removed Charging Precautions
before welding to avoid dashboard damage.Or 1. Wear safety glasses.
disconnect the cab harness (at the lower right of
cab and near the frame articulation;) from the 2. Keep the area well-ventilated while charging and
machine harness. charge at normal temperature.
4. Do not use voltage greater than 200 V 3. Never smoke while charging.
constantly. 4. Connect the positive cable first after
5. Weld area is within 1 meter from the ground charging;Disconnect the negative cable before
cable. charging.
6. The ring seal and bearing should be not located Battery Charging Regulations
between the weld area and ground cable. 1. Confirm that the battery post is clean and the
7. Never weld or cut any pipe or container filled with charging return circuit is well connected.
fuel, oil and hydraulic oil. 2. The charger positive connects the battery
68
 positive and the charger negative connects the
battery negative.Never charge the battery in
series (24 V).
3. It is recommended to use a charger rated at
constant voltage 16.0 volts and current limit 25
amperes to charge the battery until the
electrolyte indicator is green (The voltage cannot
exceed 16.2 volts, or else the water will be
electrolyzed, causing level drop and battery
failure).Turning green means the electricity is
sufficient.
4. For the battery with a battery voltage less than
11.0 volts, the battery may not be able to receive
the electricity at initial phase.The reason is that
the sulfur ratio in a badly discharged battery is
close to pure water. The battery inner resistance
is very high.This can be resolved by reducing the
charging current or changing for an alternator
with a larger power. As the charging is going on,
the sulfur ratio in the battery increases and the
charging current will restore to a normal level
gradually.
5. If a large amount of acid spills from the vent hole
of the battery while charging, stop charging
immediately and find the reason.
6. When the battery temperature is above 45
degrees centigrade while charging, stop
charging. When the battery temperature drops to
the room temperature, cut the charging current in
half and continue charging.

69
Oil Use Regulations
Use the specifications and types specified in the
table below when adding or changing various oils in
this machine, to ensure normal machine operation.

Use Position Ambient Temperature Lubricating Oil Specification Note

-15℃-50℃ API CH-4 SAE15W-40

Engine -20℃-40℃ API CH-4 SAE10W-30

-40℃-40℃ API CH-4 SAE5W-40

-5℃～40℃ ISOVG46, L-HM46

Transmission
-40℃ Above SAE5W-40

-15℃～49℃ GL-5 85W-90

Drive axle -25℃～49℃ GL-5 80W-90

-45℃～10℃ GL-5 75W-90

-5℃-40℃ L-HM 46 Recommended Oils:

Contact the local office and dealer
Hydraulic system -26℃-40℃ L-HV 46 to use designated oils by
Caterpillar (Qingzhou) Ltd.
-40℃-40℃ SAE5W-40

DOT4 or DOT3 brake oil that meets SAEJ703

Air booster pump
standard
Summer
Generic grease NGLI2
Winter Conditions
Anti-freeze YF-2 or YF-2A

-5℃ Above 0#

Fuel tank -5℃ below -20#

-5℃ below -35#

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

70
Fault Reason and Troubleshooting

The follow section describes the common fault

reasons and troubleshooting methods for this
machine for the user's reference.

71
Engine System
For the fault reasons and troubleshooting methods
for engine system, see the supplied engine
instructions.

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

2. Low speed change pressure at one shift position

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

3. High oil temperature in torque converter

1. Low transmission oil level 1. Fill to the specified level
2. High transmission oil level 2. Drain to the specified level
3. Clogged oil cooler 3. Clean or replace the cooler
4. Slipping clutch 4. Access and correct the speed change pressure
5. Excessive time of constant high-duty work 5. Stop or idle the engine for cooling

4. The machine unable to travel after started

1. Not into gear 1. Put into gear or adjust the shift lever into place
2. The speed change valve can not go back after shut off 2. Remove and check the speed change valve, and troubleshoot
the fault
3. Low torque converter pressure 3. Adjust torque converter overflow method
4. Low speed change pressure 4. See 1 and 2

5. Insufficient drive power

1. Low speed change pressure 1. See 1 and 2
2. High oil temperature in torque converter 2. See 3
3. Damaged torque converter impeller 3. Remove and check the torque converter and replace the impeller
4. Poor engine output power 4. Access the engine
5. Unreleased service brake or park brake 5. Access the brake system
Brake System
1. Poor Service Brake Holding Ability
1. Brake oil leak 1. Replace seal
2. Air in the hydraulic brake lines 2. Vent air according to vent procedure
3. Low air pressure in the air line system 3. Check the air compressor
4. Worn cup of the air booster pump 4. Replace the cup
5. Oil on the friction plate 5. Identify the reason and correct it
6. Friction plate worn to the limit 6. Replace with a new plate

2. Unable to shift into gear after braking

1. Brake valve can not return to its original position 1. Remove, check and repair

72
 2. Stuck speed change valve air valve lever 2. Remove, check and repair
3. Poor air pressure at the rear cavity of speed change shutoff 3. Access line system
valve lever

3. Brake unable to be released normally

1. Brake valve not in place, or stuck piston lever and failed return 1. Check, adjust or replace damaged parts
spring
2. Air booster pump piston can not return 2. Check, clean and correct
3. Caliper piston can not return freely 3. Clean or replace the rectangular ring seal

4. Reservoir pressure dropping fast after parking

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

5. Pressure rising slowly after startup

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

6. Deflection in braking
1. Unequal brake torque for front and rear wheels 1. Check the air compressor operation
2. Unequal air pressure for front and rear wheel 2. Inflate at specified pressure

7. Poor Parking Brake Holding Ability

1. Excessive gap between brake drum and brake disc 1. Readjust as specified
2. Oil on the brake disc 2. Clean the brake disc

Work Tool and Hydraulic System

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

2. Oil pump drawing oil or bubbles in oil

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

3. Oil Temperature too high

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

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

5. Unreliable seating of pilot valve

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

6. Poor control of pilot valve

1. Stuck or unsmooth metering valve core 1. Check the cleanliness of fluid and clean valve core and valve
hole
2. Deformed metering valve 2. Replace the spring
3. Low pressure of flow control valve 3. Check for normal operation of pilot oil supply system
4. Unsmooth operation of main valve 4. Clean valve body and valve stem
Steering System
1. Hard steering
A. Hard steering with fast or slow action
1. Insufficient oil supply from oil pump 1. Repair or replace the oil pump
2. Inflexible movement of priority valve core 2. Correct the cause of inflexible movement of priority valve core, or
replace the priority valve
3. Low control pressure of priority valve 3. Adjust the control pressure of priority valve
4. Air in oil control circuit between priority valve and steering gear 4. Rotate the steering wheel. When the rotating wheel reaches the
limit position, continue to rotate the steering wheel to force the
relief valve open in order to vent the air

B. Bubbles in the oil with irregular noise, and oil cylinder operating intermittently when rotating the steering
wheel
Air in the steering system Check the oil level and add oil if necessary Check for air leak in the
suction line and troubleshootVent air in the system

C. Smooth under no load but heavy under load

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

D. Hard steering at small throttle but back to normal when throttle increases
1. Low volumetric efficiency of oil pump 1. Replace the fuel pump
2. Large clearance between priority valve core and body 2. Replace the priority valve

2. No stop limit
When the rotating wheel reaches the limit position, rotating the steering wheel is still easy
1. The pressure setting of the two-way snubber in the valve block 1. Readjust the two-way snubber, with its opening pressure no less
mounted on the steering gear oil inlet surface lower than the than 1.25 time of the pressure setting of steering relief valve
pressure setting of steering relief valve
2. Serious wear between steering gear valve body, valve envelope 2. Replace the damaged part or steering gear

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 and valve core, or between rotor and stator, causing large
clearance

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

B. Pressure runout increasing significantly, and rotating is impossible

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

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

2. Battery not being charged or with low current

1. Damaged voltage regulator 1. Access or replace
2. Poorly connected wires or open circuit 2. Check the circuit between alternator and battery

3. Big spark between alternator brush and commutator

Seriously worn commutator Clean the commutator and remove the contaminants between the
cells

4. Overheated alternator
1. High voltage regulation by voltage regulator 1. Adjust the regulator voltage
2. Bearing worn or insufficiently lubricated 2. Replace the bearing or add lubricating oil
3. Short circuit in commutator or armature coil 3. Repair or replace

5. Hard engine start

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

Air Conditioning System

1. Inability to blow cool air
1. Loose or broken drive belt 1. Tension or replace the belt
2. Burnt fuse link, disconnected or broken wiring, damaged COOL 2. Replace the fuse link, repair the wiring, switch and blower motor
switch, or failed blower motor
3. Compressor not rotating, belt slipping on the pulley 3. Remove the compressor for repair or replacement
4. Compressor not operating, with little change of high and low 4. Repair or replace the compressor valve disc
pressure values while engine speed changing
5. Broken refrigerant system lines, or refrigerant leaking to none, 5. Repair the lines, check for system leaks, draw out vacuum and
high and low pressure value being zero add fluorine
6. Clogged reservoir dryer or expansion valve 6. Remove for repair or replacement

2. Insufficient cool air

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

3. Intermittent operation of refrigerant system

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

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

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SEM636D Regular
Maintenance Parts List
I.Maintenance Interval Schedule
A. Fluids (for different applicable temperatures, the
customer should choose oil based on the local
condition)
This list contains SEM636D special oils used for
regular maintenance.For detailed change operation,
see the Operation and Maintenance Manual

Demand First
Interval
Where used User Instructions Specifications Volume Maintenance
(h)
(L) (h)
-15℃-50℃ API CH-4 SAE15W-40

Engine -20℃-40℃ API CH-4 SAE10W-30 17 50 250

-40℃-40℃ API CH-4 SAE5W-40

-5℃～40℃ ISOVG46, L-HM46

Transmission 45 100 1000
-40℃ Above SAE5W-40

-15℃～49℃ GL-5 85W-90

Drive axle -25℃～49℃ GL-5 80W-90 10 * 2 250 1000

-45℃～10℃ GL-5 75W-90

-5℃-40℃ L-HM 46

Oil tank -26℃-40℃ L-HV 46 95 2000

-40℃-40℃ SAE5W-40

B. Safety Items

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

According to actual needs Brake oil DOT3 3 Air booter pump
According to actual needs Brake discs 2 per caliper Calipers

–35～50 YF-2 5 years or 10,000 service

Engine Cooling
–45～50 YF-2A hours

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C. Filter Elements
This list contains SEM636D genuine elements used
for regular maintenance. For detailed replacement
operation, see the Operation and Maintenance
Manual.
NOTE:The air filter needs to be cleaned when the air
filter indicator gives a warning, and needs to be
replaced after 6 consecutive cleanings.For all other
filters, if the filter alarms indicate that they need to be
replaced, replace them immediately (filter elements).

First
Where used Item Description Quantity Interval (h)
Maintenance (h)
Engine Oil filter element 1 50 250
Air filter element 1
Engine Diesel secondary element 2 250
Diesel primary element 1
Drive hydraulic Filter Element 1 100 1000
Transmission Filter Element 1 100 1000
PILOT Filter Element 1 250 1000
Oil tank Drain Element 1 250 1000
Oil tank Oil filler filter 1
2000
Diesel tank Oil filler filter 1

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

Demand Volume
Replacement time: Filter
Item Description Where used
(h) Oil Type (L) Element
(piece)
Diesel engine oil 17 Engine
50
Oil filter element 1 Engine
Hydraulic drive fluid 45 Transmission
100 Filter Element 1 Drive hydraulic
Filter Element 1 Transmission
Gear Oil 10*2 Drive axle
Filter Element 1 Hydraulic - Pilot
Drain Element 1 Oil tank
Diesel engine oil 17 Engine
250
Oil filter element 1 Engine
Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine
Diesel engine oil 17 Engine
Oil filter element 1 Engine
500
Air filter element 1 Engine
Diesel secondary element 2 Engine

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 Demand Volume
Replacement time: Filter
Item Description Where used
(h) Oil Type (L) Element
(piece)
Diesel primary element 1 Engine
Diesel engine oil 17 Engine
Oil filter element 1 Engine
750 Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine
Hydraulic drive fluid 45 Transmission
Gear Oil 10*2 Drive axle
Filter Element 1 Drive hydraulic
Filter Element 1 Transmission
Filter Element 1 Hydraulic - Pilot
1000 Drain Element 1 Oil tank
Diesel engine oil 17 Engine
Oil filter element 1 Engine
Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine
Diesel engine oil 17 Engine
Oil filter element 1 Engine
1250 Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine
Diesel engine oil 17 Engine
Oil filter element 1 Engine
1500 Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine
Diesel engine oil 17 Engine
Oil filter element 1 Engine
1750 Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine
Anti-wear hydraulic oil 95 Oil tank
Oil filler filter 1 oil tank
Oil filler filter 1 Diesel tank
2000 Hydraulic drive fluid 45 Transmission
Gear Oil 10*2 Drive axle
Filter Element 1 Drive hydraulic
Filter Element 1 Transmission

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 Demand Volume
Replacement time: Filter
Item Description Where used
(h) Oil Type (L) Element
(piece)
Filter Element 1 Hydraulic - Pilot
Drain Element 1 Oil tank
Diesel engine oil 17 Engine
Oil filter element 1 Engine
Air filter element 1 Engine
Diesel secondary element 2 Engine
Diesel primary element 1 Engine

80