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2 Caterpillar: Confidential Green
Important Safety Information
Most accidents occurred during the operation, repair and maintenance are due to the
inobservance of basic safety rules or that no preventive measures are taken. If
potential dangers are aware before the accidents, usually they can be avoided. The
operators must be warned about all the potential dangers. Besides the operators also
need to take necessary training to master basic skills and correctly operate the
machine.
Improperly performing the operation, lubrication, repair and maintenance to the
product is dangerous, as it may cause injuries or even death.
The above works shall be performed when the operator have read all the instructions
about product operation, lubrication, repair and maintenance.
There are safety precautions and warnings on the Manual and the machine. If
ignoring the warnings, it may cause injuries or death to you and others.
Note the potential dangers when you see “safety warning signs” and “warning labels”,
such as “Danger”, “Warning “ or “Caution”. The “Warning” sign is shown below:
CQL recommends the original genuine parts or parts with the same technical
parameters when the parts need to be replaced.
Ignoring the warning may cause accident, product damage, injuries or death.
Contents
Foreword................................................................................................................................... 1
Machine Overview ............................................................................................................. 3
Product and Parts Plate....................................................................................................... 8
Instruments ....................................................................................................................... 12
Safety Information .......................................................................................................... 15
Safety Signs and Explanations ......................................................................................... 15
General Safety Information .............................................................................................. 20
Operation Information.................................................................................................... 29
Operation Regulations ...................................................................................................... 32
Operator’s Control Devices.............................................................................................. 35
Operation Technology ...................................................................................................... 48
Parking ............................................................................................................................. 66
Machine Transportation................................................................................................. 68
Service & Maintenance .................................................................................................. 74
Scheduled Maintenance List ............................................................................................ 75
Storage............................................................................................................................. 105
Trouble Shooting........................................................................................................... 108
Technical Parameters....................................................................................................... 114
features high speed, high efficiency and high precision. The blade is mounted between
the front and rear axle, which makes it possible to flatten the ground and pave materials
according to various grade requirements. The machine is mainly used for flattening large
sites, the reshaping of road base, finishing side slope, trenching, and the paving and
mixing of road materials in road project. And it can also perform various operations like
ripping, bulldozing, and snow removal, etc. when equipped with scarifier, moldboard and
snow plow.
The scraper of the machine can achieve degrees of freedom, i.e. moving and
rotating along the space coordinate axes x, y, z. And each motion can be
The machine can provide good strength and stability for the road base. In the road
base construction, the machine mainly performs grading, slope cutting, and filling
embankment operation.
The machine consists of diesel engine, hydraulic system, drive system, brake system,
electrical system, structural parts, sheet parts, and cab. See the diagram below.
The machine has wider blade location range provided by the 7-hole blade rod,
standard 7 locating holes, blade connecting device, longer and higher main frame,
which also contributes to the following advantages:
System Diagram
economy.
The machine adopts Shangchai SC9D
When the machine works, the fuel in the
(6114) engine which is a kind of
fuel tank is pumped through the fuel filter
6-cylinder, 4-stroke, water cooled,
into fuel injection pump, and the fuel
turbocharging, and air-air intercooling
pressure is increased inside the pump,
engine. The engine has gained the
which ensures that different amount of
non-road diesel engine certicification of
fuel is supplied to the fuel injector
national Ⅱ emission standard(China).
according to work conditions. This is the
The engine features good cold start,
process that the fuel does work. The
plateau performance, low fuel
surplus fuel from the high pressure fuel
consumption, low noise, low emission,
pump returns to the suction pipeline
high reliability and durability.
through the fuel injector and the oil
The key parts of the machine are
return pipelines. There is a hand pump
optimized on the basis of SC8D (6114)
at the feed pump, which can be used to
diesel engine, inheriting the
release the air in the fuel pipelines. The
advantages of SC8D(6114), which
throttle handle controls engine speed
makes it more powerful.
through the flexible shaft.
High Reliability
has large safety margin and ensures parts, one is for the working devices
The lowest oil consumption is 195 The hydraulic system for working
g/kwh. Besides, it adopts piston oil devices is used to control various
cooling technology and alloy bainite working devices (blade, ripper, scarifier,
cylinder liner, which contributes to moldboard, etc.), including the lifting
change of blade cutting angle, the turn Drive axle: The drive axle of motor
of the slewing ring, and the release and grader is the key parts of chassis drive
system. Its main function is amplifying
withdrawal of the ripper, scarifier and
the torque from the engine and
moldboard, etc.
delivering it to the left and right drive
The machine adopts full hydraulic wheel, and make the wheels at the two
steering system, i.e. the steering wheel sides has differential function.
directly drives the hydraulic steering At the same time, the drive axle also
bears various kinds of acting force
gear to make power steering.
from the ground and the frame. Power
The machine also adopts advanced from the engine is delivered to
hydraulic drive fan technology. When transmission through torque converter.
the coolant is in a low temperature, the And then it is delivered to the rear drive
axle through the drive shaft, which
fan runs slow. And the fan speed will
directly drives the rear wheels and
be relatively improved when the
make the grader move.
coolant temperature rises. The
Brake system
hydraulic drive technology reduces
The brake system is composed of
engine power loss and improves the
service brake, parking brake and
work efficiency of the machine.
emergency brake.
Drive System
The service brake system adopts dual
The drive system is composed of the
circuit drum brake structure. When the
power shift transmission and rear axle,
brake pedal is pressed down, the
etc.
compressed air in air reservoir goes
Transmission:the transmission is fixed through air dryer and brake valve and
axle, straight tooth, constant engaged
enters the assistor and then the brake,
power shift transmission mounted on
and thus make the machine stop.
the front of rear frame. It has 6 gears
6 Caterpillar: Confidential Green
The parking brake is also drum type wheels, etc. The front and rear frames
brake and it is mounted at the power are connected through the articulated
There are two 12V batteries connected protection structure can effectively
in series in the electrical system, and protect the driver when there are falling
the rated voltage is 24V. The system objects or roll over accident. Through
system, control system, lighting system, the vibration absorption system can
instruments and signal system, etc. greatly reduce cab vibration and noise
work through ribbed belts. The operator’s work efficiency. The cab is
generator can feed the power supply equipped with glass doors and
unit and charge the batteries under windows which are optimally designed
normal conditions. Each control switch so that the operator can have a good
Product Plate
name.
Engine Plate
Name
Seat
Option
Shangchai D9
Common Seat
weight adjustable
Armrests are available for the
Transmission operator to rest his/her arms
( Large Seat
weight adjustable
nal
Optio
Standard Cab
Armrests are available for the
operator to rest his/her arms
Optional blade
Air Conditioning System Blade assembly(12 ft)
Startup Assembly
Options
Common Tyre
Name
Tubeless Tyre
Option Normal temperature start
system
Other Options
Electrical Equipment
Cold start switch
t
O
Left pressure
3 It indicates the left pressure within 0~1 MPa.
gauge
Cylinder
When the light is on, it indicates that the
12 location
cylinder is relocating.
indicator
High beam When the high beam light is turned on, the
13
indicator indicator is illuminated.
17 Mute indicator Press the switch to turn off the alarm sound.
Reverse Warning
Fuel Tank
Safety Lever
Lifting Hook
High-pressure Water
Please wear safety helmet, goggles and Compressed air and high-pressure water
other protective devices. may make scraps or hot water splash,
Do not wear loose clothes or jewelries, which may cause personal injury.
as they may entangle the control lever or Please wear protective suit, shoes, and
other parts of the machine. eye protectors when cleaning with
Ensure that all the guard shields are compressed air or high-pressure water.
fastened on the corresponding positions. Eye protectors include goggles and face
shield.
Do not stack sundries on the machine.
Clear all the scraps, oil, tools and other When the nozzle makes empty injection
sundries on the floor, passages and or using nozzle with valid flow deflector
stairs. and protective equipments, the
maximum air pressure for cleaning must
Properly keep the scattered objects, be declined to 205 kPa. The maximum
such as lunch-box, tools, and other water pressure for cleaning must be
objects that are not machine parts. under 275 kPa.
Get familiar with the specific gesture
signals used on the job site and the
20 Caterpillar: Confidential Green
Remaining System Pressure Liquid
Pressure may remain in the hydraulic Be careful when inspecting, maintaining,
system. When releasing the remaining testing, adjusting, and repairing the
pressure, the machine or optional parts machine. Make sure to hold the
overflowing liquid properly. Before
may move suddenly. Be careful when
opening any chambers or dismantling
dismantling the hydraulic pipes or joints, any parts containing liquid, please
as the released high-pressure oil may jet prepare appropriate containers.
out and make the oil tube whip. And the Please comply with all the local laws and
fluid penetrating into the body will cause regulations about handling various liquid.
serious injury or even death. Asbestos
Oil Penetration
Even if the engine has flamed out for a
long time, the pressure may remain in
the hydraulic circuit. If the pressure is not
released correctly, it will cause the
hydraulic oil or pipe plug jetting out at
high speed.
None hydraulic parts should be
dismantled before the pressure is
released; otherwise it will cause personal
injury.
The equipment and spare parts
produced by SEM do not contain
asbestos. SEM suggests using the spare
parts produced by SEM only. When
handling any spare parts containing
asbestos or asbestos scraps, please
follow the principles below.
Please be careful. Avoid inhaling the
dust generated during handling the parts
containing asbestos fiber. Inhaling the
dust will harm your health. The parts that
When inspecting leakage, be sure to use may contain asbestos fiber include:
board or cardboard as guard. The liquid brake friction plate, brake band, gasket
spurting under pressure may penetrate material, clutch friction plate, and some
gaskets. The asbestos fiber is usually
into human tissue and cause serious soaked in the resin or sealed by using
personal injury or even death. Even the some method. Unless the asbestos dust
liquid jetting out from a pinhole may also floats in the air, the common handling
method is harmless.
cause serious personal injury. If the
liquid spurts out onto your skin, If the floating dust may contain asbestos,
please follow the rules below:
immediately seek the doctor who is
• Never use compressed air to clean.
familiar with the injuries for treatment.
• Avoid brushing materials which contain
Containing Overflowing asbestos.
(A) at least 15m Ensure that the frame lock pin (1) has
(B) at least 500m been unlocked. Do take down the
Keep away from the hot tyre. As the
frame lock pin so that the articulation
diagram above shows, keep the shortest
distance and stay outside the shaded
parts can move.
area.
When inflating the tyre, stand behind it
and use self-connected inflating joint.
Repairing tyre and rim is dangerous. It
can only be performed by trained staffs
using correct tools through correct
procedures. Incorrect repair procedures
may cause tyre break under explosive
power which can cause serious injury or
death. So please strictly comply with the
Remove the bolt (2) for the tilting of
instructions of tyre agents.
front wheels, so that the front wheels
Lightning Damage can be ed.
rolled-up.
The field of view may be limited if the and turn the machine to downhill
which should be considered seriously. Avoid any situation that may cause
machine rollover, such as operating at
hilly areas, banks, and slopes, or
Operation crossing the ditches, ridges, or other
unexpected barriers.
The machine must be operated within
Avoid the machine working crosswise on
the permitted temperature range. The
the slope. Always drive the machine
lowest ambient temperature at which the uphill or downhill.
standard machine can work safely is
-40℃~50℃(when start the engine in the Stopping the Engine
temperature Below 0 degrees, the Do not stop the engine immediately after
engine needs to be configured the working under loads, otherwise the
corresponding auxiliary starting device; if engine parts will be overheated and worn
quickly.
higher than 43 degrees in the work
After stopping the machine and applying
environment, you need to configure the the parking brake, turn off the engine
high-temperature cooling system, detail after two minutes, so that the hot engine
please contact your local dealer), and parts will be gradually cooled down.
the relative humidity is 0~100%, unless
otherwise stated. Parking
Only operate the machine when you sit Park the machine on level ground. If it
on the driving seat. And fasten the seat has to be parked on the slope, block the
belt when operating the machine. wheels.
Operate the control devices only when
Move the control lever to neutral
the engine is running.
position.
When slowly operating the machine
Apply the parking brake.
at open sites, check if all the control
Stop the engine.
systems and protective facilities work
Turn the engine starting switch to the
normally. Special attention should be OFF position, and pull off the key.
made when moving the moldboard as it Note: When parking the machine for a
can make contact with tires and/or steps long time, turn the battery cutoff switch to
on the cabin resulting in damage. the OFF position, which will avoid battery
discharging. Short circuit of battery,
electricity leakage from some parts, or
Before operating the machine, make other artificial damage can cause battery
sure that it will not cause danger to discharging.
anyone.
No passenger is allowed unless there Noise and Vibration
Protective Device
Various types of protective devices are
used to protect the drivers. The machine
itself and its working condition determine
the type of protective device needed.
Related Operation
The basic rules must be followed when The falling objects may cause injuries
operating the machine. or death. Remove all the hanging
• To avoid injuries, no one should stay on objects and be aware of the falling
the machine or work around. Always objects.
keep control of the machine.
• Before releasing the parking brake, the Downhill Operation
service brake pedal must be pressed
down to avoid machine moving. Keep the lowest speed required under
• Drive the machine forward to achieve the downhill condition. Before going
optimal view and effective control. downhill, choose the proper gear to keep
• When turning back at narrow site or suitable speed on the slope. The throttle
travelling uphill, the engine speed should control device shall be kept at high idling
be lowered. position, and engine overspeed is not
• "Gas tank moisture and deposit Insert the lock devices (2) into the
– Release" bracket (1) before performing any of
• “Reverse alarm – Test”
• "Indicator lights and the following works.
instruments- Test" Lift the machine.
• "Rotary table driven pinion
teeth – Lubrication" Transport the machine.
• "Top of the rotary table Work near the middle of the machine.
–Lubrication "
• " Coolant level - Check" Ensure that the lock device of steering
• "Engine air filter indicator – frame is in the lockup position and the
Check "
• "Engine air coarse filter – lock pin is secured.
Clean" Before operating the machine, first
• "Engine oil level- check"
• "Fuel system oil-water unlock the lock device (2) of steering
separator - drainage" frame, and ensure it is kept in the
• "Seat belt - check"
• "Transmission and differential bracket (1) with the lock pin.
oil level – check"
ROPS Structure
Steering Frame Lockup The Roll Over Protection system (if
damage, their protective ability will be at “neutral” position before starting the
will damage the structures. Check the hydraulic oil and the
Do not weld brackets for fire lubrication oil to see if they have
performance of the structure may be the job site, work conditions and
and diagrams in the cab are clear. prevent the machine from moving.
The operator should guarantee that 6. Move the transmission control (lever)
barriers under or around the machine. 7. Move all the control lever to the
machine while the engine is running. 8. Release the control (2) of service
There are combustion products in the start the engine. Loose the key when
engine exhaust, which is harmful to
the engine is started.
human health.
Only start and run the engine in 10. Press down the throttle pedal(3)
ventilated area. Release the exhaust
until required engine speed is
outside when running in a closed
area. achieved.
Preheating
1. At lease run the engine idling for 5
engine.
brake control (12) service brake When the engine start switch (1) is
control (17) central frame side shift removing the engine start switch key, it
(19) snow plow /moldboard lift control disconnect the current in the cab, turn
(if equipped) (20) moldboard angle the engine start switch to OFF position,
control (if equipped) (21) wheel and the engine will also be stopped.
tilting control (22) right end blade lift Work – To supply current to the cab,
control (23) blade side shift handle turn the engine start switch clockwise
Note: if the engine cannot be started, The heater and air conditioner have
to OFF position before restarting the Heating – Turn the switch (2B)
temperature.
Control (2)
Air conditioning - Run the air
Temperature controller (2A)
conditioning system. Turn the switch(2B)
Temperature controller (2A) - Turn
to L, M, or H position. Adjust the
the switch from OFF position(left) to
controller (2A) to achieve the required
the MAX. position (right) to control the
temperature.
level of warm/cool air.
Pressurization - Pressurize the cab
Fan speed switch (2B)
when the air conditioner is not used to
Fan speed switch (2B) - The fan
prevent dust entering the cab. Turn the
speed switch has 3 speed gears.
controller (2A) to achieve required
Stop (OFF) – the fan will stop when the
temperature. Turn the controller (2B) to
switch is turned to OFF position.
L, M, or H position to keep dust off .
Heater - Turn the switch to the right to
Defrosting – Run the air
start the heating system.
conditioning system. Turn the switch
Air conditioner - Turn the switch to
(2B) to L, M, or H position.
the left to start the air conditioning
Eliminating the moisture in the cab with
system.
required speed. And it can avoid the
L – Low speed (39) – The lowest
moisture condensing on the
fan speed.
windscreen and the windows. Adjust
M – Medium speed (38) – the
the controller (2A) until the moisture is
temperature in the cab. switch (5) to turn off the interior top
operator. Though the amount of the controller (6) to turn on the left
(switch) is always located left to the controller (6), the indicator on the front
Blade buffering control - Turn the The direction indicator will be kept on
switch to the upper position to run the until the controller (6) is turned to OFF
switch to the lower position to close the Stop (OFF) - Turn the the controller (6)
Interior top light (5) Diethyl ether auxiliary start switch (if
engine, press down the bottom of the side of the switch (9), the instrument
switch (7), make the required amount light, rear light and driving light will be
of diethyl ether inject into the intake illuminated. Press the switch (9) to the
pipe. Release the switch(7), it will middle position, the instrument light,
return to the neutral position. rear light and driving light will be turned
Note: If the temperature is below 0 °C off. Press down the lower side of the
(32°F), the diethyl ether will switch (9), only the instrument light and
Low beam work light (8) The control handle (11) controls the
Instrument light, rear light and driving required forward gear. Thus the
right, then pull it back to the required Suggested procedures are listed
1. Turn the handle for a round to first increase the engine speed so that
check its operation function. the engine speed will be similar with
2. Ensure that the throttle control is at the original speed after downshift.
the low idling position. 11. When changing the travel direction,
3. Engage the variable speed use service brake to slow down the
(handle) (11) to the required direction and speed gear. Then release the
8. Press down the throttle control Note: when there are failures in the
9. Each time change to a higher gear, sensor, choose the “Limp Home”
When changing to a low gear, first the solenoid valves work normally and
the speed gear can work. If moving the machine when the
(13), the engine speed will be restored can be used to set fixed throttle modes
to the set value of throttle. Loosen including the AUTO, OFF and
· The service brake is pressed frame, the sudden move of blade may
· The throttle pedal is moved. before removing the lock pin, ensure
The fixed throttle will be released that there is no people at the blade
under any of the below conditions: area; that the central frame and blade
· Move switch (15) to OFF position. are centered with the machine body;
· Turn switch key to OFF position. and that the blade has been lowered to
restore function will not work. 1. Use the central frame control handle
Under Manual mode, if the throttle is (18) to move the traction frame to the
fixed, the fixed throttle indicator will be place which need to be graded. Move
OFF mode – Press the switch (15) to the floating position, and lower the
the middle position, and this will keep blade to the ground.
the throttle switch at the OFF position. 2. Move the switch (18) to the release
If the switch(15) is at the OFF position, position, and the indicator on the
the AUTO and Manual modes will not instrument panel will be illuminated.
work. Only the throttle pedal works 3. To move the connection bracket to
under OFF mode. the 1st or 2nd hole of any side outside
Central frame lock control the center, please follow the step 3.a.
central frame cylinder moves, the the central frame to the right, move the
connection device will move freely. handle (17) backward. When handle
Besides, the linkage can move at the (17) is released, it will return to the
c. Move the blade lifting handle away released, it will return to the fixed
d. At the same time, move the central Central frame, left shift -To tilt the
frame control handle (18) forward, and central frame to the left, move handle
also move the right blade lifting handle (17) forward. When handle (17) is
(23) forward. Meanwhile pull the left released, it will return to the fixed
handle (19) is released, it will return to Right end blade lift (22)
the fixed position. Blade, lifting - Move handle (22)
Moldboard angle control (20) backward to lift the right end of blade.
Blade side shift, left - Move handle released, it will return to the fixed
the left. When handle (23) is released, Lowering - Move handle (25) forward
it will return to the fixed position. to lower the snow blade feather plate.
Left end blade lift (24) When handle (25) is released, it will
backward to lift the left end of blade. Snow blade feather plate
When handle (24) is released, it will tilting control (26) (if
return to the fixed position.
equipped)
Fastening - When handle (24) is
Note: as multiple tools can be mounted
released from the lowering or lifting
on the connecting device of the
position, it will return to the fixed
machine, the controller position on
position.
your machine may be different.
Blade, lowering - Move handle (24)
Lifting - Move handle (26) backward to
forward to lower the left end of blade.
tilt the snow blade feather plate upward.
When handle (24) is released, it will
When handle (26) is released, it will
return to the fixed position.
return to the fixed position.
Snow blade feather plate lift
Fastening - When handle (26) is
control (25) (if equipped) released, it will return to the fixed
machine, the controller position on to tilt the snow blade feather plate
Lifting – Move handle (25) backward to released, it will return to the fixed
stop the wiper. Press down the switch equipped) - Press the top of the switch
(31) to activate the washer. When (35), and the reverse lights will be
releasing the switch, it will restore to illuminated under Manual mode. When
the original position under the spring the switch is at the Manual mode, the
Wiper and washer of front window illuminated. Press the bottom of the
(32) - Turn the switch(32) clockwise to switch (35), and the auxiliary reverse
activate the wiper. Turn the switch (32) light will work under Auto mode. The
Press down the switch (32) to activate illuminated when the transmission
the washer. When releasing the switch, control lever moves to any reverse
it will restore to the original position gear. Move handle (35) to the middle
under the spring force. position, and the auxiliary reverse light
Blade lighting (33) (if equipped) - Defrost fan control (36, 37)
Press the top of the switch (33) to The defrost fan adopts 3-position
bottom of the switch (33) to turn off the Front defrost fan (36) – Press the
Snow blade feather plate the defroster fan will run at low speed.
control (39)
Press the steering column tilting
Release the handle (39), the steering there is no people on or around the
column will still be kept at the required machine, and keep control of the
To avoid drive system damage, the across ditches when it is turning. Use
keep the differential unlocked until 1. When the machine is to turn right
the machine makes straight travel. during forward travel, slightly adjust the
Note: the articulation is easier when the turn the wheels to the steering direction.
machine.
tools.
2. When the machine reverses slowly, obstacles and move it along the
obstacles.
direction.
not make the blade touch tyres when frame. Then engage the central frame
1. Unlock the central frame. Move the make it 100 mm (4 inches) in front of the
tandem driven front wheels away from 3. Horizontally lower the blade to the
the rear edge of the blade. Thus the required cutting depth. Tilt the front
grading width is reduced which leads to wheels to the left to offset the side shift.
surface smooth.
1. Unlock the central frame. Move the position according to the soil property.
traction frame 200 mm (8 inches) to the First adjust the top of the blade and
left through the control lever of central make it 100 mm (4 inches) in front of the
until the road surface is smooth. When removing the lock pin of central
Under normal conditions, the grading frame, the sudden blade movement
machine body. The machine body can be Ensure that there are no persons
angled to offset the side shift caused by around the blade when removing the
the load generated in deep cutting. Turn lock pin. In addition, the turntable and
the front wheels which are tandem driven blade must restore to the central
to the rear cutting edge of the blade. position under the machine. Place the
If the wheels begin to slip, turn the frame straight and lower the blade to
grading width is reduced which leads to 1. Set the linkage position to keep the
Under normal grading work, the scraped hole. Turn the switch to lock the central
surface smooth.
ditch
If the machine swings, the tyre edge and make it level with the left tyre
sidewalls may press the slope and get rim of front wheels. Tilt the blade forward
damaged. At the same time, soils will and make the upper of blade slightly in
be pressed into the gap between tyre front of the cutting edge.
and rim and cause a flat tyre. 3. Lift the right side of blade to the
V-shape ditch
1. Set the linkage position to keep the
frame.
4. Lower the left side of blade and place
depth.
5. Tilt the front wheels to the right side. of the cutting edge.
First cut a shallow layer of soil, about 3. Lift the left side of blade to the highest
the ditch until the required cutting depth 4. Lower the right side of blade and place
depth.
54 Caterpillar: Confidential Green
for the detailed instructions about the
Maintenance Manual.
5. Tilt the front wheels to the left side. insert in the last hole of the left side.
First cut a shallow layer of soil, about While scraping the back slope at the left
50~100mm (2~4 inches). side, the lock pin of central frame should
the ditch.
6. Keep the right tyre of front wheels at range. Tilt the blade forward to make
the bottom of the ditch. And continue to deep scraping operation. Tilt the blade
cut the ditch until the required cutting backward to scrape thin soil layers.
Note: the procedure is for right side road 6. Insert the lock pin of central frame.
of the blade.
scraped.
conditions.
operation, tilt the front wheels towards 3. Place the right front wheel at the
the slope side. Tilt the front wheels off bottom of V-shape ditch.
scraping.
6. Lift the left edge and place it according 12. Set the linkage position to keep the
to required road shoulder slope. lock pin of central frame at the central
7. Tilt the front wheels to the left. hole position. Turn the switch to lock the
surface.
required depth.
required depth.
14. Place the right blade edge at the
the left.
discharge the materials to the ditch 5. Slightly tilt the front wheels to the right.
18. Pave the materials stock and finish soils on the slope and road shoulder.
the grading work. Pave the materials level and make the
hole position. Turn the switch to lock the lock pin of central frame at the central
central frame.
of left front wheel. 2. Place the right blade edge at the back
3. Lower the left side of blade to set the of right front wheel.
cutting depth.
make the scraped materials stack at the lock pin of central frame at the central
slope between the tandem wheels of hole position. Turn the switch to move
5. Slightly tilt the front wheels to the left. the engaged position.
lock pin of central frame at the central right tyre rim. And the soils must be
hole position. Turn the switch to lock discharged between the two wheels.
1. Scraping the inner slope. While operating at the other side, repeat
the procedures.
embankment.
second time.
the ditch.
4. Twist the machine to clear the road
clean.
building work.
slope surface.
8. Clear the bottom of the ditch. Twist the machine, and place the front
side of slope.
10. Cut for the last time to finish the will make the wheels slip. Keep the rear
slipping.
When clearing an old ditch, avoid the twist the machine body to make balance
performance well.
Do not twist the machine too much When the blade encounters heavy load,
when operating uphill or at steep which makes the front of the machine
the machine by torsional steering. The Note: This procedure is used for the soil
torsional steering method can keep the pile at the right side. Place the blade to
rear of the machine at the bottom of the the other side to handle the soil pile at
pile.
4. Locate the linkage, insert the lock pin 8. The right rear tyre should be at the
of the central frame into the utmost right slope base of V-shape ditch.
hole. Turn the switch to lock the central 9. Lower the right end of blade and
side.
When removing the lock pin of central
Note: To reach the left end, insert the
frame, the sudden blade movement
lock pin of central frame to the opposite
may cause personal injury.
side, and then side shift the moldboard to
Ensure that there are no persons
the left end.
around the blade when removing the
Ripper
lock pin. In addition, the turntable and While performing ripper operation, use
blade must restore to the central the first gear speed. It is better to use
position under the machine. Place the more ripper blades than running at high
force. Use the reducer to match the on the outside socket. When necessary,
traction force and ground conditions. And place the ripper shank to the highest
also use the reducer to avoid wheels position. Operate at low speed. The
Try to lower the ripper down deeply full power operation with the single
Sometimes only part of the ripper tools The multi-shank ripper is not suitable
can rip the soil deeply. Try to rip soil for deep ripping operation. Only use it
The size of ripped soil lumps depends on Use single-shank ripper for deep
The multi-shank ripper features high 3-shank ripper works well under this
yield production, and it can be used at kind of soil condition, which can rip the
tough conditions like firm and solid soil soil to the required lumps. It’s better to
and less stones. It is used where at use the ripper with the maximum
least two shanks of ripper blades are number of shanks. However, the
required. When the utilization ratio of number of hilts can not be so much as
20% during the whole operation Rocks with multi-cracks, fault, and
The multi-shank ripper is not suitable into nubs. And the machine is easily
for rocky ground condition. The central controlled during the operation. When
single shank ripper are commonly used the machine is hindered or the tyre slips,
firmly.
engine speed.
fire.
compartments.
Diagram 2
Hold the pressure relief valve (1) tightly,
to the ground.
Transportation system.
Understand the height limits on the connect the frame retaining ring to
travel line. Make sure that the machine firmly secure the front and rear frame.
has enough moving space during In addition, cover the wheel tilting
Before loading the machine onto the be lowered, and move the transmission
transport vehicle, clear the ice, snow, lever to the engaged position of
machine from slipping during transport. the OFF position, and remove the key
of the switch.
of the switch.
machine.
using.
down the tyres and other parts during As for the basic technical parameters,
long distance transport. Stop the please refer to “Technical Parameters” ,
machine for 30 minutes every 40km Operation & Maintenance Manual.
(25miles) or every 30 minutes, and
The operator is not allowed to stay on must have effective control and brake
the machine being towed, unless the capability. Thus a larger towing vehicle
Before towing the machine, make sure needed to prevent the machine from
that the traction rope or towbar is in out of control and roll over.
good condition and has enough All the different situations can not be
strength to tow the machine. The listed here. On level ground, only the
times the weight of the machine being slopes or rugged ground conditions,
towed. This is especially important for much larger traction force is needed.
mounted.
rear wheels.
the machine weight. As for the The rear lifting position of the machine
machine weight, please refer to is under the main frame.
necessary)
5℃ 0#
-5℃ -10#
-20#
-14℃
-29℃ -25#
Engine lubricant
SAE5W-40
-40℃ Replace the oil at the
SAE15W-40 first 50 hour, and then
-15℃~50℃
replace it every 250
SAE10W-30
-20℃~40℃ hours.
Transmission oil
Replace the oil at the
first 100 hour, and then
Mobil Delvac 1300 SAE15W-40
replace it every 1000
-40℃ hours.
Drive axle final drive
and wheel reductor
SAE85W-90 Replace the oil at the
-40℃
first 100 hour, and then
SAE85W-90 replace it every 1000
-20℃~40℃ hours.
Hydraulic oil
-26℃~40℃ L-HV46 low temp. hydr. oil 2000 hr
Brake system
Blade plate and side blade – Water and sediment in fuel tank
check/replace – drain
level – check
hours
V belt – check/adjust/replace
Engine oil and filter – replace
Front wheel bearing –
Maintenance at the first 100 working check/lubricate
Maintenance every 2000 working hours operation and maintenance or not. The
position.
• Fill grease at each filling point
• Check if the tyre pressure is
according to the schedule.
normal (2.6 Bar). Blade plate
• Check the rim bolt, axle assembly Adjust it to the right.
1. Move the blade to the right.
bolt, drive shaft connecting bolt 2. Lower the blade to the ground.
and other bolt to see if they are
loose.
the driving
and overheating.
locking washers.
than 1.5mm (0.06 inch), replace 2. Use two C-clamp to fix the front
5. Check the wear plate (3) and frame (2). Tighten the two
traction frame. The wear plate (3) C-clamp, till the wear plate (3)
shall contact the blade turntable contacts the upper part of the
surface in full scope. If they are blade turntable and the bottom
replace the wear plate (3). 3. Lower the blade to the ground
necessary.
parking brake. Thus the engine stops. side liner plate of the turntable if
installed.
between the bottom flange (10) of (1.95 to 2.07 inch). Adjust other
the pinion and inner surface (1) of front turntable liner plate.
9. Contact all turntable liner plates to does not move, the adjustment is
necessary.
side respectively.
necessary.
84 Caterpillar: Confidential Green
Before filling the lubricant through the
Check
The center displacement locking lever (1)
Rotate the blade to the position which
is under the front frame and above the
is 90 ° to the frame, and lower the
rotary disc.
blade to the ground. When the load on
Clean the sundries, oil stains and rusty
the traction frame ball and bracket is
spot in the locking frame hole on the center
light, move the machine backward
displacement locking lever.
slowly. Stop the machine and turn off
Fill the lubricant of right amount into the
the engine.
hole of the center displacement locking
lever.
Battery Diagram
maintenance-free battery.
battery top.
Battery
• Clean the battery terminal. Spread oil
• Tighten the fasteners of the battery. cable connected to the frame on the
starting motor.
Battery or battery cable, check/replace
9. Remove the connecting wire
1. Turn the starting switch of the engine between two batteries.
to OFF, and turn all switches to OFF. 10. Make the necessary repair.
2. The battery box is on the right of the Replace the cable or battery if
rear frame which is in the middle of the necessary.
machine. 11. Reconnect the battery according to
3. Open the battery box cover. the above procedure in the opposite
4. Turn the battery cutoff switch to OFF. sequence.
Fuse, replace
fuse. If the new fuse is blown again, please The air filter is in the engine hold, on
check the circuit. Settle the trouble first, the left of the machine.
and then start the machine. When the machine is operated every
core.
Central electric controller diagram inside of outlet pipe and seal surface of
the filter.
Reverse alarm
When the filter core has been cleaned
The reverse alarm is on the rear of the
for six times, or working for 1000 hours
machine, lower right of the hydraulic fan.
(high dust level)~2000 hours (low dust
Start the machine, and pull the variable speed
level), replace the filter core.
lever to Reverse gear. The reverse alarm
filter end cover fits the engine air inlet core after the engine starts, the new
damage the parts of the engine. clean the carbon deposit and oil. Use the
how many times it is cleaned, replace it Note: Start from the clean interior to
after one year. clean the primary filter core of the filter,
the seal may be damaged. Do not use the Aim at the direction of the hose to make
filter core with damaged pleated paper, the air flow in the filter core along the
gasket, or seal. The damaged filter core length direction of the filter, which could
would allow the dirt to pass through, which avoid the damage of the pleated paper.
may damage the engine. Do not aim at the primary filter core of
Compressed air is used to clean the primary vacuum cleaning is not able to clean the
filter core which is cleaned no more than two carbon deposit and oil.
90 Caterpillar: Confidential Green
Check the primary filter core of the filter
Check if the primary filter core of the filter is covers or plastic materials as the
clean and dry. Use a blue light of 60W in the protective packing for storage, otherwise,
dark room or similar facilities. Put the blue it will cause poor ventilation. In order to
light in the primary filter core of the filter. avoid the dirt and damage, use volatile
Rotate the primary filter core of the filter to corrosion inhibitor to pack the primary
check if there is light passing through the filter Put the primary filter core of the filter in
the box for storage. Attach a label on the
material. Compare the primary filter core of
outside of box and filter core for
the filter with the new filter core of the same recognition. The label shall include the
following information:
part number to confirm the result.
• Cleaning date
Do not use the filter core if the filter material • Cleaning times
Keep the box in dry place.
is damaged and/or there is the hole in it. Do
not use the filter core with damaged Secondary filter core of the
pleated paper, gasket or seal ring. Discard engine air filter, replace
the damaged filter core. Caution
The secondary filter core must be
Storage of the primary filter core of the
replaced. The secondary filter core is
filter
not allowed to use even if it is cleaned.
If the checked primary filter core of the filter
When the secondary filter core is
is not used, preserve it for future use. replaced, the primary filter core of the
filter shall be replaced.
If the dark smoke is still in the exhaust,
replace the secondary filter core of the
filter.
filter housing.
The above diagram shows that there
4. Cover the air inlet. Clean the interior of a magnet to distinguish the ferrous metal
5. Take the cover down from the air inlet. 6. Ferrous metal means that the steel and
Install a new secondary filter core of the iron parts are worn.
7. Install the primary filter core of the filter. aluminum parts of the engine are worn,
8. Install the air filter cover and fasten it. 9. such as main shaft bush, connecting rod
Check if there are scraps in the used filter core. It may be produced by friction
oil filter
and normal wear. If excessive scrap is
particles in the unfiltered oil, and these engine compartment. Keep little water
particles may enter the lubricating system around the bearing and electrical
and the pollutant is in suspension. Note: clean the cab filter more
Run the diesel engine till the water frequently in dusty environment.
temperature reaches 60℃, and then stop There are two fresh air filter units in the
the machine. Remove the oil drain plug. ventilation system of the cab. Each one
Note: Refer to Engine Maintenance is on the top of the door at both sides
Manual for other maintenances of the of the cab respectively.
engine. The circulating air filter unit is behind
Engine compartment-
compartment-clean the operator seat in the cab.
necessary.
3. Install new filter core of the filter unit. Check the front and rear windshield
4. Install the filter unit cover. wiper blade. Replace the windshield
Fill the gear oil till the oil is above 1/2 of Articulated bearing, lubricate
the sight glass. Before filling grease, wipe the surface of
Note: if it is necessary to watch, test, The grease filler is under the cab, on the
maintain, repair or replace the relevant liquid, left side of the machine.
1. Unscrew the oil drain plug, and Blade lifting cylinder bracket,
plug.
glass.
5. Start the machine, and run it for 5 Two blade lifting cylinders
6. Check the oil level through the --Service brake system brake ability test
sight glass. Repeat the refuel Warning: the sudden movement of the
the engine speed at once, and start the The test field shall be the dry and flat
Make sure there is no barrier and other Fasten the safety belt before the test is
The test field shall be the dry and flat ground. the parking brake system is engaged.
Fasten the safety belt before the test is This is not to test the maximum brake
Use the following methods to check if the 1. Place the machine on the slope
service brake system is engaged. This with the tilt angle of 20°.
is not to test the brake ability of the 2. Pull up the handbrake, and
Start the engine, and lift the blade system, and the wheel shall not
1. Press down the brake pedal, and press down the brake pedal.
2. Lower the gear of the variable where there is air desiccant must be equal
3. Lower the engine speed, and pull personal injury. Release the system
engine.
box.
manifold downward, and drain the water Prepare a proper container before
Then reset it. Stop the machine on the slope with the
Brake booster oil level, check gradient of 20%. The rear wheels are
hood, on the left of the machine. Unscrew the oil drain plug, and drain
horizontal position.
23L.
The main reducer oil level hole is the
Main reducer oil level, check
filling hole.
The main reducer oil level hole is on both
When filling the oil, keep the axle in the
sides of the main reducer assembly.
horizontal position. Keep the oil charge
28L.
rear right of the machine. The oil level transmission oil filter simultaneously.
slewing ring.
Two drive shafts. One is connected to the
Clean the dirt, lubricant and rust in the
engine and transmission, and the other is
center deflection locking lever.
connected to the engine and plunger
Fill the proper lubricant to the seven
pump.
holes of the center deflection locking
lever.
Central frame cylinder bracket,
Turntable drive pinion, lubricate
lubricate
The turntable drive pinion is on the
Prior to the lubrication, wipe the grease
bottom of the slewing ring.
nipple.
lubricant.
tilting bearing.
grease nipple.
right side.
Lubricating position
grease nipple.
nozzle
nozzle
Before filling the lubricant, wipe the
nozzle.
nozzle.
Safety belt, check/replace
Check the safety belt prior to the
machine.
once.
Fuel tank cover and strainer, clean After the bolt is unscrewed, drain the
one.
capacity.
is leaking.
Coolant, fill
The coolant filler on the upside of the
engine, the rear side of the engine tail
fill the hydraulic oil. pipe.
The sight glass of the cooling system the coolant cover directly may cause
the scald.
Open the right door of the engine, and the coolant cover directly may cause
tank which is above the engine. When unscrewing the coolant cover, make
The coolant must be kept at proper level it slowly to release the pressure to avoid
Tightening the pipe connection is not allowed Stop the machine on the flat ground.
if the coolant is very hot. After the coolant is cooled off, open the
coolant/antifreeze completely.
radiator.
surface of all the parts and all the run it at low speed for half an hour to
lubricating holes, and fill the oil wax. lubricate all the systems of the grader.
• During the short-term storage, the Fill grease to all the grease nozzles.
machine shall be ready to start at any ● Inspect the exterior, protective surface
should be stored on the site where it can Clear the preservers coated on the
● Place the machine on the support to crankcase, wheel reducer and drive axle,
avoid distortion of the machine body and and clean them. Fill new oil according to
each wheel and the support surface should Drain the sundries and water from
● The battery should be cutoff. If the Fill grease at all the articulated
remove the battery from the machine and Check and adjust the tyre pressure.
in Operation.
Recommended preserver cleaning methods:
Protection
Cleaning method
method
Remove the protection
Coat the
paper, and blow it with hot
surface with
and dry air, or wash it with
preserver
soda soap solution.
Coat the Clean it with hot water or
surface with detergent solution, or wipe
oil or it with organic solvent first,
painting and then clean it with hot
water or detergent solution.
Coat the Cut the polymer film apart
surface with at proper position and
protective remove it.
polymer
Coat the
rubber
surface with
Clean it with detergent.
light
resistance
compound
During operation of the grader, various kinds of troubles may occur due to natural
troubles according to the instructions in this chapter. The common grader troubles and
Regarding the engine trouble diagnosis and solutions, please refer to the
Transmission
Drive Axle
Trouble Reason Solution
1.The parts such as gear and bearing are Replace the gear or bearing.
worn overly or damaged.
2. Poor engagement between the bevel Adjust the back lash of the
pinion and bevel gear. bevel gear pair.
Abnormal 3. Improper adjustment of the bearing Adjust the bearing clearance
sounds clearance of bevel gear and bevel pinion. of bevel gear and bevel
pinion.
4.Damaged gears or bearings. Replace the gear or bearing.
5. The lubricating oil is insufficient. Fill the lubricating oil to the
standard height.
rotate works
ground connection is good, and if
the fan is damaged.
Condensation fan rotates Compressor Check if the temperature control
does not work
switch is damaged, if the relay is
actuated, and if the relay joint is
loose.
No refrigeration
Condensation fan rotate, and Check if the speed control switch is normal, if the fan
Evaporator fan
the compressor works wire is broken, and if fan grounding wire is good.
stops
Condensation fan does not Check if the fuse is fused, if the relay is normal, and
rotate, and the compressor if the wire is loose.
does not work
The evaporator fan and R-134a in the system is charged too much. Use the
compressor work
Compressor is
compressor work, and the ice, and replace the liquid reservoir.
Insufficient
normal
Max. gradeability ° 30 30
Service brake type Gas cap oil drum brake Gas cap oil drum brake