User Manual of PD165

Precaution:
1. Prior to operation, this Manual shall be read carefully and thoroughly.
Indiscretion and carelessness must be avoided.
2. Information concerning safety of personnel and machines and important
technical specifications in this Manual will be identified and highlighted by
symbols such as △and ★, which require for more attention.
3. The details for the engine operation, maintenance, service and
troubleshooting, please refer to Engine Manual.
 Code for Commissioning of New Machine

Although the machine has been carefully adjusted before leaving factory, careful operation is

needed at first 100 hours operation to run-in all parts of it.

In case the new machine is in an unreasonable hard engagement state at initiate operation

stage, its potential function may be deteriorated prematurely and lifetime shortened. Therefore,

the new machine should be carefully operated according to the following requirements:

1. Making check before starting machine (See Chapter 4.1);

2. Doing 5min idling after starting engine to make it rise in temperature normally and enter

working state;

3. Avoiding heaving load or high-speed operation;

4. Never doing rapid starting or sharp acceleration and unnecessary emergency brake or

sharp turning;

5. Observing and adjusting machine at all times to make it in good condition;

6. After 250 hours operation, see the table of first 250 hours service and the following contents

for maintenance:

★ First 250 hours service (See Section 6.1);

★ Operating hours is displayed by tachometer;

★ When changing oil filter element, check its interior for dirt. If heavy dirty is

accumulated on it, find out the cause before changing as far as possible
 Safety Precaution

1. Read the Manual thoroughly prior to start the machine and operate according to the

required order after understanding the structure and rules of the machine.

2. Operator should be trained. Don’t operate the machine when getting exhausted or

after drinking. Non-operator is not allowed to drive it.

3. Always wear work clothes and other protection according to working environment and

object.

4. Master safety device and operation method of your machine.

5. Be familiar with traffic regulations concerned and use of fire-extinguisher.

6. When adding oil or making any repairs, keep away from fire and don’t smoke.

7. Before construction operator should survey geology, environment, spaces and

underground facilities.

8. Before starting, remove all obstacles in the interior of machine, circumference and on

site.

9. Before starting, check whether the machine is in good working condition.

10. Never operate machine not in good condition and unauthorized person should not

sit in cab.

11. After starting the engine, confirm the machine is in good condition, then it is allowed

to operate.

12. Any problem discovered in trial run should be removed in time when found. When it,

even though insignificant, can not be removed in time, the machine could operate

only with the permission of the person in charge.

13. Pay attention to ventilation on working site to avoid poisoning.

14. Always use handrail and ladder when getting on or off the machine. Never jump on

or off the machine.

15. When operating at night, be sure to arrange adequate lighting system.

16. When crossing through hailstone, snow or thick fallen leaves, bush, fallen tree and

rolling rock on a slope, and driving after rain, pay attention to prevent machine from

rolling over.

I
 17. When parking the machine, the blade should be lowered to the ground and all the

lock levers placed in “Lock” position.

18. Never operate faulty machine or overload it for safety of machine and yourself.

19. For operation under particular condition see the notice of drive for particular

environment.

★ 20. Type and sort of oil and coolant used for the machine depend upon working

environment and temperature. Please select them according to The Attached table:

Sort and Consumption of Fuel, Coolant and Lubricant.

★ 21. Antifreeze should not be made up of methanol and ethanol to prevent engine from

trouble. The antifreeze is inflammable and must be kept away from flame.

★ 22. Running water should be used as coolant as much far as possible. Never use sewage

as coolant.

★23. Any leak preventive should not be added in coolant.

★24. All filters must be cleaned or changed periodically.

★ 25. Coolant, fuel, lubrication and hydraulic oil should be checked at any time and

supplemented as required.

★ 26. When starting engine, the ambient temperature should be more than -10 ℃. When the

key is turned to starting position the starting time should not be more than 10sec. The

time interval between two starts should not be less than 2min.

II
 CONTENTS

Chapter 1 Outline ................................................................................................... 1

1.1 Outline of Product ................................................................................... 1
1.2 Technical Data........................................................................................... 1
1.2.1 Main Technical Data ........................................................................ 1
1.2.2 Traction Performance Curve ........................................................... 3
1.2.3 Overall Dimension........................................................................... 3
Chapter 2 Principle of Structure.............................................................................. 4
2.1 Overview of Transmission....................................................................... 4
2.2 Radiator .................................................................................................. 6
2.3 Power Take Off (PTO)............................................................................. 7
2.4 Torque Converter .................................................................................... 8
2.4.1 Overflow valve of torque converter ............................................. 10
2.4.2 Torque converter regulator valve .................................................11
2.4.3 Scavenging pump........................................................................11
2.5 Universal Joint ...................................................................................... 12
2.6 Power-shift transmission ......................................................................... 12
2.6.1 Principle of planetary gear system.............................................. 14
2.6.2 Structure and action of clutch ..................................................... 17
2.6.3 No.3 clutch ball check valve ....................................................... 17
2.6.4 Transmission Path of Each Step of Transmission....................... 19
2.7 Axle and steering clutch........................................................................ 23
2.7.1 Axle Structure ............................................................................. 23
2.8 Steering Brake and Booster.................................................................. 25
2.8.1 Structure of Steering Brake and Booster .................................... 25
2.8.2 Working Principle........................................................................ 27
2.8.3 Operation of Hydraulic Brake Booster ........................................ 29
2.9 Final Drive ............................................................................................ 31
2.9.1Structure of Final Drive................................................................... 31
I
 2.9.2 Principle of final driving ................................................................. 32
2.10 Undercarriage ..................................................................................... 33
2.10.1 Thrust wheel Frame Assembly ................................................. 33
2.10.2 Tension Damping Mechanism................................................... 33
2.10.3 Idler Assembly .......................................................................... 35
2.10.4 Carrier Roller Assembly ............................................................ 36
2.10.5 Thrust wheel Assembly............................................................. 37
2.10.6 Track......................................................................................... 39
2.10.7 Suspension............................................................................... 40
2.11 Work Equipment ................................................................................. 41
2.11.1 Straight Tilt Dozer ..................................................................... 41
2.11.2 Angle Dozer .............................................................................. 42
2.11.3 Multi Ripper............................................................................... 43
2.12 Hydraulic System................................................................................ 44
2.12.1 Hydraulic Piping........................................................................ 44
2.12.2 Control System of Working Equipment ..................................... 51
2.12.3 Outline of hydraulic control system ........................................... 53
2.12.4 Operating Pump ....................................................................... 57
2.12.5 Hydraulic Tank .......................................................................... 57
2.12.6 Hydraulic control valve ............................................................. 58
2.12.7 Blade lift cylinder ...................................................................... 58
2.12.8 Blade tilt cylinder ...................................................................... 59
2.12.9 Ripper cylinder.......................................................................... 60
2.12.10 Structure of Hydraulic Cylinder ............................................... 60
2.12.11 Torqflow Hydraulic System...................................................... 64
2.12.12 Torqflow pump ........................................................................ 67
2.12.14 Transmission filter................................................................... 73
2.12.15 Transmission lubrication system............................................. 74
2.12.16 Steering clutch and brake piping............................................. 76
2.12.17 Hydraulic system of steering clutch and brake ....................... 77
II
 2.12.18 Steering pump ........................................................................ 79
2.12.19 Steering control valve ............................................................. 80
2.12.20 Steering relief valve ................................................................... 85
2.12.21 Steering strainer ........................................................................ 87
2.12.22 Steering filter ............................................................................. 88
2.13 Control system.................................................................................... 89
2.13.1 Engine control........................................................................... 89
2.13.2 Transmission control................................................................. 90
2.13.3 Steering brake control............................................................... 91
2.14 Electrical system................................................................................. 92
2.14.1 Starting Group .......................................................................... 92
2.14.2 Charging Group ........................................................................ 92
2.14.3 Lighting Group .......................................................................... 92
2.14.4 Battery ...................................................................................... 94
2.14.5 Fuse box................................................................................... 94
2.14.6 Other Group.............................................................................. 95
2.15 Fuel supply system ............................................................................. 96
Chapter 3 Instrument, Switch and Control Device ................................................ 97
3.1 Arrangement of instrument, switch and control device ......................... 97
3.2 Operation of instrument, switch and control device .............................. 98
3.2.1 Starting switch ............................................................................ 98
3.2.2 Instrument................................................................................... 98
3.2.3 Electrical control switch group .................................................. 100
3.2.4 Steering lever............................................................................ 100
3.2.5 Brake pedal .............................................................................. 100
3.2.6 Brake lock lever ........................................................................ 101
3.2.7 Accelerator control lever ........................................................... 101
3.2.8 Decelerator pedal ..................................................................... 101
3.2.9 Gear shift lever ......................................................................... 101
3.2.10 Transmission lock lever .......................................................... 102
III
 3.2.11 Blade control lever .................................................................. 102
3.2.12 Blade lock lever ...................................................................... 102
3.2.13 Adjustment of operator seat.................................................... 102
Chapter 4 Operation........................................................................................... 104
4.1 Check before starting.......................................................................... 104
4.1.1 Check for oil and water leakage ............................................... 104
4.1.2 Check for bolt and nut .............................................................. 104
4.1.3 Circuit check ............................................................................. 104
4.1.4 Cooling water level check ......................................................... 104
4.1.5 Fuel level check........................................................................ 104
4.1.6 Oil level check of engine oil pan ............................................... 105
4.1.7 Oil level check of steering case ................................................ 105
4.1.8 Transmission (including torque converter case) oil level check 105
4.1.9 Check for travel of brake pedal................................................. 106
4.1.10 Check for service indicator of air filter..................................... 106
4.1.11 Check for instrument............................................................... 106
4.2 Procedure and method of operation ................................................... 106
4.2.1 Position check of all the control levers before starting .............. 106
4.2.2 Starting engine.......................................................................... 107
4.2.3 Operation of machine running .................................................. 107
4.2.4 Running in water........................................................................110
4.2.5 Running in desert ......................................................................110
4.2.6 Stopping machine ......................................................................110
4.2.7 Running under cold weather......................................................110
Chapter 5 Digging and Pushing...........................................................................113
5.1 Cutting into hard and frozen ground ....................................................113
5.2 Leveling ............................................................................................... 113
5.3 Side pushing........................................................................................113
5.4 Blade Operation...................................................................................114
5.4.1 Angle blade operation................................................................ 114
IV
 5.4.2 Straight-tilt blade operation ........................................................114
5.5 Blade Adjustment.................................................................................115
5.5.1 Level adjustment for angle blade...............................................115
5.5.2 Vertical adjustment for angle blade............................................116
5.5.3 Vertical adjustment for straight-tilt blade....................................116
5.5.4 Cutting angle adjustment ...........................................................117
5.6 Method to prolong machine lifetime .....................................................117
Chapter 6 Maintenance and Service ...................................................................119
6.1 Precaution ...........................................................................................119
6.2 Description of service per 50h ............................................................ 123
6.3 Service after initial running for 250h ................................................... 123
6.4 Description of service per 250h .......................................................... 123
6.4.1 Check each greasing point ....................................................... 123
6.4.2 Check oil level (Machine is placed on the horizontal ground) ... 124
6.4.3 Change of steering filter element.............................................. 125
6.4.4 Change of transmission filter element ...................................... 125
6.4.5 Battery electrolyte level ............................................................ 126
6.4.6 Fuel filter................................................................................... 126
6.4.7 Fan belt .................................................................................... 126
6.4.8 Radiator and heat sink.............................................................. 127
6.4.9 Track shoe bolt ......................................................................... 127
6.5 Description of service per 500h .......................................................... 127
6.5.1 Fuel filter................................................................................... 127
6.5.2 Engine oil pan and filter ............................................................ 127
6.5.3 Anti-corrosion device ................................................................ 127
6.5.4 Breather.................................................................................... 128
6.6 Description of service per 1,000 ......................................................... 128
6.6.1 Lubrication ................................................................................ 128
6.6.2 Transmission and torque converter case.................................. 129
6.6.3 Steering clutch case and central transmission case ................. 130
V
 6.6.4 Final drive case ........................................................................ 130
6.6.5 Hydraulic tank and filter ............................................................ 131
6.6.6 Thrust wheel, carrier roller and guide roller .............................. 131
6.6.7 Anticorrosion device ................................................................. 131
6.7 Description of service per 2,000h ....................................................... 132
6.8 Description of service per 4,000h ....................................................... 132
6.9 Service when required ........................................................................ 133
6.9.1 Track tension ............................................................................ 133
6.9.2 Air filter ..................................................................................... 134
6.9.3 Clean the interior of cooling system.......................................... 135
6.9.4 Lubrication ................................................................................ 136
6.9.5 Check air intake preheater........................................................ 137
6.9.6 Check and tighten track shoe bolt ............................................ 137
6.9.7 Check and tighten master link .................................................. 137
6.9.8 Upside up or change end bit and cutting edge ......................... 137
6.9.9 Change fuse ............................................................................. 138
6.10 Adjustment........................................................................................ 138
6.10.1 Adjust brake pedal travel ........................................................ 138
6.10.2 Adjust guide roller clearance .................................................. 139
6.10.3 Undercarriage adjustment ...................................................... 139
6.10.4 Measure outside diameter of thrust wheel .............................. 139
6.10.5 Battery .................................................................................... 140
6.11 Sort and Consumption of Fuel, Coolant and Lubricant ..................... 140
6.12 Measure pressure of hydraulic system of pan .................................. 141
Chapter 7 Troubleshooting ................................................................................. 142
7.1 Engine ................................................................................................ 142
7.1.1 Oil pressure gauge still shows red range when speed is raised
after engine is started........................................................................... 142
7.1.2 Vapour is sprayed from top pressure valve of radiator when water
temperature gauge pointer stays in red range ..................................... 142
VI
 7.1.3 Water temperature gauge pointer still stays within red range when
engine operates ................................................................................... 142
7.1.4 Starting engine operates, but engine is still not started ............ 142
7.1.5 Engine emits white or blue exhaust gas ................................... 142
7.1.6 Engine emits black exhaust gas ............................................... 143
7.1.7 Combustion noise, abnormal exhaust sound............................ 143
7.1.8 Slap, abnormal combustion sound and mechanical noise of
engine .................................................................................................. 143
7.1.9 Hunting of engine ..................................................................... 143
7.2 Electrical System ................................................................................ 143
7.2.1 Lamp is not bright or flashes even if engine runs at high speed 143
7.2.2 Abnormal sound of AC generator ............................................. 143
7.2.3 Starting motor will not run when starting switch key is turned to
Start...................................................................................................... 143
7.2.4 Pinion of starting motor is in-and-out ........................................ 143
7.2.5 Starting motor runs, but engine runs slowly .............................. 144
7.2.6 Starting motor gear is disengaged before starting engine......... 144
7.3 Undercarriage ..................................................................................... 144
7.3.1 Oil pressure of torque converter does not rise.......................... 144
7.3.2 Torque converter overheats (Oil temperature pointer stays within
red range) ............................................................................................ 144
7.3.3 When gear shift lever is placed at high shift, machine can not start
or speed can not increase.................................................................... 144
7.3.4 When pull steering control lever at one side, machine stops, but it
does not steer or engine speed changes ............................................. 144
7.3.5 When pull steering control lever at one side, machine moves in
straight line, but does not steer ............................................................ 144
7.3.6 Steering lever is inflexible or the control is difficult.................... 145
7.3.7 Machine does not stop when brake pedal is stepped down ..... 145
7.3.8 Track departure ........................................................................ 145
VII
 7.3.9 Abnormal sound or wear of carrier roller .................................. 145
7.3.10 Blade raises slowly, or does not raise at all ............................ 145
7.3.11 Insufficient supporting capacity of cylinder or automatic falling of
ripper.................................................................................................... 145
7.3.12 Insufficient rising force or slow action of ripper.......................... 145
Chapter 8 Transportation and storage ................................................................ 146
8.1 Transportation..................................................................................... 146
8.1.1 Precaution for operation of machine......................................... 146
8.1.2 Method for loaded transport...................................................... 146
8.1.3 Railway transportation .............................................................. 147
8.1.4 Marine (water) transportation.................................................... 147
8.2 Storage ............................................................................................... 147
8.2.1 Before storage .......................................................................... 147
8.2.2 During storage .......................................................................... 148
8.2.3 After storage ............................................................................. 148
Chapter 9 Operation and maintenance of ripper ................................................ 149
9.1 Check before work.............................................................................. 149
9.2 Ripper operation ................................................................................. 149
9.3 Troubleshooting .................................................................................. 149

VIII
 Chapter 1 Outline

1.1 Outline of Product

Fig. 1-1 Outline of PD165Y-2 Crawler Bulldozer

1.2 Technical Data

1.2.1 Main Technical Data
Table 1-1 Main Technical Data of PD165Y-2
Item Value
Weight Operating weight 18200 kg
(kg) Transporting weight 17800 kg
(incl.
straight
blade Ground pressure
0.029 MPa
and (MPa)
ordinary
cab)
Model C6121ZG57
Type Four-stroke, water cooling, in-line, direct injection
Engine Nominal speed (r/min) 1850 r/min
Nominal power (kW) 131 kW
Fuel consumption
214 g/kW·h
ration
Forwar 1st 0-3.5 km/h

1
 Item Value
Travel d 2nd 0-6.1 km/h
speed
3rd 0-9.7 km/h
1st 0-4.4 km/h
Revers
2nd 0-7.5 km/h
e
3rd 0-11.9 km/h
Hydraulic torque
3-element, single stage and single phase
converter
Planetary gear and multiple disc clutch, hydraulically
Transmission
Power actuated, forced lubrication
transmis Central drive Spiral bevel gear, I-stage reduction and splash lubrication
sion Wet, multi-disc, spring pressured, manual-hydraulic
system Steering clutch
operated
Steering brake Wet, float brake with hydraulic booster
Final drive Two-step spur gear deceleration, splash lubrication
Swing type of sprayed beam, suspended structure of
Type
equalizer bar, semi-rigidity structure
Number of
2/each side
supporting rollers
Underca Number of thrust
6/each side
rriage wheels
Number of track
37/each side
shoes
Track shoe width 560 mm (standard), 510 mm (optional)
Track pitch 203.2 mm
Transmission setting
Chassis 2.0 MPa
pressure
hydraulic
Steering brake
system 2.0 MPa
setting pressure
System pressure 14 MPa
Type of operating
Gear pump
pump
Hydrauli Flow of operating
c system 240 L/min
pump
of work Type of control
equipme Hand-operated sliding valve
valve
nt Inner diameter Φ110mm× cylinder rod diameter
Lift cylinder
Φ65mm× stroke 1,026mm
Inner diameter Φ160mm× cylinder rod diameter
Tilt cylinder
Φ70mm× stroke 1,236mm
Straight-tilt Angle
Blade width 3,416 mm 4,050 mm
Blade height 1,150 mm 1,050 mm
Max. drop below
530 mm 530 mm
ground
Dozer Max. lift height 1,090 mm 1,110 mm
Max. tilt adjustment 400 mm 400 mm
Max. turn angle of
/ 25°
blade
Cutting angle 55° 55°
Mass 2,332 kg 2,268 kg
Ridger Type Parallelogram, adjustable, removable

2
 Item Value
Number of teeth 3-tooth
Pitch 950 mm
Max. loosening
572 mm
depth
Max. lift height 492 mm
Mass 1,850 kg
Min. ground
400 mm
clearance
Min. turn radius 4.5 m
Other
Climbing capacity 30°
performa
Track-center
nce data 1,880 mm
distance
Straight-tilt Angle
Dozing capacity 4.5m3 4.7 m3

1.2.2 Traction Performance Curve

Theoretical traction performance curve

Theoretical power

Theoretical speed (kw) (km/h) Effective traction force

Fig. 1-2 Theoretical Traction Perormance Curve of PD165Y-2

1.2.3 Overall Dimension

Fig. 1-3 Overall Dimension of PD165Y-2

3
 Chapter 2 Principle of Structure

2.1 Overview of Transmission

Fig. 2-1 Structure of Transmission System

1. engine 2. hydraulic torque converter 3. universal joint 4. transmission 5. central
transmission 6. steering clutch and steering brake 7. final transmission 8. undercarriage
system 12. variable speed controller

The driving force from the engine (1) is transmitted via the flywheel to the drive
case of the hydraulic torque converter (2). The drive case revolves with the pump
wheel and power from the engine turns the turbine wheel with oil according to load
fluctuation to turn the turbine shaft.
Turbine shaft power is transmitted through the universal joint (3) to the input shaft
of the transmission (4).
Select the proper step for the transmission control valve to be mounted on the top
of the transmission housing upon the working requirement so that the gear clutch
selected in the transmission meets and the power will be transmitted via the planet
gear to the bevel pinion(10) at the rear end of the transmission.
The table below lists the running direction, speed level and No. of clutch
transmitting motion:

4
 Table 2-1 Variable speed control position and drive path
Forward or reverse Gear speed Clutch engaged (transmission)
1 NO.1 NO.3
Forward 2 NO.1 NO.5
3 NO.1 NO.4
1 NO.2 NO.3
Reverse 2 NO.2 NO.5
3 NO.2 NO.4

P1. Operating pump CBJ70-E112R

P2. TORQFLOW pump CBJ40-B40L
P3. Steering pump CBJ40-B32R
A. No.1 sun gear (30 teeth)
B. No.1 planetary pinion (21 teeth)
C. No.1 ring gear (72 teeth)
D. No.2 sun gear (30 teeth)
E. No.2 planetary pinion (21 teeth) No.1 clutch (forward)
No.2 clutch (reverse)
F. No.2 ring gear (72 teeth)
No.3 clutch (1st)
No.4 clutch (3rd)
G. No.3 sun gear (30 teeth) No.5 clutch (2nd)
H. No.3 planetary pinion (21 teeth)
I. No.3 planetary pinion (21 teeth)
J. No.3 planetary pinion (78 teeth)
K. No.4 sun gear (41 teeth)
L. No.4 planetary pinion (19 teeth)
M. No.4 ring gear (79 teeth)
N. No.5 sun gear (41 teeth)
O. No.5 planetary pinion (19 teeth) Fig. 2-2 Drive Path
P. No.5 ring gear (79 teeth) 9. PTO case 10. Bevel pinion 11. Bevel gear

Q. Bevel pinion (15 teeth) R. Bevel gear (40 teeth)

S. Final drive 1st driving gear (11 teeth) T. Final drive 1st driven gear (48 teeth)
U. Final drive 2nd driving gear (11 teeth) V. Final drive 2nd driven gear (42 teeth)
Power transmitted by way of engine→torque converter→transmission to the rear of power
train is directed into the right and left direction by the bevel pinion and the bevel gear (11).
The steering clutches mounted at both of the bevel gear shaft intercept and transmit power
from bevel gear to the left (right) final drive.
The direction is changed by operating the steering control valve installed at the steering case

5
top to cut off power of steering clutch. The turning radius is determined by the steering brake
(6) mounted on the periphery of the steering clutch brake drum.
Power from the steering clutch is transmitted to the final drive flange, being transmitted under
sequential reduction by way of the 1st pinion (S) →1st gear (T) →2nd pinion (U) →2nd gear (V)
→to turn the sprocket (7).
The revolution of the sprocket drives the track (8) to turn the machine to travel.

2.2 Radiator

Hydraulic oil radiator

Torque
converter oil
Water drain valve
radiator

Fig. 2-3 Radiator

Radiator is made up of upper tank (3), radiator core (5), lower tank (4), air duct hood (2), inlet tube
(6), outlet tube (6) and relative accessories. Cooling water, after flowing through the engine
thermostat, is temporarily stored in the upper tank in order to remove air from the water. It then
flows from the inlet tube to the lower tank (hot hydraulic oil of hydraulic system and hydraulic oil of
torque converter flow into the hydraulic radiator and the torque converter radiator) through the
radiator core. As cooling water flows to the radiator core, its heat in the water (oil) of the core is
dissipated so that the temperature falls due to fan located at the rear end of radiator core. Cooling
water in the lower tank, now at a lower temperature as a result of heat radiation, is returned to the
engine block by the water pump. This radiator system is of closed type.
Pressure valve, which is equipped to upper tank, keeps upper tank pressure at less than
75KPa of gauge pressure, thus raising vapor temperature of cooling water, reducing loss of
water and increasing heat radiation efficiency. Radiator fan, which is driven by fan belt running
between the fan and pulley to engine, impels air to the radiator core, increasing cooling
efficiency.

6
2.3 Power Take Off (PTO)

The P.T.O system is installed on the engine flywheel to complete power output. When engine

turning, the engine power is outputted through an intermediate gear.

Mounting face
of steering
pump

Crankshaft center
Start motor

Steering pump
Hydraulic
transmission pump Operating pump

Fig. 2-4 PTO

7
 Mount bracket of hydraulic
transmission pump (FAL040) Mounting bracket of
operating pump
Crankshaft center

Crankshaft
center

Rear surface
of cylinder
Fig. 2-5 PTO
Table 2-2 Number of teeth of PTO gear
Code Name Number of Teeth
A PTO driving gear A 41
B Intermediate gear B 52
C Intermediate gear C 35
D Intermediate gear D 37
E Pump driving gear E 61
F Pump driving gear F 35

2.4 Torque Converter

Hydraulic-mechanical drive is equipped with one stage, three-element, single-phase, torque
converter which uses fluid to carry out automatic torque conversion, depending upon machine
load, while transmitting power from the engine. The principle components of torque converter
are pump (8) for converting mechanical energy into kinetic energy of fluid, the turbine (3) for
converting kinetic energy into mechanical energy, and the stator (5) for the fluid flow.
When drive gear (17), meshing with the internal teeth of the flywheel, is rotated by engine
starting, pump (8), constituting a unit with the dive gear and drive case (4), and mounted on
stator shaft with the bearing, is rotated. By this rotation, the fluid is thrown outward from the
pump along the pump blades by centrifugal force, and flows helically to the turbine. The fluid is

8
impelled with force against the blade of the turbine and changes its direction toward stator.
The reaction developed at the blade by this action causes the turbine (4) to rotate, and power
is transmitted by turbine shaft (18). The fluid at the turbine is directed from the central part of
the turbine to the stator where its direction is changed, and finally returned to the central part
of the pump.

Fig. 2-6 Torque Converter

1. pilot bearing 2. end shield 3. turbine 4. pump driving case 5. stator 6. stop
washer 7. spline housing 8. pump 9. torque converter case 10. stator shaft 11.
end shield 12. turbine 13. gear 14. pump assembly 15. plug screw AM8×1.25
16. retainer ring 80 17. drive gear 18. turboshaft

9
 Z direction
Pressure test port of control valve

To oil cooler

To transmission
lubrication

From transmission case

control valve

To transmission
case housing

Oil pressure test port

19. overflow valve 20. pressure regulating valve

Fig. 2-7 Torque Converter

While the fluid flows in the order of pump→turbine→stator → pump as mentioned above,

power is delivered from the pump to the turbine shaft. The pump is idled on the stator shaft (10)

through bearing. Because the turbine is fixed with spline of turbine shaft (18), turbine power is

transmitted to the universal joint through turbine shaft.

The stator can change the rotation of the fluid to increase the torque of turbine, which varies

depending on the operating condition. When the load increases, the turbine will be subject to

large resistance torque and automatically decelerate. Therefore, the torque converter can

ensure smooth transmission of mechanical force.

2.4.1 Overflow valve of torque converter

The overflow valve controls the hydraulic pressure of the fluid so that abnormally high
pressure is not applied to the torque converter. The hydraulic pressure, which is at 2MPa when
relieved from the modulating overflow valve of the transmission valves, is further reduced to

10
0.75-0.85MPa by this overflow valve. The fluid
from the transmission control valve flows through
port A and the passage A’ in the torque converter Torque converter
housing to the pump. When port A is filled up and case
Transmission
hydraulic pressure to the pump reaches 0.7MPa lubrication
valve
(7kgf/cm2), the fluid compresses spring (22), Transmission Torque converter
control valve pump
pushing up slide valve (21), and flows through
port B into the flow circuit of transmission
Fig. 2-8 Relief Valve
lubrication relief valve. When the slide valve (21)
21. slide valve 22. spring
is pushed up the fluid stayed in the chamber C
flows into the torque converter housing.
Oil temperature
test port
2.4.2 Torque converter regulator valve
This regulator valve, incorporated into the outlet
Oil pressure
test port From torque
circuit of the torque converter, maintains hydraulic converter turbine
Torque
pressure inside the torque converter at 0.2- converter Torque converter
cooler case
0.3MPa (2-3kgf/cm2) to protect the torque
converter and ensure optimum performance.Fluid
from the torque converter flows from the passage
D’ in the torque converter housing to port D until
Fig. 2-9 Regulator Valve
the port is filled up. 23. slide valve 24. spring
When hydraulic pressure in port D reaches
0.3MPa (3kgf/cm2), the fluid compresses spring (24), pushing down slide valve (23), and flows
through port E into the oil cooler circuit. When pushing down slide valve (23), the fluid stayed
at F flows into the torque converter housing. Oil oozing out from between contacting faces of
pump, turbine and stator is drained into the torque converter housing (9) after lubricating each
sliding part.

2.4.3 Scavenging pump

Oil collected in torque converter housing is
recirculated through strainer to the steering case by
means of scavenging pump, which is driven by
driving gears (13) provided on the back face of the
torque converter pump.
Fig. 2-10 scavenging pump
13. transmission gear 25. driving gear
11 26. driven gear 27. pump case 28. cover
2.5 Universal Joint

Universal joint is used to complete power transmission between torque converter and

transmission case. It can ensure for smooth power transmission while coaxality between

turbine output shaft and transmission case spindle axis is within allowance.

1. Cross universal joint assembly 2. Joint plate 3. bolt 4. bolt

Fig. 2-11 Universal Joint

2.6 Power-shift transmission

The transmission is designed to: 1. realizing forward and reverse movement of the machine; 2.
obtaining different output-drive ratio (incl. parking).
This machine is equipped with planetary type transmission and is a combination of planetary
gear system and disc clutch. Each Forward and Reverse has 3 speeds. For one of 3 speed
stages of Forward and Reverse, two of 5 disc clutches of the planetary gear system are
hydraulically locked by actuating the hydraulic control valve.
No.1 clutch is used for Forward, No.2 clutch for Reverse, No.3 clutch for 1st speed, No.4
clutch for 3rd speed, and No.5 clutch for 2nd speed.

Table 2-3 Speed ratio of transmission case

Working Working
Speed stage Gear ratio Speed stage Gear ratio
clutch clutch
Forward, Reverse,
NO.1 —— NO.2 ——
Neutral Neutral
1st NO.1, NO.3 2.080 1st NO.2, NO.3 1.600
2nd NO.1, NO.5 1.176 2nd NO.2, NO.5 0.902
3rd NO.1, NO.4 0.710 3rd NO.2, NO.4 0.546

12
 st rd nd
Forward Reverse 1 3 2
Clutch position

Fig. 2-12 Power-shift transmission

1. No.1 planetary pinion shaft 10. No.3 clutch piston 19. Bearing cage

2. No.1 clutch piston 11. No.3 clutch gear 20. Oil seal seat

3. No.1 clutch cylinder block 12. Housing 21. Output shaft

4. No.2 planetary pinion shaft 13. No.4 Planetary pinion shaft 22. Nut

5. No.2 clutch piston 14. No.4 clutch piston 23. Snap ring

6. No.2 clutch cylinder block 15. No.4 clutch oil cylinder 24. Rear case

7. Snap ring 16. No.5 planetary pinion shaft 25. No.5 clutch planetary carrier

8. Housing 17. No.5 clutch piston 26. Spring

9. No.3 piston cylinder block 18. Stopper pin 27. Snap ring

13
28. No.4 clutch planetary carrier 33. Pin 38. Input shaft

29. Disk spring 34. Front cover 39. Coupling

30. Spring 35. Transmission body 40. Snap ring

31. No.2 clutch planetary carrier 36. No.1 clutch planetary carrier 41. Bearing cage of input shaft

32. Filter 37. Shield

A. NO.1 clutch sun gear (30 teeth) J. NO.3 clutch ring gear (78teeth)

B. No.1 clutch planetary pinion (21 teeth) K. NO.4 clutch sun gear (41teeth)

C. No.1 clutch ring gear (71 teeth) L. NO.4 clutch planetary pinion (19teeth)

D. NO.2 clutch sun gear (30 teeth) M. NO.4 clutch ring gear (79teeth)

E. No.12 clutch planetary pinion (21 teeth) N. NO.5 clutch sun gear (41teeth)

F. NO.2 clutch ring gear (72teeth) O. NO.5 clutch planetary pinion (19teeth)

G. NO.3 clutch sun gear (30teeth) P. NO.5 clutch ring gear (79teeth)

H. NO.3 clutch planetary pinion (21teeth) Q. Bevel pinion (15teeth)

I. NO.3 clutch planetary pinion (21teeth)

Table 2-4 Number of Disc and Gears of Each Clutch

Name of pair
Number of plate Number of disc
Clutch No.
NO.1 clutch 2 3
NO.2 clutch 2 3
NO.3 clutch 2 3
NO.4 clutch 1 2
NO.5 clutch 1 2

2.6.1 Principle of planetary gear system

Planetary gear system (as shown in Fig. 2-13) is composed of three planetary pinion (D)

meshed with sun gear (A) and ring gear (B). Three planetary pinions are supported on the

carrier (C). When the sun gear (A) is rotated and the ring gear is fixed, the planetary gear (D)

and planetary carrier(C) start rotate around the sun gear (A). In the meantime, each planetary

pinion rotates at its own shaft. When the carrier is locked and the planetary pinion rotates at its

14
own shaft, the ring gear (B) is driven in the opposite

direction to that of rotation of the sun gear (A).

A. Sun gear B. Ring gear

C.Planetary carriage
D. Planetary pinion E. clutch
friction disc

Fig. 2-13 planetary gear system

1. When ring gear (B) is locked (Fig 2-14)

As ring gear (B) meshing with the planetary pinion is

locked, the planetary pinion (D) can not rotate at the

same position. The planetary pinion (D), therefore,

drives the carriage (C) to rotate around the sun gear

(A). The torque of the gear (A) is transmitted to the

carrier (C) to drive it in the same direction as the sun

Fig. 2-14 fixed ring
gear (A) rotates.

2. When the carrier (C) is locked (Fig 2-15)

As carrier (C) is locked, the planetary pinion (D)

meshing with sun gear (A) rotates at its fixed position.

The ring gear (B) meshing with the planetary pinion is

driven in the opposite direction to that of sun gear (A);

thus the torque of the sun gear (A) is delivered to the

ring gear (B).

No.1, 4 and 5 clutches are based on the combination
of sun gear→planetary pinion→ring gear (or carrier). Fig. 2-15 fixed carriage
In the case of No.1 clutch, the sun gear acts as a
torque source and transmits torque to the carrier of No.2 clutch. In the case of No.4 and No.5

15
clutches, the carrier acts as a torque source and transmits torque to No.4 and No.5 sun gear.

3. Double planetary pinion system (Fig 2-16)

This combination in which another planetary pinion (F)

is incorporated between planetary pinion (D) and ring

gear (B) is used.

The characteristic of double planetary pinion is that

the torque of the sun gear (A) drives the carrier (C) in

the opposite direction to the rotation of the sun gear

while the ring gear (B) is locked.

A. sun gear B. ring gear C. carrier D.
This combination of sun gear→planetary
planetary pinion F. planetary pinion
pinion→planetary pinion→carrier is used for the No.2 Fig. 2-16 fixed ring gear

clutch, by which the machine is reversed.

4. Rotary clutch (used as No.3 clutch of 1st speed) (Fig 2-17)

No.3 rotary clutch is different from No.1, No.2, No.4 and

No.5 clutches. In this type of clutch, the clutch gear (11)
of No.2 and No.3 clutches is fixed to output shaft (21).
The piston (10) of No.3 clutch presses disc (42) and plate
(43) to the planetary carrier (28) of No.4 clutch. Thus, the
frictional force enables the power transmission from the
planetary carrier (28) to the gear (11).

This rotary type clutch is generally used as a 1st speed

clutch having a large transmission torque.

Fig. 2-17 rotary clutch

16
2.6.2 Structure and action of clutch

For locking the ring gear (C) the plate (44) and

disc (45) are incorporated. The clutch comprises

piston (2), plate (44), disc (45), pin (33) and piston

return spring (30) etc. The disc’s internal teeth

engage with the ring gear’s external teeth. The

plate engages cylinder block (3) with pin (33).

Fig. 2-18 Clutch Structure

1. Clutch engaged (locked) (Fig 2-19)

Fluid from control valve flows under pressure

through the port on cylinder block (3) into piston

(2). The piston presses the plate (44) and disc (45)

together, and frictional force developed stops the

disc (45) revolution, thus locking ring gear (C) Fig. 2-19 Clutch engaged

meshing with the disc’s internal teeth.

2. Clutch disengaged (free) (Fig 2-20)

With shut off of the fluid supply from the control

valve, piston (2) returns to the initial position under

the force of piston return spring (30), thus relieving

the frictional force between plate (44) and disc (45),

bringing the ring gear (C) in neutral. Fig. 2-20 clutch disengaged

2.6.3 No.3 clutch ball check valve

A rotary type clutch is employed as No.3 clutch in transmission case.

When gear-shift lever is located at the 1st speed, the fluid flows from control valve to the left

side of No.3 clutch piston (10) and pushes the piston (10) to the right. No.3 clutch cylinder

block turning is transmitted to No.3 clutch gear (11). When gear-shift lever is put at 2nd or 3rd

17
speed，the force of spring (29) pushes piston (10)

leftward. But the centrifugal force of fluid due to turning

gear (11) acts on the left of piston (10), so the piston

(10) can not return to the left original position instantly.

Therefore, the clutch is in a partially engaged state and

can not be gear-shifted.

Ball check valve (46) mounted makes piston (10) return

leftward promptly to avoid this kind of function.

Fig. 2-21 check valve

1. Clutch engaged (Fig 2-22)

The fluid from the control valve is supplied under

pressure through the port of housing (9) to the left of

piston. Then, ball check valve (46) closes the valve

base (49) port, and the piston (10) presses clutch disc

(47) to plate (48), engaging the disc’s internal teeth

and gear’s (11) external teeth, the plate’s external

teeth and planetary carrier internal teeth, thus

effecting clutch engagement. Fig. 2-22 clutch engaged

2. Clutch disengaged (Fig 2-23)

With the shout off of fluid supply from the control valve,

the force which pushes the check valve (46) to the

valve seat (49) is eliminated, but the ball check valve

(46) is displaced outward under centrifugal force due to

the revolution. So the fluid at the left of piston (10) and

ball check valve is drained into transmission case

through the valve seat (49) channel. The fuel centrifugal

Fig. 2-23 Clutch disengaged
force of the left of piston is eliminated due to oil

drainage of check valve and the piston (10) is promptly returned to the farthest left by disc

spring (29).

18
2.6.4 Transmission Path of Each Step of Transmission

1. Forward, 1st (Fig. 2-24)

No.1 and No. 3 clutches have engaged, No. 1 clutch ring gear is locked, and No. 3 gear

connects directly to the output shaft.

Engage No. 1 clutch so that the gear ring (C) of No.1 clutch can be fixed reliably. Engage No.

3 clutch. Connect the carriage (28) of No. 4 clutch with the output shaft through the gear (11)

of No. 3 clutch.

As the gear ring (C) of No. 1 clutch is locked, and the carriage (36) of No. 1 clutch is fixed on

the transmission case (35), neither No. 1 sun gear (A) nor No. 2 sun gear (D) can move.

Therefore, No. 2 planetary gear (E) rotates around No. 2 sun gear (D), and the carriage (31) of

No. 2 clutch rotates in the direction same as No. 3 sun gear (G).

Engagement of No. 3 clutch transmits the motion of carriage (31) of No. 2 clutch to the piston

cylinder (9) of No. 3 clutch, carriage (28) of No. 4 clutch, gear (11) of No. 3 clutch and output

shaft (21).
st rd nd
Clutch position Forward Reverse 1 3 2
Clutch No.

Power from engine Power transmitted to

via torque converter final transmission
system via bevel gear
shaft

Fig. 2-24 F-R power transmission path

19
2. Forward, 2nd (Fig. 2-25)
No. 1 and No. 5 clutches engage so that the gear rings of them are locked.

As the gear ring (C) of No. 1 clutch is locked, and the carriage (36) of No. 1 clutch is fixed on

the transmission case (35), neither No. 1 sun gear (A) nor No. 2 sun gear (D) can move.

No. 2 planetary gear (E) rotates around No. 2 sun gear (D), and the carriage (31) of No. 2

clutch rotates in the direction same as No. 3 sun gear (G). Meanwhile, drive of carriage (31) is

transmitted to the piston cylinder (9) of No. 3 clutch and carriage (28) of No. 4 clutch.

When No. 5 clutch is engaged, the drive of carriage (28) is transmitted via two paths: one

transmits the drive to No. 4 sun gear (K) and the other transmits the drive to gear ring (M) of

No. 4 clutch, carriage (25) of No. 5 clutch and No. 5 sun gear (N) in order.

Gear ring (M) of No. 4 clutch and carriage (25) of No. 5 clutch are linked to rotate so that both

sun gears (K) and (N) drive the output shaft (21).

Power from engine Power transmitted to

via torque converter final transmission
system via bevel gear
shaft

Clutch No.
st rd nd
Clutch position Forward Reverse 1 3 2

Fig. 2-25 FF 2nd power transmission path

20
3. Forward, 3rd (Fig. 2-26)
No. 1 and No. 4 clutches engage so that the gear rings of them are locked.

When No. 1 and No. 4 clutches engage, gear rings (C) and (M) are locked. As the gear ring (C)

of No. 1 clutch is locked, and the carriage (36) of No. 1 clutch is fixed on the transmission case

(35), neither No. 1 sun gear (A) nor No. 2 sun gear (D) can move.

No. 2 planetary gear (E) rotates around No. 2 sun gear (D), and the carriage (31) of No. 2

clutch rotates in the direction same as No. 3 sun gear (G). Meanwhile, drive of carriage (31) is

transmitted to the piston cylinder (9) of No. 3 clutch and carriage (28) of No. 4 clutch.

When No. 4 clutch is engaged, the drive of carriage (28) is transmitted to No. 4 sun gear (K)

and output shaft (21).

Power from engine

Power transmitted to
via torque converter
final transmission
system via bevel gear
shaft

Clutch No.
st rd nd
Clutch position Forward Reverse 1 3 2

Fig. 2-26 FF 3rd power transmission path

4. Reverse, 1st (Fig. 2-27)

No. 2 and No. 3 clutches engage. No. 2 gear ring is fixed. No. 3 gear connects directly with the

output shaft.

When No. 2 clutch is engaged, gear ring (F) of No. 2 clutch is locked. When No. 3 clutch is

engaged, carriage (28) of No. 4 clutch and output shaft (21) are connected through gear (11)

21
of No. 3 clutch.

When gear ring (F) of No. 2 is fixed, planetary gear (I) engaged with gear ring (F) and

planetary gear (H) engaged with sun gear (G) cannot rotate in fixed position, but around sun

gear (G) along gear ring (F).

Rotation of planetary gears (I) and (H) is transmitted to carriage (31) of No. 2 clutch so that the

carriage (31) rotates opposite sun gear (G).

Rotation of carriage (31) is transmitted to the output shaft (21) in the same manner described

above.

5. Reverse, 2nd and 3rd

The speed of Reverse 2nd can be achieved as long as No. 2 and No. 5 clutches engage at the

same time.

The speed of Reverse 3rd can be achieved as long as No. 2 and No. 4 clutches engage at the

same time.

st rd nd
Clutch position Forward Reverse 1 3 2
Clutch No.

Power from engine Power transmitted to

via torque converter final transmission
system via bevel gear
shaft

Fig. 2-27 Reverse 1st Power Transmission Path

22
2.7 Axle and steering clutch

Fig. 2-28 Axle and Steering Clutch

1. Brake drum 2. Pressure plate 3. Clutch plate 4. Clutch discs 5. Inner drum 6.
Bearing cage 7. Bevel gear 8. Coupling 9. Cover 10. Seal ring 11. Bevel
roller bearing 12. Adjusting nut 13. Bushing 14. Nut 15. Bevel gear shaft 16. Lock
washer 17. Coupling 18. Oil seal ring 19. Piston 20. Disk spring 21. Flange 22. Nut
23. Bolt 24. Nut 25. Lock washer

2.7.1 Axle Structure

⑴ Bevel Gear
The power transmitted from engine is transmitted to the left and right steering clutch through
the bevel pinion on the rear end of transmission output shaft and mating bevel gear on the
axle. The bevel gear is installed at bevel gear shaft by eight finishing bolts. A Bevel gear shaft
is supported on the steering case through two bevel rolling bearings and bearing cage.
⑵ Steering Clutch
Structure of Steering Clutch:
A steering clutch is installed on each end of the axle to change the machine’s direction of
travel. The clutch can discontinue the flow of power from the axle to the final drive to change
the direction of travel.
The steering clutch is wet type, multiple-plate and hydraulic separated one.

23
Each steering clutch consists of the following parts:
① Inner drum (5): The inner drum (5) is fixed at the coupling (17) and the coupling is
press-fitted on the spline of bevel gear shaft (15). The inner drum also acts as oil cylinder.
② Bevel gear shaft coupling (17): The coupling makes the fluid from steering control valve
draw into the piston (19).
③ Brake drum (l): The brake drum is bolted to the final drive flange.
④ Clutch discs (4): The inner teeth of clutch disc are engaged with the external teeth of inner
drum (5).
⑤ Clutch plate (3): The external teeth of clutch plate are engaged with the inner teeth of brake
drum (l).
⑥ Pressure plate (2): The pressure plate is fixed at the piston (19) by pin and moved together
with piston.
⑦ Disk spring (20): When the steering lever is put at “Engagement” position, the disk spring
presses the pressure plate (2), clutch plate (3) and clutch disc (4) against the inner drum (5).
Turning the adjusting nut (12) makes the bearing cage (6) move to the left or the right to adjust
the tooth contact surface and gear backlash of the spiral bevel gear pair.
The coupling (17) is press-fitted on the spline of bevel gear shaft (15), then the steering clutch
is fixed at the coupling. The splash lubrication is made by the spiral bevel gear immersed in oil.
The spring (20) in steering clutch makes the clutch disc (4) press against the clutch plate (3)
between the clutch inner drum (5) and the pressure plate (2) to maintain normal contact and
pass the clutch disc (4) turning to the clutch plate (3).
When the steering lever is pulled, the steering control valve serves the function of the fluid
draining into the piston (19). The movement of the piston (19) acts on the pressure plate (2),
so the frictional contact between the clutch plate (3) and clutch disc (4) is eliminated.
When the steering lever is released, the pressure plate (2) returns to the original position
under the force of spring (20), so the frictional contact between the clutch disc (4) and the
clutch plate (3) is restored.
When the left and right steering levers are pulled simultaneously, the left and right steering
clutches are disengaged at the same time. When just the left steering lever is pulled, the left
steering clutch is disengaged. Thus, the power transmitted to the left final drive is shut off, but
the right steering clutch is in a state of engagement, so the machine moves leftward, and vice
versa.

Working principle of steering clutch:

24
⑴ When left steering clutch engaged (Fig.2-29):
Pressure Plate (2) under force of disk spring (20) presses clutch disc (4) and clutch plate (3)
against inner drum (5) and the frictional force between clutch discs (4) and clutch plate (3)
transmits power from the inner drum (5) to the brake drum (1).

Fig. 2-29 Left Steering Clutch Engaged Fig. 2-30 Left Steering Clutch Disengaged

⑵ When left steering clutch disengaged (Fig.2-30):

When the left steering clutch pulled, pressurized fluid from the steering control valve is forced
to flow through bearing case (6) and axle hub (17) to piston (19) and pushes the piston
leftward, compressing spring (20). Thus, pressure plate (2) is moved leftward to bring the
pressing force onto clutch disc (4) and clutch plate (3) to zero. As result, the left steering clutch
is disengaged to stop the power supply to the final drive. When the steering lever is released,
the pressurized fluid from the control valve is interrupted and the pressurized fluid to push the
piston is discharged. Thus the piston is returned to the original position under force of spring
(20) and the clutch is engaged. When the left steering clutch is disengaged, power is delivered
only to the right steering clutch, achieving the left turn.

2.8 Steering Brake and Booster

2.8.1 Structure of Steering Brake and Booster
Contracting band brake is installed at brake drum and immersed in oil in steering case. It
functions as steering brake while running and parking brake while stopping. When the steering
lever is pulled, first the steering clutch is disengaged, then the brake functions as braking. The
movement order is controlled by hydraulic fluid from steering control valve, so the operating
force is reduced. When the brake pedals are stepped on simultaneously, the left and right
brakes function as braking at the same time to make emergency brake without disengaging

25
steering clutch. After stepping on brake pedal while parking machine, a brake lock handle is
pulled, the brake pedal fixed at brake position and the machine is kept in a state of brake.
One end of brake band (12) is suspended through push block (16) and pin (21) at brake
support (14) and the other end of that through screw (19), adjusting nut (17) and pin (20) at
brake support (14). Two springs make brake band pull wrapped round brake drum even. The
adjusting nut (17) is used to adjust a clearance between brake lining (13) and brake drum.

Forward Center of
bevel gear
shaft

Oil Level

To/from brake valve From steering pump To brake pedal

Fig. 2-31 Steering Brake and Booster

1. Brake booster body 2. Adjusting bolt 3. Fork lever 4. Lever 5. Piston 6. Valve
rod 7. Bushing 8. Spring 9. Lever 10. Cover 11. Joint plate 12. Brake
band 13. Brake lining 14. Brake support 15. Lever 16. Push block
26
 Z-view
To brake pedal
Parking brake detent

Fig. 2-32 Steering Brake and Booster

17. Adjusting nut 18. Pin 19. Screw 20. Pin roll 21. Pin

2.8.2 Working Principle

When a steering lever (approx. half of the stroke) at one side is pulled to make machine turn to

this side, the corresponding steering clutch is to be disengaged. Therefore power transmission

to track at this side is disrupted, but the machine will make a gradual turn to this side due to

traction of track, which transmits power. When the steering lever at this side is pulled further,

the hydraulic fluid of steering control valve flows to the brake booster and the brake booster

functions to make the brake band contract the brake drum. Therefore the track at this side is

fixed and the machine will make turn in original place.

When a brake pedal is depressed, the brake booster also functions and makes the brake band

contract the brake drum. Thus the machine stops.

27
⑴ Brake operation during forward turning (Fig.2-33)

To brake pedal

When the steering lever is pulled to the end, the

piston of brake booster moves leftward, the lever

(3) turns and the lever (15) moves upward. When

machine moves forward, the brake drum turns

counterclockwise to power the brake band

counterclockwise, so the screw (19) is pulled

Brake force
leftward to make pin (18) hold down the brake
Forward
support (14). Thus the lever (15) turns

counterclockwise, taking point A as a fulcrum and

the push block (16) moves in the direction of the

Fig. 2-33 Working principle of steering brake
arrow (Q) to make the brake band being

contracted in the same steering as the brake drum and fastens the brake drum.

⑵ Brake operation during reverse turning (Fig.2-34)

When machine moves backward, the brake

drum turns clockwise to power the brake band

(12) clockwise and the push block (16) is

pushed rightward to make pin (21) hold down a

semi-circle hole of the brake support (14).

Thus the lever (15) turns counterclockwise,

Reverse
taking point A as a fulcrum and the pin (20)

moves in the direction of the arrow (R) to make

the brake band being contracted in the same

Fig. 2-34 Working principle of steering brake
steering as the brake drum and fasten the

brake drum.

28
2.8.3 Operation of Hydraulic Brake Booster

⑴ When brake pedal is not depressed and steering lever is not pulled (brake not
applied) (Fig. 2-35):
To oil cooler

If brake valve (20) operates, one oil line from

the steering pump flows to port (A), another oil

line flows directly to port (B) without passing

through steering valve.

From steering
The steering lever is not being pulled, so valve pump

(20) does not move. The oil does not flow to

port (A), but only flows to port (B). It then

passes through orifice (a) and flows to port (C).

However, the brake pedal is not being

depressed, so the flow of oil at port (D) and

port (C) is shut off. As a result, the hydraulic

pressure rises and when it exceeds the set

pressure of the relief valve (24), it flows to the

oil cooler and the hydraulic pressure is

Fig. 2-35 Working principle of booster
maintained at 2MPa (20kg/cm2).

⑵ When steering lever is pulled fully

(brake applied) (Fig.2-36):

From steering pump

Brake valve (20) operates and oil flows to port From brake valve

(A). When the hydraulic pressure in the circuit

rises, the oil at port (A) pushes piston (5) to the

left. Lever (3) and lever (4) move and apply the

brake. The hydraulic pressure at this point is

1.67MPa (16.7kg/cm2). Fig. 2-36 Working principle of booster

29
⑶ When brake pedal is depressed (brake
applied)

When the brake pedal is depressed slightly, lever

(9) pushes spool (6) to the left and the flow of oil at
port (C) and (D) is connected. Because of this, the
oil from the pump passes from port (B) and flows
through orifice (a) to port (C) and (D) (Fig.2-37).

When the hydraulic pressure at port (D) rises, Fig. 2-37 Working principle of booster

hydraulic oil pushes piston (5) to the left and

connects the flow of oil at port (D) and (A). The
oil then drains from port (A) to the steering case
and piston (5) stops. The brake pedal travels
some distance, the flow of oil at port (D) and (A)
From steering pump
is closed, hydraulic oil connects the flow of oil From brake valve

at port (D) and (A) once more. The hydraulic oil

pushes piston (5) to the left and connects the
flow of oil at port (D) and (A) once more and
drains. This movement of the piston (5) and
brake pedal and the oil flow are repeated over a
short period (Fig.2-38). Fig. 2-38 Working principle of booster

Valve rod (6) moves further to the left and connect

the flow of oil at port (B) and port (D). The volume
of oil flowing to port (D) increases and piston (5)
moves faster. Piston (5) continues to push forke
lever (3), then brake band contracts smoothly and
the brake is applied (Fig.2-39).

In this way, the hydraulic pressure rises in two

stages. At first, oil pushes piston (5) lightly and

30 Fig. 2-39 Working principle of booster

when the flow of oil at port (D) and (B) is connected, it pushes strongly. This prevents the
brake from being applied suddenly.
⑷ When brake pedal is depressed fully
(Fig.2-40)

When the brake pedal reaches the end of its travel,

the flow of oil at port (D) and port (A) remains shut
From steering pump
off and the hydraulic pressure rises further. When
the pressure reaches 2MPa (20kg/cm2), the main
relief valve functions and the oil flows into the
lubrication circuit.

2.9 Final Drive

2.9.1Structure of Final Drive Fig. 2-40 Working principle of booster

20

Fig. 2-41 Final Dirve

1. Dirve flange 2. Bearing seat 3. Primary driving gear (11 teeth) 4. Primary driven gear
(48 teeth) 5. Secondary driving gear (11 teeth) 6. Gear case 7. floating seal 8. Sprocket
hub 9. Segment teeth 10. Lock block 11. Sprocket nut 12. Sprocket shaft 13. Cover
14. Nut 15. Floating seal 16. Retainer 17. Mudguard 18. Hub 19. Sprocket shaft 20.
Nut 21. Secondary driven gear (42 teeth) 22. Nut
31
2.9.2 Principle of final driving

Final drive employs the two-step reduction method using a spur gear and splash lubrication

and floating seal tightening.

Power from bevel gear shaft and steering clutch is transmitted through brake drum to final

drive flange (1), rotating primary driving gear (3) on drive flange.

The primary driving gear engages with primary driven gear (4), rotating the secondary driven

gear (5). Power is further transmitted from the secondary driving gear to the secondary driven

gear (21) with the secondary driving gear, with speed reduction accomplished.

Due to the construction in which the secondary driven gear is bolted on final drive hub (18),

into which sprocket boss (8) is also pressed, so power is finally transmitted to the sprocket.

Final drive case functions as a lubricating oil tank for each gear. The rotating sliding parts of

the sprocket are equipped with floating seals (7) and (15) to prevent entry of dust or mud and

oil leakage.

Fig. 2-42 Working principle of final drive

32
2.10 Undercarriage
2.10.1 Thrust wheel Frame Assembly

Fig. 2-43 Track roller frame assembly

1. Idler 2. Track 3. Carrier roller 4. Sprocket guard 5. Track roller (Single flange)

6. Track roller (Double flange) 7. Track roller guard 8. Track roller frame 9. Diagonal

brace 10. Pin shaft S. single-flange D. double-flange

Thrust wheel frame assembly is used to support the total weight of bulldozer and distribute it
over the ground, and turn the driving force transmitted from the sprocket into a pull. The thrust
wheel frame assembly consists of a pair of left and right thrust wheel frames (8), idler (1),
carrier roller (3), thrust wheel (5) and (6). The track (2) around the thrust wheel frame
assembly is driven by the sprocket and guided by a front idler, carrier roller and thrust wheel.
The thrust wheel guard (7) attached on the bottom of each thrust wheel frame is used to
prevent tracks from derailing due to inlaid debris.

2.10.2 Tension Damping Mechanism

The tension damping mechanism of idler is installed on the thrust wheel frame between idler

33
and sprocket. It is used to:
⑴ Maintain a suitable track tension.
⑵ Absorb the additional force of the idler and track caused by barriers in front of the machine
during running or stone coming into the track.

Fig. 2-44 Damping Mechanism

1. Seat 2. Tension rod 3. Cylinder block 4. Piston 5. End cover 6. Front pilot 7. Recoil
spring 8. Rear pilot 9. Nut 10. Cover 11. Bushing 12. Wearing ring 13. Nipple
One end of tension rod (2) is connected with the idler seat (1) and the other end of that with
cylinder (3). The cylinder block is filled with grease pressed by piston. The front pilot (6) of
recoil spring and the piston (4) are always pushed toward bulldozer forward by recoil spring (7)
and the tension rod is also pushed forward by piston force through grease in cylinder.
When the idler, which is connected to the recoil spring through cylinder block (3), is
encountered with a shock which exceeds the initial preload of recoil spring, the tension spring
will adsorb the vibration. Furthermore, when mud, debris or snow is plugged between track
and sprocket, the recoil spring will absorb the vibration due to suddenly increasing of track
tension, preventing track, sprocket and other track and carrier rollers from damaging.
The cylinder block (3) is equipped with a nipple (13), which is used to supply grease that
makes the piston of oil cylinder drive idler forward. This leads track tension to increase. On the
other hand, unscrew the nipple to leak off grease. This leads track tension to decrease.
To decrease track tension, back off the nipple one turn. If grease leaks off uneasily, try to drive
bulldozer back and forth a short distance. Back off the nipple not more than one turn to

34
prevent lubrication sharply spraying under high pressure. Although a safeguard is used to
prevent the nipple from flying off, always remember this precaution to guarantee safety.
2.10.3 Idler Assembly

Typical thickness: 40mm

Adjusting range: 0-6mm

1. Idler 2. Bushing 3. Idler shaft 4. Cover 5. Floating seal 6. Support

Fig. 2-45 Idler Assembly

Idler (1) installed in front of each mainframe is supported on idler shaft (3) through support (6)
and bushing (2).
The idler assembly including a seat (the seat is connected with bracket (6)) can slide forth and
back along the thrust wheel frame through support (6), cover (4) and guide attached on the
thrust wheel frame and maintain track turning smoothly.
The lubrication flows to the bushing through oil hole to lubricate the moving surface of bushing
(2). Each end of the bushing is equipped with a floating seal (5) to avoid oil leakage and

35
prevent mud and water from entering.
To improve wearability, the idler should be made of silicomanganese casting and the idler
rolling path engaged with track link subject to induction hardening.
2.10.4 Carrier Roller Assembly

1. Bracket 2. Carrier roller shaft 3. Shaft ring 4. Floating seal

5．密封环 6．托链轮 7．盖板

Fig. 8．螺母
2-46 Carrier Roller Assembly
The carrier rollers are arranged on the top of the thrust wheel frame at two sides. It functions
as supporting the top half of entire track under normal travelling in order to prevent swing and
rocking due to dead weight. Carrier roller, rolling path and flange made of particular alloy steel
are hardened and flange is used to bear a push load (longitudinal load). Thus track sliding off
from carrier roller can be avoided.
A drilling oil hole for lubrication (oil) supply to sliding surface of bushing is made on the shaft.
One end of bearing is equipped with a floating seal to prevent mud and water from entering.

36
2.10.5 Thrust wheel Assembly
Thrust wheels are arranged under the thrust wheel frame at two sides. It functions as evenly
distributing the total weight of bulldozer through thrust wheel over tracks.
Thrust wheel assembly consists of thrust wheel (1), bushing (2), floating seal (4), shaft (5) and
outer cover (3). Thrust wheel is made of particular alloy steel, quenched and tempered.
There are two types of thrust wheels: one type has an outer flange only and the other has both
inner and outer flanges. Thrust wheel bears push load (longitudinal load) and single and
double flanges are alternatively arranged. The oil hole on the thrust wheel shaft is used to fill
lubrication for lubricating sliding surface of bushing. Both ends are equipped with floating seal
to avoid oil leakage and prevent mud and water from entering.

⑴ Single flange (Fig.2-47)

1. Track roller (single flange) 2. Bushing 3. Track roller outer cover 4. Floating seal 5.

Track roller shaft

Fig. 2-47 Track Roller (single flange)

37
⑵ Double-flange (Fig. 2-48)

1. Track roller (double-flange) 2. Bushing 3. Track roller outer cover 4. Floating seal 5.

Track roller shaft

Fig. 2-48 Track roller (double-flange)

38
2.10.6 Track

⑴ Purpose and Type of Track

The track is designed to support the bulldozer to ensure the adherence performance of the

bulldozer so that it can have enough drive force.

⑵ Structure of Track (Fig. 2-49)

1. Dust seal ring 2. Pin 3. Master dust seal ring 4. Master pin 5. Track link 6.
Master pin shaft 7. Bushing 8. Single grouser track shoe 9. Shoe bolt 10. Shoe nut

Fig. 2-49 Track

39
2.10.7 Suspension

⑴ Purpose of Suspension
The suspension is designed to connect the frame and undercarriage system to realize

damping and ensure the machine can swing upwards and downwards on uneven ground.

⑴ Structure of Suspension (Fig. 2-50)

1. Equalizer bar 2. Center pin 3. Support pin 4. Bushing 5. Dust seal ring

Fig. 2-50 Suspension

This machine is equipped with a semi-rigid suspension. The equalizer bar (l) is assembled on
the mainframe through center pin (2) with two ends supported on the thrust wheel frame. The
weight of front half of bulldozer is transmitted to the thrust wheel frame through the equalizer
bar because of this construction of equalizer bar, but the vibration from the thrust wheel frame
to the mainframe absorbed by the equalizer bar. The support pin on the thrust wheel frame at
two sides is used to make the main body not too high when bulldozer travelling and operating.
Furthermore, the equalizer bar is designed to rotate around the center pin.
To lubricate the equalizer bar, the mainframe is equipped with an oil cup. The grease is
supplied to the centre pin through a filler pipe and oil hole in the centre pin to lubricate the
sliding surface between shaft and bushing.

40
2.11 Work Equipment
2.11.1 Straight Tilt Dozer

1. Blade 2. Cutting edge 3. End bit 4. Brace 5. Tilt cylinder (left)

brace (right) 6. Push arm 7. Trunnion 8. Yoke
Fig. 2-51 Straight Tilt Dozer

The arched blade (1) is made up of high tensile strength alloy steel
and very rigid enough to bear heavy operation. The cutting edge (2) is
made of carbon steel. Its both ends have cutting edge, so the
opposite end also can be used. The end bit (3) is a casting, which has
excellent wearability and high strength. The push arm (6) is also
made of high tensile strength steel and in box section. Its front part is
connected to the blade through a connection and the rear part
articulated to the thrust wheel frame by means of the trunnion (7). The
push arm moves up and down due to movement of the blade lift
cylinder.
The right side of blade is connected by means of brace and push arm,

41
and the left side of that by means of tilt cylinder (5).
The tilt cylinder (5) is designed to make the blade (I) tilting leftward or rightward to meeting the
special requirement of work.
2.11.2 Angle Dozer

1. Blade 2. Cutting edge 3. End bit 4. Upper brace 5.

U-frame 6. Trunnion 7. Lower brace 8. Yoke 9.

Spheric hinge 10. Connection

Fig. 2-52 Angle Dozer

The arched blade (l) is made up of high tensile strength alloy steel and very rigid enough to
bear heavy operation. The cutting edge (2) is made of carbon steel. Its both ends have cutting
edge, so the opposite end also can be used. The end bit (3) is a casting, which has excellent
wearability and high strength. The U-frame (5) is also made of high tensile strength steel and

42
in box section. Its front part is connected to the blade through a connection and the rear part
articulated to the thrust wheel frame by means of the trunnion (6). The push arm moves up
and down due to movement of the blade lift cylinder. The blade is supported on the U-frame
through spheric ringe (9), lower brace (7) and upper brace (4).

2.11.3 Multi Ripper

Z-view

1. Ripper bracket 2. Ripper cylinder 3. Upper rod 4. Beam 5. Shank 6. Point 7.

Lower rod
Fig. 2-53 Ripper

43
The upper rod (3) and lower rod (7) are fixed to the ripper bracket (1) with the pin A and pin D.

The bracket is installed at the rear surface of steering case by nuts. The beam (4) is installed

at the other end of upper and lower rods by pin B and pin C.

The ripper shank (5) is installed on the beam by pin. The point (6) is fixed at the shank .The

bottom of ripper cylinder for lifting and lowering (digging) shank is fixed on the bracket (1) and

the piston rod on the beam (4). For the digging depth of point, the ripper cylinder (2) is

stretched and shortened by the quadric link mechanism (a parallelogram consisting of pin A, B,

C and D) to drive shank (5) up or down and make the all points keep an optimum digging

angle during digging. Depending on ground hardness, one shank or two shanks can be

removed to make the ripper operate in a state of two shanks or one shank.

2.12 Hydraulic System

2.12.1 Hydraulic Piping

⑴ Straight-tilt blade lifting hydraulic piping (Fig 2-54, Fig 2-55)

The blade lifting hydraulic piping of work equipment consists of hydraulic oil piping (1),

hydraulic control valve (2), blade lifting cylinder (3), operating pump (4) and hydraulic oil filter

(5) etc. The operating pump (4) is mounted on the top of PTO case. The hydraulic oil in the

hydraulic oil tank flows through the operating pump and becomes high-pressure hydraulic oil,

and then flows into the cylinder (3) after changing direction through hydraulic control valve to

realize lifting of the blade.

44
 1. Hydraulic oil tank 2. Hyraulic control valve 3. Blade lifting cylinder 4. Operating
pump 5. Hydraulic oil filter

Fig. 2-54 Straight-tilt blade lifting hydraulic piping

Schematic Diagram:

Hold

Float Lower Lift

1. Operating pump 2. Check valve 3. Main relief valve 4. Blade lifting

control valve rod 5. Suction valve for raise 6. Suction valve for lower 7. Blade
lifting cylinder 8. Hydraulic oil filter 9.Hydraulic tank
Fig. 2-54 Principle of straigh blade lifting hydraulic piping
45
⑵ Straight blade’s tilt hydraulic piping (Fig.2-56, Fig.2-57)
The bulldozer provided with straight blade has blade tilting device. The pipeline from the

hydraulic tank (1) to the blade tilting cylinder (3) passes through the center of top push arm (4)

and cannot be seen from outside. The hydraulic oil in the hydraulic tank flows through the

operating pump and becomes high-pressure hydraulic oil, and flows into the cylinder after

changing direction through hydraulic control valve (2) to realize titlting of the blade.

1. Hydraulic tank 2. Hydraulic control valve 3. Tilt cylinder 4. Push arm

铲 tilt hydraulic piping
Fig. 2-56 Straight blade’s
铲
46
Schematic diagram:

Right tilt Lift tilt

1. Operating pump 2. Check valve 3. Main relief valve 4. Blade

tilting control valve rod

5. 倾斜油缸 6. 液压油过滤器 7. 液压油箱铲
Fig. 2-57 Schematic diagram of straight blade tilting hydraulic piping
铲

47
⑶ Angle blade lifting hydraulic piping (Fig. 2-58, Fig. 2-59)
The blade lifting hydraulic piping of work equipment consists of hydraulic oil piping (1),

hydraulic control valve (2), blade lifting cylinder (3), operating pump (4) and hydraulic oil filter

(5) etc. The operating pump (4) is mounted on the top of PTO case. The hydraulic oil in the

hydraulic oil tank flows through the operating pump and becomes high-pressure hydraulic oil,

and then flows into the cylinder after changing direction through hydraulic control valve to

realize lifting of the blade.

1. Hydraulic tank 2. Hydraulic control valve 3. Blade lifting cylinder 4. Operating pump
5. Hydraulic oil filter

Fig. 2-58 Angle Blade Lifting Hydraulic Piping

48
Schematic Diagram:

Hold

Float Lower Lift

1. Operating pump 2. Check valve 3. Main relief valve 4.

Blade lifting control valve rod 5. Suction valve for lower 6. Suction valve

for raise 7. Blade lifting cylinder 8. Hydraulic oil filter

9.液压油箱
Fig. 2-59 Schematic Diagram of Angle Blade Lifting Hydraulic Piping
铲

49
⑷ Hydraulic piping of ripper (Fig. 2-60, Fig. 2-61)
The bulldozer may be provided with ripper upon user’s request. The hydraulic piping of ripper

consists of hydraulic oil tank (1), hydraulic control valve (2), ripper lifting cylinder (3), operating

pump (4) and hydraulic oil filter (5) etc. The operating pump (4) is mounted on the top of PTO

case. The hydraulic oil drained by the operating pump flows into the ripper lifting cylinder (3)

after changing direction through hydraulic control valve (2) to realize lifting of the ripper.

1. Hydraulic oil tank 2. Hydraulic control valve 3. Ripper cylinder

铲
Fig. 2-60 Hydraulic piping of ripper
铲

50
 Schematic Diagram:

Lift Lower

1. Operating pump 2. Check valve 3. Main relief valve 4. Suction valve for

ripper lifting 5. Overload valve for ripper lifting 6. Suction valve for lower 7.

Overload valve for lower 8. Ripper cylinder 9. Hydraulic oil filter

10.液压油箱 Fig.
11.液压控制阀
2-61 Schematic Diagram of hydraulic piping of ripper

2.12.2 Control System of Working Equipment

1. Straight-tilt and angle blade lifting control (Fig. Lowe

Rise
2-62)
When the control lever moves forward, the motion of link

lever and rotor shaft pulls out the blade lifting valve rod of

the hydraulic control valve to realize descending and floating

of the blade. In the contrast, when the control lever moves

backward, the blade will raise.

Fig. 2-62 Blade lifting control

铲
51
2. Tilting control of straight-tilt blade (Fig. Right tilt

2-63)
When the control lever moves rightward, the

motion of link lever and rotor shaft presses in the

blade tilting valve rod of the hydraulic control

valve to realize descending and floating of the

blade. In the contrast, when the control lever

moves leftward, the blade will tilt leftward.

Fig. 2-63 Tilting control

left (rise)

3. Ripper lifting control (Fig. 2-64)

When the ripper control lever moves rightward,

the motion of link lever and rotor shaft presses in

the ripper valve rod of the hydraulic control valve

to realize raise of the ripper. In the contrast, when

the control lever moves leftward, the ripper will

descend.

4. Locking of control lever Fig. 2-64 Ripper lifting control

In order to avoid mis-operation, the both the blade 铲

control lever and the ripper control lever are provided with locking devices.

When the locking device presses downward, the motion of link lever and rotor shaft locks the

end of the control lever with the hole of the locking plate so that it cannot move.

The angle blade is provided with stopper to stop the blade control lever from moving leftward

or rightward.

52
2.12.3 Outline of hydraulic control system

1. Straight-tilt dozer (Fig. 2-65)

Blade lifting
control valve

Blade lifting
control valve

Left tilt Raise

Hold Hold
Right tilt Lower
Float

1. Operating pump 2. Main relief valve 3. Flow control valve 4.

Blade tilt control valve 5. Tilt cylinder 6. Check valve 7. Blade

lifting control valve 8. Blade lifting cylinder 9. Suction valve for raise 10.

Suction valve for lower 11. Hydraulic oil filter 12. Hydraulic oil tank

A．主安全阀测压口 Fig. 2-65 Hydraulic control system (straight-tilt blade)

53
 2. Straight-tilt dozer with ripper (Fig. 2-66)

blade lift blade tilt ripper lift

①raise ○,Aleft incline ○,Draise
②hold ○,Bhold ○,Ehold
③lower ○,Cright incline ○,Flower
④float

1. Operating pump 2. Main relief valve 3. Flow control valve 4. Tilt control valve
5. Tilt cylinder 6. Check valve 7. Blade lifting control valve 8. Blade lifting cylinder
9. Suction valve for raise 10. Suction valve for lower 11. Check valve 12. Ripper control valve
13. ripper cylinder 14. suction valve for ripper raise 15.suction valve for ripper fall 16. ripper
lift overload valve
17. 松土器下降过载阀
Fig. 2-6618. 液压油滤清器
Hydraulic 19.
control system 液压油箱 blade and ripper)
(straight-tilt A. 主安全阀测压口

54
 3. Angle dozer (Fig. 2-67)

①raise
②hold
③lower
④float

1. operating pump 2. main relief valve 3. check valve 4. blade lift control valve 5. blade lift

cylinder 6. suction valve for raise 7. suction valve for lower 8. hydraulic oil filter

9. hydraulic tank A. main relief valve test port

Fig. 2-67 Hydraulic Control System (angle dozer)

55
4. Angle dozer with ripper (Fig. 2-68)

blade ripper
①raise ○,Draise
②hold ○,Ehold
③lower ○,Flower
④float

1. operating pump 2. main relief valve 3. check valve 4. blade lift control

valve 5. blade lift cylinder 6. suction valve for raise 7. suction valve for lower

8. check valve 9. ripper control valve 10. ripper lift cylinder 11. suction valve for raise

12. suction valve for lower 13. lift overload valve 14. lower overload valve 15.

hydraulic oil filter 16. hydraulic oil tank A. main relief pressure pickup plug

Fig. 2-68 Hydraulic control system (angle dozer and ripper)

56
2.12.4 Operating Pump

1. driving gear shaft 2. front cover of pump 3. pump body 4. rear cover of pump 5.

driven gear

Fig. 2-69 Operating Pump

Technical parameter of operating pump:

Model: CBJ70-E112R
Type: gear pump
Flow: 230L/min (2,000rpm)
Adjusting pressure: 14MPa (140kgf/cm2)

2.12.5 Hydraulic Tank

From hydraulic oil filter

To operating pump

Fig. 2-70 Hydraulic Tank

57
2.12.6 Hydraulic control valve

1. filling valve 2. lift valve 3. tilt valve 4. ripper vlave 5. oil return valve 6. lift valve rod 7. tilt valve rod
8. ripper valve rod 9. main relief valve P. high-pressure oil inlet T. oil drain A1. to small chamber of lift
cylinder B1. to large chamber of lift cylinder A2. to small chamber of tilt cylinder B2. to large chamber
of lift cylinder A3. to small chamber of ripper cylinder B3. to large chamber of ripper cylinder
Fig. 2-71 Hydraulic control valve

2.12.7 Blade lift cylinder

1. bushing 2. gland 3. cylinder head 4. cylinder 5. piston rod 6. axle bushing 7. nut

8. bushing 9. gasket 10. bushing 11. dust seal 12. shield 13. back-up ring 14. slipper

seal 15. back ring 16. wearing ring 17. piston 18. valve seat 19. piston valve
Fig. 2-72 Blade lift cylinder

58
 Technical Parameter Unit: mm

O.D. of piston rod 65

I.D. of cylinder 110
Actual stroke of piston 1026
Max. length of cylinder 1744
Min. length of cylinder 708
Piston nut spanner width 55

2.12.8 Blade tilt cylinder

1. bushing 2. gland 3. cylinder head 4. cylinder 5. piston rod 6.

nut 7. bushing 8. piston 9. wearing ring 10. back-up ring

11. bushing 12. gasket 13. bushing 14. dust seal

Fig. 2-73 Tilt cylinder

Technical Parameter Unit: mm

O.D. of piston rod 70

I.D. of cylinder 160
piston stroke 140
Max. length of cylinder 1236
Min. length of cylinder 1096
Piston nut spanner width 80

59
2.12.9 Ripper cylinder

1. bushing 2. gland 3. cylinder head 4. cylinder 5. piston rod

6. nut 7. bushing 8. gasket 9. bushing 10. dust seal 11.

back-up ring 12. slipper seal 13. back ring 14. wearing ring 15. piston

Fig. 2-74 Ripper cylinder

Technical Parameter Unit: mm

O.D. of piston rod 75

I.D. of cylinder 160
piston stroke 350
Max. length of cylinder 1080
Min. length of cylinder 730
Piston nut spanner width 80

2.12.10 Structure of Hydraulic Cylinder

⑴ General
Hydraulic cylinder is a device, which converts fluid energy into mechanical energy for

straight-line movement. There are oil ports at both head (piston rod end) and bottom end of

cylinder. If the oil enters at the head end the piston moves towards the bottom and the oil at

the bottom is drained to the tank. In the same way, if the oil enters at the bottom end the piston

moves towards the head and the oil at the head is drained to the tank.

The piston, therefore, can be moved in two directions. This type of piston is called a

60
double-acting piston.

⑵ Structure and function

① Cylinder
The cylinder is made of steel pipe and a bottom plate is welded on at the bottom end. The
valve seat
inside of cylinder is finished by honing to
piston valve
prevent wear of the piston rings or oil leakage. valve seat low-pressure
oil
piston rod

② Piston valve
The piston valve (Fig. 2-75) is installed in the

piston of the blade lift cylinder of the

straight-tilt-dozer. As shown in the figure below,

the piston valve opens to let the oil on the high high-pressure oil

pressure side flow to the low pressure side. In Fig. 2-75 piston valve

this way, it functions to relieve the pressure

when the piston reaches the end of its stroke.

When the blade of the straight–tilt-dozer is tilted,

the stroke of the piston rods in the right and left

cylinder is different (Fig 2-76).

Fig. 2-76 piston valve

When this happens, the piston valve on the fully

retracted side opens and releases the high

pressure oil into the low pressure side. This

prevents the hydraulic pressure from rising and

as a result prevents the blade from twisting (Fig

2-77).

Fig. 2-77 piston

61
valve
In addition to this, the piston valve also has the following functions:

If the piston rod is removed quickly and is suddenly stopped when it reaches the end of its

stroke, there will be a sudden surge of pressure in the circuit.

If more oil is sent to the cylinder, the pressure in the circuit will rise too high and oil will start to

be relieved through the main relief valve of the control valve.

When the piston reaches its stroke end every time, the operation of piston valve is as follows:

piston rod piston piston valve

a. When piston is moving (Fig. 2-78)

Oil sent from the hydraulic pump pushes the

piston and piston valve to the right. The piston

valve is being pushed to the right, so it is in

contact with the piston valve seat at the

valve seat valve seat
tapered part. This prevents the oil from passing

and as a result, the pressure in the cylinder Fig. 2-78 working principle
piston valve
rises and pushes the piston rod to the right.

b. When piston valve functions (Fig.

2-79)
Just before the piston reaches the end of its
stroke, the tip of the piston valve contacts the
cylinder bottom (or cylinder head). The piston valve seat valve seat
valve stops in this position, but the piston rod
Fig. 2-79 working principle
continues to move to the right. As a result, a
gap is formed between the tapered part of the piston valve and piston valve seat. The high
pressure oil in the cylinder escapes through this gap, so the hydraulic pressure stops rising.
In this way, the piston valve prevents surge pressure from being generated and also prevents
oil from being relieved through the piston valve. The oil simply passes through the piston valve
to the low pressure side of the circuit. It is undesirable for surge pressure to be generated and
the circuit to be relieved every time the piston reaches the end of its stroke. Therefore, to
prevent this, the piston valve functions before the piston reaches the end of its stroke. This
releases oil into the low pressure side and prevents surge pressure from being generated and
the circuit from being relieved. At the same time, it reduces the shock when the piston hits

62
head or bottom end of the cylinder.
gasket
③ Cylinder head dust seal
a. There are two types of cylinder head. One is
mounted on the cylinder (Fig. 2-80) with bolts as
piston
shown in the figure. The other has a thread and rod

is screwed directly into the cylinder.

b. A bushing (bronze) is fitted in the central hole
of cylinder head, so that the piston rod does not
slide directly in contact with the cylinder head.
In addition, a packing is fitted to prevent the oil bushing

inside the cylinder from leaking through the gap Fig. 2-80 cylinder

between the cylinder head and piston rod. head

Furthermore, there is a dust seal, which prevents the dirt

cylinder
on the piston rod from entering the cylinder when the
piston rod is retracted.
piston rod

wearing ring

④ Piston piston rod

The piston (Fig. 2-81), which slides inside the cylinder, is piston
fitted with piston rings (Fig. 2-82) to prevent oil from
Fig. 2-81 Piston
entering low pressure side through the piston from the
back ring
high pressure side.
slipper ring
If hydraulic pressure is applied from the other side, the
back-up ring
back ring changes shape and the slipper seal is pushed
against the cylinder to prevent oil leakage.
In addition, both the piston and the cylinder are made of
steel, so they will scratch each other if they slide directly
in contact. To prevent this, the piston is fitted with a wear
ring made of bakelite with a cloth filling.

Fig. 2-82 piston ring

63
2.12.11 Torqflow Hydraulic System

1. coarse strainer 2. variant pump 3. fine filter 4.

transmission control valve 5. torque converter 6. oil cooler

Fig. 2-83 Torqflow Hydraulic System

The principal components comprising the torqflow hydraulic circuit are the strainer (1), torqflow
pump (2), oil filter (3), transmission control valve (4), torque converter relief valve, torque
converter (5), torque converter regulator valve , oil cooler (6) , transmission lubricating relief
valve and torque converter scavenging pump etc. (Fig 2-83).
Oil in the transmission case is sucked up to torqflow pump through strainer (1), and supplied
to transmission control valve (4) through oil filter (3). The transmission control valve is divided
into the modulating relief valve group and the torque converter relief valve group. The oil
relieved to a pressure of 2MPa (20kgf/cm2) from the modulating relief valve is supplied to
torque converter relief valve.
The torque converter relief valve is set at 0.75-0.85 MPa (7.5-8.5kgf/cm) and controls oil
pressure to be fed to the torque converter .The oil delivered through this valve is then directed
to the lubrication circuit. The oil is then directed out of the torque converter and to torque
converter regulator valve.
The regulator valve is set at 0.2-0.3MPa (2-3kgf/cm2) and maintains the torque converter
inside pressure. The oil of 0.2-0.3MPa (2-3kgf/cm2) supplied by the regulator valve is directed
through oil cooler (6) where it is cooled to transmission lubricating relief valve.

64
 The lubricating relief valve is set at 0.12MPa (1.2kgf/cm 2) and supplies oil to all sliding parts of
the transmission and PTO.
Oil used for lubricating torque converter or oil oozing out of each contacting face of the
converter is returned from the converter to the transmission case by means of scavenging
pump.
Principle of variable speed circuit (Fig. 2-84):

setting pressure 2MPa

setting pressure 1.25MPa

st
No. 3clutch (1st speed)
No. 4clutch (3st speed) setting pressure
No. 5clutch (2 speed) setting pressure 0.75-0.85MPa
0.2-0.3MPa

No. 2clutch (reverse)

No. 1clutch (forward)
cracking pressure 0.1MPa setting pressure
0.12MPa

engine 1850rpm hour

1. Transmission case 2. Strainer 3. Torqflow pump 4. Filter 5. Modulating relief valve 6. Quick return valve 7. relief
valve 8. speed valve 9. Forward-reverse valve 10. Torque converter relief valve 11. Torque converter 12. Torque
converter regulator valve 13. Oil cooler 14. Lubricating relief valve 15. PTO case lubrication 16. Transmission
lubrication 17. Torque converter case 18. Strainer 19. Scavenging pump A. Plug for transmission modulating relief
pressure (ZG 1/8) B. Plug for transmission 1st speed clutch pressure (ZG 1/8) C. Plug for torque converter relief pressure
(ZG 1/8) D. Plug for torque converter regulator pressure (ZG 1/8) E. Adapter for torque converter oil temperature

Fig. 2-27 Principle of variable speed circuit

The fundamental components of the transmission hydraulic system are the oil strainer (2),
torqflow pump (3), control valve group and oil cooler (13), pipes, which are connected from
lubricating relief valve (14) to oil cooler (13) and from oil strainer in transmission bottom to
torqflow pump suction port. The control valve group consists of the speed valve group and the
forward-reverse valve group.
The hydraulic control system is used for selecting one of the three forward and reverse speeds.
The forward and reverse valve (9) and the speed valve (8) feed oil to the specified clutches so
65
that the desired traveling direction and speed of the machine can be attained. Oil pressure for
this purpose is regulated by the modulating relief valve (5).
When the engine is started and the transmission control lever is placed in the “Neutral”
position, oil from the oil pump is directed to the modulating relief valve (5). This valve keeps
2MPa (20kgf/cm2) of oil pressure.
Structure of variable speed circuit (Fig. 2-85)
st nd nd
Forward Reverse 1 speed 3 speed 2 speed

① Neutral ② 1st speed ③ 2nd speed ④ 3rd speed A. Forward B. Reverse

(The speed valve is placed in “Neutral” and the forward-reverse valve in “Forward”.)

Fig. 2-85 Structure of variable speed circuit

66
2.12.12 Torqflow pump

1. Drive gear shaft 2. Pump front cover 3. Pump body 4. Pump rear cover 5. Driven gear

Fig. 2-86 Torqflow pump

Technical Parameter of torqflow pump:

Model: CBJ40-B40L
Type: gear pump
Delivery: 40L/min
Rated pressure: 4MPa (20kgf/cm2)

67
2.12.13 Transmission control valve
The transmission control valve consists of modulating relief valve and reducing valve (Fig. 2-87).

detent ball directional valve spool

plug for modulating relief pressure st
plug for 1 speed
clutch pressure

Z-view

plug for forward-reverse clutch F-R lever

F-R lever speed lever

speed lever
to torque converter

reverse
forward
from oil pump
2 speed
3nd speed
1rd speed

from A from B
neutral
st

68
1. Stopper 2. Valve core (B) 3. Valve core spring 4. Valve core (A) 5. Modulating relief valve spool 6. Modulating
valve spring (Large) 7. Modulating valve sleeve 8. Modulating valve spring(Small) 9.Side cover 10. Reducing
valve spool 11. Piston 12. Stopper 13. Reducing valve spring 14. Sleeve 15. Quick return valve 16. Stopper 17.
Directional valve spool 18. Spool 19. Sleeve 20. Cover 21.Speed valve spool 22. Valve body 23. Speed valve
body 24. Speed valve spool detent pin F. To Forward clutch R. To Reverse clutch ⑴ To 1st clutch ⑵ To 2nd clutch
⑶ To 3rd clutch
Fig. 2-87 Transmission control valve

Schematic diagram of hydraulic system of transmission control valve (Fig. 2-88):

reducing valvel

modulating relief valve to torque converter

st nd rd
1 speed 2 speed 3 speed
speed valve
st
1nd clutch
3rd clutch
2 clutch

F-R valve
quick return forward clutch
from pump valve reverse clutch

1. Modulating relief valve

⑴ Function
The modulating relief valve acts as both the filling time modulating time
setting pressure 2MPa
modulating valve and the relief valve. The
function of this valve is to prevent abrupt rising
of oil pressure applied to a clutch when the gear
oil pressure (MPa)

shift lever is shifted. The modulating

engagement of the clutches prevents the
machine from starting with a shock, increases
the durability of the power transmission system
and improves operator comfort.

The time taken to fill up the closed spaces in the

clutch with oil is called “filling time”. When the gear shift lever (engaged) modulating time (sec.)

Fig. 2-89 Principle of modulating

spaces fill up with oil (point B), the oil pressure
relief valve
starts rising. The modulating valve then automatically commences operating so as to raise the

oil pressure at a suitable rate to the set valve, causing the clutch to engage smoothly (point D).

69
⑵ Working principle (Fig. 2-89)
① When machine moving forward at 1st speed (Point
A in the curve) (Fig 2-90)
The modulating relief valve functions as a relieve
valve. The hydraulic oil from torqflow pump flows into
reducing valve through the oil port (e) of quick return
valve (15).
The hydraulic oil via centre hole of quick return valve
flows through throttle (g) to the right side of
modulating sleeve and pushes the modulating sleeve
(7) to the left.
Another hydraulic oil circuit from torqflow pump flows into the piston valve (2) through the
throttle (f) of quick return valve to push the regulating relieve valve (5) to the right. When the
modulating relieve valve (5) is pushed to the right and the modulating sleeve (7) to the left, the
modulating spring (6) and (8) are compressed so that they are in a state of balance. Under this
circumstance the hydraulic oil is released and flows to the torque converter.
② Immediately after shifting the gearshift lever to 2nd speed (point B in the curve) (Fig 2-91)
Immediately after a speed change, oil from pump
flows into clutch pack and fills up clutch. Quick return
valve (15) moves to the left by the oil flow to port (e).
At the same time valve (5) and sleeve (7) are returned
by the force of spring (6) and (8) and oil of chamber (c)
flows to drain port (a), and oil of chamber (a) flows to
drain port (b).

③ When the oil pressure starts to rise

When the 2nd clutch piston is filled up with oil, the oil
almost ceases to flow and the pressure at port (e) and
(h) of the quick return valve (15) becomes roughly
equal. And then the oil pressure of circuit rises,
causing quick return valve (15) to move to the right
and the oil of port (a) does not flow to drain port
(b)(Fig 2-92).

70
When the clutch piston is filled up with oil, the oil pressure
of port (c) through orifice (f) in the quick return valve (15)
rises. Under the force of the oil pressure of port (c), the
modulating valve (5) moves to the right. This causes port
(i) to open, thus connecting the torque converter circuit to
the relief (Fig 2-93).

On the other hand, the oil passing through the center hole
of quick return valve (15) flows into port (a) through orifice
(g).
After filling port (a), the oil pressure rises and the
pressurized oil pushes modulating sleeve (7) to the
causing spring (6) and (8) to compress.
As the oil pressure increases gradually, the oil pressure of
each port increases too, causing modulating sleeve (7) to
move to the left. And then modulating valve (5) continues
to move to the left and closes torque converter relief port
(i), causing spring (6) and (8) to compress (Fig 2-94).

④ When pressure is rising and oil pressure rise is completed (Fig 2-95)
When closing the torque converter relief port (i), the oil
pressure of port (c) rises again, and pushes modulating
valve (5) to the right to open relief port (i), causing
spring (6) and (8) to compress so that the oil pressure of
the circuit increases.
As result, modulating valve (5) continues to move to the
right and left and increase the pressure until modulating
sleeve (7) strikes valve body (j). When this happens, the
oil flows to relief port (i) and the oil pressure ceases to
rise, so that the relief pressure reaches the set pressure
of modulating valve: 2MPa (20kgf/cm2).

71
2. Reducing valve
Reducing valve (10) is equipped in the circuit between quick return valve (15) and speed valve
(21), and keeps the oil pressure on the 1st clutch at 1.25MPa (12.5kgf/cm2). When this
pressure is reached, the 1st clutch circuit is closed. (Fig. 2-87)

As the pressure in the 1st clutch circuit increases, the

reducing valve spool (10) and piston (11) are pushed by
the pressure oil through orifice of reducing valve spool
(10), causing the reducing valve spool(10) to be moved
to the left (Fig 2-96).

As the oil pressure in the 1st clutch increases further, the

reducing valve spool (10) is moved left to the limit, closing
the circuit from the pump to the 1st speed circuit. Thus
the oil pressure on the 1st clutch is maintained at
1.25MPa (12.5kgf/cm2) (Fig 2-97).

Fig. 2-97 Principle of reducing valve

In the “Neutral” position, the oil from the pump works on the
1st clutch when the engine is started. This is to shorten the
time to fill cylinders Forward and Reverse with pressurized oil,
which assists machine starting. When the gear shift lever is
shifted to Forward-1st speed position, enough oil is supplied
by the pump to fill Forward cylinder. When the lever is then
shifted from Forward-1st to Foeward-2nd position, the oil is
supplied to only 2nd clutch cylinder as Forward clutch is
already full. Thus the modulating time is shortened (Fig.98).
Fig. 2-98 Principle of reducing valve

72
2.12.14 Transmission filter

73
2.12.15 Transmission lubrication system
1. Transmission lubrication chart (Fig. 2-100)

Fig. 2-100 Transmission lubrication system

Hydraulic oil provided by torqflow pump is used for lubricating the transmission and torque
converter and controlling the transmission. This pump is driven by P.T.O. The oil in the
transmission case is sucked up by the torqflow pump.
Foreign particles and dirt in oil are removed by the strainer before oil is sucked into the pump.
This assures that clean oil is fed into the transmission control valve. Valves in the control valve
unit act to flow oil to the transmission clutches. Oil left from the control valve is flowed to the
torque converter, and oil is cooled by the oil cooler and sent to the lubrication relief valve,
which prevents the transmission lubricating oil pressure from exceeding 0.12MPa(1.2kgf/cm2)
of the setting pressure. The existence of foreign material in the transmission lubricating circuit
blocks smooth oil flow, which would cause an excessive rise in oil pressure of oil circuit.
All clutches, bearings and gears are lubricated by the oil from oil cooler.

74
2. Lubricating relief valve (Fig. 2-101)

1. Valve body 2. Cover 3. Spring seat 4. Spring 5. Lubriating relief valve spool
6. cover 7. bushing 8. bushing 9. cushion

Fig. 2-101 Lubricating relief valve

75
2.12.16 Steering clutch and brake piping
The hydraulic steering system mainly consists of strainer (1), steering pump (2), steering filter
(3), steering control valve (4), brake booster, relief valve and oil cooler (5). (Fig. 2-102)

1. Steering strainer 2. Steering pump 3. Steering filter 4. Steering control valve 5. Oil
cooler
Fig. 2-102 Steering clutch and brake piping

The hydraulic oil inside the steering case passes through magnet strainer (1) and is sucked up
by steering pump (2). From here it passes through steering filter (3) and flows to steering
control valve (4), brake booster and relief valve.
The oil relieved by relief valve [set pressure: 2MPa (20 kgf/cm 2)] flows to the oil cooler by-bass
valve.
If the oil pressure in the oil cooler by-pass valve exceeds the set pressure of 1.26MPa
(12.6kgf/cm2), due to reason such as clogging of oil cooler (5) or the lubrication system, the oil
is relieved to the steering case.
When the steering lever is pulled halfway, the oil flowing to steering control valve (4) flows to
steering clutch. When the steering lever is pulled fully, the oil flows to the steering clutch and
brake booster. This disengages the steering clutch and at the same time actuates the brake.

76
2.12.17 Hydraulic system of steering clutch and brake
1. Schematic diagram of hydraulic system of steering clutch and brake (Fig. 2-103)

1. Steering strainer (magnet type) 2. Steering pump 3. Steering filter 4. Relief valve 5. Oil
cooler by-pass valve 6. Oil cooler 7. Steering control valve 8. Brake valve 9. Brake booster
10. Left steering clutch 11. Right steering clutch 12. Steering case
A. Plug for relief valve pressure (ZG1/8) B. Plug for left steering clutch pressure (ZG1/8)
C. Plug for right steering clutch pressure (ZG1/8) D. Plug for left brake booster pressure
(ZG1/8)
E. Plug for right brake booster pressure (ZG1/8) F. Plug for by-pass valve pressure (ZG1/8)
Fig. 2-103 Principle of hydraulic system of steering clutch and brake

77
2. Structure of hydraulic system of steering clutch and brake (Fig. 2-104)
Engine running, both steering levers are not pulled and both brake pedals are not depressed:

Fig. 2-104 Hydraulic system of steering clutch and brake

78
2.12.18 Steering pump
1. Structure (Fig. 2-105):

1. Driving gear shaft 2．Front pump cover 3. Pump body 4. Rear pump cover 5.

Driven gear

Fig. 2-105 Steering pump

2. Technical Parameter：
Model: CB-Hd40
Type: gear pump
Delivery: 40 ml/r
Rated pressure: 4MPa (40kgf/cm2)

79
2.12.19 Steering control valve
1. Structure of steering control valve (Fig. 2-106A, Fig. 2-106B)
The steering control valve includes two steering valves (12) and controls the oil line to left and
right steering clutches, left and right brake valves (20) and oil line to left and right brake
boosters.

1. steering valve body

7. lever
8. adjusting bolt
9. shaft
10. spring
11. guide sleeve
12. steering valve rod
13. spring
14. piston
15. cock
16. guide seat
17. shaft
18. spring
19. spring
20. brake valve body
21. spring
22. piston
23. cock

Fig 2-106A Steering control valve

80
 2. Pipe 3. Brake valve body 4. Bolt 5. Shim 5. Lever

Fig. 2-106B Steering control valve

2. Working principle of steering control valve
⑴ When steering rod is not pulled (steering clutch is engaged, without brake) (Fig. 2-107):
The hydraulic oil flows from the steering pump to
relief valve (24), A chamber of steering control valve
and brake booster. However, the oil circuit of
steering valve and brake booster is cut off, so the
circuit pressure rises. When the pressure is higher
than the setting pressure 2MPa(20kgf/cm2) of relief
valve (24), hydraulic oil will be input to oil cooler.
⑵ When steering rod is slightly pulled
(semi-engagement of steering clutch, without
brake):
When steering rod is pulled, the lever (7) pushes the
compression spring (10) in the direction showed by
the arrow. The spring pushes the steering valve rod
(12) along the arrow to close chamber B and
chamber G and connect to chamber A and chamber B. The hydraulic oil will be filled into the
steering clutch. When the steering clutch is filled with hydraulic oil, the oil pressure will rise.
(Fig. 2-108)
81
The hydraulic oil flows to chamber C via the orifice (a)
pushes the piston (14) and the reaction force pushes
the steering valve rod (12) along the arrow and
compresses the spring (10). The steering valve rod
(12) closes chamber A and chamber B and cuts off
the hydraulic oil to chamber B. In such case, the oil
pressure in the valve and the spring are balanced. If
the steering rod is pulled further, the spring (10) will
be compressed further and the steering valve rod will
be pushed rightward. Repeat the above action to
further improve the oil pressure. The oil pressure and
the spring are in a new balanced state after the oil
pressure rises. The steering clutch disengages
partially. (Fig. 2-109)
⑶ When the steering rod is pulled to the blocking
position (when the steering rod is pulled further after
being pulled to such stroke, it can be pulled only with
larger force than the former one) (steering clutch
disengaged, without brake):
When the steering rod is pulled to the blocking
position, the shaft (9) moves along the arrow and
contacts the guide sleeve (11). The shaft (9) pushes
the guide sleeve (11) which then pushes the steering
valve rod (12) so that the pressure in chamber B
rises and the steering valve rod (12) does not move
leftward. The spring (10) is completely compressed
and the hydraulic pressure reaches 1.89MPa
2
(18.9kgf/cm ) (modulating process completed). The
hydraulic pressure still rises to 2MPa (20kgf/cm2), i.e.
the pressure set by relief valve. The steering clutch
completely disengages. (Fig. 2-110)
⑷ When the steering rod is further pulled (steering
clutch disengaged; oil pressure in brake circuit starts
rising):
The shaft (9) contacts the guide sleeve (11), so the
opening amount of chamber A and chamber B is
identical to the shift amount of shaft (9). (Fig. 2-111)

82
Under the action of adjusting bolt (8), the shaft
(17) moves rightward and pushes the brake valve
rod (20). In such case, chamber E and chamber
H are cut off and chamber D and chamber E are
connected. The hydraulic oil flows into the brake
booster through chamber E. (Fig. 2-112)
The hydraulic oil flowing to chamber F through
the orifice (b) pushes the piston (22) and the
reacting force pushes the brake valve rod (20)
leftward. The spring (18) is compressed. The
brake valve rod (20) cuts off the oil circuit from
chamber D to chamber E. The system pressure
and the force of spring (18) are balanced. (Fig.
2-113)
If the steering rod is further pulled, the spring (18)
will be compressed further. In such case, the
spring force rises and the oil pressure balanced will rise with the spring force. The brake acts.
⑸ When the steering rod is pulled to the end (steering
clutch disengaged; brake applied):
The shaft (9) moves rightward until touching the
stoppers (G) and (H). After that, the shaft (9) cannot
move rightward any more and the steering valve rod
(12) cannot move further. Under the pushing force of
the adjusting bolt (8), the shaft (17) can move
rightward to push the brake valve rod (20). (Fig. 2-114)
However, even if the shaft (9) reaches the terminal of
the travel, shaft (17) has not reached the terminal
of the travel. Therefore, the hydraulic oil flows into
chamber (F) through the orifice (b) pushes the
piston (22), and the reacting force pushes the
brake valve rod (20) leftward and compresses the
spring (18). The brake valve rod (20) cuts off the
hydraulic oil from chamber D to chamber E. The
Fig. 2-115 Principle of steering control valve
system pressure and the force of spring (18) are
balanced. When the steering rod is pulled to the end, the force of spring (18) reaches the max.
value. The circuit pressure balancing with the force of spring (18) also reaches the max. value
1.67MPa (16.7kgf/cm2). The brake process is completed and the brake band holds the brake
drum. (Fig. 2-115)

83
⑹ When the steering rod is recovered (steering
clutch engaged, without brake):
Shaft (9), shaft (17), brake valve rod (20) and
steering valve rod (12) all return to their original
positions under the action of the spring force. In
such case, the steering valve rod (12) cuts off
the oil circuit from chamber A to chamber B and
connects chamber B and chamber G. The
hydraulic oil in the steering clutch is then
drained to the steering clutch case through Fig. 2-116 Principle of steering control valve

chamber B and chamber G. (Fig. 2-116)

In addition, the brake valve rod (20) cuts off the oil circuit from chamber D to chamber E and
connects chamber E and chamber H. The hydraulic oil in the brake booster then flows to the
steering clutch case through chamber E and chamber H.

84
2.12.20 Steering relief valve

1. Structure of steering relief valve (Fig. 2-117):

Fig. 2-117 Steering relief valve

The steering relief valve includes relief valve and oil cooler bypass valve. The latter is used to
prevent from abnormal high pressure caused by blocking of oil cooler or other position. Setting
pressure of relief valve: 2MPa (20kgf/cm2); setting pressure of oil cooler bypass valve: 1.2MPa
(12.0kgf/cm2).

85
2. Working principle of steering relief valve (Fig. 2-118):
The hydraulic oil from the steering pump

flows to chamber A, and then flows to

the spool (10) through the orifice (a) of

the relief valve (8). When the hydraulic

pressure rises, the hydraulic oil will push

the spool (10). Under the reacting force,

the relief valve moves to the right and

the rod (8) connects chamber A and

chamber B. The one part of the

hydraulic oil flows into the oil cooler

through chamber C of the bypass valve,

Fig. 2-118 Principle of steering relief valve
and the other part flows into chamber D

of the bypass valve. In such case, the hydraulic pressure is kept to 2MPa (20kgf/cm 2). The oil

circuit pressure rises if the oil cooler is blocked. The hydraulic oil in chamber D will push the

bypass valve rod (2) along the arrow to connect chamber C and chamber E. The hydraulic oil

will be drained to the oil tank and the hydraulic pressure will become 1.26MPa (12.6kgf/cm2).

86
2.12.21 Steering strainer

Structure (Fig. 2-119):

1. Strainer cover 2. Spring 3. Screen 4. Magnet 5. Strainer case

Fig. 2-119 Steering strainer

87
2.12.22 Steering filter
1. Structure (Fig. 2-120):

1. Cover 2. Spring 3. Spring guide 4. Valve 5. Spring 6. Bracket 7. Element 8. Filter case

Fig. 2-120 Steering filter

2. Working principle:
The hydraulic oil from steering pump flows into the case via the inlet. After being filtered by the
element (7), it is fed to the inlet of the control valve from the outlet. If the element (7) is
seriously blocked, the valve (4) will open when the front-rear pressure different of it reaches
0.3MPa (3kgf/cm2).

88
2.13 Control system
2.13.1 Engine control
A fuel lever is installed on the dashboard. Decelerator pedal is equipped in the front of right
foot. When the decelerator pedal is depressed, the absorber prevents the fuel control lever
from moving. When machine arriving at the top of a slope, or when dumping dirt from a cliff,
the travel speed will increase suddenly when unloaded. Slow down the engine speed by
depressing the decelerator pedal.

idling
full speed

1. Fuel control lever 2. Decelerater pedal 3. Absorber

Fig. 2-121 Engine control

89
2.13.2 Transmission control
1. The transmission control lever system consists of transmission control lever and safety
switch to ensure the engine may be started and the speed may be switched only in neutral
position. (Fig. 2-122)
⑴ Transmission control lever
When moving the gear shift lever from the “Neutral” position to 1st, 2nd or 3rd position, each
part moves in the direction shown by the arrow, resulting in pulling the speed valve spool (4).
The transmission control lever is mounted on the left control frame to realize three kinds of
speed (F, R) of the dozer. There is only one transmission control lever.
When the gear shift lever moves from the forward position to the reverse position, each part
moves in the direction shown by the arrow, resulting in pulling the F-R valve rod (5).

Gear shift lever

forward
reverse

safety lever

1. Gear shift lever 2. Safety lever for gear shift lever 3. Transmission control valve 4. Speed
valve lever 5. Forward-Reverse lever F. Forward position R. Reverse position N. Neutral
position
Fig. 2-122 Transmission control

⑵ Safety switch (Fig. 2-123)

The safety switch of circuit is mounted in the starting circuit. Only when the gear shift lever is
in N position, the starting circuit will be connected (safety switch connected). Then, the starting
switch can be used to start the engine.
If the gear shift lever can push the safety switch and disconnect the starting circuit (safety
switch disconnected) when the gear shift lever is in any position other than Neutral, the engine
cannot be started when turning the starting switch.

90
 To engine oil pressure indicator
To charging indicator
safety switch
connected disconnected

To engine R
disconne
connected cted
disconne
cted
disconne
cted

disconne
Terminal (magnetic field) R
cted

To battery
neutral

Fig. 2-123 Circuit diagram of safety switch

2.13.3 Steering brake control
There are two steering control levers, respectively in charge of left and right steering of the
machine. They are arranged on the left control frame side by side.
When pulling the steering lever (l) to the neutral position as shown in the figure, the steering
control valve functions, the clutch is disengaged and brake is not applied.
When pulling the steering fully, the clutch is disengaged and brake is applied.
The brake pedal is mounted in front of the left foot. Only one can control the action of left and
right brakes at the same time.
When depressing the brake pedal (2), the brake booster functions and the brake is applied.
If the brake pedal is depressed fully and the brake lever is pulled, the brake pedal can be
locked to the depressed brake position.

clutch off clutch off

brake off brake on

brake

release

1. Steering control lever 2. Brake pedal 3. Hand brake lever

Fig. 2-124 Steering brake control

91
2.14 Electrical system
The electrical system is used to complete the tasks such as starting of dozer, operating
condition supervision of diesel engine and working lighting to reduce the work volume of the
operator and improve the operation comfort.
The electrical system mainly consists of battery, DC starting motor, AC generator, starting
switch, neutral switch, rocker switch set, lights and various instruments, sensors and
connecting conductors.
Working principle of electrical system:
The electrical system is a DC 24V system using single-wire negative earthing system. The
starting motor is started directly in electrical manner. Two batteries in parallel feed the starting
motor with 24V power. The circuit of battery is connected through the relay. The starting switch
is used to start the diesel engine. When the diesel engine is started, the starting motor stops
working. The whole system will be fed by the generator. Meanwhile, two batteries will be
charged.
2.14.1 Starting Group
1. The Starting Group is composed of starting motor, battery relay (power switch) and
starting switch.
2. When starting switch is set to “On” position, the battery relay is switched on to make the
battery negative pole be connected with the unit body. It means that the machine is in normal
starting state.
3. When the starting switch is turned clockwise to “Start” position further, the electromagnetic
coil on the starting motor is turned on and the gear pushed out, at the same time, the starting
motor switched on to make the diesel engine operated (the starting time normally is within 3-5
seconds).
4. After diesel engine running, the output voltage at generator midpoint is connected to the
timer to accumulate operating time of the diesel engine.
5. To stop the diesel engine, the starting switch must be counterclockwise turned to the end
(automatic reposition). At this time, the stop electromagnet above starting motor is attracted to
close the throttle at the oil spray pump, so the diesel engine stops.
2.14.2 Charging Group
1. The Charging Group is composed of AC generator and volt gauge etc.
2. The AC generator is the self-rectified one with an integrated circuit regulator. The output
voltage is 28V and the output current is 50A.
3. The generator is a maintenance-free one due to its integration. Just pay attention to the
tension of the generator belt, which drives the generator.
4. The volt gauge will indicate the output voltage of the generator after the engine is started.
2.14.3 Lighting Group
The lighting of machine is composed of front lamp, rear lamp, ceiling lamp and gauge lamp,
which are controlled by the light switch on the instrument box (ceiling lamp in the cab is
provided with switch).

92
Schematic diagram of electrical system (Fig. 2-125):

Fig. 2-125 Principle of electrical system

93
2.14.4 Battery
When the diesel engine runs, the starting switch shall always be in ON position so that the
generator will charge the battery. When the diesel engine stops running, it is not
recommended to use the lighting and other electrical equipment for long time, or the battery
will suffer from excessive discharging which will have impact on next start. If the starting motor
is used when the battery has seriour lack of power (electrolyte level lower than 1.175), both
the battery and the starting motor will be damaged. In such case, charge the battery at first
and then use it. When checking or operating the battery, turn off the egine and turn the key to
OFF position befor starting.
Hydrogen generated by the battery may cause explosion.
Do not let the ignited flame approach the battery or do things causing spark.
The electrolyte of battery is thinned vitriol which may burn your clothes or skin. Flush
with a lot of water when splashing to your clothes or skin. Flush with fresh water and see
doctor if splashing into your eyes.
When disassembling the battery, first disconnect the cable (usually the negative pole) from the
bond. When assembling, connect the positive pole at first.
Prevent the tool from touching the cable and frame connecting the positive pole, or
spark may occur.
When mounting the terminals, tighten them. Prevent from positive pole touching
negative pole. If the terminals are too loose, there may be danger such as spark or explosion.
2.14.5 Fuse box
The fuse box is located in the left battery cover (Fig. 2-126).

Fig. 2-126
The fuse box is used to protect the electrical equipment. Its specification shall meet the
requirement of the circuit diagram. If the fuse is burn out too many times (or burn out after
being replaced) during working, check it immediately to eliminate the failure. Before replacing
the fuse, disconnect the starting switch. If the fuse is eroded, white powder is visible, or the
fuse is loosened from the base, replace it with the one having the same capacity. Do not
change the specification and material of the fuse, or the electrical equipment may be
damaged.

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Specification and control circuit of fuse: (Fig. 2-127)

No. Cap. Circuit Remark

①A 30A Cab
①B 30A Lighter, standby
② 5A Instrument
③A 40A A: heating pan
③B 40A B: A/C
④ 30A Starting
A: front lamp, gauge
⑤A 15A
lamp
⑤B 15A B: rear lamp
A: horn, reverse
⑥A 20A
alarm
B: ether starting,
⑥B 20A
warm air

Fig. 2-127
2.14.6 Other Group
The dozer is provided with horn (Fig. 2-128), fan (Fig. 2-129), front and rear windscreen wiper
and lighter etc.

Fig. 2-128 Fig. 2-129

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2.15 Fuel supply system
Fuel tank is located at the rear part of machine. The fuel is injected into the fuel tank via filter
screen. The dipstick can be seen after filler cap removing. The fuel flows into fuel pump and oil
filter via the fuel tank. The fuel shutoff valve and the water drain valve are installed in the rear
of the oil tank.

1. Oil tank 2. Fuel filter 3. Dipstick 4. Water drain valve 5. Fuel shutoff valve 6. (PT)

Fuel spray pump

Fig. 2-130 Fuel supply system

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 Chapter 3 Instrument, Switch and Control Device
3.1 Arrangement of instrument, switch and control device (Fig.
3-1, Fig. 3-2, Fig. 3-3, Fig. 3-4 and Fig. 3-5)

⑶
⑷
⑺
⑵ ⑻
⑼
⑽

⒇
4. Blade control lever 9. Brake lock
lever 10. Blade lock lever

Fig. 3-2 Instrument, switch and control device

⒀
1. Accelerator control lever 2. Steering ⑿ ⒁
control lever (left) 3. Steering control lever
⑾ ⒂
(right) 7. Transmission lock lever 8. Gear
shift lever 20. Horn switch
Fig. 3-1 Instrument, switch and control
⒃
⒅ ⒄
device
11. oil pressure gauge 12. water temp. gauge
13. volt gauge 14. torque converter oil temp.
gauge 15. timer 16. lighter 17. starting switch
18. electrical control switch group 1
Fig. 3-4 Instrument, switch and control device
⑸

⑹ (21) ⒆

5. decelerator pedal 6. brake pedal 19. electrical control switch group 2 21. ceiling lamp switch

Fig. 3-3 Instrument, switch and control Fig. 3-5 Instrument, switch and control device

device

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3.2 Operation of instrument, switch and control device
3.2.1 Starting switch
There are four positions on this switch: FLAME OUT, OFF, ON and Start. (Fig. 3-6)
OFF:
The key insertion position is OFF position and all of the
circuits are disconnected at this time.
ON:
Turn the key to ON position. In such case, the battery
relay is connected. The negative pole of the battery
connects to the relay bond. The power is on. Charging,
lighting and various instruments connect with the power.
Connect corresponding switch upon need.
START:
When the key is turned from ON to Start position, the engine is started. When the key is
released, it will be returned to ON position automatically。
★The time for key to stay at Start position should not be more than 10 sec.
FLAME OUT:
When the key is turned from ON to FLAME OUT position,
the engine is stopped.
3.2.2 Instrument
1. Oil pressure gauge (Fig. 3-7): The range of oil pressure
gauge is 0-10 bar (approx. 0-1MPa). It indicates the
pressure of engine lubricating oil. When the engine is
running, the normal working range is 3.15-4.85 bar.
★For cold start, sometimes the pressure is low. In such case,
preheating will be required.
Fig. 3-7 Oil pressure gauge
If the oil pressure is too low or too high, turn off the engine
immediately and check it. The work can be recovered only when the indicator is in the normal
range.

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2. Water temperature gauge (Fig. 3-8):
The range of water temperature gauge is 40-120℃. It
indicates the temperature of cooling water of the engine.
When the engine runs normally, the temperature range is
80-100℃. If the temperature is too high, reduce the speed of
the engine so that the indicator goes to the normal position.
Stop the engine and inspect the water level if necessary.

Fig. 3-8 Water temp.

3. Torque converter oil temperature gauge (Fig. 3-9): gauge

The range of oil temperature gauge is 50-150℃. It indicates

the temperature of hydraulic oil in the torque conveter. Its
normal working range is 50-120℃. If the temperature is too
high, reduce the working load and wait until the oil
temperature falls and the indicator goes to the normal position.

4. Volt gauge (Fig. 3-10): Fig. 3-9 Oil temperature gauge

⑴ Prior to normal operation:

It indicates the voltage of battery. If the indicator points to the
green area, i.e. higher than 24V, it means the battery is normal;
if it is lower than 24V, it means the battery voltage is too low and
start may be difficult. If the engine cannot be started, recharge
the battery.
⑵ During normal running:
It indicates the charging voltage. The indicator shall point to the
Fig. 3-10 Volt gauge
green area, i.e. approx. 28V. If the voltage is too low or too high,
find the reason and operate after troubleshooting.

5. Timer (Fig. 3-11):

It indicates the running time of the engine. The timer has 1
increment per each hour of running. The working time displayed
by the timer is the basis for periodic maintenance and failure time
judgment.

Fig. 3-11 Timer

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3.2.3 Electrical control switch group
Using of switch in the electrical system is relatively simple. All the switches are provided with
clear marks. Operate them as required. The rocker switch shall be subject to the printed figure.
Press the side with mark to start and release it to close.
1. Electrical control switch group 1 (Fig. 3-12): mounted on the instrument box
⑴ instrument lamp switch
④ ⑤
⑵ front lamp switch
⑶ rear lamp switch
① ② ③
⑷ ether start switch
⑸ warm air switch Fig. 3-12 Control switch group 1

2. Electrical control switch group 2 (Fig. 3-13:

mounted on the front top of the cab
⑴ front wiper switch
⑵ rear wiper switch
⑶ left door wiper switch
⑷ right door wiper switch
⑸ alarm lamp or radio switch

Fig. 3-13 Control switch group 2

3.2.4 Steering lever
Pulling the steering lever backward will realize left and
right turning of the dozer. The left lever controls left
turning and the right one controls right turning. To
ensure slow turning, pull the corresponding lever to
the half position so that the clutch disengages and the
dozer turns slowly. If the lever is completely pulled
backward, the dozer will turn around to the original Fig. 3-14 Steering lever

position. (Fig. 3-14)

3.2.5 Brake pedal

When the machine runs at high speed, step down the brake
pedal under the instrument box can stop the left side and the
right side of the machine. (Fig. 3-15)
Without desired brake, do not step on pedals.
★ Never use brake pedals except for emergency or brake.
Fig. 3-15 Brake pedal

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3.2.6 Brake lock lever
When parking, the brake pedals are stepped on and the lock lock
lever is placed in Lock to lock the brakes.
After parking, the brake pedals must be locked. (Fig.
3-16) unlock

Fig. 3-16 Brake lock lever

idling
3.2.7 Accelerator control lever full speed
To set the lever to low-idling position, push it to “l”. To set
lever to high-speed position, push it to “2”. (Fig. 3-17)
After setting the lever to low-idling position and then turning
the starting key to “OFF” position, the engine will be
stopped.

Fig. 3-17 Accelerator lever

3.2.8 Decelerator pedal

This pedal is used to reduce engine speed.
When arriving at the top of a slope, or when dumping earth
from a cliff, the machine will increase its speed with the sudden
loss of load. At this time slow down the machine by depressing
the decelerator pedal. (Fig. 3-18)

Fig. 3-18 Decelerator pedal

3.2.9 Gear shift lever

Three-speed forward and three-speed reverse travels can be
easily selected by simply shifting the gear shift lever to any
desired speed position (F: Forward, R: Reverse, N: Neutral). (Fig.
3-19)

Fig. 3-19 Gear shift lever

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3.2.10 Transmission lock lever
Lower the lock lever to lock it at neutral position.
When stopping the machine for a period of time, be
sure to turn the gear shift lever to Neutral and set it at the
unlock
lock position. (Fig. 3-20)
lock
3.2.11 Blade control lever
Fig. 3-20 Transmission lock lever
The control lever normally is located at the hold position ”2”.
To raise the blade, pull the control lever to the position “l”; To
lower the blade, push the control lever to the position “3”.
When push the control lever further to the position “4”, the
blade will be in floating state.
When operate straight-tilt blade, pull the control lever to the
“A” position to make the blade tilt right; pull the control lever
Fig. 3-21 Blade control lever
to “B” position to make the blade tilt left. (Fig. 3-21)

3.2.12 Blade lock lever

When the lock lever is set to upper position (A) to make the
blade under free condition, the blade can be lifted and tilted.
(Fig. 3-22)
When the lock lever is set to the lower position (B) to lock
the blade tilt control lever, the blade can be only lifted. When
the lock lever is set to such position, the blade will be
Fig. 3-22 Blade lock lever
locked.
During operation and maintenance the blade lock lever must be always placed at the
lock position. (Fig. 3-22)
3.2.13 Adjustment of operator seat
The machine is provided with adjustable operator seat. The operator may adjust the seat to the
optimal condition based on his/her own condition. (Fig. 3-23)
1. Head cushion
The operator seat is provided with head cushion which can move and be pulled off along the
height. The expansion link of the head cushion is provided with damp system allowing stepless
adjustment of cushion head to ensure the comfort of the operator in off hours other than
operation. High head cushion may have impact on the rear vision of the operator, so it is
necessary to be adjusted to the proper position during operation.

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2. Backrest
Pull up the lever in the spindle so that the
backrest will move towards the seat surface
automatically. To adjust the direction, apply
some force to the backrest. When the
backrest comes to a proper position, release
the lever to lock it automatically. Step
adjustment from 30° to 120° to the seat
surface is allowable.
3.Forward and backward adjustment
Pull the right rod under the mattress outward
to adjust the seat to the desired position
forward and backward. Then, release the rod.
Fig. 3-23 Operator seat
The seat will be locked automatically. The
adjustment range is ±75mm.
4. Load carrying
Turn the handle in front of the damp system to effect stepless load carrying adjustment. The
dial window is located on one side so that the operator can adjust to the optimal condition
suitable to his/her weight. Stepless adjustment from 50Kg to 130Kg is available.
5. Seat height
The seat is provided with manual adjustment through lifting. Lift the mattress along the height.
One-way circulation and three-step adjustment are provided. The range of adjustment is 30mm
per each step.
6. Waist support adjustment
The waist adjustment knob on the left of the back is used to adjust the curve of the waist
support so that the backbone of the operator can fit with the back for the most comfortable
adjustment.
7. Armrest
Adjusting knob is provided in the armrest. Turning the knob manually may effect stepless
adjustment. The armrests can be flipped up when unnecessary.

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 Chapter 4 Operation
4.1 Check before starting
★ Check before starting must be customarily carried out. Never neglect and be careless of it,
because it is concerned in person and machine safety.
4.1.1 Check for oil and water leakage
Check the machine around for oil and water leakage and such abnormality, especially check
the connections of high pressure hoses, hydraulic cylinder, final drive, thrust wheel, carrier
roller floating seals and radiator for tightness. If any leakage and abnormality are found out,
remove them.
4.1.2 Check for bolt and nut
Check the bolt and nut for tightness and retighten them if required. Particularly check the bolts
of air cleaner, sprocket segment, engine hood and track shoe.
4.1.3 Circuit check
Check electrical wire for breakdown, short circuits and loose terminals.
4.1.4 Cooling water level check
Remove the radiator cover “1” (Fig. 4-1) to check the water level. Add cooling water if it does
not reach the desired position.
When cooling water is too warm, loosen the cover “1” slowly to release the internal
pressure, then open it to prevent hot water from spraying.

Fig. 4-1 Check cooling water level Fig. 4-2 Check fuel level

4.1.5 Fuel level check

After removing cover pull out fuel dipstick “G” to check fuel level. (Fig. 4-2)
After shift fill up the fuel tank through the filler “F”.
★ Check and clean the breather hole in cover from time to time. If the hole is clogged, it may
have influence on fuel feed of engine.

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4.1.6 Oil level check of engine oil pan
Oil level should be between high and lower markets of the oil dipsticks “G”. (Fig. 4-3)
★ Oil should be added from the filler “F” if required, but oil level should not be over higher
marker. (Fig. 4-4)
★ Oil type should be in accordance with ambient temperature. Please select it according to
attached table: Sort and Consumption of Fuel, Coolant and Lubricant (See the attached table).
★ When checking oil level, the machine should be parked on the horizontal ground. The
check must be carried out 15 minutes later after engine stop.

Fig. 4-4 Engine oil pan inlet

Fig. 4-3 Check engine oil pan level

4.1.7 Oil level check of steering case

Oil level should be checked with the dipstick “G” and oil added from the filler “F” if required.
(Fig. 4-5)
★ When operating on more than 25 slope, adding oil till the level reach the higher marker.

Fig. 4-6 Oil level of transmission

Fig. 4-5 Oil level of steering case

4.1.8 Transmission (including torque

converter case) oil level check
Oil level should be checked with the dipstick “G” 15
minutes later after engine stop. (Fig. 4-6)
Add oil from the filler “F” if required. (Fig. 4-7)
Fig. 4-7 Transmission oil filler

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4.1.9 Check for travel of brake pedal
The standard travel of brake pedal is 95-115mm. In
case the travel is more than 115mm or the brake is
defective, please adjust it according to content of
the adjustment section. (Fig. 4-8)
Fig. 4-8 Travel of brake pedal

4.1.10 Check for service indicator of air

filter
When the window of service indicator of the air filter is
red, it means the element is blocked and shall be
cleaned or replaced immediately. (Refer to
maintenance chapter.) (Fig. 4-9)

Fig. 4-9 Service indicator of air filter

4.1.11 Check for instrument

Observe whether all the instruments operate normally. (Fig.
4-10)

★ The machine should be thoroughly checked, adjusted Fig. 4-10 Check for instrument

and repaired to make it operate normally. Then operate it

strictly according to the requirement of “Safety Notice”.

4.2 Procedure and method of

operation
4.2.1 Position check of all the control
levers before starting
Check for position of each control lever before
operating: (Fig. 4-11)
1. The fuel control lever is at engine idling position
(See Fig. 3-17). Fig. 4-11 Control lever
2. The brake lock lever is at lock position (Fig. 3-16).

106
3. Transmission gear sift lever is at the neutral position “N” (Fig. 3-19).
4. Transmission lock lever is at the lock position (Fig. 3-20).
5. The blade is on the ground and the lock lever is at the lock position (Fig. 3-22).
4.2.2 Starting engine
1. The fuel control lever is placed in low idling position (front end) (Fig. 3-17).
2. The starting key is set from OFF to START. The starting motor will drive the engine. After
starting engine release the key to make it return to ON position automatically (Fig. 3-5).
★Do not leave the key in Start position for more than 10 seconds.
★Restart the engine after 2 minutes when the previous start is failed.
★Observe the oil pressure gauge indicator after starting to decide whether the engine has built
up the lubricating oil pressure.
★When fuel is exhausted, it should be added before starting engine. Then the element of oil
filter should be full of fuel to make the air removed from the fuel system and restart engine.
★For cold start, see the “Cold weather operation”.
3. Preheat and check is required after starting engine.
⑴ Run engine at low speed and make sure the pressure gauge shows green range.
⑵ Pull fuel control lever to make middle-speed idling of engine for about 5 minutes.
⑶ Run the engine under load when the water temperature indicator is in the green area.
⑷ Check all gauges for proper operation.
⑸ Check for normal coloration of exhaust and any abnormal noise or vibration.
⑹ Check for oil and water leakage.
★ The process from (1) to (3) is called preheating. If the engine is cold and the engine oil
pressure is out of the required range after starting, wait until it falls into the required range and
then continue preheating.
★When preheating is over, avoid accelerating the engine abruptly.
★ When the engine has run for more than 20 minutes without load, apply load to it, or it may
run at low temperature, resulting bad burning, serious wear of moving parts, or even oil
accumulation in the turbocharger, which may cause oil leakage from the bottom of the turbine.
4.2.3 Operation of machine running
See Fig. 3-1, Fig. 3-2 and Fig. 3-3:
1. Unlock the lock lever (7), (9), (10) and release the blade control lever (4), brake pedal (6)
and gear shift lever (8).
2. Push the blade control lever (4) to the lift position “1” to raise the blade 40-50cm off ground.
3. Raise the ripper to the highest position (if any).

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4. Pull the fuel control lever (1) to increase the engine speed.
5. Push the horn button (20) to sound the horn.
6. Move the gear shift lever (8) to the desired shift to start machine.
★Step down the decelerator pedal when starting to reduce the engine speed for impact damp.
When start at sharp gradient, drive the engine at full speed, keep stepping down the brake
pedal, push the gear shift lever to 1st position, and slowly release the brake pedal so that the
dozer will move slowly.
★ If the gear shift lever does not move from the position, due to the action of the relief valve,
the dozer will not move even if the engine is started. In such case, push the lever to N position
and then to the desired position.
7. Gear shift of machine forward and backward
★ The machine can change speed during running, so no stopping will be required when
changing speed.
★ To change speed during running, step down the decelerator pedal. Change the speed after
the speed falls down to avoid impact which will cause damage to the machine.
8. Left/right turning (Fig. 4-12)
Pull left/right steering lever halfway backwards so that the left/right steering clutch disengages
and the machine turns slowly to the left/right.
9. Left/right pivot turn (not allowed in usual condition) (Fig. 4-13)
Pull left/right steering lever to the end backwards so that the left/right steering brake acts and
the machine makes a left (right) pivot turn.

Fig. 4-12 Left/right turn Fig. 4-13 Left/right pivot turn

108
10. Running on ramp
When running on a ramp, the longitudinal gradient shall not exceed 30° and no reverse is
allowed when creeping.
Neither gear shift nor passing through barrier is allowed on sharp ramp.
The machine running on ramp may suffer from lateral sliding easily, so drive the machine
at low speed in straight line. Never drive laterally on large ramp.
When falling gradient, pull the gear shift lever to the low-speed position and apply brake
with the engine. If the engine has overspeed, reduce the speed using the brake pedal.
★ When starting on sharp ramp, firstly step down the brake pedal, pull the gear shift lever to
“1” position and meanwhile release the brake pedal.
★ Do not stop the machine on a ramp unless in special condition. If it is unavoidable to stop
the machine on a ramp, the head shall face the downward side and the brake pedal shall be
locked. In case of large gradient, insert the blade into the earth to prevent from gliding of the
machine.
11. Turning on ramp
Pull left/right steering lever halfway backwards so that the left/right steering clutch disengages
and the machine makes a small turn leftward/rightward. (Fig. 4-14)
Pull left/right steering lever to the end backwards so that the left/right steering brake acts and
the machine makes a large turn leftward/rightward. (Fig. 4-15)

Fig. 4-14 Small turn on ramp Fig. 4-15 Large turn on ramp
In case of turning during gliding by right of the weight of the machine, the machine shall
turn opposite when the steering lever is pulled halfway.
Try to avoid turning on the ramp.
Do not turn on soft earth or clay soil.
Do not make pivot turn at high speed.

109
4.2.4 Running in water
Before going into the water, investigate the water depth and the condition of soil under
the water to prevent from accident due to too-deep water or being trapped in earth.
★ The carrier roller shall not be covered with water and the cooling fan shall not touch the
water.
★When working in seawater or other corrosive water, wash the machine with clean water after
finishing the work.
4.2.5 Running in desert
When running in desert or other flying particles, try to seal the machine and clean the air filter
from time to time.
★Provide desert-type air filter if necessary.
4.2.6 Stopping machine
See Fig. 3-1, Fig. 3-2 and Fig. 3-3:
1. Pull back the fuel control lever (1) to decrease engine speed (Fig. 3-17).
2. Move the gear shift lever (8) to the Neutral position (Fig. 3-19).
3. Depress the brake pedal (6) and lock it by lock lever (9) (Not locked for temporary stop) (Fig.
3-15 and Fig. 3-16).
4. Lock gear shift lever (8) by lock lever (7) (Not locked for temporary stop) (Fig. 3-20).
5. Turn blade control lever (4) to lower position “3” to make blade on the ground (Fig. 3-21).
6. Press the blade lock lever (10) to the lock position to lock the blade control lever (4) (Fig.
3-22).
7. When ripper is provided, descend the ripper onto the ground and then lock the ripper control
lever.
8. Stop engine:
★ Run engine at low speed for 5 min. and cool down the engine, then stop it. Otherwise, the
engine lifetime will be shortened.
Turn the starting key to FLAME OUT position; after the machine is stopped, take off the key.
4.2.7 Running under cold weather
It is difficulty to start engine due to too low temperature and freezing cooling water etc. It is
harmful to the engine. So the following measures should be taken:
1. The oil and water are selected according to the attached table: “Sort and consumption of
fuel, coolant and lubricant”.
⑴ Replace the lubricating oil of each device with specified low-viscosity oil;
⑵ Use light oil which is 5℃ lower than the ambient temperature for fuel;
⑶ Add antifreezing agent into the cooling water.

110
2. When temperature is lower than 0C, the appropriate antifreeze should be selected
according to the lowest temperature in order to prevent cooling water from freezing.
⑴ Use standard antifreezing agent. Do not use the one containing methanol or ethanol, or it
may cause failure of the engine.
⑵ Prior to adding antifreezing agent, completely drain the water in cooling system and clean
the inside. Fill the antifreezing agent after removing the scale deposit.
Antifreezing agent is inflammable, so avoid any possible fire.
Generally, antifreezing agent contains antirusting agent which includes alkali. Try to avoid
skin and eye exposure.
★ When the weather becomes warm, drain the antifreezing agent (excl. permanent
antifreezing agent), and fill clean water after washing the cooling system.
⑶ Following measures shall be applied when no antifreezing is provided:
a. The starting temperature of the engine thermostat is 79℃. Usually, even in cold season,
circulating water in cooling system is cold when the engine is running. Freezing may occur if
the water in radiator is standstill. In such case, the thermostat shall be removed and
meanwhile pay attention to the value of water temperature gauge. Keep the water temperature
normal.
b. After finishing the work each day, the cooling water in oil cooler, radiator and engine body
shall be drained completely to prevent from frost cracking of the machine.
★Water drained for freezing prevention is anticorrosive and can be reused next time.
c. Anticorrosive tank (if any) shall be removed after finishing the work each day to prevent from
freezing. Close the inlet and outlet valves of the tank. Seal the orifice. Wrap it with cloth. Place
it in warm place to prevent from freezing.
3. Particularly pay attention to that the snow and water on the piston of hydraulic cylinder
should be cleaned away; otherwise the cylinder may be damaged due to freezing.
4. When temperature drops, the battery ability may decrease. It normally makes the charge
capacity reduce and the electrolyte freeze. The charge level of battery should be kept to about
100 and isolated to prevent low temperature.
★ The relation between specific gravity of electrolyte and rate of charge is shown in the
following table.
Fluid temp.
20℃ 0℃ -10℃ -20℃
Charge rate
100% 1.28 1.29 1.30 1.31
90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26

111
★ If the electrolyte level drops, add distilled water in the next morning before operation to
prevent fluid from freezing at night.

4. Use of ether starting device (if any) (Fig. 4-16)

panel handle

To reservoir

Fig. 4-16 Use of Ether

⑴ Open the dust-proof cover of reservoir and press starting fluid into the reservoir.
Add appropriate starting fluid according to air temperature.
Temp. (℃) -10 -20 -30 -40
Adding capacity
10 20 25 30
(ml)
⑵ Push the engine fuel control lever to low idling position.
⑶ When starting engine, push and pull the handle of hand pump to make the engine start until
the engine operates normally.
⑷ When temperature is lower than -30C, spray some starting fluid beforehand, then start the
engine in time. At this time continue fluid injection until operation becomes stable.
⑸ During starting the fluid injection should be slowed down or stopped when strike occurs.
Adjust the spraying capacity to make engine start stable.
⑹ After successful starting the starting fluid left at the reservoir can be used for next time
starting.
★The starting fluid is selected in accordance with local temperature. When temperature is 0C
- -25C, the CH-20 starting fluid is used. When temperature is -10C - -40C, the CH-40
starting fluid is used.
The starting fluid should not be used together with air-induction preheater. Starting fluid
is inflammable and it should be kept away from fire and prevented from sunning.

112
 Chapter 5 Digging and Pushing

Select reasonable machine and equipment, adjust the equipments to requirement and apply
right operation method according to pushing job, can prolong machine lifetime and reduce
operator’s labor and raise working efficiency.
PD165Y-2 Bulldozer is designed for ordinary operating condition.
Blade is divided into straight-tilt blade and angle blade which are used for different terrain and
working object. Ripper is optional according to customer.
Its valid distance per trip should preferably be 70 meters at maximum. If longer, use of scraper
is more economical.

5.1 Cutting into hard and

frozen ground
Hard and frozen ground can be dug effectively
by a tilted or angled blade. If the ground is
harder, use a ripper for better efficiency. (Fig.
5-1)
Fig. 5-1 Hard and Frozen Ground

5.2 Leveling
Uneven ground surfaces remaining after digging
can be leveled off by the following methods (Fig.
5-2):
⑴ Operate the machine at low speed with the
blade fully loaded with soil and uneven ground is
Fig. 5-2 Leveling
filled and cut by advancing machine.
⑵ A flat finished surface is also possible by slowly
backing the machine with the blade fully “floating”.
★ However, avoid this on rocky ground, as it may
damage the blade.

5.3 Side pushing

Use the angle blade for single side pushing. (Fig. 5-3)
Do not use one end bit of blade for uprooting.
Fig. 5-3 Side pushing

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★ During earthmoving, try to avoid sharp starting, emergency brake and sharp turning as far
as possible.

5.4 Blade Operation

5.4.1 Angle blade operation
Angle blade operation (Fig. 5-4):

raise

lower

Fig. 5-4 Angle blade operation

1. When the handle is placed at (1) (raise position), the blade is raised.
2. When the handle is placed at (2) (hold position), the blade is stopped and held at this
position.
3. When the handle is placed at (3) (lower position), the blade is lowered.
4. When the handle is placed at (4) (float position), the blade can be floated up and down.
5.4.2 Straight-tilt blade operation
Straight-tilt blade operation (Fig. 5-5):
When the handle is placed at A or B, the blade will tilt right or left. The remaining four places
are similar to angle operation.

tilt right tilt left

Fig. 5-5 Straight-tilt blade

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5.5 Blade Adjustment
5.5.1 Level adjustment for angle blade
In case of single-side pushing, adjust the blade to 25°:
(Fig. 5-6)

Fig. 5-6 Level angle adjustment

1. Raise blade 40-50cm off ground and place a wood

under the pushing frame (Fig. 5-7).

Fig. 5-7 Level angle adjustment

2. Pull out pins (l) located at two sides (Fig. 5-8).

Fig. 5-8 Level angle adjustment

3. Remove the pushing arm (2) from the pushing
frame (Fig. 5-9).

After removing the pushing arm, pay attention to

free swing of end bit. Fig. 5-9 Level angle adjustment

4. Make the blade at an angle, then place the pushing

arm (2) on the desired position and lock it with pin (1) (Fig. 5-10).

Fig. 5-10 Level angle adjustment

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5.5.2 Vertical adjustment for angle blade
1. Raise blade 40-50cm off ground and place a wood under the pushing frame (Fig. 5-7).
2. Loosen the setting bolt (l) (Fig. 5-11).
3. Insert the adjusting lever into hole A on the upper support lever (2) and turn the adjusting
lever to lengthen or shorten the upper support lever (2).
Right tilt of blade: right side shortened and left side lengthened; left tilt of blade: left side
shortened and right side lengthened.
4. When tilting to the desired height, fix the blade with bolt (1).

★ The tilt amount can be Fig. 5-11 Vertical

adjusted to max.angle adjustment
400mm (5°30′) which cannot be exceeded (Fig.
5-12).

Fig. 5-12 Vertical angle adjustment

5.5.3 Vertical adjustment for straight-tilt blade
The blade control lever is placed at A or B (right or left)
side (Fig. 5-5) and the blade can right tilt 470mm, or left
tilt 445mm.
Furthermore, if turn the adjusting lever (2) once more to
make the brace (1) stretch or shorten, the left and right
maximum tilt can reach about 860mm (Fig. 5-13).
When the blade is located at the highest or lowest
position, the left and right tilt can not be controlled.

Fig. 5-13 Vertical angle adjustment

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5.5.4 Cutting angle adjustment
The standard blade cutting angle () is 55.
The arm length (L) can be adjusted to the optimum length by lever (1) according to different
soils (Fig. 5-14).

Fig. 5-14 Cutting angle adjustment

5.6 Method to prolong machine lifetime
Machine lifetime, especially undercarriage lifetime greatly varies depending on maintenance
and operation method. For this purpose keep the following points in mind:
1. Select the track shoe that best suits the type of soil.
2. Do not allow shoe slipping to occur during operation. If shoe slipping occurs, reduce load
until slipping stops.
3. Avoid sudden start, acceleration and unnecessarily high speed travel and sudden brake and
sharp turns as far as possible.
4. Always operate machine in a straight line whenever possible. When making turns, be
careful not to allow the machine to stay to one side, so operation in both turning directions can
be done properly. Make turns with the largest possible radius.
5. During operation, when the ground inclines to the right or left, do not always operate there.
Reverse the machine to the horizontal and resume
operation.

6. Never make machine travel over large hard

obstacle and work on it, otherwise idle and sprocket
will leave ground (Fig.5-15).

Fig. 5-15 Prolong life cycle

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7. Working along a slope machine moves down hill.

Never make transverse travel across slope. Don’t

reverse when moving up along slope (Fig.5-16).

8. Before operation, clear off large rocks and other

Fig. 5-16 Prolong life cycle
obstacle on site.

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 Chapter 6 Maintenance and Service
6.1 Precaution
To prolong machine lifetime, assure person-machine safety, raise working efficiency and
increase economic coefficient.
In addition to reading the requirement concerned mentioned in “Safety Notice”, operator and
serviceman must also observe the following precautions.
1. Serviceman must be familiar with the machine structure, performance,
assembly-and-disassembly procedure, technical requirement and precaution before handle it.
2. For difficult service and maintenance item, the best way is to consult the manufacturer if you
can not handle it.
3. Routine maintenance should be made before machine starting and after each shift. Before
maintenance park machine on the horizontal ground, lower blade and lock out locking device,
then make maintenance.
4. For maintenance with engine operated, two persons are required to incorporate. One
person sits down in cab and the other makes maintenance. Be careful that your body never
contacts moving parts.
5. Before maintenance, the place around maintenance part should be thoroughly cleaned and
washed, especially the place around filler, filter, fitting and case cap cleaned to prevent dust
from entering oil.
6. Keep in mind that high pressure exists in hydraulic circuit. Before you add oil, drain off oil
and make check and maintenance, release the pressure first.
7. Pressure release procedure is as follows: lower blade and ripper on the ground, shut down
engine and set the control lever of hydraulic system to each shift gear 2-3 times in succession,
then slowly loosen oil cap or pipe connection.
8. Before oil change drive machine to make oil temperature rise to 30C-40C, then drain off it.
Use clean oil and grease.
9. Oil check and change should not be carried out on site in dust cloud. Otherwise dust could
enter oil.
10. Never handle electric system, wearing raincoat or in rain.
11. Be careful that spray hot water may hurt person when checking and adding cooling water.
12. Remove air from oil circuit after oil filter element and strainer are replaced.
13. Never add oil with screen of filler removed.
14. Before gearbox maintenance empty your pocket. Be careful that dropping spanner and nut
etc. into the gearbox may result in trouble.
15. Oil must be kept away from fire and never replace lighting with fire.
16. Thoroughly wash parts surface before O-ring, gasket or other seals are changed and then
they should be assembled carefully.

119
In order to make you thoroughly know and master maintenance items and content in different

period give the following table.

★For engine maintenance concerned, see the engine operation manual

No. Item Content Section

Check before starting 4.1

1 Check for oil and water leakage Check 4.1.1

2 Check bolt and nut Check and tighten 4.1.2

3 Check circuit Check and process 4.1.3

4 Check cooling water level Check and supply 4.1.4

5 Check fuel level Check and supply 4.1.5

6 Check oil level in engine oil pan Check and supply 4.1.6

7 Check oil level in steering case Check and supply 4.1.7

Check oil level in transmission
8 Check and supply 4.1.8
(including torque converter)
9 Check brake pedal travel Check and adjust 4.1.9

10 Check service indicator of air filter Check 4.1.10

11 Instrument Check 4.1.11

Service per 50h 6.2

Drain off water and
1 Fuel tank 6.2
settlement
Service for initial 250h 6.3

1 Fuel filter Change element 6.3 ⑴

Change oil and filter
2 Engine oil pan and filter 6.3 ⑵
element
Transmission and torque Change oil and clean
3 6.3 ⑶
converter screen
Change oil and clean
4 Steering case 6.3 ⑷
screen
5 Final drive case Change oil 6.3 ⑸
Change oil and filter
6 Hydraulic oil tank and filter 6.3 ⑹
element
7 Engine throttle clearance Check and adjust 6.3 ⑺

Service per 250h 6.4

Check all greasing points 6.4.1

1 Equalizer bar Lubricate 1 point 6.4.1 ⑴

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No. Item Content Section

2 Brace Lubricate 6 points 6.4.1 ⑵

3 Cylinder support Lubricate 4 points 6.4.1 ⑶

4 Cylinder support shaft Lubricate 2 points 6.4.1 ⑷

5 Piston rod bearing Lubricate 2 points 6.4.1 ⑸

Check oil level 6.4.2

1 Final drive case Check and supply 6.4.2 ⑴

2 Hydraulic tank Check and supply 6.4.2 ⑵

Change steering filter element Change filter element 6.4.3

Transmission filter Change filter element 6.4.4

Battery electrolyte level Check 6.4.5

Drain off water and
Fuel filter 6.4.6
settlement
Fan belt Adjust tension 6.4.7

Radiator, carbon fin Check and clean 6.4.8

Track shoe bolt Check and tight 6.4.9

Service per 500h 6.5

1 Fuel filter Change filter element 6.5.1

Change oil and filter
2 Engine oil pan and filter 6.5.2
element
3 Anti-corrosion device (if any) Change filter element 6.5.3

4 Breather Clean 6.5.4

Service per 1,000h 6.6

Lubrication 6.6.1

1 Universal joint Lubricate 2 points 6.6.1 (a)

2 Pin shaft of track frame brace Lubricate 2 points 6.6.1 (b)

3 Track tension cylinder Lubricate 2 points 6.6.1 (c)

Transmission and torque Change oil and clean
6.6.2
converter filter screen
Steering case (including bevel Change oil and clean
6.6.3
gear case) filter screen
Final drive case Change oil 6.6.4
Change oil and filter
Hydraulic oil and filter 6.6.5
element
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No. Item Content Section
Check lubrication
Thrust wheel, carrier roller and idler 6.6.6
condition
Anti-corrosion device (if any) Replace 6.6.7

Service per 2,000h 6.7

1 Engine intake and exhaust Clean and check 6.7 (a)

2 AC generator and starting motor Check and replace 6.7 (b)

3 Engine throttle clearance Check and adjust 6.7 (c)

4 Engine damper Check and replace 6.7 (d)

Service per 4,000h 6.8

1 Water pump Check 6.8

Service as required 6.9

1 Track Check tension 6.9.1

2 Air filter Check, clean or change 6.9.2

3 Cooling system Clean 6.9.3

Lubrication 6.9.4

1 Brake pedal shaft of steering clutch Lubricate 2 points 6.9.4 (a)

2 Decelerator pedal shaft Lubricate 1 point 6.9.4 (b)

3 Gear shift lever shaft Lubricate 1 point 6.9.4 (c)

4 Blade control lever shaft Lubricate 2 points 6.9.4 (d)

Electric heater for air inlet Check 6.9.5

Track shoe bolt Check and tighten 6.9.6

Master link Check and tighten 6.9.7

End bit Upside down or change 6.9.8

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6.2 Description of service per 50h
Fuel tank
Loosen the valve at bottom of fuel tank to drain off impurity and mixture of oil and water.

6.3 Service after initial running for 250h

1. Fuel filter
2. Engine oil pan and filter
3. Transmission (including torque converter)
4. Steering clutch case
5. Final drive case
6. Hydraulic oil and its filter
7. Engine throttle clearance
For the detail method of maintenance, see the content of services per 500 hours, 1,000 hours
and 2,000 hours.

6.4 Description of service per 250h

★ Maintain according to the content of 50 hours service at
the same time.
6.4.1 Check each greasing point
Please grease according to the arrowed points.

1. Equalizer bar (Lubricate 1 point) (Fig. 6-1)

Fig. 6-1 Equalizer bar

2. Brace of equipment (Lubricate 6 points) (Fig. 6-2)

Fig. 6-2 Blade Brace

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3. Cylinder support (Lubricate 4 points) (Fig. 6-3)
4. Cylinder support shaft, Lubricate 2 points (Fig. 6-4)

Fig. 6-4 Cylinder support shaft

Fig. 6-3 Cylinder support
5. Piston rod bearing, Lubricate 2 points (Fig. 6-5) 滑

6.4.2 Check oil level (Machine is placed on the

horizontal ground)
1. Final drive case (Fig. 6-6)
Loosen the oil plug “F” to check oil level in the case. If the oil
level is lower than the hole edge, supply oil to the hole edge.
Fig. 6-5 Piston rod bearing

Fig. 6-6 Oil level in final drive case

2. Hydraulic tank (Fig. 6-7)

Shut down machine for approx. 5 minutes, then check it.
If the oil level is not between the upper and lower lines
of oil gauge “G”, add the appropriate hydraulic oil from
filler “F”.

Fig. 6-7 Oil level in hydraulic tank

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6.4.3 Change of steering filter element

1. Remove the floor.

2. Remove bolt (1) and cap (2), then pull out filter element (3) from the case (Fig. 6-8).

3. Clean case interior and the removed parts. A new filter element is used when required. After

refresh oil into the case, fix the cap (2) with bolt (1).

4. After assembling the filter element, loosen the air plug (4), start the engine until the oil

overflows, then retighten the air plug (4).

Fig. 6-8 Change steering element

6.4.4 Change of transmission filter element

1. Remove the floor.

2. Dismount bolt (1), remove cap (2) and pull out filter element (3) from filter (Fig. 6-9).

3. Clean the case interior of filter and the removed parts from it, then assembly a new filter

element. After filling oil, tighten bolt (1) and close cap (2).

4. After changing filter element, loosen air plug (4) and start engine until no air bubble appears

and oil overflows from the air plug (4), then tighten the air plug (4).

Fig. 6-9 Change transmission filter element

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6.4.5 Battery electrolyte level
The machine is provided with maintenance-free battery which requires no service and
maintenance in general (Fig. 6-10).
The charge indicator A of battery shall be always green or the open-circuit voltage shall
be 12.45V or higher.

Fig. 6-10 Battery

If non-maintenance-free battery is used by the

user, proper maintenance and service shall be
provided by the user (Fig. 6-11).
If the electrolyte level is lower than the setting
value (about 10-12mm on pole plate), the distilled
water should be supplied. The electrolyte has
Fig. 6-11 Battery
been changed due to leakage of sulphuric acid, so
the sulphuric acid of the same density should be added.
When checking the electrolyte the through hole on the battery cap should be
cleaned .The battery should be kept away from fire.
6.4.6 Fuel filter
Remove water and settlement (For detail, see the engine operation manual).

6.4.7 Fan belt

1. The belt sag should be measured by a 6 kg
pressure between fan pulley and engine pulley.
The suitable sag is not more than 10mm.
2. When the belt should be adjusted, loosen the
fixed tension nut and tighten the adjusting bolt to
tension the belt (Fig. 6-12).
★ Check the pulley for damage and check the
V-slot and belt for wearing and the contact for
Fig. 6-12 Fan belt
suitability.
★ If the belt has been stretched, but can not be adjusted further, or is broken, the two belts
must be replaced at the same time.

126
6.4.8 Radiator and heat sink
Loosen bolt (1), open radiator guard (2) and clean heat sink of
mud or other things with compressed air or vapour (Fig. 6-13).
★Check the belt for damage or other defect.
★Check the clamp for looseness.

Fig. 6-13 Radiator and heat sink

6.4.9 Track shoe bolt

If the track shoe bolt is loose, it will result in damage.
The bolt should be tightened in time, even if one bolt
is loose.
Tightening torque: 745±59Nm
Initial torque: 294±30Nm. Then tighten the bolt with
torque of 1,200±100 (Fig. 6-14).
★ There are central holes on two ends of master pin Fig. 6-14 Track shoe bolt

of the track.

6.5 Description of service per 500h

★Maintain according to the content of service per 50 hours and 250 hours.

6.5.1 Fuel filter

Change filter element (See the engine operation manual for detail).

6.5.2 Engine oil pan and filter

Change oil and filter element (See the engine operation manual for detail).
★The oil must be changed once every 6 months regardless of working time.

6.5.3 Anti-corrosion device

Change filter element (if any, see the engine operation manual for detail).

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6.5.4 Breather

Remove the breather and clean breather interior

of dust with diesel oil.

1. Transmission breather (Fig. 6-15)

Fig. 6-15 Transmission breather

2. Breather of steering case (Fig. 6-16)

Fig. 6-16 Breather of steering case

3. Breather of final drive case (Fig. 6-17)

Fig. 6-17 Breather of final drive case

6.6 Description of service per

1,000

Maintain according to the content of service per

50, 250, 500 hours at the same time.

6.6.1 Lubrication

(as indicated by the arrow)

Fig. 6-18 Universal joint

1. Universal joint (2 points) (Fig. 6-18)

128
2. Pin shaft of diagonal brace track brace (2 points) (Fig. 6-19)

Fig. 6-19 Pin shaft of diagonal brace

track brace
3. Track tension cylinder (2 points) (Fig. 6-20)

Fig. 6-20 Track tension cylinder

6.6.2 Transmission and torque converter case

Clean and teplacement of strainer and filter of transmission and torque converter case (Fig.
6-21):
1. Remove the cover under the machine.
2. Unscrew the drain plugs ① and ② to d rain the oil and tighten them after drain.
3. Unscrew the bolt ③, and remove the cover ④ together with the strainer of torque converter.
4. Remove the tube ⑤, unscrew the bolt ⑥, and then take off the cover ⑦. Take out the strainer
of transmission together.
5. Clear off the dirt adhered to the strainer and clean the inside of the strainer and the case
with clean diesel oil.
6. Reassemble the strainer.

torque converter Transmission

Fig. 6-21 Transmission and torque converter
strainer

129
7. Replace the filter element of transmission as required in the content of service per 250h.
8. Fill the specified amount of oil through inlet “F” (Fig. 4-31).
9. Refer to the inspection item and confirm the specified oil level.
★Amount of changing oil: 52L

6.6.3 Steering clutch case and central

transmission case
1. Remove the drain plug (P) located at lower part of case,
drain off oil, then retighten the drain plug (Fig. 6-22)

Fig. 6-22 Steering case

2. Remove the floor on the left of the cab.

3. Remove the strainer bolt ① to take off the cover ② and take
out the spring ③ and screen ④ (Fig. 6 -23).

4. Reassemble after washing the screen and other

disassembled parts. Replace the screen if it is broken.

5. After replacing the screen, fill the specified amount of oil

Fig. 6-23 Strainer
from the inlet “F” (refer to service per 250) (Fig. 6-24).
★Amount of changing oil: 52L

6.6.4 Final drive case Fig. 6-24 Steering case

Remove oil injection plug (F) at two sides first, then take out
drain plug (P) and retighten the drain plug after draining off oil.
An amount of oil is added from filler (F). (See the description of
service per 250 hours.)

Fig. 6-25 Final drive case

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6.6.5 Hydraulic tank and filter
Change hydraulic oil and wash the filter (Fig. 6-26):
1. Lower blade on the leveling ground and stop engine. Turn blade control lever
forward-backward and left-right each for one time, then slowly loosen cap of filler (F) and take
out the cap after removing air from case.
2. Loosen off drain plug (P) under the hydraulic tank and empty the tank, then retighten the
drain plug.
3. Remove bolt (1) and take out cap (2) and the filter element. Wash the removed parts and
change for new filter element.
4. Fill new oil to the indicated oil level from filler (F) (see the description of service per 250
hours).

6.6.6 Thrust wheel, carrier

Fig.roller and guide
6-26 Change hydraulicroller
oil and clean filter

Lubrication of thrust wheel, carrier roller and guide roller (Fig. 6-27):
1. Park the machine on the level ground. Check thrust wheel, carrier roller and guide roller for
oil consumption one by one.
2. Slowly loosen the sealed bolt. If oil leaks, tighten it immediately.
3. If there is still no oil leak after the bolt is loosened off, it means that the oil is too small.
Consult with manufacturer about it in time.

Fig. 6-27 Lubrication of thrust wheel, carrier roller and guide roller
6.6.7 Anticorrosion device
Anticorrosion device (if any) shall be replaced as required in the manual of engine.

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6.7 Description of service per 2,000h
Maintain according to service per 50, 250, 500 and 1,000 hours at the same time.
1. Engine intake and exhaust device
Wash engine intake and exhaust pipe and check sediment in pipe and check pipe for damage.
Change it when required (See the engine operation manual for detail).
2. AC generator
⑴ Provide the generator with maintenance each time when the machine has worked for
1,000h. Carefully clean the slip-ring to make it smooth and clean. Check the carbon brush. If it
is seriously worn, replace it.
⑵ Apply lithium base or sodium base grease to the bearing.
Precaution of using generator:
★ Do not check whether the generator works normally through positive-to-ground strike, or the
rectifier diode may be broken.
★ The tension of V-belt of the generator shall be proper. Generally, the center section of the
rubber belt can be pressed down by 10-15mm.
★ If machine often operates at night, repair it once every 1,000 hours (See the engine
operation manual for detail).
3. Starting motor
The starting motor shall be provided with maintenance each time when the machine has
worked for 1,000h. Check the commutator and electric brush. If the surface of commutator is
seriously burn, polish it with fine sand paper. The electric brush shall be replaced immediately
if it is seriously worn or broken. Apply lubricating oil to moving parts such as bearing.
4. Engine throttle clearance
Adjust throttle clearance (For detail see the engine operation manual).
5. Engine damper
Check rubber surface of damper for crack and fracture. Change it if any.

6.8 Description of service per 4,000h

Maintain according to service per 50, 250, 500, 1,000 and 2,000 hours at the same time.
Change water pump for relaxation and leakage. If the above situation occurs, repair or change
it.

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6.9 Service when required
Check and maintain the following places ifrom time to time.
6.9.1 Track tension
Due to different operating conditions and soil conditions, the tension of track shall be detected
from time to time upon the change of wear so that it will remain in standard tension condition.
Detection and adjustment shall be carried out in the condition same as the operating condition:
1. Inspection and repair (Fig. 6-28)
Park the machine on level ground (do not apply
brake when going forward). Place a straight bar on
track between carrier roller and guide roller. The
measurement should be made at middle position.
If the distance between the bar and grouser is
20-30mm, it means that the tension is suitable.
Fig. 6-28 Track tension
Make proper adjustment if the tension is out of the
standard.
2. Adjustment (Fig. 6-29)
① To increase the tension, fill the grease through
pressurizing with the oil lubricator ①. To decrease the
tension, loosen the oil lubricator ① counterclockwise by
1 turn to drain the grease.
The high-pressure grease in the cylinder may be
Fig. 6-29 Track tension
injected. Never loosen the oil lubricator ① by more than
1 turn. In such case, do not loosen other parts. If the
grease does not overflow smoothly, move the machine
slightly forward and backward several times.
② If the track is still loose after filling grease, it means
the pin sleeve is seriously worn. Reverse or replace the
pin sleeve.
★The injected grease can make the adjusting clearance
Fig. 6-30 Track tension
“S” to 0. If this limit is reached, but the track tension is
still not enough, it means that track pin and pin sleeve are worn out seriously and they must be
changed (Fig 6-30).

133
6.9.2 Air filter
For specific maintenance of air filter, please refer to the use and maintenance manual of diesel
engine.
1. Inspection (Fig. 4-9)
When the sight glass of maintenance indicator of the air filter is red, it means the air filter
element is blocked. Turn off the engine immediately and wash or replace the element.
2. Clean and change external filter elemen (Fig. 6-31)
① Remove bolt, cap and external filter element.
② Clean filter case interior and cap.
③ Clean and check filter element and assemble it (See Section 6.9.2.4 “Clean external filter
element”).
★ When the external filter element was cleaned 6 times or used for one year to time limit, it
should be changed at the same time together with the internal filter element.
★When sealing washer (5) and wing nut (4) are damaged, they must be changed at the same
time (Fig.6-32).

Fig. 6-31 Air filter Fig. 6-32 Air filter

★ With just cleaned external filter element, if the sight glass is still red, the internal and
external filter elements must be also changed together even if the external filter element is
cleaned less than 6 times.
★Check and tighten fixed nut of internal filter element.
3. Change internal filter element
① Remove cap and external filter element and take out
internal filter element.
② Seal air inlet to prevent foreign matter entering into the
engine pipe.
③ Clean case interior of air filter.
Fig. 6-33 Clean external element
④ Tighten a new internal filter element to connector by nut.
⑤ Assemble external filter element and cap.
★Absolutely do not reassemble the used internal filter element.

134
 When cleaning and changing filter, do not start engine.
4. Clean external filter element (Fig. 6-33)
① Cleaning with compressed air: Blow the interior of the external filter element with dry
compressed air (less than 0.7MPa) along the internal wrinkle, and then blow it along the
external wrinkle. Finally do the interior repeatedly until it is cleaned.
When using compressed air, wear safety goggles and the other safety protection.
② The following several methods are in need of spare filter element.
Using tap water: Use tap water of the pressure less than 0.3MPa to flush the inside and
outside crease of the element repeatedly. Check when it is dry.
Using detergent: Use warm solution containing neutral detergent to clean the element and
flush it with clean water. Dry it.

6.9.3 Clean the interior of cooling system

For cleaning cooling system interior, changing antifreeze and anti-corrosion device (if any),
see the following table:
Antifreeze should be kept away from fire because it is inflammable.
Antifreeze type Interval of cooling system
Interval of anti-corrosion
interior cleaning and
antifreeze change device change
Permanent Every year (autumn) or every
antifreeze(suitable for all 2,000 hours
seasons) Every 1,000 hours service or
Other than permanent Every year (autumn) or first
antifreeze including ethylene 2000 hours operation when cleaning cooling
glycol base (suitable for
system interior or changing
one season in winter)
Antifreeze is not used Every 6 months (spring and cooler
autumn), (exhausted in spring
and added in autumn)
The proportion of cooling water to antifreeze is determined by the following table, referring to
local former lowest temperature.
The temperature below 10C is better when determining mixing proportion.
The mixing proportion of water to antifreeze is as follows:
Lowest atmospheric
-5 -10 -15 -20
temperature (C)

Total of antifreeze (L) 14.5 19 22.5 26

Total of water (L) 48.5 44 40.5 37

⑴ Shut down engine and tighten vale of anti-corrosion device (if any).

135
⑵ Slowly loosen off filler cap (1) of radiator (Fig. 4-1).
Be careful that spraying hot water will hurt person.
⑶ Open the drain valve (Fig. 2-3) at the bottom of the radiator to drain the cooling water.
⑷ Close the drain valve and fill tap water from the inlet until the water level approaches the
inlet.
⑸ Run the engine at high speed, and open the drain valve until water is trained off and stop
the engine 10 minutes later.
★During flushing, adjust flow of added water to make radiator full of water.
⑹ After rinsing, drain off water and then close drain valve.
⑺ Clean cooling system once more with detergent according to its instruction.
⑻ After cleaning with detergent water, drain off it, and then close the drain valve and fill up
cleaning water (running water).
⑼ Run the engine at high speed and open all drain valves to make water pass through cooling
system until cleaning water is drained off from drain valve.
★ During flushing, adjust water flow to make injecting water capacity equal to draining water
capacity and radiator full of water.
⑽ After water thoroughly becomes clear, shut down the machine, and close drain valve.
⑾ Change filter element of anti-corrosion device and open its valve (if any).
⑿ Add cleaning water until it overflows from water filler.
⒀ Run the engine at low speed for 5 minutes and then at high speed for 5 minutes to exhaust
cooling system of air (Water filler is open at this time).
⒁ Stop the engine and wait for 3 minutes, then supply water to the indicated level, finally
tighten water filler cap.

6.9.4 Lubrication
Apply the lubricating oil to the place showed by the arrow:

1. 1 place at steering clutch brake pedal shaft (Fig. 6-34)

Fig. 6-34 Brake pedal shaft

2. 1 place at decelerator pedal shaft (Fig. 6-35)

3. 1 place at gear shift lever shaft

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Fig. 6-35 decelerator pedal shaft
4. 2 places at blade control lever shaft (Fig.6-36)

6.9.5 Check air intake preheater

Fig. 6-36 Blade control lever shaft
Iif any, see the engine operation manual for detail

6.9.6 Check and tighten track shoe bolt

See 6.4.9.

6.9.7 Check and tighten master link

If any:
1. Tighten bolt with 30030Nm torque first. Then check contact surface of master link for
tightness.
2. After checking for tightness retighten the bolt by 18010.

6.9.8 Upside up or change end bit and cutting edge

1. One side of end bit and cutting edge is worn out, while the other is well, turn over or rotate
them to reuse. Otherwise replace them.
2. After removing cutting edge and end bit, clean the related mounting face, then assemble
them.
3. The tightening torque of nut is 45050Nm.
4. After checking and assembling, running for several hours, retighten the nut.

★When end bit, cutting edge, bolt and nut are worn out
or damaged, they must be changed in time and blade
body must not be damaged (Fig. 6-37).

Fig. 6-37 End bit and cutting

edge

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6.9.9 Change fuse
The fuse is mainly used to protect the electrical parts and conductors. When the fuse is burn
out or oxidized or loose from the bracket, it shall be replaced.
Replace the fuse with the one having the same specification.

6.10 Adjustment
6.10.1 Adjust brake pedal travel
When brake disc is worn out, the brake pedal travel will increase. At this time the clearance
between brake drum and brake disc should be adjusted.
When the standard clearance between brake disc and brake drum is 0.3mm, the pedal travel
is 95-115mm (Max. travel: 115mm) (Fig. 4-8).

1. Remove the rear cover (Fig. 6-38).

2. Remove the brake case cover (1). Tighten the adjusting Fig. 6-38 Rear cover

nut (2) with 90N·m torque so that the brake belt

holds against the brake drum (Fig. 6-39).
3. After brake band contracts brake drum, loosen nut
(2) by 1＋5/6 turns to make the clearance between
brake disc and brake drum reach 0.3mm.
Accordingly, the brake pedal travel is 95-115mm.
★ After adjustment, if the brake is not functioned, it
Fig. 6-39 Brake adjustment
should be repaired.
★After shutdown depress the brake pedal (with force of 300N) to measure break pedal travel.

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6.10.2 Adjust guide roller clearance
The cover (2) is clamped on left and right guide roller
bracket with a clearance of 0.5-1.0 to side face of
track frame to force idler move along track roller frame
guide. Therefore, when guide roller moves, the cover
(2) will be worn to expand its left-right swing or incline.
This will cause idler to depart from track, or master
link and guide roller to be worn unevenly. To avoid
those accidents, adjust the clearance between cover
(2) and track roller frame.
Fig. 6-40 Guide roller clearance
Adjustment of guide roller clearance (Fig. 6-40):
1. Let the machine move 1-2m on the level ground, then measure the clearance “A” between
cover and track roller frame (at four places: left, right, inside and outside).
2. If the clearance is more than 4mm, loosen bolt (1), remove cover(2), take away some
gaskets (3) and adjust each side clearance to 0.5-1.0mm (the thickness of each gasket (3) is
1.0mm).

6.10.3 Undercarriage adjustment

1. Adjust track tension (see 6.9.1).
2. Measure grouser height (Fig. 6-41).
Measure the grouser height as showed in the figure
when the track is not slack.
★Standard grouser height (H) 60mm
Fig. 6-41 Grouser height
★Repair limit (H) 25mm
When close to the repair limit, immediate repair shall be
done to extend the service life.

6.10.4 Measure outside diameter of thrust

wheel
1. Measure the height (dimension C) of track link (Fig. 6-42).
2. Make the working face of the link of dimension C touch
the thrust wheel raceway. Measure dimension B.
Fig. 6-42 Track link height

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3. Calculate the outside diameter of thrust wheel (dimension A).

A= (B—C)×2

★Basic dimension (A): 210mm

★Repair limit: 195mm

When close to the repair limit, immediate repair shall be done to extend the service life.
6.10.5 Battery

The machine is provided with maintenance-free battery which does not need frequent supply

of electrolyte. For long-time shutdown, remove the battery and charge the battery once every

month with 10A for 14-16h. Store the battery in full condition, or its service life will be

shortened. In addition, keep the top of the battery case clean and dry to prevent from current

leakage. Keep good contact of the battery and the terminal. Remove any oxide. Apply geoline

to the terminal and connecting head of the battery to prevent from rust. Never put any tool or

other metal substance on the battery, or short circuit may occur and the battery may be

damaged.

6.11 Sort and Consumption of Fuel, Coolant and Lubricant

Season Month Consumption per

Nov. to Feb. of next
Position Type March to October unit (L)
year
Cooling
water Antifreeze Soft water 79
# #
-20 or -10 light
Engine Fuel
diesel oil 0# light diesel oil 300

Lubricant CF-4 10W-30 diesel oil 27.5

Torque converter and
transmission CF-4 10W-30 diesel oil 52

Steering case CF-4 10W-30 diesel oil 70

Hydraulic tank CF-4 10W-30 diesel oil 80

Final drive case CF-4 10W-30 diesel oil 31×2

Guide roller, thrust roller,
carrier roller CF-4 10W-30 diesel oil 0.25 (each

Note: The above lubrication is designed for operating temperature from -20℃ to 40℃. Other

proper lubrication shall be selected when out of such range.

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6.12 Measure pressure of hydraulic system of pan

1. The machine is provided with a centralized pressure gauge for hydraulic system on the left

wing panel (Fig. 6-43).

Fig. 6-43 Centralized pressure

gauge
2. Pressure value of hydraulic system (Fig. 6-44)

② ④ ⑥

① ③ ⑤ ⑦

Fig. 6-44 Centralized test

point
No. Code Item Value
Right steering clutch oil
① RC
pressure
Left steering clutch oil 1.89-2.00 MPa
② LC
pressure
Right steering brake oil
③ RB
pressure
Left steering brake oil 1.67-2.00 MPa
④ LB
pressure
Torque converter safe
⑤ IN 0.75-0.85 MPa
pressure
Torque converter
⑥ OUT 0.20-0.30 MPa
adjusting pressure
Safe pressure for
⑦ T/M 2 MPa
transmission adjusting

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 Chapter 7 Troubleshooting
The following may not remove all trouble, but it is useful to give a reference to troubleshooting.
★Engine troubleshooting (For detail see the operation manual).
7.1 Engine
7.1.1 Oil pressure gauge still shows red range when speed is raised after
engine is started
1. Check whether the oil sump has sufficient oil, and supply oil to the indicated oil level if
necessary.
2. Check whether the oil filter element is blocked, and replace it if necessary.
3. Check whether the oil pipe or connector is badly fixed or has oil leakage due to damage.
4. Replace the pressure gauge.
7.1.2 Vapour is sprayed from top pressure valve of radiator when water
temperature gauge pointer stays in red range
1. Supply cooling water and check for water leakage.
2. Adjust fan belt tension.
3. Replace the cooling water and wash the inside of the cooling system.
4. Clean or repair heat sink.
5. Change thermostat.
6. Tighten radiator cover or change its sealing lining.
7. Tighten radiator cover or change its sealing lining.
7.1.3 Water temperature gauge pointer still stays within red range when
engine operates
1. Change thermostat.
2. Change water temperature gauge.
7.1.4 Starting engine operates, but engine is still not started
1. Supply fuel.
2. Check fuel system for air introduction.
3. Change spraying pump and nipple.
4. Check throttle clearance.
5. Check engine compressive force.
★Refer to relevant part of electrical system (See engine operation manual).
7.1.5 Engine emits white or blue exhaust gas
1. Adjust the oil sump to the specified capacity.

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2. Change with specified fuel.

3. Check the pressure booster for oil leakage.

7.1.6 Engine emits black exhaust gas

1. Clean or change air filter element.

2. Change spraying nipple.

3. Check engine compressive force.

7.1.7 Combustion noise, abnormal exhaust sound

Change oil nipple.

7.1.8 Slap, abnormal combustion sound and mechanical noise of engine

1. Change with specified fuel.

2. Check preheating situation.

3. Adjust throttle clearance.

7.1.9 Hunting of engine

Check the intake side of the fuel pipeline for air leakage.

7.2 Electrical System

7.2.1 Lamp is not bright or flashes even if engine runs at high speed

1. Belt is not tightened enough.

2. Check and repair circuit.

7.2.2 Abnormal sound of AC generator

Change alternator.
7.2.3 Starting motor will not run when starting switch key is turned to Start

1. Check circuit.

2. Charge the battery.

3. Check and repair the starting switch.

7.2.4 Pinion of starting motor is in-and-out

1. Check and repair the circuit.

2. Charge the battery.

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7.2.5 Starting motor runs, but engine runs slowly
1. Charge the battery.
2. Change the starting motor.
7.2.6 Starting motor gear is disengaged before starting engine
1. Check and repair the circuit.
2. Charge the battery.
7.3 Undercarriage
7.3.1 Oil pressure of torque converter does not rise
1. If oil pressure of transmission is normal, check oil pipe of torque converter and connection
for leakage.
2. If oil pressure of transmission drops excessively, check or change transmission oil pump.
3. If oil pressure of transmission drops excessively, add oil into transmission.
4. If oil pressure of transmission drops excessively, clean and change transmission oil strainer
and filter, clean oil coolant and etc.
7.3.2 Torque converter overheats (Oil temperature pointer stays within red
range)
1. If water temperature is normal, clean oil coolant.
2. If water temperature rises excessively, see Engine and Item 7.3.1.
7.3.3 When gear shift lever is placed at high shift, machine can not start or
speed can not increase
1. Add oil into steering case.
2. If the oil pressure of torque converter does not rise, refer to 7.3.1.
3. If oil pressure of transmission is normal, check or change related clutch seals, plates and
discs in transmission.
4. Check, repair or change steering gear pump.
7.3.4 When pull steering control lever at one side, machine stops, but it
does not steer or engine speed changes
1. Check and adjust steering clutch.
2. Repair steering oil pump and pipe leakage part.
3. Change steering pump.
4. Adjust steering linkage.
7.3.5 When pull steering control lever at one side, machine moves in
straight line, but does not steer
1. Refer to 7.3.4.
2. Adjust the brake.

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7.3.6 Steering lever is inflexible or the control is difficult

1. Adjust the play.

2. Clean, check and repair the steering valve.

3. Supply the oil to the specified amount.

7.3.7 Machine does not stop when brake pedal is stepped down

Adjust the brake.

7.3.8 Track departure

Adjust track tension.

7.3.9 Abnormal sound or wear of carrier roller

Adjust the track tension.

7.3.10 Blade raises slowly, or does not raise at all

1. Add oil into hydraulic tank to the specified amount.

2. Check, repair or replace the operating pump.

3. Check or repair the hydraulic control valve and operating pipeline.

7.3.11 Insufficient supporting capacity of cylinder or automatic falling of
ripper

1. Check whether the operating pipeline has leakage.

2. Check whether the cylinder piston is properly sealed.

7.3.12 Insufficient rising force or slow action of ripper

1. Add oil into hydraulic tank to the specified amount.

2. Check, repair or replace the operating pump.

3. Check and repair the hydraulic control valve and operating pipeline.

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 Chapter 8 Transportation and storage

8.1 Transportation
8.1.1 Precaution for operation of machine
When driving the machine, observe all the highway rules and the traffic regulation, such as
land transport vehicle and vehicle restriction regulations etc.
1. Take necessary protective measures and obtain the license of road access in accordance
with corresponding road transportation laws.
2. Cheek the load limit of bridge and the space size of tunnel before passing through bridge
and tunnel.
3. When running on spread road, use platform trailer to transport in order to protect the road
surface. For short-distance running, cushion shall be used to protect the road surface.
Pitch road is very soft in summer. Special attention shall be paid.
8.1.2 Method for loaded transport
1. Use special platform for loading.
2. When using ladder to load/unload the machine on the trailer, following rules shall be
observed:
⑴ (Fig. 8-1)Apply reliable brake to the trailer. Stop the
wheels with wood pad. The ladder shall be placed in
accord with the center of the machine and reliable fixture
shall be provided. Fig. 8-1 Loaded

The ladder must have an enough width, length and transport

thickness to support machine safety load and unload. It could be strengthened underneath by
square wood if necessary.
⑵ The ladder shall be placed in proper direction. Then,
load/unload the machine slowly and smoothly (Fig. 8-2).
When running along the ladder, the running
direction can not be adjusted. If direction adjustment is Fig. 8-2 Loaded

required, the machine should be back to flat ground, transport

then adjust it.

⑶ Machine should be put in proper position on the trailer,
then put the square wood under the front and rear of the
Fig. 8-3 Loaded
track and fixed by a firm link or cable to avoid accident
transport
due to on-the-road slipping out (Fig. 8-3).

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⑷ Fall down the working device. Place each control lever to the position described below and
take off the starting key:
Place the accelerator control lever in idling position.
Place the gear shift lever in neutral position and lock it.
Place the blade control lever and ripper control lever in hold position and lock them.
The brake lock lever is placed in “Lock” position.
★ If the blade width exceeds trailer width, the blade should be angled or disassembled and
separately shipped.

8.1.3 Railway transportation

When transporting the machine on railway, following rules in addition to above rules shall be
observed:
⑴ When the blade width (1) is larger than the width specified for railway transportation, remove
the blade, place it under the machine and fix it reliably.
⑵ When lifting, use the special lifting tools provided by the transport department. Pay attention
to the lifting position (gravity center) and avoid collision.
★For the shipment line, limits for road, height and weight shall be considered.
Loading/unloading of the machine shall be carried out on flat and firm place. Keep it
certain distance away from the side street.

8.1.4 Marine (water) transportation

★ For long distance marine transportation the antirusting measures should be taken. The
exposed cylinder piston rod etc. should be applied with antirusting oil.
★For special requirements in transportation of the machine, please contact us.

8.2 Storage
8.2.1 Before storage
To place the machine in storage for an extended period, the following measures must be
followed to minimize maintenance when reusing:
1. Thoroughly wash the machine and park it indoors in a dry place. Don’t park it outdoors.
In case it is indispensable to store the machine outdoors leave it on flat ground with wood
plated and cover it with canvas.
2. Lubricate, grease the machine and replace with new oil before storage.
3. Uncovered part of piston rod should be slightly applied with oil.
4. Conductor at the terminal of battery should be removed and the battery covered or removed
and separately stored.
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5. When you estimate that the ambient temperature will fall down below 0℃, add the antifreeze

into coolant beforehand.

6. All control levers and pedals should be set as follows:

Gearshift lever is set to neutral position and locked.

Fuel control lever is set to low idling position.

Blade control lever and ripper control lever are set to holding position and locked.

Blake pedal is set to free position.

8.2.2 During storage

Start the engine once a month and move the machine for a short distance, so that new oil film

will be formed over the surface of all movable parts and engine components.

When operate working equipment, wipe off the grease on the cylinder piston rod.

8.2.3 After storage

After storage (if the machine is kept without cover or the rust preventive operation once a

month is not made), treat the machine as follows before operation:

1. Remove the drain plug on oil pan and other oil tank to drain the intruded water.

2. Remove the cylinder head, lubricate the valves and rockers and inspect the valve action.

3. To expel air from hydraulic system, turn the engine at low speed and operate as follows:

a. Each cylinder should move back and forth 4-5 times and piston stops at 100mm far from the

stroke end.

b. Next, each cylinder should move back and forth 34 times and move to the stroke end.

★ If the engine operates at high speed at the beginning or the piston moves to the stroke end,

the intruded air may damage piston pad etc.

4. If the engine operates at high speed at the beginning or the piston moves to the stroke end,

the intruded air may damage piston pad etc.

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 Chapter 9 Operation and maintenance of ripper

9.1 Check before work

1. Check bolt and nut for loosen or drop.

2. Check oil pipe for leakage.

During machine running raise ripper, insert pin into pin hole at lower part of shank and lock

ripper control lever.

9.2 Ripper operation

There are three gearshifts for ripper control handle: “Hold”, “Raise” and “Lower”.

★ Slowly lower ripper. Never fast drop it on the hard ground to prevent shank tip from

damaging.

1. Adjust depth: The ripping depth can be adjusted using three pin holes (A) on ripper shank.

Pull out split pin (1) and take out pin (2), then adjust dipping depth (Fig.9-1).

2. Change tip or shank protector.

Pull out pin (3) as showed by the arrow for replacement (Fig. 9-1).

Fig. 9-1 Ripper

9.3 Troubleshooting

Ripper moves slowly or cylinder fails:

1. Supply oil.

2. Clean or repair pipeline, valve or pump.

3. Repair or change related seals of cylinder piston.

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