CHAPTERⅠ STRUCTURE AND CONTROL DEVICES OF THE WHOLE MACHINE

SECTIONⅠ STRUCTURE AND MAIN SPECIFICATIONS OF THE WHOLE MACHINE

I. STRUCTURE OF THE WHOLE MACHINE (Fig.1-1)

1. Lift cylinder of blade 2. Fuel tank 3. Track 4. Sprocket

5. Track frame 6. Blade arm 7. Idler 8. Blade

Fig.1-1 Structure of the whole machine

II. OVERALL DIMENSIONS AND MAIN SPECIFICATIONS

1. Overall dimensions of the ZD220-3 bulldozer (Fig.1-2; unit: mm)

Fig.1-2 Overall dimensions of the whole machine

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 Note: Dimensions in Fig.1-2 are of the bulldozer equipped with straight-tilt blade;
Dimensions in brackets ( ) are those of the bulldozer equipped with angle blade.
2. Main specifications of the whole machine see the following table:
Main specifications of the whole machine
Item (unit) Main specifications Item (unit) Main specifications
Overall weight (kg) 24000 Model NT855-C280(third generation)
Max. Travel Forward (F) 11.2 Engine Rated power 175kW/1800r/min
speed(km/h) Reverse (R) 13.2 Max. torque 1078N.m/1250r/min

SECTIONⅡ CONTROL DEVICES

I. LAYOUT OF CONTROL DEVICES (Fig.1-3)

1. Fuel control lever 2. Transmission control lock lever 3. Steering control lever
4. Brake pedal 5. Decelerator pedal 6. Brake lock control lever
7. Blade control lever 8. Ripper control lever 9. Working equipment lock lever

Fig.1-3 Layout of control devices

II. FUNCTIONS OF EACH CONTROL DEVICE

1. Fuel control lever (Fig.1-4)
The control lever is used to control the speed
and output power of engine.
L ——Idling position
H ——High speed position
2. Transmission control leverⅠ(Fig.1-5)
The machine can gain 3 forward speeds and 3
reverse speeds through the transmission control
leverⅠ. You can change to the desired speed easily
by moving the transmission control leverⅠ. (F is
for forward gear, R is for reverse gear, N is for
Fig.1-4 Positions of fuel control lever
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neutral)
3. Steering control leverⅡ（Fig.1-5）
Pull one of control levers to the half
stroke, the vehicle will make a large turn to
the side slowly. Pull the lever to the end of
its stroke, the vehicle will make a pivot turn.
4. Brake pedal (Fig.1-6)

Fig.1-5 Transmission and steering control lever

Depress the cross-section part of the two pedals at the

Fig.1-6 Brake pedal
same time, both the left and right brakes act at the same
time. Pull one of steering control lever to the half stroke and depress the brake pedal at the same
side, the vehicle will make a pivot turn to the same side.
Notice: Don’t rest your feet on the brake pedals when it is
not necessary to brake the machine.
5. Decelerator pedal (Fig.1-7)
It’s used to decelerate engine speed.
When the vehicle arriving at the top of a slop or when
dumping earth at the edge of a cliff, the vehicle will speed up
because of sudden loss of load, thus may cause danger. At this
time, slow down the vehicle by depressing the decelerator pedal.
6. Brake lock lever (Fig.1-8) Fig.1-7 Decelerator pedal
It is used to lock the brake pedal when parking the vehicle.
When depress the brake pedal, set the lever in “ Lock ” position to lock the brake. When
depress the brake pedal, set the lever in “ FREE ” position, the brake is released.
Notice: Be sure to lock the brake pedal after parking the vehicle.
7. Transmission control lock lever (Fig.1-9)
It’s used to lock the transmission control lever when parking the vehicle.
Notice: When parking the vehicle for some time, be sure to set the transmission control
lever in “ NEUTRAL ” (Free) position, and set the lock lever in “ Lock ” position.

Fig.1-8 Brake lock lever Fig.1-9 Transmission control lock lever

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 8. Working equipment lock knob (Fig.1-10)
When pushing the knob forward, the working
equipment control lever is locked. When pushing the
knob backward, the working equipment control lever
is at free state.
Notice: When parking or repairing the vehicle,
lower the blade and set the working equipment lock
knob in “ Lock ” position.
9. Blade control lever (Fig.1-11) Fig.1-10 Working equipment lock knob
Usually the blade control lever is in “ HOLD ” position ②. When pull the control lever to
position ①, the blade will be raised (Fig.1-12), push to position ③, the blade will be lowered,
further to position ④, the blade will be kept in “ FLOAT ” state.
Notice: When the control lever is at the position ④, must pull it back by hand because it
can not return to the “HOLD” position automatically.
When operating the straight tilt blade, if the control lever is moved to position A, the blade
will tilt to right; to position B, tilt to left (Fig.1-13).
Notice:
1) When the blade is at the position ①, ② or ③, the blade can be tilted.
2) Positions A and B are only suitable for the straight-tilt blade.
3) When the tilt cylinder reaches the end of its stroke, be sure to move the control lever
back to the “ HOLD ” position ② at once.
4) When the blade is in the highest or lowest position, don’t operate the blade to tilt.

Fig.1-11 Blade control lever Fig.1-12 Blade raise and lower Fig.1-13 Blade tilt
10. Ripper control lever (Fig.1-14)
The control lever is always in “ HOLD ” position ②. When move the control lever to
position ①, the ripper will be raised (Fig.1- 15); to position ③, the ripper will be lowered.
When pushing the knob forward (Fig.1-16), the ripper control lever is locked. When
pulling the knob backward, the ripper control lever is at free state, and the ripper can be operated
to raise or lower.
Notice: When parking or repairing the vehicle, be sure to lower the ripper and set the lock
knob in “ LOCK ” position.

Fig.1-14 Ripper control lever Fig.1-15 Ripper raise and lower Fig.1-16 Ripper control lock lever
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III. ELECTRONIC MONITOR (FIG.1-17)
Main functions of electronic monitor are as the following:
1. Self-checking of gauges

Fig.1-17 Electronic monitor

Before starting the engine, when the starting switch is turn to the “ ON ” position, all the
indicator and pilot lamp will be light, and the buzzer will sound. After 3 seconds, the pilot lamp
becomes off, the buzzer stops giving alarm and the indicator continuously operates normally,
through which the monitor indicator system and warning system are self-checking.
2. Indicator of coolant temperature and pilot lamp (Fig.1-18)
If the water temperature is normal, the green range of indicator will be light, if the water
temperature excesses the limit, the red range of the indicator will be light. At this time, the pilot
lamp is flickering, and the buzzer sounds to give out alarming. On this situation, stop working
and run the engine at idling speed until the green range of the indicator becomes light.
3. Oil temperature indicator and pilot lamp of torque converter (Fig.1-19)
If the oil temperature is normal, the green range of indicator will be light; if the oil
temperature excesses the limit, the red range of the indicator will be light. At this time, the pilot
lamp is flickering, and the buzzer sounds to giving out warning. On this condition, stop working
and run the engine at idling until the green range of the indicator becomes light.

Fig.1-18 Display of coolant temperature Fig.1-19 Display of torque converter oil temperature

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 4. Indicator and pilot lamp of hydraulic oil temperature (Fig.1-20)
Functions of the indicator and pilot lamp are same as that of the above-mentioned item 3.
5. Indicator and pilot lamp of fuel level (Fig.1- 21)

Fig.1-20 Display of hydraulic oil temperature Fig.1-21 Display of fuel level

The indicator is used to indicate the fuel level in fuel tank. When the engine is running, if
the fuel is enough, the green range will be light. If only the red range is light, it indicates the fuel
in the fuel tank is less than 80L. At the same time, the pilot lamp flickers to indicate it’s
necessary to refill the fuel.
6. Indicator and pilot lamp of battery capacity (Fig.1-22)
When the starting key is turned to “ ON ” position,
if the green range of indicator be light, it indicate the
battery capacity is enough; if only the red range is light,
it indicate battery capacity is not enough, at this time it
is necessary to charge the battery.
7. Battery charging pilot lamp (Fig.1- 23)
After starting the engine, if the battery charging
indicator becomes light, it indicates the operation of Fig.1-22 Display of battery capacity
charging system is normal.
Notice: When the engine is running, if the charging indicator is not light or is flashing, or
charging indicator is light when the engine stops running, it indicates:
(a) The generator is in trouble;
(b) The R terminal of generator is defective in connection.

Fig.1-23 Charging pilot lamp Fig.1-24 Pilot lamp of air cleaner element
8. Pilot lamp of air cleaner element (Fig.1- 24)
If the air cleaner element is clogged with dust, the pilot lamp will flicker, and the buzzer
will sound to give off a warning. At this time, it is necessary to clean or replace air cleaner
element.
9. Safety starting signal lamp (Fig.1-25)

Fig.1-25 Starting signal lamp Fig.1-26 Pilot lamp of engine oil pressure Fig.1-27 Timer
When the engine is not be started and the control lever is in neutral position, the pilot lamp
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should be light. If the lamp isn’t light, it indicates: a. The switch of neutral position is in trouble;
b. The adjustment of the switch of neutral is defective.
After starting the engine, if the pilot lamp go out, it indicates that operation of safety relay
is normal. If the pilot lamp doesn’t go out, it indicates that: a. The generator is in trouble, or the
wire connection is defective; b. The safety relay is in trouble.
10. Pilot lamp of engine oil pressure (Fig.1-26)
During the engine is running, if the engine oil pressure is abnormal, the green pilot lamp
will be light; if oil pressure is lower than the lowest limit, the red pilot lamp will be light, and the
buzzer will sound. At this time, it is necessary to stop the engine at once.
11. Timer (Fig.1-27)
The timer indicates the total work hours of the machine. When the engine is running (even
if the vehicle does not travel), the timer will rotate.
IV. OTHER DEVICES
1. Starting switch (Fig.1-28)
“OFF”: This position is to insert and take out the starting key.
When the starting key is in this position, all the circuits are cut off.
“ON”: When the starting key is rotated to this position, the
circuits are on.
“START”: When the key is rotated to this position, the
starting motor will drive the engine. After the engine has been Fig.1-28 Starting switch
started, release the key at once, and the key will go back to “ON” position automatically.
“HEAT”: This position is used to start the engine in low temperature. After completing the
preheating, release the key and the key will go back to “OFF” position automatically. Then, turn
the key to “START” position at once.
2. Horn button (Fig.1-29)

Fig.1-29 Horn button Fig.1-30 Dome lamp switch

When pressing down the button, the horn will
sound.
3. Dome lamp switch of cab (Fig.1-30)
When the switch is turned to “ ON ” position, dome
lamp will become light.
4. Switches in cab (Fig.1- 31)
These switches are used to control the following
devices:
① Rear working lamp
Fig.1-31 Switches in the cab

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 ② Dome lamp
③ Electrical fan
④ Rear washer
⑤ Front washer
Each switch is also used to water the door and window, therefore each switch has the
following 3 functions:
A. Watering of door and window (Fig.1- 32)(optional)
B. Wiping of door and window (Fig.1- 33)
C. Washing of door and window (watering and wiping) (Fig.1- 34)

Fig.1-32 Watering switch of Fig.1-33 Wiping switch of Fig.1-34 Washing switch of

door and window door and window door and window
5. Lock of door (Fig.1- 35)
When the door is opened, the lock will lock the
door in the “OPEN” position.
1) When the door forces and press the lock ①, the
door is locked at “OPEN” position.
2) After pressing in the button ② on the lock, the
door is free at once.
6. Fuse box (Fig.1- 36, Fig.1- 37) Fig.1-35 Lock of door
Fuse wire is used to prevent the electric units or wires from being destroyed. If fuse
gathers rust or be covered with a layer of white powder, replace it at once.
Notice:
When replacing fuse, adopt fuse with the same capacity.
When replacing fuse, it’s necessary to turn off the starting switch.

Fig.1-36 Fuse box Ⅰ Fig.1-37 Fuse boxⅡ

As for arrangement of fuses and current capacities of electrical parts, referring to the
following tables:

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 Fuse boxⅠ Fuse boxⅡ
Capacity Capacity
No. Circuit No. Circuit
of fuse of fuse
① 30A Generator ① 10A Washer of front window
② 30A Starting switch ② 10A Washer of rear window
③ 10A Headlamp ③ 10A Dome lamp of cab
④ 10A Horn button ④ 10A Cigar lighter
⑤ 10A Cab 1 ⑤ 10A Cassette recorder
⑥ 10A Cab 2
7. Air conditioner
A. Appearance of control panel (Fig.1-38)

Fig.1-38 Appearance of control panel

B. Operation method
ON: on; ▽ △: Temperature setting (lower, raise); : warm; : cool; : wind
speed; OFF: off
Press the key “ON”, the power supply will be turned on, and the power supply pilot
lamp will become light; press the key “OFF”, the power supply will be cut off.
Press the key “ ” or “ ”, the air conditioner will begin cooling or heating.
Press the key “ ”, the wind speed will be alternated among the three speeds: high,
medium and low.
Press the keys “▽ △”, the temperature is set within 10℃~30℃.
C. Main functions:
a. After turning on the starting switch, press the key “ON”, the setting temperature is set
at 20℃ automatically by digital tube. After 3 seconds, the air conditioner displays the
ambient temperature, and the power supply pilot lamp becomes light, and all of output
control circuits have no output.
b. Press the key “ ▽ △ ” to adjust the setting temperature. The setting indoor
temperature range is 10℃~30℃. The temperature resolution is 1℃ when adjusting
the setting temperature. After 3 seconds, the air conditioner will display the ambient
temperature again.
c. Press the key “ ”, the heating function will be turned on (off) when the indoor

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 temperature is 1.5℃ lower (higher) than the setting temperature. When the air
conditioner system is in the heating state, the heating lamp and the pilot lamp of
blower will be light, but the cooling lamp goes out. Only when the air outlet fan is
opened, can the warm key function. The warm key and cool key cannot function at the
same time.
d. Press the key “ ”, the cooling system will be turned on (off) when the indoor
temperature is 1.5℃ higher (lower) than the setting temperature. When the air
conditioner system is in the cooling state, the cooling lamp and the pilot lamp of
blower will be light, but the heating lamp goes out. Only when the air outlet fan is
opened, can the cool key function.
e. Press the key “ ”, the wind speed will be alternated among the high speed, medium
speed and low speed. The defaulted working state is high speed.
f. Press the key OFF to cut off the power supply and all of outputs.
D. It has the following two functions during the running-in and the operation and
maintenance of a new machine:
a. “Forced cooling”. When setting the temperature at 10℃, i.e. the lowest setting
temperature, keep pressing the cool key for 5 seconds without release, the air
conditioner system will go into the forced cooling state; otherwise, the digital tube will
display “L0”. Press the key △ or ▽ to release from the forced cooling.
b. Forced heating: when setting the temperature at 30 ℃ , i.e. the highest setting
temperature, keep pressing the warm key for 5 seconds without release, the air
conditioner system will go into the forced heating state; otherwise the digital tube will
display “HI”. Press the key △ or ▽ to release from the forced heating.
E. Precautions of operating the air conditioner.
① Cooing with the air conditioner, it’s necessary to refresh the operator’s cab usually.
When cooling with the air conditioner, smoking in the operator’s cab is bad to the
operator’s eye.
② When cooling with the air conditioner, be sure to stop circulation of hot water. If the
hot water circulate in the heater, it is just like there is a thermos bottle in the operator’s
cab and it will lower the cooling efficiency. Be sure to set the heating control switch
into the “ OFF ” position. If not use the air conditioner to heat for a long period, it’s
necessary to shut off the water inlet and outlet
valve.
③ Take care not to be too cold in operator’s cab.
When the temperature of the operator’s cab is
lower 5-6 ℃ than the outdoor temperature, the
operator can feel cold as soon as he enters the cab.
Too low temperature in the operator’s cab is
harmful to the health. So it’s necessary to set the
temperature in the operator’s cab at a proper value.
8. Operator’s seat (Fig.1-39)
Adjust the operator’s seat according to the following
methods for meeting the comfortability of operator to the
great extent.
Fig.1-39 Operator’s seat
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 A. Height adjusting:
Clockwise turn the knob (2), the seat is lowered, oppositely, the seat is raised. The
adjustable amount is 50mm.
B. Forward / backward adjusting
Pull out the control lever (3) to adjust the seat to the desired position and release the
control lever. The forward / backward adjustable amount is 160mm (8 steps).
C. Adjusting the seat according to the operator’s weight
Clockwise turn the knob (4) to suit for the light operator to ride, oppositely suit for the
heavy operator to ride. Therefore, adjust the seat according to the weight to gain the
comfortability.
D. Adjusting the tilt
Pull the knob (5) up to adjust the tilt of the back to the desired position, then release the
knob.
9. Fan in the operator’s cab
The operator’s cab is equipped with 24V direct current electric fan. When not using the air
conditioner, the fan can supply a comfortable working environment for the operator.

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 CHAPTERⅡ OPERATION
SECTIONⅠ CHECK BEFORE STARTING
Notice: Be sure to do the check before starting. Don’t look down on it for the safety of
personnel and machine.
I. CHECKING ITEMS BEFORE STARTING
1. Check for any leakage of oil or water
Look around of the vehicle, check for any leakage of oil or water and abnormal
phenomena, especially for the sealing of hose connector, hydraulic cylinder, final drive, track
roller, carrier roller floating sealing and water tank. If any leakage and abnormal phenomena is
found, it is necessary to repair.
2. Check the bolts and nuts
Check for the tightness of bolts, nuts that are easy to become loose, retighten them when
necessary, especially for the bolts of air cleaner, carrier roller support and track shoe.
3. Check the circuit
Check for the damage of wire, short circuit and the looseness of terminals.
4. Check coolant level
1) After screw off the cover ① of water tank (Fig.2-1), check whether the level is at the
specified height (Fig.2-2). If necessary, fill water.
2) Refilling of the coolant is proceeded after stopping the engine. At first, fill up the water
tank (until the water overflows out of the tank), then, start the engine. Check after idling
for 5 minutes. If the level is lower than the specified high (Fig.2-2), refill the coolant.
Notice:
1) Once the water quantity refilled is much more than the normal, check for any leakage
of water. If this is the case, repair at once.
2) When checking the coolant level, don’t only depend on the level monitor.
3) When the coolant temperature is over-hot, it is necessary to screw loose the cover ①
slowly to release the internal pressure of the tank before open the cover so as to
prevent hot water spurting out and hurt personnel.

Fig.2-1 Water filler of water tank Fig.2-2 Water level of water tank
5. Check oil level in engine oil pan (Fig.2- 3)
1) Pull out the oil-stick to read the oil level in the side marked with “ENGINE STOPPED”
after the engine has been stopped.
2) When the engine is idling, first confirm the pointer of the engine oil pressure gauge and
water temperature gauge stay within the normal range, then pull out the oil-stick G to
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 read the oil level in the side marked with “ENGINE IDLING”.
3) If it is necessary to Refill engine oil, open the oil filler F and fill the oil.
Notice:
1) According to ambient temperature, select the
engine oil referring to the appended table
“Kind and capacity of fuel, coolant and
lubricant ”. When checking oil level, park the
vehicle on the flat ground.
2) When refilling oil, the oil level should lower
than the level marked “ H ”.
3) When checking oil level, don’t only depend on Fig.2-3 Oil filler of engine oil pan
the engine oil level monitor.
6. Check fuel level
1) Screw off the cap of fuel tank and pull out the oil-stick to check oil level.
2) After finished working very time, fill the fuel through the screen.

Fig.2-4 Oil filler of fuel tank Fig.2-5 Oil filler cap of fuel tank
Notice:
1) When proceeding dozing, it is necessary to fill enough fuel for preventing air from
entering into fuel piping.
2) If the breather ① (Fig.2- 5) of fuel tank cap is clogged, the fuel in the tank will be
stopped flowing into the engine. Therefore, the breather should be often checked and
cleaned.
3) When filling the fuel, don’t make the fuel overflow out of the tank for preventing fire.
7. Check the oil level in steering clutch case (including transmission and torque
converter) (Fig.2-6)
Check the oil level with oil-stick. If necessary, fill
the oil through the oil filler F.
Notice:
1) According to ambient temperature, select the
lubricating oil referring to the appended table
“Kind and capacity of fuel, coolant and
lubricant ”. Fig.2-6 Oil filler of steering case
2) When checking the oil level, it is necessary to
stop the engine.
3) Operating on the slope more than 20°, the oil level should be in the position H (high).

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 8. Drain water and sediment in fuel tank (Fig.2-7)
Loosening the valve ① on the bottom of fuel tank, open the drain vale to drain water and
sediment out of fuel tank .

Fig.2-7 Drain port of fuel tank Fig.2-8 Travel of brake pedal

9. Check brake pedal travel (Fig.2-8)
With engine running, the standard travel of brake pedal is 110~130mm ( the control force
is 15Kg ). With engine stopped, the travel is about 75mm. If the brake pedal travel is more than
190mm, it indicates the brake function isn’t enough, adjust it according to the part
“ ADJUSTMENT ”.

SECTIONⅡ METHODS AND PROCEDURES OF OPERATION

I. CHECK THE POSITION OF EACH CONTROL LEVER BEFORE

STARTING
1. Adjust the operator’s seat to make the operator step down the brake pedal ① to the end of
the pedal travel with the operator’s back on the back of the seat.(Fig.2-9)

Fig.2-9 Braking lock control Fig.2-10 Brake lock lever

Fig.2-11 Transmission control lock lever Fig.2-12 Lock lever of blade and ripper control
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 2. Brake lock lever ② is at the locked position (Fig.2-9, Fig.2-10).
3. Transmission control lever ⑥ is set in the Neutral position (Fig.2-13), Transmission
control lock lever ③ is set in the Lock position (Fig.2-11).
4. The blade and ripper should be lowered to the ground, their control levers ⑤,④should be
set at lock position (Fig.2-12).

II. STARTING THE ENGINE

1. Pull the fuel control lever ⑦ to idling position
(Fig.2-13).
2. Turn the starting key to start position (Fig.2-14).
3. After starting the engine up, loose the starting key,
the key will go back to On position automatically.
Fig.2-13 Fuel control lever
(Fig.2-15)
Notice:
a. If engine fails to start, repeat the starting procedure after an interval of 2minutes. Don’t
leave the key in “ Start ” position for more than 20 seconds.
b. Starting in cold weather is according to “ Operation in cold weather ”.
c. When starting the engine after using up the fuel, fill enough fuel and fill the element of
fuel filter up with fuel to drain out the air from fuel system before starting the engine.

Fig.2-14 Key to Start position Fig.2-15 Key to On position

III. CHECK AFTER STARTING THE ENGINE

After starting the engine, the following checks should be carried out:
1. Running the engine at low speed until the pilot
lamp of engine oil pressure becomes green.
2. Pull the fuel control lever and idle the engine at the
medium speed for 5minutes (Fig.2-16).
Notice: Don’t run the engine at idling or high
speed for more than 20 minutes. If it is necessary to idle
the engine, increase the load of the engine now and then
or the engine speed to the medium speed.
Fig.2-16 Fuel lever in
3. After preheating the engine, check each indicator medium speed position
and pilot lamp for normal operation.
Notice: Be sure to run the engine with light load continuously until the green range of the
engine water temperature indicator becomes light.
4. Check the color of exhaust gas and abnormal noise or vibration of engine.
Notice:

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 1) Before warming up the engine, avoid the sudden speeding-up.
2) If oil pressure pilot lamp of engine flashes up and the buzzer begins to sound
intermittently, it is necessary to stop the engine at once and check for the trouble.

IV. OPERATION OF TRAVELLING THE BULLDOZER

Before travelling, check the ambient for safety.
1. Push the working equipment control lock knob backward (Fig.2-17).
2. Pull the control levers of blade and ripper to lift the blade and ripper up 40~50cm above the
ground (Fig.2-18).

Fig.2-17 Working equipment control lock knob Fig.2-18 Positions Raise of work equipment
3. Depress the medium crossed part of left and right brake pedal ① and set the brake lock
lever ③ in the position Free, then release the brake pedal (Fig.2-19).
4. Release the transmission control lock lever (Fig.2-20), and pull the transmission control
lock lever to the position Free.

Fig.2-19 Brake pedal, decelerator pedal and brake lock lever Fig.2-20 Transmission control lock lever
5. Depress the decelerator pedal ② to
decrease the engine speed so as to start the
vehicle without shock (Fig.2-19).
6. Set the transmission control lever ① to
the desired position for travelling the
vehicle. Pull the fuel control lever ② to
speed up the engine (Fig.2-21).
7. Gear shifting
Operate the transmission control lever ①
to change to any traveling speed without Fig.2-21 Fuel and transmission control lever
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stopping the machine (Fig.2-22). After speeding
down the vehicle, carry out the forward/reverse gear
shifting to prevent the shock. Depress the decelerator
pedal ② to speed down the engine, and set the
transmission control lever ① to the desired forward
/reverse speed positions. Then, release the
decelerator pedal to speed up the engine.
8. Turning
A. Making a large turn to the left (right): Pull the
left (right) steering lever ③ to its half stroke, Fig.2-22 Speed changing and turning
the vehicle will make a large turn to left (right) (Fig.2-22, Fig.2-23).
B. Making a small turn to the left (right): Pull the left (right) steering lever to the end of its
stroke, the left (right) steering clutch disengages and the brake functions, the vehicle will
make a small turn to left (right) (Fig.2-22, Fig.2-24).

Fig.2-23 Make a large turn to the left (right) Fig.2-24 Make a small turn to the left (right)

V. PARKING
1. Push the fuel control lever to the idling position to decrease the engine speed.
2. Push the transmission control lever to the Neutral (N) position.
3. Depress the medium crossed part of left and right brake pedal, the machine will be stopped,
and pull the brake lock lever to the lock position.
4. Lock the transmission control lock lever.
5. Push the control levers of blade and ripper to the Lower position for lowering the blade and
ripper to the ground (Fig.2-25).
6. Push the working equipment control lock
knob forward to Lock position.
Notice: Park the vehicle on the hard flat
ground and avoid parking on the danger place as
far as possible.
7. Stopping the engine
1) Idling the engine for 5 minutes to cool
it. Fig.2-25 Blade and ripper control

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 2) Turn the key ① to OFF position to stop the engine, and then pull out the key (Fig.2-26,
Fig.2-27).

Fig.2-26 Starting key Fig.2-27 Starting key positions

3) If stop the engine suddenly before it is cooled down, the service-life of engine will be
shortened greatly. Don’t make the engine stopped suddenly except an emergency.

VI. OPERATION IN SPECIAL WEATHER

1. Precautions in cold weather:
When temperature is low, it is difficult to start up the engine and the cooling water is like to
freeze and it isn’t good to the machine. Therefore, adopt proper precautions to protect the
machine.
(1) Select the oil and water according to the appended table of “ Kind and capacity of fuel,
coolant and lubricating oil ”.
(2) When the ambient temperature is lower than 0℃, add the anti-freeze to prevent the
coolant from being frozen according to the lowest temperature. As for the mixture ratio
of water and anti-freeze and operation method, refer to “ Maintenance when necessary:
Clean the inner of cooling system ”.
(3) During winter evening, the water without the anti-freeze should be drained out to
prevent the spare parts from being damaged because of freezing.
Note: not to forget to drain out the water in oil cooler.
(4) It’s necessary to use the standard anti-freeze, be sure never to make antifreeze with
methyl alcohol or ethanol, otherwise it will cause trouble of engine.
(5) Before adding the mixed anti-freezing solution, clean the cooling system thoroughly.
(6) When the weather becomes warmer, drain out the anti-freezing solution (except the
permanent anti-freezing solution) and clean the cooling system, and then replace with
the clean water.
(7) Anti-freeze is flammable, be careful of fire.
(8) Especial note: Clean up the snow or water on the piston rod of hydraulic cylinder, or it
will wear out the oil seal of cylinder.
(9) When the temperature drops down, the capacity of battery will drop down and the charge
capacity will reduce and the electrolyte will freeze. Keep the charge rate of battery near
100% and insulated it to protect it to stand though the lower temperature.
The following list is the variation
iation of specific gravity of electrolyte with charge rate.
18
 Temperature
of fluid 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
Note: If the electrolyte level is low, add the distilled water before operation in the morning
to prevent the electrolyte from being frozen during the night.
2. Starting the engine in cold weather
1) Push the fuel control lever to the idling position.
2) Turn the starting key to “Heat” position (Fig.2-28).
3) After warming up the engine, turn the key to “Starting” position for starting the engine
(Fig.2-29).

Fig.2-28 Key in “Heat” position Fig.2-29 Key in “Start” position

4) After releasing the starting key, the starting key will go back to “On” position
automatically (Fig.2-30).
Note: If the engine fails to start up, repeat the
procedures of 2), 3), 4) after 2 minutes.
3. Operation on a slope
1) When descending a slope, make a large turn to the
left (right) (Fig.2-31). Pull the right (left) steering
control lever to its half stroke, the vehicle will make Fig.2-30 Key in “On” position
a large turn to the left (right).

Fig.2-31 Make a large left turn Fig.2-32 Make a small left turn

19
 2) When descending a slope, make a small turn to the left (right) (Fig.2-32). Pull the left
(right) steering control lever to the end of its stroke, the vehicle will make a small turn to
the left (right).
Precautions:
a) Don’t park the vehicle on the slope except the special condition. If it is necessary to
park on a slope, park the vehicle with the vehicle head down the slope, and lock the
brake pedal. If the slope is steeper, insert the blade into the earth to prevent the vehicle
from sliding down.
b) When the vehicle is traveling on a slope, the longitudinal slope should not be above
30°, don’t reverse the machine when climbing a slope.
c) It’s necessary to travel at lower speed in a straight way, don’t travel transversely or turn
on a slope.
d) Don’t shift the gear or climb over an obstacle on a steep slope.
e) To start traveling on a steep slope, firstly depress the brake pedal (left and right), then,
loosen the brake pedal slowly at the same time as moving the transmission control lever
to the 1st gear.
f) When descending a slope, set the transmission control lever in the lower speed position
and make the engine function as brake. If there is dangerous of over-speeding of engine,
decrease the speed with the brake pedal.
g) Operating on a slope, there should be enough fuel in fuel tank. Or, the engine may stop
because of lack of oil due to the tilting of the machine body. If the engine stops, the
brake effect will decrease.
h) Operating on a slope over 20°, the engine oil of every part must be to the highest
level.
4. Travelling in water
1) Before traveling in the water, first check the water depth and earthiness condition below
the water to avoid the trouble because of over-deep water level and earth sinking with
load.
2) The water level should not be more than the center of idler (Fig.2-33).

Fig.2-33 Schematic drawing of idler center

3) If operating in the sea or the corrosive water, the vehicle should be cleaned up with the
clean water after finished operation.
5. Travelling in the desert
When travelling in the desert or place full of dust, make the vehicle sealed well as far as
possibly, and the air cleaner must be cleaned up in time.
20
 CHAPTER Ⅲ DOZING OPERATION
It is very important for prolonging the service life and relieving the operator’s fatigue as
well as promoting the productivity to choose suitable machine and the adjusting and operating
method of the blade according to the operating object.
There are two types of blades: straight-tilt blade and angle blade. Select the proper type of
blade according to different operating object and terrain.
The optimum bulldozing distance is within 70m. For long bulldozing distance it is more
economical to use scraper machinery to do the job.

SECTIONⅠOPERATION OF BLADE AND RIPPER

For the operation of blade and ripper, refer to the part “SECTION Ⅱ CONTROL
DEVICES” in CHAPTERⅠ.

SECTIONⅡDOZING OPERATIONⅡ

I. CUTTING THE HARD OR FROZEN SOIL (FIG.3-1)

Fig.3-1 Cutting the hard or frozen soil Fig.3-2 Leveling operation

When cutting hard or frozen soil, machine with straight-tilt blade or angle blade will dig
efficiently. If the ground is extremely hard, using a ripper will increase the working efficiency.
II. LEVELING OPERATION (FIG.3-2)
Level the uneven ground after dozing and
digging according to the following procedure:
(a) With the blade full of earth, the machine
travels forward at low speed to level the
uneven ground by filling or scrapping.
(b) The machine travels backward slowly
dragging the blade to level the uneven
ground with the blade in floating position.
Notice: In stony area, never drag the blade
to level the uneven ground, otherwise it will
damage the blade. Fig.3-3 Dozing earth to one side

III. DOZING EARTH TO ONE SIDE (FIG.3-3)

Adopt angle blade when the earth is dozed to only one side.

21
 Never dig the tree roots with the end bit of the blade.
Notice: During dozing forward, avoid sudden acceleration, sudden brake and sudden
turning as far as possible.

SECTIONⅢ ADJUSTMENT OF THE BLADE

I. ADJUSTMENT OF ANGLE BLADE
1. The adjustment of turning angle for the angle blade
The blade can be adjusted to turn left (or right) horizontally at an angle of 25°.(Fig.3-4)
1) Lift the blade to 400~500mm above the ground level, and place one wooden block under
the U-frame.
2) Pull out the pins ① on both sides, remove the push arm ② from the U-frame.(Fig.3-5)
3) To angle the blade, fit the push arm ② to the desired bracket, (There are three brackets
on each side of the frame) and insert pins ①.

Fig.3-4 Adjustment of turning angle for the angle blade Fig.3-5 Angle blade
Notice: Take care that blade will move freely after removing the push arm.
2. The adjustment of the tilting amount for the angle blade
Max. Tilting amount of the blade: 500mm (Fig.3-6)
1) Lift the blade 400~500mm above the ground level and place a block under the U-frame.
2) Loosen the set bolts ①, turn the two braces on both sides to elongate and shorten their
lengths by inserting a steel bar into the hole ② of the brace on each side.
3) Tilt the blade to the desired height and tighten the set bolt ① (Fig.3-7).

Fig.3-6 Tilting height of the angle blade Fig.3-7 Adjustment of blade brace
Notice:
1) The length L (Fig.3-7) of the brace is normally 1338mm, and the tilting amount of the
blade should be within 500mm.
2) Never intend to tilt the blade more than 500mm, otherwise unexpected consequences will

22
 occur.
3) To turn brace with an adjusting bar, first make the blade away from ground level, then, tilt
it.
3. Adjustment of the shims
Standard thickness of the shims between the blade
lift cylinder piston rod and cover is 4mm (Fig.3-8).
Remove part of shims to adjust the clearance
between the spherical surfaces of the cylinder piston rod Fig.3-8 Adjustment of the shims
end and cover. Proper clearance is 0.2~0.6mm.
II. ADJUSTMENT OF STRAIGHT-TILT BLADE
1. Tilting of the straight-tilt blade
Operate the blade control lever to tilt the blade
425mm. When necessary, change the length (L)
(Fig.3-9) of the left brace to tilt the blade to 500mm
further.
Notice:
1) Normally the length (L) (Fig.3-9) of the Fig.3-9 Brace of straight-tilt blade
brace is 1287mm, and the tilting amount of the blade is within 500mm.
2) Never try to tilt the blade more than 500mm, otherwise unexpected damage will
occur.
2. Adjustment of the shims
Adjust the thickness of the shim to make the axial clearance (A) (in position as shown by
arrows Fig.3-10) of spherical joints is not more than 1mm.
a) Remove shim ① and tighten bolt ② to eliminate the clearance of the spherical joint.
(Fig.3-11)
b) Measure the clearance (A) and remove the bolt ②.
c) Fit the shim ① whose thickness is (A+1) mm and tighten bolt ②.

Fig.3-10 Spherical joint of straight-tilt blade Fig.3-11Shims of the spherical joint

Notice: Make sure the spherical joint can turn freely after turning tight the bolt.

SECTIONⅣ METHOD OF PROLONGING THE SERVICE LIFE OF THE MACHINE

The service life of the machine, especially the service life of the undercarriage, depends on
the method of operation and maintenance to great extent. So remember the following points in
your mind:

23
 1. Select proper machine with proper crawler according to soil conditions.
2. During operation, don’t slip the track as far as possible. If the track is slipping, reduce the
load until the track stop slipping.
3. Avoid sudden travelling, sudden acceleration and unnecessary travelling at high speed,
sudden brake and sudden turning as far as possible.
4. Always drive the machine to travel on straight line. Don’t always turn to one side. It would
better to turn to both sides alternatively and turn with max. turning radius.
5. During dozing, if a slope with a small decline to left or right occurs on working surface,
drive the machine backwards to flat ground, then, doze the earth to make the working
surface flat and continue operating again. Don’t go on operating on a slope.
6. Never try to make the machine handle or lash against hard obstacles or obstacles that is
difficult to deal with or let the machine travel across them. Otherwise idler or sprocket will
be off ground. (Fig.3-12)
7. When operating on a slope, the machine should push earth downward from the top of the
hill. Never travel across a slope transversely. When ascending a hill, don’t reverse the
machine. (Fig.3-13)
8. Before operating, get rid of huge stone or other obstacles in working site.

Fig.3-12 Schematic drawing of Fig.3-13 Schematic drawing of

operation on hard surface operation on a slope

24
 CHAPTER Ⅳ MAINTENANCE AND SERVICE
SECTIONⅠ SAFETY OPERATION PRECAUTIONS
Proper maintenance and service is very important. It can prolong the service life of machine,
avoid accident and personal injury, promote operation efficiency, and increase economical
benefit. The operator and serviceman must observe to the following items besides reading the
contents and relative requirements of SAFETY HINTS.
1. Only when the serviceman and maintainer have understand the structure, performance,
assembling and disassembling procedure, technical requirements of the machine and
precautions very well, can they do the maintenance and service. Never do maintenance and
service blindly.
2. If the maintenance and service is difficult for you to do, you’d better consult the
manufacturer.
3. Generally, the daily maintenance is carried out before starting the engine and after finishing
operation every day. To maintain the machine, park the machine on flat ground, lower the
blade and ripper to ground level, set the locking device in LOCK position, then carry out
the maintenance.
4. To carry out maintenance with engine running, it is required that there should be two
persons to carry out the job cooperatively, one in cab, the other carry out maintenance. Take
care not to touch any moving components.
5. Before maintenance, clean and wash the nearby area around the points to be maintained,
especially thoroughly clean the nearby area of oil filler, filter, oil fitting, case cover to
prevent dust from getting into oil.
6. Remember the pressure in hydraulic circuits is very high. When refilling, draining oil or
checking and maintenance, first release the pressure in them. The method to release
pressure is as follows:
Lower the blade and ripper onto ground and stop the engine, move the control levers
of the hydraulic system to each position 2 to 3 times, then loosen the filler cap or pipe joint
slowly.
7. To replace engine oil, first starting the machine to raise the oil temperature to 30℃~40℃,
then drain the oil.
8. Always use clean oil and grease. Do not inspect or replace oil in dust area, otherwise dust
will enter into oil.
9. Don’t handle electrical system in rain.
10. When checking or adding cooling water, take care not to be injured by hot water spilt out.
11. Bleed the air from the oil circuit after replacing engine oil filter element or strainer.
12. Do not refill oil without the strainer near to the oil filler.
13. Before service gear boxes, empty your pocket. Take care not to drop wrench, nut or other
things into cases so as to cause unnecessary trouble.
14. Make the oil far away fire. Don’t illuminate with fire or flame instead of lamp.
15. To replace O-ring, gasket or other sealing parts, thoroughly clean the parts surface and
install them carefully.

25
 SECTIONⅡ MAINTENANCE TABLE, POSITION OF OIL FILLER AND OIL DIPSTICK
I. MAINTENANCE TABLE:
The maintenance table sees the following table:
No Item Service Remark
Check before starting
1 Oil and water leakage Check
2 Nuts and bolts Check and retighten
3 Electric circuit Check and retighten
4 Cooling water level Check and add
5 Oil level of engine oil pan Check and add
6 Fuel oil level Check and add
7 Oil level in steering clutch case Check and add
8 Water and sediment in fuel tank Drain water and sediment
9 Dust indicator Check, clean air cleaner element
10 Travels of brake pedals Check and adjust
Initial 250 hours service
1 Fuel filter Replace cartridge
Steering clutch case (incl.
2 Replace oil and clean strainer
Transmission and torque converter)
3 Hydraulic tank and filter Replace oil and filter element
4 Final drive case Replace oil
5 Engine valve clearance Check and adjust
Every 250 hours service
Lubrication Check and grease the following points
1 Fan pulley 1 point
2 Tension pulley and its bracket 2 points
1 point for straight-tilt blade
3 Screw of brace
2 points for angle blade
4 Cylinder support shaft 2 points
5 Cylinder support yoke 4 points
6 Tilt cylinder ball joint 1 point for straight-tilt blade
7 Brace ball joint 1 point for straight-tilt blade
8 Arm ball joint 3 points
9 Diagonal arm ball joint 2 points
10 Ripper hinge joints 18 points
11 Engine oil pan and oil filter Drain oil and replace filter element

26
No Item
Transmission oil
12
steering oil filter
13 Final drive case
14 Hydraulic oil tank
15 Alternator drive belt
16 Water pump drive belt
17 Battery electrolyte
18 Fuel tank bottom strainer
1 Fuel filter
2 Breather cap
3 Fan belt
Lubrication
1 Universal joint
2 Diagonal brace
3 Tension rod of idler
4 Radiator fin
5 Steering clutch case
6 Final drive case
7 Hydraulic tank and filter
8 Undercarriage
9 Turbocharger
10 Corrosion resistor
1 Lubrication
2 Equalizer bar shaft
3 Brake pedal
4 Breather cap of engine crankcase Clean
5 Turbocharger
6 Engine valve clearance
7 Engine damper
1 Water pump
2 Fan pulley and tension pulley
1 Air cleaner
Service Remark
filter and
Replace filter elements
Check oil level and replenish oil
Check oil level and replenish oil
Adjust tension
Adjust tension
Check electrolyte level
clean
Every 500 hours service
Replace filter element
Clean
Adjust tension
Every 1000 hours service
Check and grease the following points
8 points
2 points
2 points
Check and clean
Replace oil, clean strainer element
Replace oil
Replace oil and filter element
Check and grease
Check play of rotor
Replace cartridge
Every 2000 hours service
Check and grease the following points
1 point
5 points
Clean
Check and adjust
Check or replace
Every 4000 hours service
Check for pulley looseness and water leak
Check for looseness
When necessary
Clean or replace
27
 No Item Service Remark
Clean interior of the system and replace
2 Cooling system
coolant
3 Track tension Check and adjust
4 Track shoes bolts Check and tighten
5 Cutting edge and end bit Reverse or replace
6 Air intake heater Check or replace

II. POSITION OF OIL FILLER AND OIL DIPSTICK (FIG.4-1, 4-2)

1. Water filler of radiator
2. Engine oil filler
3. Engine oil dipstick
4. Oil drain valve of engine oil pan
5. Oil filler of final drive case
6. Drain valve of fuel tank
7. Fuel tank filler
8. Steering case filler

Fig.4-1 Positions of oil filler

9. Hydraulic tank oil filler
10. Oil level inspection window of hydraulic tank
11. Cooling water drain valve
12. Drain valve of hydraulic tank
13. Drain plug of steering case
14. Drain plug of final drive case

Fig.4-2 Positions of oil filler

SECTION Ⅲ MAINTENANCE
I. INITIAL 250 HOURS SERVICE
Carry out the following maintenance after a new machine has been run for initial 250 hours.
1. Fuel filter
2. Steering clutch (Incl. Transmission and torque converter)
3. Hydraulic tank and filter
4. Final drive case
5. Engine valve clearance
As for method of replacing and service, details see EVERY 500 HOURS, 1000 HOURS
AND 2000 HOURS SERVICES.
II. EVERY 250 HOURS SERVICE
1. Lubrication
Grease the lubricator fittings shown by arrows.

28
1) Fan pulley (Fig.4-3): 1 point
2) Tension pulley and its bracket (Fig.4-4): 2 points

Fig.4-3 Fan pulley Fig.4-4 Tension pulley and its bracket

3) Screw of brace
Straight-tilt blade (Fig.4-5): 1 point; Angle blade (Fig.4-6): 2 points

Fig.4-5 Screw of brace of straight-tilt blade Fig.4-6 Screw of brace of angle blade
4) Oil cylinder support shaft (Fig.4-7): 2 points; (Fig.4-8):2 points

Fig.4-7 Oil cylinder support Fig.4-8 Working equipment oil cylinder bracket
5) Oil cylinder support yoke (Fig.4-9): 4 points

Fig.4-9 Oil cylinder support yoke Fig.4-10 Tilt oil cylinder ball joint

29
 6) Tilt cylinder ball joint for straight-tilt blade (Fig.4-10): 1 point
7) Brace ball joint for straight-tilt blade (Fig.4-11): 1 point

Fig.4-11 Brace ball joint Fig.4-12 Arm ball joint

8) Arm ball joint for straight-tilt blade (Figs.4-12,4-13): 3 points
9) Diagonal arm ball joint for straight-tilt blade (Fig.4-13): 2 points

Fig.4-13 Diagonal arm ball joint Fig.4-14 Ripper hinge points

10) Ripper hinge points (Fig. 4-14): (1) upper connecting rod (8 points); (2) piston rod end
of cylinder (2 points); (3) lower connecting rod pin (4 points); (4) lower connecting rod
shaft (4 points)
2. Engine oil pan and filter
1) Remove the cover plate at the bottom of the
machine body (Fig.4-15).
2) Remove the oil drain plug ① and loosen
drain valve ② to drain oil, screw them
tightly after draining.
3) Turn the cartridges of engine oil filter and
by-pass engine oil filter counterclockwise to
remove them with filter wrench and discard
them.
4) Fill up new cartridges of engine oil filter and Fig.4-15 Oil drain plug of oil pan
by-pass engine oil filter with engine oil and coat the packing surfaces with engine oil.
Install the cartridges on the filter seats. Make sure the packing surfaces of cartridges
contact perfectly with the sealing surfaces of the filter seats, then turn the cartridges
3/4~1 turn by hand.
30
 5) After replacement of filter cartridges, supply
engine oil through oil filler F (Fig.4-16). After
running the engine at idling speed for a while,
check the oil level.
6) Lubricant used depends on ambient temperature.
Refer to appended table KIND AND CAPACITY
OF FUEL, COOLANT AND LUBRICANT.
7) Replace oil every 6 months.
8) Before install cartridge of filter, be sure to fill Fig.4-16 Oil drain plug of oil pan
engine oil in it.
9) Be sure to use genuine brand filter cartridge.
3. Transmission oil filter and steering oil filter
1) Remove the bolt ①, lift cover ②, take out the filter element and valve together with
cover ② (Fig.4-17,4-18)

Fig.4-17 Transmission and steering oil filters Fig.4-18 Structural drawing of oil filter
2) Remove the dish tightening nut ④ of valve, take out the filter element ③ from the
filter. Clean interior of the filter body and the detached parts, then install a new element.

Fig.4-19 Oil filler of final drive case Fig.4-20 Hydraulic tank

Notice: Be sure to use genuine brand filter element.
4. Final drive case
Remove plug G, refill lubricating oil from the plug hole if the oil doesn’t reach the lower
edge of the plug hole. (Fig.4-19)
Notice:
a. The lubricant used depends on ambient temperature. Refer to the appended table
KIND AND CAPACITY OF FUEL, COOLANT AND LUBRICANT.
b. When maintaining, park the machine on flat ground.
5. Hydraulic tank (Fig.4-20)

31
 Put the blade and ripper horizontally on ground and stop the engine, check oil level after 5
minutes. If the oil level lower than the red line in the inspection window G, supply hydraulic oil
from oil filler F.
Notice: When oil is hot, don’t remove the cap, otherwise there will be a danger that the hot
oil will spill out. When removing the cap, turn the cap slowly to release the pressure in tank.
The lubricant used depends on ambient temperature. Refer to the appended table KIND
AND CAPACITY OF FUEL, COOLANT AND LUBRICANT.
Before starting the engine, the routine conventional check should be carried out.
6. Alternator drive belt
Press the belt between the alternator and drive belt with a force of about 60N in the
direction shown by the arrow in the Fig.4-21. The standard deflection is 10mm. Otherwise adjust
the tension. To adjusting, loose the nut tightening the alternator and move the alternator.
Notice:
a. When the belt can’t be readjusted because of excessive deflection or there is rupture,
cut or cracks on it, replace the belt. Be sure to replace the two belts at the same time.
b. Check and adjust the tension again after the new belts have been installed and have
been used for 1 hour.
c. Never contacts v-belt with the bottom of the v-slot.

Fig.4-21 Adjustment of engine belts

7. Water pump drive belt (Fig.4-21)
The method of check and adjustment is as same as alternator drive belt.
8. Battery electrolyte
If the electrolyte level is lower than the prescribed level (10～12mm above the electrode
plate), supply distilled water (Fig.4-23). Should any of electrolyte be spilled out and its capacity
decrease, have it replenished with electrolyte of the same concentration. Before check electrolyte
level, clean the air vent hole on the battery cover.
Notice:
a. Don’t use metal funnel when supplying electrolyte.
b. Don’t bring spark or fire to the vicinity of the battery so as to avoid gas explosion.
c. Should any electrolyte be splashed onto the skin or clothes, wash it immediately with

32
 plenty of water.
9. Fuel tank bottom strainer (Fig.4-22)
Close valve ①, remove the cap ②, take out the
strainer element from the strainer case, clean it and the
case.
III. EVERY 500 HOURS SERVICE
Carry out EVERY 250 HOURS SERVICE at the same
time.
Fig.4-22 Bottom of the fuel tank
1. Fuel filter
1) Close the valve ① at the bottom of fuel tank (see Fig.4-22).
2) Remove the fuel filter cartridge ③ with filter wrench (Fig.4-23).
3) Fill the new filter cartridge up with clean fuel oil and coat a thin layer of engine oil on
the sealing surface.
4) Install cartridge, turn it tight by hand until the sealing surface of sealing gasket contacts
with the filter seat. Then turning it 1/2~3/4 turn further (Take care not to turn it too
tight).
Notice: Be sure to use genuine brand filter cartridge.

Fig.4-23 Fuel filter Fig.4-24 Breather cap of steering case

2. Breather cap
Remove the breather cap, wash the dust accumulated inside it with fuel oil.
1) Steering clutch (Fig.4-24): 1 point
2) Final drive (Fig.4-25): 2 points
3. Fan belt
Check v-belt. Replace it on the following cases:
1) If the v-belt contacts with the slot bottom of the
pulley.
2) If there are cracks or peelings on the v-belt.
Notice: As for replacing method, refer to
“ Adjustment of fan belt”. If an automatic tension device
is mounted, the adjustment of the fan belt is Fig.4-25 Breather cap of final drive
unnecessary.
IV. EVERY 1000 HOURS SERVICE
Be sure to carry out EVERY 250 AND 500 HOURS SERVICE at the same time.

33
 1. Lubrication
Force the grease into the lubricator fitting shown by the arrows.
1) Universal joint (Fig.4-26): 8 points
2) Diagonal brace(Fig.4-27): 2 points
3) Idler tension rod (Fig.4-28): 2 points

Fig.4-26 Universal joint Fig.4-27 Diagonal brace

Fig.4-28 Idler tension rod Fig.4-29 Radiator grill

2. Radiator fins (Fig.4-29)
Loosen the bolt of radiator grill ① and open it, blow away the dust, mud or dead leaves
and other dirt on the fins with compressed air. Also can use water or steam instead of
compressed air.
Notice: Check radiator rubber pipe for cracks or brittleness. Replace it when necessary.
Check the clamps of rubber pipe for loosening.
3. Steering clutch case (Incl. transmission and torque converter)
1) Remove the drain plug ① at the bottom of the machine body to drain oil. (Fig.4-30)

Fig.4-30 Bottom of the machine body Fig.4-31 Oil drain plug of torque converter
2) Remove the cover at the bottom of the machine body oil drain plug ② of torque
converter and to drain oil (Fig.4-31). After draining, tighten the drain plugs ① and
34
 ②.
3) Remove the left floor plate, bolt ①, cover ②, steering clutch strainer ⑤ and
magnet ⑥. (Fig.4-32, 4-33)

Fig.4-32 Left floor of machine body Fig.4-33 Strainer of steering clutch

4) Clean the interior of the strainer case, strainer and the other detached parts, then reinstall
them into original positions. If the strainer is damaged, replace it with a new one.
5) After replacing the transmission and steering filters elements (refer to EVERY 250
HOURS SERVICE), refill specified amount of engine oil from the oil filler F (Fig.4-34).
Lubricant used depends on the ambient temperature. Refer to the appended table KIND
AND CAPACITY OF FUEL, COOLANT AND LUBRICANT.

Fig.4-34 Oil filler Fig.4-35 Final drive

4. Final drive case (Fig.4-35)
1) Remove the oil plugs G of oil filler from both sides of the machine body, then, remove
the oil drain plug P to drain oil, retighten the plug P after draining oil.
2) Refill a specified amount of engine oil from oil filler F (Refer to EVERY 250 HOURS
SERVICE).
Notice: Lubricant used depends on the ambient
temperature. Refer to the appended table KIND AND
CAPACITY OF FUEL, COOLANT AND
LUBRICANT.
5. Hydraulic tank and oil filter
1) Remove the drain plug ① at the bottom of the
tank and loosen the drain valve ② to drain
oil. Then retighten the plug ① and the drain
valve ② after draining (Fig.4-36). Fig.4-36 Drain plug and valve of
2) Remove bolt ③, cover ④ and filter element Hydraulic oil tank

35
 ⑤ (Fig.4-37).
3) Clean the interior of the filter and the detached parts, then mount a new element.
4) Fill with a specified amount of hydraulic oil through the oil filler F (Fig.4-38). (Refer to
EVERY 250 HOURS SERVICE)

Fig.4-37 Oil filter of hydraulic oil tank Fig.4-38 Oil filler of hydraulic oil tank
Notice:
a. Lubricant used depends on the ambient temperature. Refer to the appended table
KIND AND CAPACITY OF FUEL, COOLANT AND LUBRICANT.
b. Be sure to use genuine brand filter element.
6. Undercarriage
Park the machine on flat ground, and check the oil level of track rollers, carrier rollers and
idlers one by one (Fig.4-39).

Fig.4-39 Track Fig.4-40 Corrosion resistor

1) Loosen the sealing plug ① slowly and see if the oil is oozing through the screw thread.
If it is so, it is the proof that oil is plenty. So, immediately retighten the plug.
2) If oil doesn’t ooze out even if the plug has been removed away, it is the proof that oil
level is low. At this time, ask the local distributor of the Company to make necessary
repair.
7. Rotor play of turbocharger
Please contact with local distributor of our company for necessary check or repair.
8. Corrosion resistor (water filter element) (Fig.4-40)
1) Close water inlet valve and outlet valve of corrosion resistor.
2) Turn the cartridge of the corrosion resistor counterclockwise to remove it with filter
wrench.

36
 3) Replace with a new cartridge with engine oil coated on the sealing surface.
4) When installing the cartridge, turns it further by 1/2~3/4 turn after the sealing surface
touches the cover (Be careful not to tighten it excessively).
5) After replacement, open the valves.
Notice: Be sure to use genuine brand cartridge.
V. EVERY 2000 HOURS SERVICE
Carry out the EVERY 250 HOURS, 500 HOURS AND 1000 HOURS SERVICE at the
same time.
1. Lubrication
Fill the grease to the lubricator fittings shown by the arrows.
1) Equalizer bar shaft (Fig.4-41): 1 point
2) Brake pedal shaft (Fig.4-42): 5 points

Fig.4-41 Equalizer bar shaft Fig.4-42 Brake pedal shaft

2. Turbocharger
Excessive black carbon and greasy filth adhering to the impeller may deteriorate the
proper performance of the turbocharger. Sometimes they may damage the turbocharger.
Please contact with the local distributor of our company for necessary check or cleaning.
Notice: Be careful not to use steel brush or the like so as to avoid damaging the surface of
the impeller.
3. Valve clearance
Please contact with the local distributor of our company to check the valve clearance
because this job requires special tools.
4. Engine vibration damper
Note: The engine is equipped with viscous vibration damper.
Check damper for bump, run-out and any reduction of damp fluid. Estimate the thickness
of the damper with eyes to check it for distortion or deformation of front cover plate, or feel both
sides of the damper around it with finger to check if there any distortion or deformation. If this is
the case, contact with local distributor of our company for necessary check and replacement.
VI. EVERY 4000 HOURS SERVICE
Notice: Carry out EVERY 250 HOURS, 500 HOURS, 1000 HOURS and 2000 HOURS
SERVICE at the same time.
1. Water pump
Check pulley for looseness, grease or water for leak. If so, contact with local distributor of

37
our company for repairing or replacing the water pump.
2. Fan pulley and tension pulley
Check pulleys for looseness and grease leakage. If there is any looseness, contact with
local distributor of our company for repair or replacement of pulley assembly.
VII.SERVICE WHEN NECESSARY
Check and service the following items in time
according to actual conditions.
1. Air cleaner
1) Check:
Clean air cleaner element whenever the pilot light
of monitor air cleaner element flickers. Before cleaning,
stop the engine.
2) Clean or replace outer filter element
a. Remove the wing nut ① and outer filter element Fig.4-43 Air cleaner
(Fig.4-43, 4-45).
b. Clean interior of air cleaner case.
c. Clean and check outer filter element (As for cleaning method, refer to “Method for
cleaning outer filter element”). After each cleaning operation of outer filter element,
tear off a letter code card (Fig.4-44) on the inner filter element. Install the cleaned outer
filter element and removed parts.

Fig.4-44 Outer element of air cleaner Fig.4-45 Air cleaner element

Notice:
a. Replace the outer filter element if it has been cleaned for 6 times or used for a year. At
the same time replace the inner filter element.
b. If the sealing washer ② or wing nut ① is damaged, replace them (Fig.4-45).
c. Check mounting nut of inner filter element for looseness. If loose, retighten it.
3) Replace inner filter element (when the outer filter element has been cleaned 6 times or
inner filter element has been damaged).
a. First remove the outer filter element, then remove the inner filter element.
b. Cover the air inlet.
c. Clean the interior of the air cleaner case, then remove the cover of the air inlet. Fit a
new inner filter element onto the connector and tighten the nut. Fit outer filter
element.
Notice:
a. Never try to use the cleaned inner filter element.
38
 b. Do not replace or clean the filter elements of the air cleaner when engine is running.
4) Method for cleaning the outer filter element
a. With compressed air (Fig.4-46)
Direct dry compressed air (less than 0.7MPa)
to blow the element from inside along its folds,
then direct it from outside along its folds and
again from inside, then check the element.
When using compressed air, wear safety
goggles and other things required for sake of
safety.
Fig.4-46 Outer element of air cleaner
b. With water
Rinse element with city water (less than 0.3MPa) along its folds from inside, then from
outside and again from inside. Dry and check it
c. With detergent
To clean the grease, dirt and black carbon on the element,
soak and rinse the element in warm water containing neutral
detergent, then rinse it with clean water. Dry and check it.
Notice:
a. Direct dry compressed air (less than 0.7MPa) to blow
element from inside to outside repeatedly to quicken
drying. Never dry the element by heating.
b. It is also very efficient to use warm water (approx.40℃) Fig.4-47 Outer element
instead of soapsuds.
c. After cleaning and drying, if small holes or thinner parts are found on element when it
is checked with electric bulb, replace the outer element (Fig.4-47).
d. If the outer element is usable, pack and store it in dry place.
e. When cleaning outer element, never knock or strike it with other objects.
f. Never use the outer element of uneven folds or deformed element, also not use the
element of damaged sealing washes.
2. Cleaning interior of cooling system
1) Clean the interior of cooling system, replace coolant and corrosion resistor according to
the following table:
Table of cleaning the interior of cooling system
Interval for cleaning interior of cooling Time for replacing
Type of antifreeze
system and replacing coolant corrosion resistor
Perform once a year (in autumn) or 2000 Perform when
Permanent antifreeze
hours (depends on which one comes carrying out
(suitable for all seasons)
first) EVERY 1000
Non-permanent antifreeze Perform once 6 months (in spring and HOURS SERVICE
containing ethylene glycol autumn)(Drain the antifreeze in spring or cleaning interior
base (suitable for winter) and add antifreeze into water in winter) of cooling system
Perform once 6 months or 1000 hours or when replacing
No antifreeze
(depends on which one comes first) coolant

39
 Notice:
a. Park the machine on flat ground when cleaning the interior of cooling system or
replacing coolant.
b. Use permanent antifreeze as far as possible. If the permanent antifreeze isn’t
available, use the antifreeze containing the ethylene glycol base.
c. Be sure to replace cartridge of corrosion resistor (water filter element).
d. Be sure to use city water as cooling water.
e. Antifreeze is inflammable, so keep it away fire.
Cleaning methods:
a) Stop the engine, close the water inlet and outlet valves (1) of corrosion resistor
(Fig.4-48).
b) Turn the radiator cap ② slowly to open it (Fig.4-49).

Fig.4-48 Corrosion resistor Fig.4-49 radiator water filler

Notice: If the water is very hot, don’t remove the cap to prevent hot water from
spilling out. When remove the radiator cap, turn it slowly to release the pressure in
radiator.
c) Loosen water drain valve ③ on the bottom of radiator and water drain valves on
both sides of oil cooler to drain cooling water (Fig.4-50).
d) Close water drains valves, then fill clean
water (city water) until the water reaches the
edge of filler.
e) When the water comes to the edge of filler,
idle the engine and open the water drains
valves. At the same time refill the radiator
continuously with clean water. Stop
supplying water until the clean water has
flowed out of the drain valves continuously
Fig.4-50 radiator water drain valve
for 10 minutes.
Notice: When draining water, adjust the water flowing speed to make the amount
of water refilled in equal to that of water drained, and keep the tank always is full of
water.
f) After cleaning, stop the engine. Open the water drain valves to drain up water. Then
close the drain valves.
g) Use detergent available on market to clean cooling system. Be sure to adhere to the

40
 usage of the detergent.
h) After cleaning, drain up water and close drain valves. Then supply clean water (city
water) slowly until the water level come to the edge of the filler.
i) When the water level comes to the edge of the filler, idle the engine and open the
valves to drain water. At the same time supply clean water to radiator continuously
until clean water is seen flowing out from the drain valves.
Notice: When draining water, adjust the water speed to make the feeding amount
equal to draining amount so as to ensure the radiator is full of water.
j) When the water becomes absolutely clean, stop the engine and close all drain valves.
k) Replace the cartridge of corrosion resistor and open water inlet and outlet valves.
Notice: As for replacement of corrosion resistor, refer to EVERY 1000 HOURS
SERVICE.
l) Supply water until the water overflow out of the filler.
m) After idling engine 5 minutes, run the engine at middle speed for 5 minutes to bleed
air accumulated in the cooling system.
Notice: When bleeding the air, the radiator cap should be kept open.
n) Stop the engine, supply water to specified level after 3 minutes. Then tighten the
cap.
3. Track tension
1) Check:
Park the machine on flat ground without stepping
down the brake, place a rod on the track between the
sprocket and idler (Fig.4-51). When the distance
between rod and track shoe grouser at the middle span
is 20~30mm, the track tension is suitable.
2) Adjust:
a) To increase the track tension, force in grease Fig.4-51 check of track tension
through grease fitting (Fig.4-52). On the other hand, discharge grease by turning the
plug to the opposite one turn to decrease the tension. If the track tension is still small
even though the grease is forced in such a quantity that the distance S diminishes to
0mm (Fig.4-53), it indicates the pin bushing has become thin due to excessive wear.
Please contact with the local distributor of our company for repair or replacement of
track.

Fig.4-52 Adjusting rod of idler Fig.4-53 Adjusting distance of idler

b) When loosening the plug, do not loosen it more than one turn. Also be careful not to

41
 loosen any parts other than the plug.
c) If the plug or other parts are excessive loose, the parts would be liable to fly out under
high pressure of grease refilled. If grease can’t be forced in easily, try moving the
machine back and forth for a short distance.
4. Check and tighten the shoe bolts
If the track shoe bolts become loose, the track shoes would be liable to breakdown. Be
sure to retighten loose bolts as soon as the bolts are found to become loose.
1) First, tighten the bolt with a torque of 400±40N.m, then check whether the nuts and
track shoes contacts with the touching surface of links tightly.
2) Tighten it further after check, turn it an angle of 120°±10°.
5. Reversing or replacing the cutting edge and end bit (Fig.4-54)
When cutting edge and end bit are worn to
the vicinity of mounting surface, reverse cutting
edge and replace end bit. If the both sides of
cutting edge are worn seriously, replace cutting
edge.
1) Lift the blade to a proper height, place a
block under the push arm to prevent blade
from dropping.
2) Remove cutting edge and end bit and
Fig.4-54 Replacement of
clean the mounting surface. cutting edge and end bit
3) Replace with new end bit and reverse
cutting edge (or replace with a new one), and tighten them with the nuts. The tightening
torque is 627±78Nm (64±8kgm).
4) After operating for several hours, retighten nuts.
6. Air inlet heater
Check air inlet heater before starting operation in every winter. Remove the air inlet heater
from the coupling seat of engine air inlet, and check the electrical circuit for normal operation
and dirt.
When check and replace air inlet heater, replace old seal washer with new one.

SECTION Ⅳ ADJUSTMENT OF EACH COMPONENT

I. STEERING BRAKE
1. Check
When the brake linings are worn, steering
will be difficult due to increased steering pedal
travel. When the travel exceeds 190mm (braking
fore is reduced), make the following adjustment:
a) Standard travel:110~130mm (operating
force is 150N when the engine is running
at idling speed) (Fig.4-55)
b) 75mm (when the engine is stopped)
2. Adjustment Fig.4-55 Adjustment of pedal travel
42
 a. Remove the rear cover and inspection hole cover
(Fig.4-56).
b. Tighten adjusting bolt ① with the torque of
50N.m to make the brake linings contact tight
with brake drum (step down the brake pedal to
confirm the contacting state).
c. Turn the adjusting bolt ① 7/6 turns to the
opposite direction to make the clearance between Fig.4-56 Steering brake
the brake drum and brake band be 0.3mm.
d. Be sure to make both pedals travels equal, otherwise braking flexibility of both sides is
not identical.
II. IDLER
Due to passive rotation of idler for long time, the idler side guide plates, up-and-down guide
and guide plate will be worn gradually. Thus causes idler to swing to left or right, or incline to
one side, which will cause the track link to slide off idler or idler and track links be worn
unequally due to this swing or inclination. Therefore, adjust idler timely to make it rotate
normally according to the following procedure:
1. Adjustment of sides clearance:
Move the machine 1~2m on flat ground to make track tension evenly, then stop the
machine and check clearance A between external cover of idler and track frame (left, right, top
and bottom four clearances on each side) (Fig.4-57).
If any of four clearances exceeds 4mm, loosen bolt ①, pull out a certain amount of
shims ② (Fig.4-57) to adjust the clearance to standard value of 0.5~1.0mm. The thickness of
each shim is 0.5~1.0mm.
Notice: When loosening bolt ①, be careful not to loosen bolt more than 3 turns.

Fig.4-57 Adjustment of side clearance of track frame Fig.4-58 Idler

2. Adjustment of the clearance between slide plate and idler brackets:
Measure the clearance B (Fig.4-58) between idler bracket ③ and slide plates ④ and
clearance C between hanging plate ⑤ of track frame and wear plate ⑥ of track frame. If the
sum (B+C) exceeds 5mm, adjust it to 2mm.The method is: take out the necessary amount of
shims from shim ⑦ to reduce the thickness of shim ⑦ to required value and add the
removed shims to the shim ⑧. The procedure of the adjustment is as follows:
Under normal condition, clearance C is zero (C=0mm).

43
 1) Measure clearance B, subtract 2mm from the measured value B, the result is the
adjusted thickness of shims. For example: when B is 5mm (B=5mm), the thickness of
adjusted shims is 3mm (5-2=3mm).
2) The shim ⑦ and ⑧ can be pull out.
3) Loosen the bolt ⑨ (4 bolts on internal and external side) until the force of spring is
fully released.
4) Loosen the bolt ①, take careful not to loosen it more than 3 turns.
5) Pry up the hanging plate ⑤ to adjust it with a lever to make the clearance C=0mm.
Take out the shim ⑦ whose thickness has been calculated in the step 1).
6) Add the removed shim ⑦ to shim ⑧ (8 positions, internal side and external side of
left and right idlers, front and rear of each side).
Notice: The total thickness of shim ⑦ and shim ⑧, after adjusting, should be equal
to that of before adjusting. The pre-load of spring mounted on guide device would be
improper if the total thickness of shim increases or decreases improperly (shim ⑦ and
⑧ are grouped by some 1mm thick shims and 2mm thick shims).
7) Tighten bolt ⑨ of spring seat.
8) The tightening torque of bolt ① is 500~620Nm.
Notice: Max. Allowable adjusting amount of hanging plate in the vertical direction is
6mm.
III. DECELERATION PEDAL
When the fuel control lever is placed at half stroke position with deceleration pedal
(clearance A=0) stepped down, if the engine speed is not within the range of 800~850rpm, make
the following adjustments (Fig.4-59):
1. Loosen lock nut ①, make adjustment by turning
screw ② to make engine speed be 850rpm
when stepping down the deceleration pedal
(clearance A=0)
2. After adjusting, lock the nut ②.
Note:
a. Increasing the force of stepping down the pedal
to overcome the force of spring will make the
engine run at idling speed.
b. To confirm the engine speed precisely, an Fig.4-59 Deceleration pedal
engine speed gauge is required. Please contact with local distributor of our company.
IV. FAN BELT
The fan belt tension is a constant because it is equipped with an automatic tension device
and the fan belt tension has nothing to do with elongation of v-belt. So it is unnecessary to adjust
the tension unless the belt are damaged.
When replacing v-belt, two belts should be replaced at the same time.
V. UNDERCARRIAGE
1. Adjustment and check of track tension
When operating in stony area, the track should be tighter.
When operating in clay and sandy soil area, the track should be looser. (As for adjusting
44
and checking method, refer to “MAINTENANCE
WHEN NECESSARY”)
2. Measure of the grouser height
Take a tightened track shoe, measure the height
of grouser (Fig.4-60)
a. Standard height of grouser (H): 72mm
b. Service limit (H): 25mm
3. Measure of the external diameter of track
roller (Fig.4-61) Fig.4-60 Measure of the grouser height
Check and measure size “C” and “B” of link,
calculate the external diameter of track roller “A”: A=(B－C)×2
a. Standard diameter(A): 222mm
b. Service limit (A): 198mm

Fig.4-61 Measure of external diameter of track roller Fig.4-62 Shank of ripper

VI. ADJUSTMENT OF BLADE

(Refer to “CHAPTER Ⅲ DOZING OPERATION”)
VII.ADJUSTMENT OF RIPPING DEPTH OF RIPPER (FIG.4-62)
The ripping depth of ripper can be adjusted through the two pin mounting holes on the
upper part of the shank. Generally the lower hole are used. To increase the depth of ripping depth,
the upper hole is used. To adjust, direct a steel bar with tip at the end against pin ①, then
hammer the bar to pull out the pin ②. Thus the mounting position of shank hole is changed.
VIII. REPLACEMENT OF RIPPER SHANK SLEEVE AND TOOTH TIP
(FIG.4-74)
If the shank sleeve and the tooth tip of ripper shank are worn seriously, replace them. To
replace, hammer out the pins as shown by arrows in the Fig.4-62.
To prolong the service life of ripper, exchange mounting positions of three shanks sleeves
and teeth tips according to wearing degree of three teeth tips.

45
 CHAPTERⅤ TROUBLE-SHOOTING
Not all trouble conditions and trouble-shooting methods are included in this chapter, but
most of common troubles are included in it.

SECTIONⅠENGINE
I. WHEN ENGINE RUNS AT HIGH SPEED, ENGINE OIL PRESSURE
PILOT LAMP FLICKERS CONTINUOUSLY:
1. Supply engine oil to specified level.
2. Replace engine filter element
3. Check pipes and joints for oil leakage.
4. Replace pilot lamp.
II. STEAM EMITS OUT FROM THE TOP OF RADIATOR (PRESSURE
VALVE); WATER LEVEL PILOT LAMP OF RADIATOR FLICKERS:
1. Add cooling water and check for water leakage.
2. Adjust fan belt tension.
3. Clean interior of cooling system.
4. Clean or repair radiator fins.
5. Replace thermostat.
6. Tighten radiator cap or replace the sealing pad.
7. Replace water level pilot lamp.
III. THE WHITE RANGE OF THE WATER TEMPERATURE INDICATOR
IS LIGHT UP:
1. Replace water temperature pilot lamp.
2. Replace thermostat.
3. Replace water temperature sensor.
IV. ENGINE DOESN’T START UP WHILE STARTING MOTOR IS
RUNNING:
1. Refill fuel
2. Check fuel system for air.
3. Rectify or replace oil pump or injector.
4. Check valve clearance.
5. Starting motor speed is low (refer to electrical system).
V. WHITE OR BLUE EXHAUST GAS:
1. Adjust amount of oil in engine oil pan according to regulation.
2. Replace with specified fuel.
3. Check turbocharger for oil leakage.
VI. BLACK EXHAUST GAS:
1. Clean air cleaner element.
2. Replace oil injector.
3. Clean or replace turbocharger.
46
VII. ABNORMAL COMBUSTION NOISE OR MECHANICAL NOISE:
1. Replace with specified fuel.
2. Check engine for overheating.
3. Replace muffler.
4. Adjust valve clearance.

SECTIONⅡ ELECTRICAL SYSTEM

I. LAMPS BECOME DIM WHEN ENGINE RUNS AT HIGH SPEED;
LAMPS TWINKLE WHEN ENGINE IS RUNNING:
1. Check terminal for looseness and circuit for cut-off;
2. Adjust alternator belt tension.
II. BATTERY CHARGING PILOT LAMP DOESN’T GO OUT WHEN
ENGINE IS RUNNING AT HIGH SPEED:
1. Replace alternator;
2. Check and repair electric circuitry.
III. ALTERNATOR SOUNDS ABNORMAL: REPLACE ALTERNATOR.
IV. STARTING MOTOR DOESN’T RUN WHEN STARTING KEY IS
TURNED TO START POSITION:
1. Check and repair electrical circuitry;
2. Charge the battery;
3. Replace starting motor.
V. PINION GEAR OF STARTING MOTOR RUNS ABNORMALLY:
CHARGE THE BATTERY.
VI. STARTING MOTOR TURNS SLOWLY:
1. Charge battery;
2. Replace starting motor.
VII. STARTING MOTOR HAS DISENGAGED BEFORE THE ENGINE IS
STARTED UP:
1. Check and repair circuitry;
2. Charge the battery.
VIII. ENGINE OIL PRESSURE PILOT LAMP STILL LIGHTS WHEN THE
ENGINE STOP RUNNING (STARTING KEY IS SET IN ON
POSITION):
1. Replace engine oil pressure sensor;
2. Check and repair wiring.
IX. THE EXTERNAL CASE OF INTAKE AIR PRE-HEATER ISN’T HOT
WHEN FELT BY HAND:
1. Check and repair wiring;
2. Replace intake air pre-heater;

47
 3. Check and repair pre-heater switch.

SECTION Ⅲ CHASSIS
I. OIL PRESSURE IN TORQUE CONVERTER DOESN’T RISE (MACHINE
CANNOT TRAVELS):
1. Check and repair air leak points of oil pipe and pipe connector;
2. Check, repair or replace gear pump;
3. Replenish transmission with oil;
4. Clean and replace transmission oil filter.
II. HYDRAULIC TORQUE CONVERTER OVERHEATS:
1. Tension or replace fan belt;
2. Refer to the SECTION of ENGINE;
3. Clean or replace oil cooler;
4. Refer to the part “Torque converter oil pressure doesn’t rise”.
III. MACHINE DOESN’T TRAVEL WHEN TRANSMISSION CONTROL
LEVER IS SET TO ANY GEAR
1. Replenish steering clutch case with oil;
2. Refer to the part “Torque converter oil pressure doesn’t rise”;
3. Check, repair or replace gear pump;
4. Clean oil filter.
IV. MACHINE MOVES STRAIGHT WHEN STEERING LEVER ON
EITHER SIDE IS PULLED: ADJUST BRAKE.
V. MACHINE DOES NOT STOP WITH THE BRAKE PEDAL STEPPED
DOWN: ADJUST BRAKE.
VI. TRACK SLIPS OFF FROM THE LINKS AND SPROCKET IS WORN
EXCESSIVELY: ADJUST TRACK TENSION.
VII. BLADE DOESN’T RISE OR RISE TOO SLOWLY: SUPPLY OIL TO
HYDRAULIC TANK.

48
CHAPTER Ⅵ TRANSPORTATION AND STORAGE OF BULLDOZER
SECTIONⅠTRANSPORTATION
When transporting machine, understand and observe traffic rules, road transportation
vehicle law and vehicle limit rules etc.
When traveling across a bridge or tunnel, check the load limit of the bridge and the space
size of the tunnel.
When load a machine onto a trailer with a gangplank, observe the following rules:
(Fig.6-1).

Fig.6-1 Loading and unloading machine with gangplank

1. Properly apply the brakes on the trailer and insert blocks beneath the tires to ensure that it
does not move.
2. Make sure the gangplank has sufficient width, length and thickness to ensure the machine
to be safely loaded and unloaded. When necessary, insert a block under it to reinforce.
3. Take aim at the direction of the gangplank, then slowly load or unload the machine.
4. Do not change the traveling direction of the machine while it is travelling on the gangplank.
To change the traveling direction of the machine, first back the machine to ground from the
gangplank, then change the traveling direction.
5. Make sure loading the machine onto the proper part of the trailer. Hold it securely in place
by applying square timber to front and rear track shoe and by fastening machine with chain
or wire rope to avoid accident due to on –the-road slipping out.
6. Lower the blade, keep various control levers in the following places:
(1) Fuel control lever in IDLING position. Pull out the starting key.
(2) Transmission control lever in NEUTRAL position.
(3) Blade control lever in HOLD position.
(4) Brake lock lever in LOCK position.
Notice:
a. If the width of blade is more than that of trailer, change the direction of blade or remove
the blade and remount it.
b. Take anti-rusting measures and coat the part of cylinder piston rod exposed in air with
anti-rusting oil for a long distance marine transportation.

SECTIONⅡ STORAGE
I. BEFORE STORAGE
To store the machine for quite a long time, the following measures must be taken to ensure
that it can be returned to operation with minimum service.
1. After every part is cleaned and dried, house the machine in a dry building. Never leave it

49
 outdoors. In case it is indispensable to leave it outdoors, lay wood plates on the ground and
park the machine on the wood plates and cover it with canvas.
2. Before storage, supply sufficient fuel and lubricant and replace engine oil.
3. Apply a thin coat of lubricant on metal surface (piston rods).
4. As to batteries, remove the terminals and cover it completely and store separately.
5. When the atmospheric temperature is anticipated to drop to below 0℃, add antifreeze in the
cooling water beforehand.
6. All control levers and pedals are set as follows:
a. Transmission control lever in the NEUTRAL position.
b. Fuel control lever in the Low speed position.
c. Blade control lever in the HOLD position.
d. Brake pedal in FREE position.
II. DURING STORAGE
Start the engine and travel the machine for a short distance once a month so that the new oil
film will be generated on the surface of every part of the machine and engine.
Notice: To operate the working equipment, wipe off the grease on hydraulic cylinder piston
rods.
III. AFTER STORAGE
After storage (when it is kept without cover or the rust-preventive operation once a month
is not made), be sure to do the following treatment before operation.
1. Remove the drain plugs on oil pan and other cases to drain water mixed in them.
2. Remove the block head and lubricate every valves as well as rocker arm, inspect the valve
operation.
3. Run the engine at low speed to exhaust air from hydraulic system and carry out the
following operation: Each cylinder should be moved back and forth 4-5 times and piston
should stop at 100mm far from the stroke end. Next, each hydraulic cylinder should be
moved back and forth 3 or 4 times to the stroke end.
Note: If the engine operates at high speed or the piston moves to the stroke end at the very
beginning, the intruded air may damage piston ring.
4. After the engine is started, run it until it is warmed up successfully.

50
 APPENDED TABLE: KIND AND CAPACITY OF FUEL,
COOLANT AND LUBRICANT
Meet with
RATED
PARTS NAME AND MODEL STANDARD
CAPACITY(L)
Grade 1 light fuel:
Fuel tank Winter: -10#~-50# 480 GB 252-2000
Summer: 0#
Viscosity grade
accords with the
Diesel engine oil
CF-4 15W/40 45 standard SAE; the
pan
performance grade
accord with the API.
Steering case Hydraulic drive oil: 6# 122 Q/SH 013.01.022-1991
Grade CD diesel engine oil:
Hydraulic tank 110 GB 11122-1997
10w/30#
Track roller (each) 0.28~0.32
Gearing oil for heavy-duty
Carrier roller (each) 0.41~0.53 GB 13895-1992
vehicle: 85W/90
Idler (each) 0.28~0.32
Grade CD diesel engine oil:
Final drive 36 GB11122-1997
10W/30#
Bearings and
2# or 3# Lithium soap grease GB 7324-1987
articulating parts
Winter(0 ℃ ):water added
with antifreeze
Radiator Summer: water 79
Or water added with
antifreeze for all around year

51