POWERPLUS D85EX-15 BULLDOZER

OPERATIONAL & MAINTENANCE MANUAL

 Contents
Foreword ....................................................................................................................... 1
Code for commissioning of new machine ...................................................................... 3
Safety Notices ............................................................................................................... 3
Chapter1 ― General .................................................................................................... 6
1 Product appearance........................................................................................ 6
1.2 Technical parameters ...................................................................................... 7
1.2 Technical parameters ...................................................................................... 8
1.3 Dimensions ..................................................................................................... 9
Chapter 2 ― Structure and Principle ........................................................................11
2.1 Transmission description (figure 2-1a) (figure 2-1b) ......................................11
2.2 Radiator ........................................................................................................ 14
2.3 Power take off (P.T.O) ................................................................................... 16
2.4 Torque converter (figure 2-5a, 2-5b) ............................................................. 17
2.5 Cardan joint .................................................................................................. 21
2.6 Transmission................................................................................................. 22
2.7 Bevel gear..................................................................................................... 33
2.8 Steering clutch .............................................................................................. 36
2.9 Steering brake............................................................................................... 38
2.10 Final drive ..................................................................................................... 40
2.11 Running system ............................................................................................ 42
2.12 Hydraulic system .......................................................................................... 50
2.13 Electrical system ........................................................................................... 80
2.14 Working equipment ....................................................................................... 82
Chapter 3 ― Function and Operation of Each Equipment .................................. 87
3.1 Arrangement of instruments and control devices .......................................... 87
3.2 Usage of instruments and control devices .................................................... 88
Chapter 4 ― Driving .................................................................................................. 94
4.1 Pre start up check(Figure 4-1) ...................................................................... 94
4.2 Start-up of engine (Figure 4-2) ...................................................................... 94
4.3 Manual operation of fuel cut valve ................................................................ 95
4.4 Operation of engine ...................................................................................... 95
4.5 Shutdown of engine ...................................................................................... 96
4.6 Start-up of the bulldozer (Figure 4-4) ............................................................ 96
4.7 Forward, reverse and transmission of bulldozer ........................................... 97
4.8 Turning of bulldozer ...................................................................................... 97
4.9 Temporary stopping of bulldozer (Figure 4-7) ............................................... 98
4.10 Operation during cold weather ...................................................................... 99
Chapter 5 ― Maintenance ....................................................................................... 103
5.1 Maintenance considerations ....................................................................... 103
5.2 Maintenance list .......................................................................................... 104
5.3 Specific tasks of maintenance ..................................................................... 107
5.4 Wear parts................................................................................................... 129
5.5 Adjustment .................................................................................................. 130
Chapter 6 ― Safety Operation Code and Safe Construction Technology ....... 140
6.1 Safety operation code ................................................................................. 140
6.2 Safe construction technology ...................................................................... 143
Chapter 7 ― Common Fault and Troubleshooting ............................................... 150
7.1 Electrical ..................................................................................................... 150
7.2 Engine ......................................................................................................... 151
7.3 Chassis ....................................................................................................... 152
Chapter 8 ― Electrical System ............................................................................... 153
8.1 Electronic monitor ....................................................................................... 153
8.2 Starting motor .............................................................................................. 156
8.3 Charging system ......................................................................................... 157
8.4 Lighting system ........................................................................................... 157
Chapter 9 ― Transportation and Storage .............................................................. 158
9.1 Transportation ............................................................................................. 158
9.2 Storage ....................................................................................................... 159
(Annex) ................................................................................................................... 161
Chapter 1 ― Structural Principle ........................................................................... 161
1. Hydraulic principle ....................................................................................... 161
1.1 Lifting hydraulic pipe line of straight blade bulldozing plate (Figure 1-1 and
Figure 1-2) .................................................................................................. 161
1.4 Main operating valve of working equipment (Figure 1-6) ............................ 165
1.5 Pilot control handle of push broach (Figure 1-7) ......................................... 167
1.6 Overflow valve (Bulldozer)(Figure 1-8)........................................................ 167
Foreword

POWERPLUS D85EX-15 Bulldozers adopt advanced hydro-mechanical transmission

and hydraulic operation technologies and are provided with electronic monitor with
three-stage alarm. They are characterized by advanced and reasonable whole structure,
reliable quality, easy-to-operate and high productivity.

Such bulldozers can be provided with several auxiliaries such as single cab, ROPS cab,
air-conditioned cab, canopy, straight blade dozer, angle blade dozer, U-blade dozer and
ripper according to customer’s demands.

Bulldozer is mainly used for earthwork in large project sites such as mines area,
roadbed, reservoir and power plant while bulldozer is applicable to low specific pressure
areas such as marshland.

For continuous and further improvement and modification, contents contained in this
document may vary from real products. Please inform the commerce department
without delay in the event of occurrence of difference.

In order to be in compliance with the requirements of Construction Machinery and

Equipment ―Methodology to Formulate Model Numbers, some modifications were
made in model numbers of our products.

Notes:

1. Prior to operation, this instruction manual shall be read carefully and thoroughly.
Indiscretion and carelessness must be avoided.

2. The bulldozer is designed specially for application on muddy and soft grounds.
Misuse such as frequent operation on hard ground and road with rocks will
shorten lifespan of chassis，and even cause deformation or break-down of track
shoe and crushing of track pin. In this course, unnecessary losses on users will
be resulted.

3. Information concerning safety of personnel and machines and important

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technical specifications in this manual will be identified and highlighted by
symbols as ！and ★, which require for more attention.

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Code for commissioning of new machine

Though the product was successfully commissioned in shop, careful operation is still
required during the initial 100 operating hours for running-in of parts.

Improper operation in the initial phase will lead to early failure of structures and
functions of bulldozer and shorter lifespan. Therefore, the following work shall be done
with care for new bulldozer:

1. Check prior to start-up (refer to Section 4.1 of Chapter 4);

2. Keep the bulldozer in idling operation for at least 5 minutes after start-up so that it
will warm up normally and come into work state gradually;

3. Avoid heavy-duty or high-speed operation;

4. Avoid hasty start-up, fast acceleration, unnecessary emergency shut-down or

shape turning;

5. Observe and make adjustment at any time to keep vehicle in normal conditions;

6. After 250 operating hours, vehicle shall be inspected and maintained according to
maintenance program for initial 250 operating hours and the following items:

Maintenance program for initial 250 operating hours (refer to Section 5.2 of Chapter 5);

Operating hours are subject to the value shown on the timer;

When replacing oil filter element, check it for dirt. In the event of severe dirt
accumulation, reason shall be found out prior to replacement, so as to eliminate hidden
problems.

Safety Notices

1. Prior to start-up, this instruction manual shall be read thoroughly. The bulldozer
can't be operated in required sequence only until full understanding of structural
principles is ensured.

2. Only trained driver with certificate can take the post. Personnel who is under the
alcohol influence, overtired or irrelevant to this job shall not serve as the driver.

3. Labour protective garments and other protective articles shall be worn according
to working environment and conditions.

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4. The driver shall be familiar with safety devices on the bulldozer and their
operation.

5. The driver shall be familiar with related traffic regulations and operation of fire
fighting equipment.

6. During fuel filling or repair, the bulldozer shall be kept away from heat resources.
Smoking is by no means allowable.

7. Before construction, the driver shall get familiar with information such as
geological conditions of project site, surrounding environment and underground
facilities.

8. Before start-up, barriers inside and outside the bulldozer and in surrounding field
shall be removed.

9. Before start-up, check the bulldozer for technical conditions.

10. Driving is unallowable if the bulldozer is in imperfect conditions. Irrelevant

personnel shall not stay in the cab.

11. After start-up of engine, check the bulldozer to ensure it in normal conditions.

12. In the event of fault detected during commissioning, it shall be eliminated

promptly.

13. For minor faults or faults that immediate elimination is impossible, operation can’t
be resumed without approval of leader.

14. Ventilation and cooling measures shall be taken in working place to avoid
positioning and sunstroke of driver and overheat of vehicle.

15. Get on and off the bulldozer by means of stairs and handrails instead of jumping
to ensure safety.

16. Sufficient lighting facilities shall be provided during night driving or operation.

17. Be careful when crossing slope areas covered by hail, snow, thick falling leaf,
bush, downtree and rolling rock and driving after rain on slope to avoid overturn.

18. After stopping, keep the bulldozer into breaking state. Put the bulldozing plate on
the ground. Keep blocking rods of all operation devices into locking positions.

19. Operating with malfunctions or over operating is prohibited in order to ensure

safety of personnel and vehicle.

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20. For operation in special conditions refer to driving considerations in special
conditions.

21. Model and type of oil and coolant used in vehicle is dependant on working
environment and temperature. Usage of them shall conform to Table of Fuel,
Lube Oil and Coolant.

22. Antifreeze solution shall not be prepared by mixing carbinol and ethanol or
engine fault is likely to occur. For antifreeze solution is combustible, it shall be
kept away from heat resources.

23. Soft water such as tap water shall be used as cooling water. Usage of hard water
such as well water shall be avoided.

24. Addition of preservative into cooling water is prohibited.

25. Regularly clean or replace filters.

26. Check and fill coolant, fuel, lube oil and hydraulic oil as required any time.
Start-up of engine: Key shall not stay in starting position for more than 20s during
non-cold period. Ether device can be used during cold period but starting can’t
last for more than 20s either. In case of failure to start, start again 2 minutes later.

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 Chapter1 ― General
1 Product appearance

Figure 1-1 D85EX-15 Bulldozer

Figure 1-2 D85EX-15LGP Bulldozer

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 1. Engine
2. Lifting cylinder
3. Cab
4. Fuel tank
5. Track
6. Bogie
7. Sprocket
8. Carrier roller
9. Push rod
10. Front idler
11. Cutting blade
12. Bulldozing plate
13. Blade edge
14. Ripper

1.2 Technical parameters

Model D85EX-15 D85EX-15LGP
Item
Weight (kg) Operation weight 27250 26000
(including straight
tilt blade and single Specific pressure (MPa) 0.082 0.039
cab)
Engine Model CUMMINS NT855-C280
Type Inline, water-cooling, PT pump injection,
turbocharged
Rated speed (r/min) 1800 1800
Rated power (HP) 245 245
Fuel consumption rate (g/kw.h) <235 <235
Transmission Transmission pressure setting 2.45 2.45
hydraulic system (MPa)
（Mpa） Steering pressure setting (MPa) 1.69 1.69
Braking pressure setting (MPa) 2.16 2.16
Hydraulic system of Pressure setting (MPa) 14
working equipment Lifting cylinder 120mm1054mm2 120mm1293mm2
Bore×stroke×quantity
Tilt cylinder 200mm130mm1 200mm130mm1
Bore×stroke×quantity
Travel speed (km/h) Forward 1st 0-3.8
2nd 0-6.8
3rd 0-11.6
Reverse 1st 0-4.6
2nd 0-8.1
3rd 0-13.5

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1.2 Technical parameters
Model D85EX-15 D85EX-15LGP
Item
Transmission Torque converter 3-element, single-stage, single phase
system Transmission Planetary gear, multiple-disc clutch,
hydraulic actuated, forced lubrication by
gear pump
Bevel gear Spiral bevel gear, single-stage reduction,
splash lubricated
Steering clutch Wet, multiple disc clutch, spring loaded,
hydraulically separated, manual—
hydraulically actuated
Steering brake Wet, pin slide type brake, hydraulic booster
Final drive Spur gear, double reduction, splash
lubrication
Running system Type Running system of whole bogie,
three-point-supported, semi-rigid
suspended
Number of sprocket 2per side
Number of carrier roller (per side) 6 (4-single, 2-double) per 8 (5-single,
side 3-double) per
side
Type of track Single grouser (38 per Triangle track
side) shoe (45 per
side)
Track shoe width (mm) 540mm 910mm
Track pitch (mm) 216mm 216mm
Transmission Transmission pressure setting 2.45 2.45
hydraulic system (MPa)
（Mpa） Steering pressure setting (MPa) 1.69 1.69
Braking pressure setting (MPa) 2.16 2.16
Hydraulic system of Pressure setting (MPa) 14
working equipment Lifting cylinder 120mm1054mm2 120mm1293m
Bore×stroke×quantity m2
Tilt cylinder 200mm130mm1 200mm130mm
Bore×stroke×quantity 1

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 Tractive force ×1000Kg

Travel speed
Figure 1-3 Traction Characteristic Curve for Bulldozers

1.3 Dimensions

Figure 1-4 Dimensions of Bulldozer

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Figure 1-5 Dimensions of Bulldozer

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 Chapter 2 ― Structure and Principle

2.1 Transmission description (figure 2-1a) (figure 2-1b)

Figure 2-1a Transmission Diagram

In the centre of bulldozer frame, there are engine (1), torque converter (2), cardan joint
(3) and transmission (4) located from front to back and engine’s power is transferred in
the same direction. The rear of the transmission is connected with bevel gear, after
which steering clutch (6), steering brake (7), final drive, segment sprocket (8) and track
(9) are transversally located at both sides that means after the bevel gear engine’s
power will be transferred to track through left and right ways.

The torque converter is a type of transmission device that transfers energy through
movement of liquid. It can improve output characteristics of engine and provide the
bulldozer with automatic adjustment to load variation. Therefore, it simplifies operation,
improves passage performance and comfort of vehicle and prolongs lifespan of
machineries.

The power-shift transmission, controlled by transmission control valve (5), changes

speed without shutdown of vehicle, which used together with the torque converter can
significantly lessen labour intensity of driver.

The constant engaged steering clutch, controlled by the steering control valve, transfers
power to the final drive in normal operation. Disengagement of clutch at one side
enables steering towards this side.

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The band-type steering brake, controlled by brake valve and brake pedal, is used for
braking and facilitating steering of the bulldozer. The brake band winds around ex-circle
of the outer steering clutch drum. It,

The final drive, serving as a reduction unit, transfers power to drive the track via the
segment sprocket, so as to make the bulldozer move.

Figure 2-1b Transmission Diagram

A. First sun gear (gear tooth number 33)

B. First planetary gear (gear tooth number 24)
C. First gear ring (gear tooth number 81)
D. Second sun gear (gear tooth number 21)

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 E. Second planetary gear (gear tooth number 23）
F. Second planetary gear (gear tooth number 24）
G. Second gear (gear tooth number 81)
H. Third sun gear (gear tooth number 81）
I. Third planetary gear (gear tooth number 24)
J. Third gear ring (gear tooth number 81)
K. Fourth sun gear (gear tooth number 24）
L. Fourth planetary gear (gear tooth number 19）
M. Fourth gear ring (gear tooth number 81)
N. Fifth gear ring (gear tooth number 42）
O. Driving gear (gear tooth number 30)
P. Driven gear (gear tooth number 24）
Q. Bevel pinion (pinion tooth number 21）
R. Bevel gear (gear tooth number 49）
S. First pinion of final drive (pinion tooth number 12)
T. First gear of final drive (gear tooth number 45）
U. Second pinion of final drive (pinion tooth number 12）
V. Second gear of final drive (gear tooth number 55)

P1 Oil pump of working equipment P2 Oil pump of transmission P3 Oil pump of

steering

1. Engine
2. Torque converter
3. Cardan joint
4. Transmission
5. Control valve
6. Steering clutch
7. Steering brake
8. Segment sprocket
9. Track
10. Power take off (P.T.O)
A. Bevel pinion
B. Bevel gear
C. Pinion of final drive
D. Gear of final drive
E. Sun gear

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 F. Planetary pinion
G. Gear ring

The following table shows the travel direction and speed of bulldozer and engagement
of transmission clutches:
Travel direction Speed Clutch combination
Forward 1st NO.1 NO.5
2nd NO.1 NO.4
3rd NO.1 NO.3
Reverse 1st NO.2 NO.5
2nd NO.2 NO.4
3rd NO.2 NO.3

2.2 Radiator
The radiator is mainly made up of upper tank (1), radiator core (12), lower tank (10) and
other auxiliaries. (Refer to figure 2-2)

The cooling water flows into the upper tank (1) via the thermostat. After air contained is
removed, water flows into the lower tank (10) via the radiator core (12). Heat contained
in water is dispersed under the action of fan at the rear of the radiator when water flows
through the radiator core (12) so that the water is cooled down . And then cooling water
will be pumped to cylinder of the engine.

The heat radiation system is a closed loop. The pressure valve on the tank keeps water
pressure in tank at 0.075Mpa, so as to raise the boiling temperature of cooling water,
reduce water losses and improve heat radiation efficiency.

Power of the fan (13) is transferred from pulley in front of the engine via V-belt. Cooling
performance of the radiator is enhanced by forced air supply of the fan.

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 Figure 2-2 Radiator
1 Upper tank 2 Hose 3 Feed pipe 4 Fan shroud 5 Hose 6 Pulley
7 Shaft 8 Shaft sleeve 9 Outlet pipe 10 Lower tank 11 Fan cowl
12 Radiator core 13 Fan

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2.3 Power take off (P.T.O)
Flywheel housing assembly and transfer case assembly (refer to figure 2-3 and 2-4)

The flywheel housing is mainly used to cover and secure the flywheel and output the
power.

Figure 2-3 Flywheel Housing Assembly

1 Flywheel housing 2 Idler (Z=51) 3 Bearing
4 Drive gear of transfer case (Z=56) 5 Bearing 6 Cover

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 Figure 2-4 Transfer Case Assembly
1 Flywheel housing 2 Transfer case 3 Driven gear 4 Transfer-case cover
5 Main shaft 6 Driving gear 7 Cover 8 Driven gear 9 Lubricating pipe
10 Dispatcher

The transfer case is installed above the flywheel housing

Gear on the flywheel housing drives the main shaft (5) and the driving gear (6) to turn so
that the driven gears (3) and (8) rotate. Remove the cover (7) and install the oil pump
of working equipment. The driven gear (3) drives the oil pump of transmission. Install
the oil pump of steering in front of the flywheel housing. Lube oil for gear and bearing of
the transfer case is supplied by oil return hose of engine oil cooler, which is dropped to
each position by the lubricating pipe (9) after being despatched by the dispatcher (10).

2.4 Torque converter (figure 2-5a, 2-5b)

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Figure 2-5a

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 Figure 2-5b Torque Converter Assembly
1 Drive gear 2 Drive housing 3 Turbine 4 Torque converter casing
5 Pump wheel 6 Gear 7 Reactor shaft 8 Cover 9 Coupling
10 Turbine output shaft 11 Reactor shaft bossing 12 Impeller
13 Oil pump housing 14 Oil pump gear 15 Primary filter 16 Drainage plug
17 Turbine hub 18 Pressure plate 19 Guide 20 Pressure regulating valve
21 Overflow valve

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The pump wheel, turbine and impeller are filled with working oil. When the pump wheel
is rotating, oil is brought to the turbine blade, so as to drive turbine to turn. The oil flows
into the impeller and then returns to the pump wheel. In this course, closed circulation of
oil is realized.

It is possible to increase the turbine moment, for the flow motion of liquid can be
changed by the impeller. However, the turbine moment varies from the working
conditions, which means that higher load will result in larger resistance moment on the
turbine and speed reduction of the turbine. Therefore, stable transmission can be
guaranteed through hydraulic torque converter.

Power input route :drive gear → drive casing → pump wheel

Power output route is:turbine → turbine hub → turbine output shaft

A safety relief valve is installed at the oil inlet of the torque converter (see Figure 2-6).
Set the pressure to P=0.85-0.89Mpa to protect the torque converter from being
damaged by any high pressure.The pressure oil from the transmission control valve
flows to the oil pump side through the oil port A and then the oil circuit of the hydraulic
torque converter casing.

The oil port A is filled with pressure oil which will compress the spring (23) and push
upward the slide valve (22) immediately after the hydraulic pressure applied to the
pump wheel reaches 0.7Mpa. After that, the pressure oil may flows to the overflow valve
loop for transmission lubrication through the oil port B.Meanwhile, a pressure-regulating
valve (see Figure 2-7) is installed at the oil outlet of the torque converter to assure the
maximum efficiency of the torque converter and keep certain amount of oil within it. Set
the pressure to P=0.3-0.47Mpa. The pressure oil from the hydraulic torque converter
will get fully charged within the oil port C after it passes through the passage in the
hydraulic torque converter casing. When the oil pressure reaches to 0.3Mpa, the
pressure oil will compress the spring (25) and push forward the slide valve (24), and
then flows into the oil cooler loop through the oil port D.

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 Figure 2-6 Overflow Valve Figure 2-7 Pressure-Regulating Valve

In addition, an scavenge oil pump is equipped on the lower part of the torque converter
casing to remove the working oil leaked from the transfer case, flywheel housing,
lubricator and the torque converter, and to enable oil return to the rear axle case.

2.5 Cardan joint

Task of the cardan joint is to transfer power between the torque converter and the
transmission. It can guarantee a smooth transfer when proper alignment difference
between the turbine output shaft and the main shaft centre line of the transmission is
within permissible range.

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 Figure 2-8 Cardan Joint

1 Universal couplings of cross shaft type 2 Gusset plate 3 Bolt 4 Bolt

2.6 Transmission
The transmission is of power-shift planetary mechanism (see Figure 2-9)

Tasks:
Realize forward and reverse of the bulldozer
May achieve various output transmission ratio (including shut-down)

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 Figure 2-9 Transmission
1 Transmission case 2 Cylinder of No.1 clutch 3 Piston of No.1 clutch
4 Drive plate of brake 5 Friction plate 6 Plate
7 First-, second- and third-line planet axles 8 Piston of No.2 clutch
9 Cylinder of No.2 clutch 10 Cylinder of No.3 and No.4 clutches
11 Piston of No.3 clutch 12 Piston of No.4 clutch 13 Plate
14 Fourth-line planet axle 15 Outside hub of No.5 clutch
16 Cylinder of No.5 clutch 17 Steel ball of oil drain valve 18 Rear case
19 Casing 20 Output shaft sleeve 21 Input shaft 22 Bearing seat 23 Cover
24 Bearing seat 25 Bearing baffle 26 Piston of No.5 clutch
27 Inside hub of No.5 clutch 28 Fourth planetary line spring 29 Butterfly spring
30 Fourth-line planetary frame 31 Third planetary line spring

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32 Second-line planet axle 33 First planetary line spring
34 First-, second- and third-line planetary frames 35 Bolt
36 Second-line planet axle 37 Bearing seat 38 Bearing seat 39 Shaft end baffle
40 Coupling
No.1 clutch associates to forward clutch
No.2 clutch associates to reverse clutch
No.3 clutch associates to 3rd gear clutch
No.4 clutch associates to 2nd gear clutch
No.5 clutch associates to 1st gear clutch
A. First sun gear (gear tooth number 33)
B. First planetary gear (gear tooth number 24)
C. First gear ring (gear tooth number 81)
D. Second sun gear (gear tooth number 21)
E. Second planetary wheel (gear tooth number 23) Second planetary gear (gear tooth
number 24)
F. Second gear ring (gear tooth number 81)
G. Third sun gear (gear tooth number 33)
H. Third planetary gear (gear tooth number 24)
I. Third gear ring (gear tooth number 81)
J. Fourth sun gear (gear tooth number 42)
K. Fourth planetary gear (gear tooth number 19)
L. Fourth gear ring (gear tooth number 81)
M. Fifth gear ring
N. Drive gear (gear tooth number 31)
O. Driven gear (gear tooth number 29）
P. Bevel pinion (pinion tooth number 21)
Q.

The transmission adopts planetary gear and multiple-disc clutch. It is controlled by

hydraulic control valve and provides three gear speeds in forward direction as well as in
reverse direction.

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 Travel direction Speed Working clutches
Forward 1st No.1, No.5
2nd No.1, No.4
3rd No.1, No.3
Reverse 1st No.2, No.5
2nd No.2, No.4
3rd No.2, No.3
l Principle of planetary gear mechanism and structure of clutch
1. Principle of planetary gear mechanism

The planetary gear mechanism

comprises the sun gear (A), planetary
gear (B), gear ring (C) and planetary
frame (D). (See Figure 2-10).The
planetary gear (B) is installed on the
planetary frame (D) and engaged with
the sun gear (A) and the gear ring (C).

Figure 2-10 Principle of Planetary Gear Mechanism

A. Sun gear
B. Planetary gear
C. Gear ring
D. Planetary frame
If the gear ring is fixed, motion is
transferred from the sun gear (A) to the
planetary gear (B). In this case, the
planetary gear (B) rotates itself and
around the sun gear (A)The left figure
shows that the planetary frame and the
sun gear (A) rotate in the same direction.
(See Figure 2-11)
Figure 2-11

25
 If the planetary frame (D) is fixed, motion is
transferred from the sun gear (A) to the
gear ring (C) via the planetary gear (B) so
that the gear ring (C) rotates. The left figure
shows that the gear ring (C) and the sun
gear (A) rotate in opposite directions.(See
Figure 2-12)

Figure 2-12

This is the structural principle of the first-, third- and fourth-line planetary mechanisms of
this transmission.

In the first-line planetary gear mechanism, the sun gear (A) is the driving gear. In the
third- and fourth-line planetary gear mechanisms, the planetary frame (D) is the driving
element. It is possible to reverse the output revolution direction, if required, by adding
another planetary gear set (E) (See Figure 2-13).The motion route “A→B→E→C” is the
structural principle of the second-line planetary gear mechanism.

Figure 2-13
A. Sun gear
B. E. Planetary gear
C. Gear ring
D. Planetary frame

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2. Structure of each clutch
The No.5 clutch of the transmission is of lockup clutch. (See Figure 2-14)

Figure 2-14 No.5 Clutch

Gear ring of each planetary line is fixed by clutch (See Figure 2-15).

Figure 2-15 Fixing of Gear Ring

27
The pressure oil from the control valve pushes the piston (3) to achieve the engagement
of clutches. (See Figure 2-16)

Figure 2-16 Engagement of Clutches

Disconnect the pressure oil and push clutches to their original positions with the return
spring (33) so that the disengagement of clutches is achieved. (See Figure 2-17).The
butterfly spring (42) is used for speeding up the piston (3) and improving the separation
performance of driving and driven friction plates.

Figure 2-17 Disengagement of Clutches

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Figure 2-18 shows the structure of the No.5 clutch. During separating, the working oil in
the gap behind the cylinder (16) is under the action of centrifugal force generated due to
rotation. Therefore, rapid separation of friction plates can’t be guaranteed if only the
butterfly spring (29) is used.Semi-disengagement may occur as a result and more faults
are likely to occur during the next shift. Therefore, the steel ball oil drain valve (17) is
provided.

Figure 2-18 No.5 Clutch

During combining, the pressure oil from the control valve enters the oil chamber to push
the piston (26). At the same time, the pressure oil pushes the steel ball of the oil drain
valve (17) to block hole on the valve seat. In this course, the clutch combines rapidly.

Figure 2-19 Engagement of No.5 Clutch

29
When the pressure oil from the control valve is disconnected, the steel ball (17) moves
in the direction of the arrow under the action of the centrifugal force (see Figure 2-20).
Then the hole of the valve seat opens and the working oil in the gap behind the cylinder
(16) flows out from this hole so that normal separation of friction plates is guaranteed.

Figure 2-20 Disengagement of No.5 Clutch

II. Power transmission path of each speed gear of transmission

Transmission path of 1st gear forward (see Figure 2-21)

No.1 and No.5 clutches engage simultaneously. Power transmission path: A→B→（34）
→J→O→P→Q (in this case, J, N, H, K, L of No.5 clutch become integrated)

30
 Figure 2-21 Transmission Path of 1st Gear Forward

III. Transmission path of 2nd gear forward (see Figure 2-22)

Power transmission path: A→B→（34）→J→（30）→L→K→P→Q

Figure 2-22 Transmission Path of 1 nd Gear Forward

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lll Transmission path of 3rd gear forward(see Figure 2-23)
No.1 and No.3 clutches engage simultaneously.
Power transmission path: A→B→（34）→J→I→H→O→P→Q

Figure 2-23 Transmission Path of 3rd Gear Forward

IV. Transmission path of 1st gear reverse (see Figure 2-24)
No. 2 and No.5 clutches engage simultaneously.
Power transmission path: D→E→F→（34）→I→J→(J and K integrated)→O→P→Q

Figure 2-24 Transmission path of 1st gear reverse

32
V. Transmission paths of 2nd gear reverse and 3rd gear reverse
The travel speed of 2nd gear reverse can be achieved through engaging No.2 and No.4
clutches simultaneously. The travel speed of 3rd gear reverse can be achieved through
engaging No.2 and No.3 clutches simultaneously.

2.7 Bevel gear

The main tasks of the bevel gear:
Change the power transmission direction (from longitudinal to transverse) and
distribute engine’s power to final drives and tracks at left and right sides
Single-stage reduction, increase torque

The bevel gear, steering clutch and steering brake are installed inside the rear axle case.
(See Figure 2-25). The bevel gear consists of bevel gear (8) (engaged with output gear
Q of the transmission), cross axle (9), bearing seat (7) and bearing.

Correct engagement of pair bevel gears can be accomplished by means of adjusting the
spacer (10) and the spacer between the bevel pinion assembly of the transmission and
the housing. Checking backlash and mesh mark helps to judge whether the correct
engagement is achieved. The standard backlash of a pair of spiral bevel gears is
0.25-0.33MM. The mesh mark shall be in the midway length of the gear. (see Figure
2-26)

Lubrication is realized in a manner of half submission and half splashing.

33
 Figure 2-25 Bevel Drive and Steering Clutch
1 Outer drum 2 Pressure plate 3 Outer friction plate 4 Internal tooth washer
5 Inner drum 6 Gear hub 7 Bearing seat 8 Bevel gear 9 Cross axle
10 Spacer 11 Large spring 12 Small spring 13 Bolt

Figure 2-26 Correct mesh mark

34
If the engagement is not correct, make adjustment according to the following table.

Marks on driven gear Revolutions Movement direction of

gear
Forward Move the driven gear Driving gear
towards the driving gear.
If the backlash is too Driven gear
narrow, move the driving
gear outward.

Move the driven gear

away from the driving
gear. If the backlash is
too wide consequently,
move the driving gear
inward.
Move the driving gear
towards the driven gear.
If the backlash is too
narrow then, move the
driven gear outward.
Move the driving gear
away from the driven
gear. If the backlash is
too wide consequently,
move the driven gear
inward.

35
Reverse Move the driven gear
towards the driving
gear. If the backlash is
too narrow, move the
driving gear outward.
Move the driven gear
away from the driving
gear. If the backlash is
too wide consequently,
move the driving gear
inward.
Move the driving gear
towards the driven gear.
If the backlash is too
narrow then, move the
driven gear outward.

Move the driving gear

away from the driven
gear. If the backlash is
too wide consequently,
move the driven gear
inward.

2.8 Steering clutch

One steering clutch is provided each in the left and right chambers of the rear axle box.
It is used for connecting or disconnecting power from the bevel gear to the left and right
final drives so that actions such as forwarding, reversing, turning and stooping of whole
bulldozer can be conducted.

For structure of steering clutch see Figure 2-25. It is mainly made up of outer and inner
drums, pressure plate, outer and inner frication plates and spring.

The steering clutch of this bulldozer is of wet, multiple disc, spring loaded, hydraulic
separated and constant mesh type.

36
In normal operation, the outer frication plate combines with the inner frication plate
under the action of the spring. The power transmission path: cross axle → gear hub (6)
→ inner drum (5) → internal tooth washer (4) → outer frication plate (3) → outer
drum (1) → drive disc of final drive.
The pressure oil from the steering control valve flows into the inner chamber of the gear
hub (6) (see Figure 2-27) and pushes the piston (10), bolt and pressure plate in the
direction of arrow (overcome the pressure of large and small springs). As results, the
internal tooth washer (4) separates from the outer frication plate (3) and the outer drum
(1) stops transferring, so as to disconnect the power transmission path.

Figure 2-27
If the oil pressure is disconnected, under the action of pressure of large and small
springs, the above-mentioned parts will move in the direction as shown in the following
figure. As results, the internal tooth washer combines the outer frication plate again and
the power transmission resumes. (See Figure 2-28)

37
 Figure 2-28

2.9 Steering brake

The steering brake of this bulldozer is of wet, band and floating type. It is provided with
hydraulic booster (see Figure 2-29 and Figure 2-30).

There are two sets of steering brakes, which work coordinating with the steering
clutches.

Figure 2-29 Steering Brake

38
1 Casing 2 Rocker arm 3 Rocker arm 4 Spring 5 Slide valve
6 Valve body 7 Piston 8 Rocker arm 9 Cover 10 Stud bolt 11 Return spring
12 Cover 13 Adjusting bolt 14 Support 15 Lever 16 Block 17 Rod 18 Tail end
19 Brake lining 20 Brake band 21 Return spring 22 Sleeve 23 Flange
The brake band winds the outer drum of the steering clutch tightly to make the final
drive gear stop transferring power. Consequently, turning and stopping of vehicle can be
realized.

1 Principle
When the outer drum of the steering clutch rotates forward (see Figure 2-30a),
applying slight braking force on the brake pedal will lead to lesser clearance
between the brake band and the outer drum, even contacting of local parts. The
upper part of the brake band props against the tail end (18) to bring the pin A into
the slot of the support (14) under the action of the friction force. If applying
braking force continuously, the rod (17), pin B and lever (15) will move in the
direction given in the figure to wind the outer drum tightly. In this case, point A is
considered as the pivot point for rotation.
When the outer drum of the steering clutch rotates reverse (see Figure 2-30b), the
tail end (18), pin A and lever (15) will move in the direction given in the figure, so as
to wind the outer drum tightly. In this case, point C is taken as the pivot point for
rotation. The braking effects of both actions are basically the same.

Figure 2-30

39
2 Booster
The steering brake is provided with braking booster, which significantly reduces the
braking effort of the driver. The booster is made up of rocker arm (2), valve body (6),
slide valve (5), piston (7) and rocker arm (8). For hydraulic principle please refer to
sections concerning hydraulic system.

Figure 2-31 Structure of Booster

2.10 Final drive

The final drive adopts spur gear and double reduction mechanism. Figure 2-32 and
Figure 2-33 shows its structure.The final drive is made up of left and right parts. Both
figures give the left part.

40
 Figure 2-32 Final Drive
1 Drive disc 2 Bearing seat 3 Primary driving gear 4 Primary driven gear
5 Secondary driving gear 6 Secondary driven gear 7 Gear hub 8 Drive sprocket
9 Segment sprocket hub 10 Drive wheel nut 11 Supporting 12 Cover
13 Floating oil seal 14 Oil seal cover 15 Floating oil seal 16 Oil seal cover
17 Housing 18 Shield 19 Axle shaft

41
 Figure 2-33 Final Drive
1 Drive disc 2 Bearing seat 3 Primary driving gear 4 Primary driven gear
5 Secondary driving gear 6 Secondary driven gear 7 Gear hub
8 Drive sprocket 9 Segment sprocket hub 10 Drive wheel nut 11 Supporting
12 Cover 13 Floating oil seal 14 Oil seal cover 15 Floating oil seal
16 Oil seal cover 17 Housing 18 Axle shaft

The final drive is used for increasing the output torque via the double reduction gear and
transferring power to the running system via the drive sprocket (8).

It adopts splash lubricated method and floating oil seal structure.

2.11 Running system

The running system mainly consists of bogie (7), segment sprocket cover (3), front idler
(1), carrier rollers (4) and (5), sprocket (2) and track tensioning device (see Figure 2-35).
It bears not only the dead weight of the bulldozer but also the horizontal thrust during
bulldozing. The running system has left and right parts. The figure shows the left part.

42
 Figure 2-34 Running System

1 Front idler 2 Sprocket 3 Segment sprocket cover

4 Carrier roller (single flange, 4 per flange)
5 Carrier roller (double flanges, 2 per flange) 6 Shield 7 Bogie frame

43
 Figure 2-35 Running System (D85EX-15LGP)
1. Front idler 2. Sprocket 3. Segment sprocket cover
4. Carrier roller (single flange, 5 per flange)
5. Carrier roller (double flanges, 3 per flange) 6. Shield 7. Bogie frame

I. Track tensioning device

The track tensioning device is used for guaranteeing that the track has sufficient
tightness and avoiding occurrence of jounce during running and derailment during
winding. For the structure see Figure 2-36.

44
 Figure 2-36 Track Tensioning Device
1 Base 2 Tappet 3 Cylinder 4 Piston 5 End cover 6 Front spring seat
7 Large buffer spring 8 Small buffer spring 9 Rear spring seat 10 Nut
11 End cover 12 Sleeve 13 Oil seal 14 Wear ring 15 Oil seal 16 Oil nipple
17 Oil plug

II. Front idler

The front idler is used for guiding the chain links and the track. For structure see Figure
2-37.

45
 Figure 2-37 Front Idler
1 Front idler 2 Sleeve 3 Shaft 4 Guide plate 5 Floating oil seal 6 Guide

III. Carrier roller

The carrier roller is used for supporting the bulldozer and preventing lateral derailment
of the track. The carrier roller can be divided into single-flange structure and
double-flange structure. Figure 2-38 shows the latter one. Both structures differ from
each other only in shape of carrier roller hub (1).

46
 Figure 2-38 Double-Flange Carrier Roller
1 Carrier roller hub 2 Sleeve 3 Cover 4 Floating oil seal 5 Shaft
IV. Sprocket
The sprocket is used for supporting the track to prevent over sagging, jounce and lateral
derailment of the track. For structure see Figure 2-39.

Figure 2-39 Sprocket

1 Support 2 Shaft 3 Floating oil seal 4 Bracket 5 Cover 6 Nut
7 Floating oil seal seat 8 Floating oil seal seat

47
V. Track

The track is used for transferring weight of the bulldozer and guaranteeing the
adherence performance and sufficient driving force of the bulldozer. For structure see
Figure 2-40 and Figure 2-41.

Figure 2-40 Track Assembly

1 Dust proof ring 2 Dowel pin 3 Sealing ring 4 King pin 5 Chain links
6 Main shaft sleeve 7 Shaft sleeve 8 Track shoe 9 Track bolt 10 Track nut

48
 Figure 2-41 Track Assembly
1. Dust proof ring 2. Dowel pin 3. Sealing ring 4. King pin 5. Chain links
6. Main shaft sleeve 7. Shaft sleeve 8. Track shoe 9. Track bolt 10. Track nut

VI. Balance beam

The balance beam connects the frame and the running system. It acts as a buffer and
keeps the left and right bogie frames moving up and down with respect to each other
when the bulldozer is in uneven ground applications. For structure see Figure 2-42.

49
 Figure 2-42 Balance Beam
1 Balance beam 2 Shaft 3 Shaft sleeve 4 Shaft sleeve

2.12 Hydraulic system

The hydraulic system comprises: hydraulic system of working equipment and
transmission hydraulic system.

Hydraulic system of working equipment

Principle and structure of hydraulic system of working equipment for bulldozers are as
shown in figures 2-43, 2-44, 2-45 and 2-46.

50
 L:Lowering
R:Rising
F:Floating
LT:Left tilting
RT:Right tilting
Figure 2-43 Principle of Hydraulic System of Working Equipment

51
 RT:Right tilting
LT:Left tilting
L:Lowering

F:Floating
R:Rising

Figure 2-44 Principle of Hydraulic System of Working Equipment (D85EX-15LGP)

52
Figure 2-45 Structure of Hydraulic System of Working Equipment

53
 Figure 2-46 Structure of Hydraulic System of Working Equipment
1 Lifting cylinder 2 Tilt cylinder 3 Quick drop valve
4 Oil pump of working equipment 5 Oil pump of transmission 6 Filter mesh
7 Oil filter 8 Primary filter 9 Overload valve 10 Oil supply valve
11 Oil supply valve 12 Reversing valve 13 Reversing valve 14 Reversing valve
15 Oil supply valve 16 Oil supply valve 17 Overflow valve 18 Oil filter
19 Revolution servo valve 20 Revolution servo valve 21 Revolution servo valve
22 Steering brake valve 23 Ripper cylinder 24 Inlet check valve
25 Inlet flow check valve 26 Inlet check valve 27 Rear axle case
28 Oil tank of working equipment

54
1. Oil pump of working equipment

The oil pump of working equipment is driven by gear of the transfer case to transform
mechanical energy into hydraulic energy. For structure see Figure 2-47.

55
 Figure 2-47 Oil Pump of Working Equipment
1 Driving gear 2 Front pump cover 3 Sleeve 4 Pump body 5 Rear pump cover
6 Diaphragm seal 7 Ring 8 Sealing ring 9 Driven gear

2. Hydraulic principle of working equipment (see Figure 2-48)

Figure 2-48 Hydraulic Principle of Working Equipment

56
Principle: The working oil is pumped from the oil tank of working equipment (28) into the
reversing valves (12), (13) and (14) by the gear pump. If no working equipment is
operated, the oil returns to the oil tank via the reversing valves and the oil filter (18). In
the event of blocking of filter element, the oil returns to the oil tank via relief valve of the
oil filter. Through operating the reversing valve (14) or (13), the lifting cylinder can be
controlled, so as to achieve actions such as rising, lowering, holding and floating of the
blade. Besides, such operation will lead to control of tilt cylinder, so as to achieve
actions such as left tilting and right tilting of the blade. Through operating the reversing
valve (12), the ripper cylinder can be controlled, so as to realize rising, lowering and
holding of the ripper.

The inlet check valves (24) and (26) are installed in front of the reversing valve to
prevent nosedive during reversing of each working equipment.

The flow valve (25) is installed to enable the tilt cylinder have proper motion speed. (See
Figure 2-49)

Figure 2-49 Flow Valve Figure 2-50 Overflow Valve

The over load valve (9) is provided to prevent over loading, which may cause
over-pressure of system, during ripping.
During operation, in case of over loading, the system pressure may exceed the
pressure setting (14.0MPa) temporarily. At this time, the overflow valve (17) (see Figure
2-50) opens, via which the working oil returns to the oil tank, so as to protect the system.
Figure 2-47 Overflow Valve

57
If the directions of the external force and the piston movement are the same, the
cylinder will be in a vacuum state. Therefore, the oil supply valves (10), (11), (15) and
(16) are provided (see Figure 2-51 and Figure 2-52).

Figure 2-51 Oil Supply Valve (Lifting Cylinder)

Figure 2-52 Oil Supply Valve (Ripper Cylinder)

The above-mentioned valves are installed in the oil tank of working equipment.

The oil tank of working equipment is of closed structure (see Figure 2-53) in order to
prevent dust polluting the working oil.

58
 Figure 2-53 Oil Tank of Working Equipment
1 Slide valve of lifting cylinder 2 Slide valve of tilt cylinder
3 Slide valve of ripper cylinder 4 Filter
A. Inlet B. To lifting cylinder bottom (lowering) C. D. To ripper
E. To tilt cylinder bottom (left tilting) F. To tilt cylinder head (right tilting)
G. To lifting cylinder head (rising) H. Suction port for pump

3. Lifting cylinder

The lifting cylinder is of double acting piston type (see Figure 2-54).

59
 Figure 2-54 Lifting cylinder
1 Sleeve 2 Gland 3 Cylinder head 4 Cylinder 5 Piston rod 6 Sleeve
7 Nut 8 Bl-metal bushing 9 Seal ring 10 Bl-metal bushing 11 Dust seal
12 Baffle 13 Sealing ring 14 Wear ring 15 Piston 16 Valve seat 17 Buffer valve

The buffer valve (17) is provided to prevent hydraulic impact and over-pressure when
the piston arrives to cylinder head or bottom. Principle: The pressure oil pushes the
piston (15) (see Figure 2+55 (a)) towards the cylinder bottom. When the piston is close
to the bottom, the contacting of front end of the buffer valve rod with the bottom leads to
separation of rod from the beveled sealing surface. As a result, the front chamber of the
cylinder connects with the rear chamber with hydraulic pressure released so that the
speed slows down and loads are released.(Figure 2-55 (b))

The principle also applies when the piston moves towards the cylinder head.

60
 Figure 2-55 Principle of Buffer Valve

The quick drop valve (Figure 2-56) is installed on the bottom of the lifting cylinder. It
automatically makes the cylinder connect differentially when feeding oil from the
cylinder bottom (blade lowering). This provides the cylinder piston with large drop speed
before the blade cutting earth, so as to prevent occurrence of vacuum state in the
cylinder.

Figure 2-56 Quick Drop Valve

Principle (see Figure 2-57 and Figure 2-58)

Principle of quick drop valve

61
The oil from the reversing valve enters the cylinder bottom from port A while the oil at
the other side of the cylinder returns to the oil tank via port B and throttle hole C (see
Figure 2-57).Due to throttling action of the throttle hole C, oil pressure difference forms
at this point. Under the pressure’s action, the quick drop valve plug opens. Oils at both
sides communicate with each other via port B and port A (see Figure 2-58). As results,
the piston movement speeds up and differential connection realizes.

When the blade cutting earth, the cylinder movement slows down and the throttling
action becomes insignificant. In addition, it reduces the pressure difference, bringing the
quick drop valve plug to its original position and releasing the differential connection.
Therefore, the cylinder may output sufficient thrust force.

If the oil enters the cylinder from the head side, the quick drop valve will not operate.

4. Tilt cylinder

The tilt cylinder is of double acting piston type. For structure see Figure 2-59.

Figure 2-59 Tilt Cylinder

1 Cover 2 Gland 3 Cylinder head 4 Cylinder 5 Piston rod 6 Nut 7 Base
8 Retainer 9 Seal ring 10 Wear ring 11 Piston 12 Baffle 13 Bl-metal bushing
14 Sealing ring 15 Bl-metal bushing 16 Dust seal

5. Revolution servo valve

In order to operate the reversing valve easily and improve the fine-tuning performance,
the revolution servo valve is provided. For its structure see Figure 2-60.

62
 Figure 2-60 Revolution Servo Valve
1 Sleeve 2 Oil seal 3 Oil seal 4 Pin 5 Spring 6 Rod 7 Rotor 8 Piston
9 Bayonet lock

The oil used in the revolution servo valve comes from the steering pump and returns to
the rear axle case. (See Figure 2-61)

Figure 2-61 Hydraulic Principle of Revolution Servo Valve

1. Valve bushing 6. Handle 7. Plug 8. Piston 12.Cylinder 13. Connecting rod

The output end of the revolution servo valve is connected with the slide valve rod via the
connecting rod to control the reversing of the slide valve. Positioning mechanism is
provided at the closed position.

63
Operate the handle (6) to make the plug (7) rotate through an angle in the clockwise
direction (see Figure 2-62). Channels A and C open and the pressure oil enters the
cylinder (12) from the bottom to push the piston (8) and the sleeve (1). The sleeve (1)
rotates through an angle in the clockwise direction and the connecting rod (13)
promotes the movement of the reversing valve rod. Channels A and C disconnect then
due to the rotation of the sleeve (1) and the piston (8) stops moving. Continuous
movement will be only maintained through continuously operating the handle (6).

Operate the handle (6) to make the plug (7) rotate through an angle in the
counter-clockwise direction (see Figure 2-63). Channels B and C open and pressure
relief of the pressure oil in the cylinder (12) bottom is conducted.At the other side of the
cylinder, the pressure oil pushes the piston (8) and the sleeve (1). The sleeve (1) rotates
through an angle in the counter-clockwise direction and the connecting rod (13)
promotes the movement of the reversing valve rod. Channels B and C disconnect then
due to the rotation of the sleeve (1) and the piston (8) stops moving. Continuous
movement will be only maintained through continuously operating the handle (6).

Figure 2-62 Figure 2-63

Figure 2-61 shows the neutral working condition. In this case, channels A and C or
channels B and C disconnect. The piston and the sleeve stay in a standstill state.

When operating the handle, only frication force between the plug (7) and the sleeve (1)
need to be overcame. In addition, the output force is provided by the cylinder. Therefore,
the operating force on the handle is lessened significantly.

II. Transmission hydraulic system

Principle of transmission hydraulic system (see Figure 2-64)

64
Figure 2-64 Principle of Transmission Hydraulic System

65
 Figure 2-65 Principle of Transmission Hydraulic System
1 Magnetic primary filter 2 Oil pump of transmission 3 Oil filter
4 Pressure regulating valve 5 Quick return valve 6 Pressure reducing valve
7 Speed valve 8 Directional control valve 9 Relief valve
10 Overflow valve of torque converter 11 Torque converter
12 Oil thermometer of torque converter
13 Pressure regulating valve of torque converter 14 Oil cooler
15 Overflow valve for lubrication of transmission
16 Lubrication of transmission 17 Lubrication of transfer case
18 Torque converter housing 19 Scavenge oil pump 20 Rear axle case

66
 Pressure testing port of overflow valve of torque converter (PT1/8)
Pressure testing port of pressure regulating valve of torque converter (PT1/8)
Pressure testing port of clutch of transmission (PT1/8)

The oil pump of transmission is of gear pump type, connecting with the transfer case. It
is used for changing mechanical energy into hydraulic energy.

The oil flows into the transmission pump via the primary filter and the rear axle case.
Then it enters the speed valve and the directional control valve via the fine filter. In this
course, actions such as forward, reverse and transmission can be conducted. At the
same time, the oil overflowed from the pressure-regulating valve enters the torque
converter together with the oil overflowed from the steering control valve. There is an
overflow valve installed at the inlet of the torque converter. The oil overflowed by this
valve flows into the torque converter housing (18) and the rear axle case. The
pressure-regulating valve at the outlet of the torque converter keeps the oil in the torque
converter under a sufficient working pressure. The oil flowed through the
pressure-regulating valve is used for lubricating the transmission and the transfer case
after being cooled down by the oil cooler.

One scavenge oil pump is provided in the torque converter to discharge the oil inside
the torque converter housing into the rear axle case, for the housing is filled with oil
overflowed from the overflow valve, leaked from the torque converter and exhausted
from the transfer case lubricating process.

For structure of the speed control valve see Figure 2-66.

67
 Figure 2-66 Speed control valve
1 Stopper 2 Small spring of pressure-regulating valve 3 Spring seat
4 Spring of pressure regulating sleeve 5 Spring of pressure regulating valve
6 Pressure regulating valve 7 Piston valve (A) 8 Pressure regulating valve
9 Piston valve (B) 10 Cover 11 Stopper 12 Spring of piston valve
13 Quick return valve 14 Sleeve of quick return valve 15 Piston
16 Pressure reducing valve 17 Spring of pressure reducing valve
18 Stopper 19 Control valve body (A) 20 Stopper 21 Stopper
22 Spring of relief valve 23 Directional control valve

68
24 Control valve body (B) 25 Relief valve 26 Piston 27 Cover
28 Speed control valve

The valve (8) is the pressure regulating valve. The adjustment pressure is 2.45Mpa to
ensure engagement of clutches of each speed gear other than 1st gear. When this
value is reached, the pressure regulating valve opens and supplies oil to the torque
converter.

The valve (13) is the quick return valve. The combined action of this valve and the
pressure regulating valve (8) can guarantee smooth engagement and complete
disengagement of clutches.

During the shifting of the transmission, pressure of the system will be changed as
shown in Figure 2-67. At the moment of shifting, the pressure drops dramatically and
the complete disengagement of clutch is achieved. Then the pressure rises slowly to
make the clutch engage smoothly, so as to avoid impact and prolong the lifespan of the
transmission system.

Figure 2-67 Pressure Curve

The valve (16) is the pressure reducing valve, which is installed especially for the 1st
gear clutch. The outlet pressure of the valve is 1.25Mpa (that is the engagement
pressure of the 1st gear clutch).

69
The valve (25) is the start-up safety valve. The valve is provided in order to prevent
occurrence of accidents if the engine is started and the bulldozer runs suddenly when
the transmission handle is positioned at speed gear (1st, 2nd and 3rd gear).The vehicle
can be started only when the transmission handle is positioned in neutral gear and each
gear is engaged in turn after applying the valve.

2. Steering and braking hydraulic system

For structure and principle of steering and braking hydraulic system see Figure 2-68
and Figure 2-69.

Figure 2-68 Structure of Steering and Braking Hydraulic System

70
 Figure 2-69 Principle of Steering and Braking Hydraulic System
1.Magnetic primary filter 2.Oil pump of transmission 3.Oil filter
4.Main pressure reducing valve for steering 5.Steering control valve
5a. Steering valve 5b. Brake valve 6.Steering clutch 7.Brake booster
8. Rear axle case
Pressure testing port of right clutch
Pressure testing port of left clutch
Pressure testing port of right clutch
Pressure testing port of left brake booster
Pressure testing port of right brake booster

71
The steering pump is of gear pump type, connecting with the transfer case. It is used for
changing mechanical energy into hydraulic energy.

The oil in the real axle case flows through the magnetic primary filter and is pumped out
by the steering pump. It is sent to the main pressure reducing valve for steering, the
steering control valve and the brake booster via the oil filter.

The oil overflowed form the main pressure reducing valve flows into the torque
converter loop.

In the steering and braking loop, there is one branch oil channel connecting with the
revolution servo valve that is used to facilitate the driver to operate the working
equipment. The oil from the revolution servo valve returns to the rear axle case.

For structure of the steering control valve see Figure 2-70.

Figure 2-70 Steering Control Valve

72
1 Valve body 2 Rod 3 Valve rod 4 Spring 5 Retainer 6 Control spring
7 Brake 8 Steering valve 9 Piston 10 Return spring 11 Detent plug
12 Detent plug 13 Return spring 14 Piston 15 Brake valve 16 Valve body
17 Rod 18 Control spring 19 Return spring 20 Guide device 21 Adjusting spring
22 Rod 23 Retainer 24 Return spring 25 Retainer 26 Spacer ring

Functions of the steering control valve:

When the steering valve and the brake valve are in neutral position: (See Figure
2-71)

The engine oil flows from the steering pump into the main pressure reducing valve (27)
and the steering control valve via oil inlets A and D. Since channels communicating with
the steering clutch and the brake booster are closed, the oil pressure in the channels
rises continuously. As a result, the main pressure reducing valve (27) opens. The oil
flows into the torque converter loop. If no operation of the steering control lever is
conducted by the driver, engine oil pressure relief will be continued to keep the clutch in
engagement state and the brake in disconnection state. In this case, the loop pressure
is 2.16Mpa.

73
 Figure 2-71
When the oil pressure in the steering valve rises: (See Figure 2-72)

When pulling the steering control lever, the rod (22) pushes the valve rod (3) in the
direction of the arrow → to compress the spring (6). The steering valve (8) is then
pushed by the spring force in the direction of the arrow →, so as to close the channel
between oil inlets B and G. At the same time, the channel between oil inlet A and B open.
The oil flows into the steering clutch. When the channel between the pump and the
clutch is filled with engine oil, the oil pressure will rise again. The oil enters the oil cavity
C via the hole “a” to push the piston (9). The reaction force of the oil pressure pushes
the steering valve (8) in the direction of the arrow ←. Consequently, the spring (6) is
compressed and the channel between oil inlets A and B is closed (Figure (b)). In this
state, the oil pressure in the channel between the oil inlet and the clutch
counterbalances the spring (6) load so that the oil pressure keeps stable. Pulling the
steering control lever to a further extent results in gradual increase of the spring (6) load.
The pressure of oil from the oil inlet B rises correspondingly. Consequently, parts of the
clutch act.

74
 Figure 2-72

When the oil pressure of the steering valve reaches the maximum value: (See
Figure 2-73)

When the state given in (2) is reached, further pulling the steering control lever will lead
to the contacting of the retainer (5) and the steering valve (8). The height of the spring (6)
will be minimized also. At this time, the valve rod (3) pushes the steering valve (8) via
the spring to make the force on the steering control lever increase dramatically. If pulling
the steering valve forward again, the valve rod (3) will start compressing the spring (4).
As a result, the operating load of the spring and the return oil pressure behind the oil
inlet B will increase gradually. When the operating load of the spring (4) reaches the
maximum value and the oil pressure in the channel reaches 1.57Mpa, complete
disengagement of the steering clutch is accomplished.

Figure 2-73

75
 When the oil pressure of the brake valve rises:(See Figure 2-74)

When the state described in (3) is reached, further pulling the steering control lever
results in that the adjusting bolt (21) pushes the rod (17) in the direction of the arrow and
then pushes the brake valve (15). The channel between oil inlets E and F is closed
while the channel between oil inlets D and E is open. Therefore, the oil flows into the
brake booster (Figure (a)). Besides, the oil in the cavity E flows into the cavity F via the
hole “b” to push the piston (14). The reaction force pushes the brake valve (15) back in
the direction of the arrow and compresses the spring (18). Consequently, the channel
between oil inlets D and E is blocked. In this state, the oil pressure in the channel
between the oil inlet E and the booster counterbalances the spring (18) load so that the
oil pressure keeps stable (Figure (b)). Pulling the steering control lever to a further
extent results in gradual increase of the spring (18) load. The oil pressure behind the oil
inlet E rises correspondingly. Consequently, the bulldozer is braked.

Figure 2-74
When the oil pressure of the brake valve reaches the maximum value:(See Figure
2-75)

76
Pull the steering control lever to its end-of-travel and the valve rod (3) moves in the
direction of the arrow → until the retainers (23) and (25) contact with each other. The
steering valve (8) stops moving. The adjusting bolt (21) pushes the rod (17) in the
direction of the arrow → to press the brake valve (15). The rod (17) can’t reach its
end-of-travel even though the valve rod (3) reaches. At the same time, the oil in the
cavity F pushes the piston (14) via the brake valve (150) and the hole “b”. The
reaction force of the oil pressure pushes the brake valve (15) in the direction of the
arrow →, so as to compress the spring (18). As a result, the channel between oil inlets
D and E is closed. In this state, the oil pressure of the channel between the oil inlet and
the booster counterbalances the spring force of the spring (18).The spring load reaches
the maximum value, so as to remain the oil pressure at a certain value and to complete
the braking. In this case, the return oil pressure behind the oil inlet E is 1.69Mpa.

Figure 2-75
When the steering valve and the brake valve are in neutral position: (See Figure
2-76)

Release the steering control lever. The valve rod (3), the shaft (17), the brake valve (15)
and the steering valve (8) are pushed back by springs in the direction of the arrow. Then
the steering valve (8) closes the channel between inlets A and B and opens the channel
between inlets B and G, so as to exhaust the oil in the steering clutch into the rear axle
case via the oil outlet G. In addition, the brake valve (15) closes the channel between
inlets D and E and opens the channel between inlets E and H, so as to exhaust the oil in
the brake booster into the rear axle case via the oil outlet H.

77
 From pump:

To rear axle case

From brake booster

To rear From steering

axle case clutch
Figure 2-76

Functions of the brake booster:

The steering and braking system is provided with booster. Applying the brake booster to
the bulldozer aims at lessening the driver’s effort to operate the steering control lever
and the brake pedal.

① When disengagement of the brake is conducted (see Figure 2-77 (a)),

there are two flow paths for the engine oil from the steering pump.
One path is that the oil flows to the cylinder port A of the booster via
the steering control valve (25). The other is that the oil flows directly
to the cylinder port B without passing through the steering control
valve. Since no operation of the steering control lever is conducted,
the steering control valve (25) doesn’t act and the channel to the
cylinder port A is closed. Therefore, the engine oil flows into the port B
only and then to the port C via the hole “a”. The channel between oil
inlets C and D is closed, for the brake pedal isn’t pressed. The oil
pressure in the channel rises continuously until the main pressure
reducing valve (26) is open. Then the oil flows into the torque
converter loop. At this time, the normal oil pressure in the loop is
2.16Mpa.
② When braking the bulldozer by pulling the steering control lever (see
Figure 2-77 (b)): Pull out the steering control lever completely to

78
 make the steering control valve act. Then the oil flows into the oil inlet
Am and pushes the piston (7) in the direction of the arrow ←. The top
of the piston (7) pushes the rod (8) so that braking is achieved. At this
time, the normal oil pressure in the loop is 1.69Mpa.
Torque converter loop Oil drainage

From
steering pump
From steering pump
From brake valve
From
steering clutch

Figure 2-77
Torque converter loop Oil drainage

Steering pump

From steering pump

From brake valve
Steering clutch

Figure 2-78

79
 ③ When braking the bulldozer by pressing the brake pedal slightly (see
Figure 2-78):Press the pedal. The rod (2) pushes the slide valve (5) in
the direction of the arrow ←, so as to open the loop between oil inlets
C and D. Consequently, the oil flows from the pump to the oil port B
and then to oil ports C and D via the hole “a”. The oil entering the oil
port D pushes the piston (7) in the direction of the arrow ←. The
channel between oil ports D and A opens due to increase of the
pressure. Then the oil flows into the real axle housing via the oil port
A. Further press the pedal to make up the oil that lost when the oil
flows through the open channel. Press the oil port A to a small size by
the slide valve (5). The above operations act continuously at a short
period. The top of the piston pushes the rod (8) downward, so as to
tighten the brake band smoothly (Figure 2-79 (a)). See Figure 2-75.
When the pedal reaches its end-of-travel, the channel between oil
inlet D and A closes. The main pressure reducing valve opens and
the engine oil flows into the torque converter loop. At this time, the
normal oil pressure in the loop is 2.16Mpa. (See Figure 2-79 (b))
From steering pump

Figure 2-79

2.13 Electrical system

The electrical system consists of four parts:

2.13.1 Electronic monitor with three-stage alarm (for details see Chapter 8)

80
2.13.2 Starting motor

2.13.3 Charging system

2.13.4 Lighting system

The power of the bulldozer is supplied by negative ground 24V battery.
Principle of electrical system (see Figure 2-80)

Figure 2-80 Principle of Electrical System

81
2.14 Working equipment
Working equipment refers to blade and ripper that can conduct all operations of the
bulldozer.
I. Blade
The blade has several types. For instance, the bulldozer has straight tilt blade, angle
blade and U-blade while the bulldozer has straight tilt blade.
1. Straight tilt blade
Structure of straight tilt blade (see Figure 2-81 and 2-82)

Figure 2-81

82
 Figure 2-82 Straight Tilt Blade
1 Bulldozing plate 2 Blade edge 3 Cutting blade 4 Push rod 5 Adjusting screw
6 Tilt cylinder 7 Arm 8 Base

Bulldozing plates are welding plates with longitudinal rib installed inside. The front arc
plate is constructed by high strength low alloy steel. Therefore, the bulldozing plate
features high rigid and excellent durability. The left and right push rods are of box
structure, characterized by high bending strength and anti-pressure stability. The front
part of the push rods are connected with the bulldozing plate via cross-joint and the rear
part is jointed with the base (8) fixed on the bogie. Therefore, the movement of the
blade is quick and easy.

83
Under the action of the lifting cylinder, the push rods and the bulldozing plate fluctuate
around the base (8) so that the rising and lowering of the blade is conducted. The
cutting angle of the push broach can be changed through changing the length of the
adjusting screw (5). The tilt cylinder (6) can make the push broach tilt to the left or right
with respect to the direction at right angle to the ground.

The blade edge (2) has two cutting edges, which are on the top and bottom respectively.
If one edge is worn out, the other one can be used. Therefore, the lifespan of the blade
is prolonged.
2. U-blade
Structures of the U-blade and the straight tilt blade differs only in shape of the bulldozing
plate.
Connection and principle of the U-blade are the same as these of the straight tilt blade.
3. Angle blade

Structure of angle blade (see Figure 2-83)

Figure 2-83 Angle blade

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1 Pin 2 Base 3 Arch framing 4 Lower support 5 Upper support 6 Screw
7 Cutting blade 8 Bulldozing plate 9 Blade edge 10 Pin 11 Pin 12 Bolt 13 Nut
14 Pin 15 Pin 16 Pin

The bulldozing plate is jointed with the arch framing (3) via the upper support (5) and the
lower support (4).The arch framing is jointed with the base (2) fixed on the bogie frame.
Under the action of the lifting cylinder, the arch framing and the blade fluctuate around
the base (2).Remove the pin (1) and install the lower support (4) on bases of the arch
framing. There are three optional bases so that the bulldozing plate has three different
working positions that are straight blade and tilt blades with an angle of incline of 25
degree to the left and to the right.

II. Ripper

The ripper can be used together with the blade to provide the bulldozer with high
efficiency. It has two types: single shank and multiple shanks.

Structure of 3-shank ripper (see Figure 2-84)

Figure 2-84 Structure of 3-shank ripper

1 Bracket 2 Connecting rod 3 Connecting frame 4 Pin 5 Pin 6 Pin 7 Pin
8 Beam 9 Shank 10 Tip 11 Protector 12 Pin 13 Pin

85
The ripper is of four-bar mechanism installed behind the rear axle case.The bracket (1),
connecting rod (2), connecting frame (3) and beam (8) are jointed together. The four
joints are vertexes of a parallelogram. Therefore, optimum cutting angle can be
guaranteed no matter how the ripper cylinder moves.

The shank has one upper hole and one lower hole so that two installation positions are
provided for adjustment of penetration. After a period of using, rotate the tip (10) by 180
degree so as to prolong its lifespan.

For hard ground, it is possible to install only the centre shank or shanks at both sides, so
as to facilitate ripping.

Structure of single shank ripper (see Figure 2-85)

Figure 2-85 Single Shank Ripper

1 Bracket 2 Connecting rod 3 Tip 4 Protector 5 Shank 6 Beam 7 Tilt cylinder
8 Lifting cylinder 9 Pin cylinder

Principles of the single shank ripper and the 3-shank ripper are the same. Differences
lie in addition of split pin remover to adjust the position of the shank and the penetration
and addition of tilt cylinder to adjust the cutting angle of the tip.

86
 Chapter 3 ― Function and Operation of
Each Equipment
3.1 Arrangement of instruments and control devices

Figure 3-1

87
1 Oil pressure gauge 2 Oil thermometer 3 Water thermometer 4 Timer
5 Alarm LED 6 Lamp switch 7 Self-test button 8 Start switch 9 Blade block rod
10 Blade control lever 11 Transmission control lever 12 Throttle control lever
13 Left steering control lever 14 Right steering control lever
15 Transmission block rod 16 Brake pedal 17 Reduction pedal
18 Brake block rod

3.2 Usage of instruments and control devices

3.2.1 Throttle control lever

Push the control lever forward (see Figure 3-2①) to low

speed-idling position of the engine. Pull the control rod
backward to the position ② as shown in Figure 3-2 and the
engine speed increase. Place the control lever in the position
③ as shown in Figure 3-2 and then the engine speed is in
the rated value, that is the normal speed of engine when the
bulldozer is working.
Figure 3-2 Throttle Control Lever

Place the control lever in the idling position (position ① as shown in Figure 3-2) and
the start switch is in closed position. Then the engine stops working.

3.2.2 Transmission control lever

The bulldozer is provided with three gear speeds in forward
direction as well as in reverse direction, which are
controlled by the transmission control lever. (See Figure
3-3).Prior to starting the engine, place the transmission
control lever in neutral “N” position. After the start-up of the
engine, place the level in required position.
Figure 3-3 Transmission Control Lever

3.2.3 Transmission block rod

The transmission block rod is the blocking device for

the transmission control lever. When the bulldozer is
standstill, place the transmission control lever in the
neutral “N” position and lock it by means of this
rod.(See Figure 3-4)
Figure 3-4 Transmission Block Rod

88
3.2.4 Left steering control lever

Pull the left steering control lever backward. The left

steering clutch is disengaged and the vehicle turns left.
Pull the lever to the end. The left steering brake starts
and the vehicle turns left in place. (See Figure 3-5)

Figure 3-5 Left and Right Steering Control Levers

3.2.5 Right steering control lever

The right steering control lever controls the right turning of the Bulldozer. The operation
is same as the left steering control lever (see Figure 3-5).

3.2.6 Reduction pedal

(See Figure 3-6). The reduction pedal is used for

slowing down the engine. This pedal controls two gear
speeds of the engine. It generally applies to 1st gear
speed, i.e. 800-850 rpm. Further press the pedal to the
2nd gear speed and then the engine is in idling state.
When the bulldozer unloads earth in top of a slope or
beside a cliff, the speed may increase and accident
may occur due to relief of load. In this case, the driver
shall press the reduction pedal to reduce the speed.
Figure 3-6 Reduction Pedal

89
3.2.7 Left and right brake pedals

When the bulldozer turns, the brake pedal can be

used together with the steering control level in
order to facilitate the driver’s operation. (See
Figure 3-7).Pull the steering control lever
backward with a travel of 90mm first and press the
brake pedal at the same side of the lever. Then the
bulldozer turns in place. When the vehicle works in
flat ground, in the event of emergency that
requires emergency braking, press the central
position of the brake pedal to start the left and right
brake pedals.
Don’t put foot on the pedal when no operation of
brake pedal is required.
Figure 3-7 Left and Right Brake Pedals

3.2.8 Blade control lever

Operation positions of blade control lever.(At the right side the driver seat)(See Figure
3-8)
Position 1, rising of the blade
Position 2, blocking (hold), keep the blade in one
position;
Position 3, lowering of the blade
Position 4, floating, the blade freely rises and
lowers to adjust to the uneven ground (under the
action of gravity). When the control level is in
floating position, the blade can keep in this state
even the control lever is not operated by hand:
Position A:right tilting of blade
Position B:left tilting of blade
Figure 3-7

Place the blade control lever in position A and position B to make the bulldozing plate in
left and right tilt positions respectively. Tilting operation of the bulldozing plate can be
conducted both in rising or lowering positions. But if the bulldozing plate is in the
highest or the lowest positions, no tilting operation is possible.

During the tilting operation, if the tilt cylinder is in the end-of-travel, the piston rod shall

90
be pushed back without delay.

3.2.9 Blade block rod

The blade block rod is the blocking device for the

blade control lever. Pull the rod in the direction of the
arrow to block the blade control lever. (See Figure
3-9)
Figure 3-9 Blade Block Rod

3.2.10 Horn button

The horn sounds immediately after the button is

pressed.
Figure 3-10 Brake Block Rod

3.2.11 Brake block rod

The brake block rod is the blocking device for the

brake pedal. After blocking, the brake stays in
blocking state even the driver’s foot leaves the
pedal.(See Figure 3-10)

Figure 3-10 Brake Block Rod

Press the left and right brake pedals (press the central position of the brake pedal) and
place the rod in “lock” position. In this way, the brake pedal is blocked. Press the left and
right brake pedals and place the rod in “release” position. In this way, the blocking is
released.

If it intends to lock the brake pedal to stop the movement of the bulldozer by means of
the brake block rod, it can only be down when the engine is in service. If the engine is
standstill, the brake booster is out of service and the braking force reduces. There is
great risk of stopping in slope road. Therefore, the brake block rod shall be operated
when the engine is in service.

91
3.2.12 Ether start switch

The ether start switch is the quick exhaust

valve used for the engine during cold weather.
Pull out and press down the knob. The sprayed
ether is drawn in the pipe to help the engine
start. (See Figure 3-11)
Figure 3-11

3.2.13 Lamp switch

It is used to control the instrument lamp,

headlight and rear spot light.

3.2.14 Start switch

The position “off” is for the key inserting. If the

switch is in off position, the electrical system is
in disconnected state.The position “on” means
the battery relay (power switch) turns on. The
position “start-up” means the engine starts.
After start-up, the key returns to the position
“on” when the driver’s hand leaves the key.(See
Figure 3-12)
Figure 3-12 Start Switch

3.2.15 Oil pressure gauge of engine

During operation of the engine, if it displays

green, the oil pressure is in normal range.

If the engine oil cools down, the indicator points

to non-green area. After pre-heating, the
indicator displays green again. (See Figure
3-13)
Figure 3-13 Oil Pressure Gauge of Engine

92
3.2.16 Water thermometer of engine

During operation of the engine, if the indicator

displays green, the water temperature is normal. If
the indicator displays red, reduce the loads and
keep the engine in idleing state until the indicator
displays green again. (See Figure 3-14)
Figure 3-14 Water Thermometer of Engine

3.2.17 Timer

The timer is used for recording the working hours of the engine, according to which the
regular maintenance is conducted.

3.2.18 Electronic monitor with three-stage alarm

The device is used for monitoring the normal operation or failure of the bulldozer. For
details see Chapter 8.

93
 Chapter 4 ― Driving

4.1 Pre start up check(Figure 4-1)

Figure 4-1

4.1.1 Check according to the daily maintenance list (see Section 5.2 of Chapter 5).

4.1.2 Lock the brake pedal (3).

4.1.3 Place the transmission control lever (2) in neutral “N” position and lock it by the
transmission block rod.

4.1.4 Lower the blade to contact the ground and lock the blade control lever (6) by
the blade block rod (7).

4.1.5 Place the throttle control lever (1) in the idling position.

4.2 Start-up of engine (Figure 4-2)

Figure 4-2

4.2.1 Insert the key into the start switch and turn to start position. Then the engine
starts.

4.2.2 Check the oil pressure gauge of the engine during starting.

4.2.3 The key stays in the start position no more than 20s.

94
4.2.4 If failing to start up, place the key in “on” position for at least 2m and then start
up again.

4.2.5 If difficulty exists in starting, check the fuel cut valve. Operate the manual knob
to open the valve. After starting, place the knob to its original position.

4.2.6 After starting, the key returns automatically to “on” position.

4.3 Manual operation of fuel cut valve

Figure 4-3

When the electrical system of the fuel cut valve breaking down, the fuel cut valve shall
be operated manually. For starting method see Figure 4-3. Turn the knob (1) inward to
open the valve so that the oil in the PT pump flows into the injector. Then the engine
starts. Return the knob to its original position and the engine stops running.

4.4 Operation of engine

After starting, immediate operation of engine shall be avoided until warming up.

Procedures:

95
(1) Keep the engine in idling state (the throttle control lever in idling position) and the
oil pressure gauge is in normal range. Idling operation shall not last for more than 20min
or oil leakage may occur in the oil pan of the booster.
(2) Operate the throttle control lever and keep the engine in no-speed medium-speed
operation for approximate 5min.
(3) Keep the engine in light-load operation until the water thermometer is in normal
range.
Check after warm-up:check the instrument and colour of the engine exhaust gas for any
abnormal noise and vibration. Check oil, fuel and water for leakage.

4.5 Shutdown of engine

1. Prior to shutdown of the engine, keep the engine in idling state for 5min and cool
down the engine gradually. Then shut down the engine.

2. Turn the key of the start switch in “off” position and pull it out during shutdown.

Shutdown of the engine prior to cooling down will shorten the lifespan of generator
parts. Therefore, emergency shutdown can only be conducted in the event of
emergency.

4.6 Start-up of the bulldozer (Figure 4-4)

Figure 4-4

Start-up of the bulldozer can be conducted after the engine operates normally.
Procedures are as follows:

96
Pull the throttle control lever (1) backward to increase the engine speed;
Release the bulldozing plate control lever by means of the block rod (7) and lift the
blade to a height 400-500mm above the ground by means of the bulldozing plate
control lever.
Press the central position of the brake pedal (3) and release the brake pedal through
using the brake block rod (4) to return the brake pedal into normal position.
Release the transmission control lever (2) by means of the transmission block rod and
place the lever in 1st gear position. Then the bulldozer starts driving;
During starting, press the reduction pedal and place the transmission control lever in 1st
gear forward position. Release the reduction pedal slowly to increase the engine
speed gradually, so as to avoid quick start-up;
After starting, place the transmission control lever in required gear.

4.7 Forward, reverse and transmission of bulldozer

Place the transmission control lever in required gear.Transmission can be conducted
during driving. Stopping is not needed.

Press the reduction pedal when shifting gears. After the engine speed is reduced,
operate the transmission control lever to change the driving direction of the bulldozer.

4.8 Turning of bulldozer

During driving, if it intends to turn left (right), pull the steering control lever on left (right)
to midway, the steering clutch is disengaged (you can feel this action). Then the
bulldozer turns slowly (big turning).See Figure 4-5. Pull the steering control lever to end
position and press the brake pedal at the same side. The bulldozer turns in place (small
turning).(See Figure 4-6)

97
 Figure 4-5 Figure 4-6

If it intends to give a big turning on left in slope ground, pull the right steering control
lever to midway. Then the bulldozer turns left slowly (reverse operation). If it intends to
turn left in place, pull the left steering control lever to end position (reverse operation is
unallowable). (See Figure 4-6)

4.9 Temporary stopping of bulldozer (Figure 4-7)

Figure 4-7

During temporary stopping of bulldozer, there is no need to shutdown the engine.

Procedures:

98
Push the throttle control lever (1) forward to keep the engine in low-speed state;
Place the transmission control lever (2) in neutral “N” position and lock the lever by
operating the transmission block rod (5).
Press the central position of the brake pedal and lock the brake pedal by operating the
brake block rod (4).
Operate the bulldozing plate control lever (6) to lower the blade to contact with the
ground. Lock the bulldozing plate control lever by operating the bulldozing plate
block rod.

4.10 Operation during cold weather

4.10.1 Preparation
It is hard to start the engine during cold weather, for it is easy for the cooling water get
frozen. Therefore, addition of antifreeze solution into the cooling water is required.
When the temperature is below 0℃, add the antifreeze solution in accordance with the
instructions.
Prior to adding the antifreeze solution, discharge the cooling water and clean the
cooling water tank to remove scale. Check the radiator, water pump and water hose for
leakage. Then add the antifreeze solution.

For antifreeze solution is combustible, it shall be kept away from heat resources.

The switch-on temperature of the thermostat is 77℃(if the water temperature is below
77℃, the water flows into the radiator) if no antifreeze solution is added. In order to
prevent the radiator from freezing, the thermostat can be removed. In order to hold the
temperature of the engine, side cap and venetian cover are provided. Special attention
shall be given to inner thermal insulation of engine.

Observe whether the water thermometer is in normal range during operation.

The performance and the charging capacity of the battery reduce if the temperature
reduces. Therefore, the charging rate shall be rise to above 75% and attention shall be
given to thermal insulation.

The charging rate varies with temperature (see the following table). It is converted from
the specific weight of the electrolyte.

99
 Charging rate Electrolyte 20℃ 0℃ -10℃ -20℃
temperature
100% 1.28 1.29 1.3 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

Moreover, make up distilled water to the battery prior to the next day’s operation instead
of after this operation.

4.10.2 Start-up of engine

It is hard to start the engine during cold weather. Ether device can be used. Operation
methods and procedures are as follows:(See Figure 4-8)

Figure 4-8

100
Prior to operate the start switch, pull the ether start knob and wait for 2-3min. Place the
start switch in start position to start the engine. Push the ether start knob for no more
than 2s and ether is sprayed to facilitate the start-up of the engine. After starting, the
start switch returns automatically to running position. If the first start-up is failed, start
again 2min later. After starting, when the engine slows down to almost shutdown, start
the ether device. But the engine speed shall be no more than 1000rpm during
operation.During normal operation, ether device shall not be used, for addition of
excess ether will result in abnormal explosive. Therefore, excess usage of ether shall be
avoided.

The following shall be observed. Keep ether away from heat resources. Touching shall
be avoided. If human beings get touch of the ether, wash it immediately by water. The
empty ether barrel shall have valve plug (on the barrel top) closed and inner pressure
released. Disperse all inner liquefied gas. Standby ether barrel shall be stored in safety
place other than the body. Regulations relative to storage of oil pipe shall be followed for
place where large amount of barrels are stored.

4.10.3 Post-daily operation

Remove mud and water from the body and park it on hard and dry cement floor. If no
appropriate place is found, lay wood plate on the ground and place the bulldozer on
the plate to prevent the attachments freezing or running system freezing and
sticking to the ground or next day’s operation will be affected.
Remove the water on the piston rod surface of the hydraulic cylinder to avoid damage of
seal ring which may occur if the mud and frozen water enter the seal ring.
Remove the drain pipe plug and discharge water in the fuel system to avoid freezing at
night.

If the cooling water contains no antifreeze solution, open the cock of the water tank
under the radiator and the cock (or plug) at the right of the cylinder parts to discharge
the cooling water completely, so as to avoid freezing at night. However, if the water
contains anticorrosive agent, it can be reused and filled in the water tank in the next day.

If new water is used, replace three DCA-4L anticorrosive agents in the protection
device.

101
Remove the clamping head of the protection device and use the cotton waste for
thermal insulation, so as to prevent freezing. Install the clamping head again in the next
day. Tighten the cock of the protection device when removal of the clamping head.

The performance of the battery reduces obviously in low temperature. Therefore,

thermal insulation measures shall be taken. Cover it properly or place it in warm indoor
space. Install the battery again in the next day.

4.10.3 After the cold weather

1. Replace the lubrication oil in each equipment with the oil of rated viscosity if the
weather is warm.
2. Discharge the antifreeze solution completely. Clean the cooling system and fill the
system with clean soft water. Add new anticorrosive agent.
3. Remove the ether barrel and keep it in special cool place.

102
 Chapter 5 ― Maintenance
Correct and prompt technical maintenance means frequent and regular inspection,
cleaning, lubrication, adjustment and fastening of bulldozer. In this way, it can improve
the production efficiency, lessen wearing and avoid accidents, so as to improve the
economical efficiency, prolong the lifespan of the bulldozer and save repair costs.

Maintenance hours required for the bulldozer is recorded by the timer.

Maintenance shall be taken earlier than the designated time if the working conditions
are poor.

5.1 Maintenance considerations

Maintenance considerations
Regulation relative to oil pipe in the “safety operation code” shall be observed during
maintenance.
When conducting maintenance operations under the vehicle, notes shall be given in the
driver’s seat or give warnings around the bulldozer if necessary.
If the maintenance requires lifting the blade, support shall be given under the blade to
prevent it from falling.
When lifting the vehicle body by means of the blade, lock the control lever and fill up the
clearance under the track to avoid falling of whole body.
The engine shall be in standstill when cleaning the vehicle, filling oil, checking the fan
belt for tightness and checking the running parts and associated parts.
Shut down the engine and disconnect the connection between the battery and the
vehicle when maintaining, checking and charging the battery. Turn off the charger
when removing the battery and the charger.
Keep away from the open fire during maintenance, including smocking and electric
spark.
Be careful not to loss anything when opening the gear box and the rear axle case.
The pressure shall be released when filling and discharging oil and other inspection for
the hydraulic system. Procedures: Lower the blade to contact the ground and shut
down the engine. Operate each control lever for two or three times and release the
cover of the control lever slowly.
Use special tool to adjust the oil pressure otherwise accident may occur when
maintenance with great difficulty is carried out.
Irrelevant personnel shall not be involved and get close to the working place during
inspection and maintenance.

103
 Keep the oil filling parts, oil scale surface and any other oil filling containers clean. Use
clean oil and clean consistent grease. Check and change of oil shall be carried out
in an environment with few dusts. Such measures aims at preventing dusts
entering.
Keep the engine in medium-speed state for 5-10min to remove air in the oil lines after
the maintenance of the oil filter.
Add appropriate amount of lubrication. Excess or insufficiency is unallowable.

5.2 Maintenance list

I. Oil list

Usage of the fuel, lubrication oil and water varies with the temperature. Adjustment
and replacement are conducted according to the following table.
Parts Oil Usage of fuel and Designated amount Optional amount Alternative
lubrication oil oil model
dependent on the No.
temperature
-10 0 10 20 30

Oil pan of the Engin 15W-40 (grade CD) 47 47 27 27

engine e oil
Transmission, SAE30 122 122 90 90 8#
rear axle case, SAE10W hydraulic
bevel gear transmissi
(including on oil
torque
converter)
Final drive SAE30 36 each 51 each 36 each 36 each 15#
case for left for left and for left and for left hypoid
and right right side right side and right gear oil
side side
Oil tank of SAE10W 110 110 70 70 8#
working hydraulic
equipment transmissi
on oil
Fuel tank Diesel 0# Diesel 450 450 - -
(above 5℃)
-10＃ diesel
(above -5℃)
-20# diesel
(above -5℃)
Cooling system Water Antifreeze 79 79 - -
solution

104
II. Daily maintenance list

Item Hour Complete

examination
Check for oil leakage and water leakage Required
Check each part for looseness of bolts or nuts Required
Check for short-circuit, break line and poor contact Required
Check and make up the cooling water Required
Check and make up the fuel Required
Check the oil pan of the engine for oil volume Required
Check torque converter, transmission, rear axle case, final drive Required
case for oil volume
Remove water and sediment from the fuel tank Required
Check the electronic detector Required
Check the travel of the steering control lever Required
Check the travel of the brake pedal Required

III. 250 and 500-hour maintenance list

Item Hour More than

250-hour
Add lubrication oil (consistent grease)
Cool down the fan shaft (one) Required
Tension the axle (one)
Brace Straight tilt blade (one) Required
Angle blade (two)
Tee (one) Required
Ball joint of cylinder (two) Required
Bracket of cylinder (four) Required
Ball joint of tilt cylinder (two) Required
Ball joint of diagonal brace (two) Required
Ball joint of brace (three) Required

105
 Item Hour More than More than
250-hour 500-hour
Check and make up the oil
Oil tank of final drive Required
Oil tank of working equipment Required
Adjust the drive belt tightness of the generator Required
Required
Clean and replace the torque converter, Required
transmission and steering oil filter element
Check and tighten the track shoe bolt Required
Check the liquid level of the battery Required
Clean of the vent hole
Venting device of the final drive case Required
Venting device of the real axle case Required
Check the ether start device Required

IV. 1000-hour maintenance list

Item Hour More than 1000-hour

Add lubrication oil (consistent grease)
Diagonal brace of bogie (two) Required
Cardan joint (two) Required
Main shaft of torque converter (one) Required
Track tensioning device (two) Required
Check and clean the radiator Required
Replace the oil of torque converter, transmission and real Required
axle case
Clean the torque converter, steering and braking loop and Required
filter element
Replace the oil in the oil tank of working equipment and Required
replace the filter element

106
V. 2000-hour maintenance list

Item Hour More than 2000-hour

Add lubrication oil (consistent grease)
Shaft of balance beam (one) Required
Shaft of reduction brake (two) Required
Operating shaft of transmission control lever (three) Required
Linkage mechanism shaft of brake pedal (six) Required
Linkage mechanism shaft of throttle control lever (three) Required
Linkage mechanism shaft of bulldozing plate control lever Required
(three)

VI. Unscheduled maintenance

Change cooling water Twice annually (spring, autumn) or after

1000-hour
Check, clean and replace air filter Unscheduled maintenance
Check and adjust track tension Adjust at any time

5.3 Specific tasks of maintenance

5.3.1 Daily maintenance

1. Check for water leakage and oil leakage

Check the bulldozer, especially high-pressure hose connector, hydraulic cylinder,
floating oil seal and radiator, for water leakage and oil leakage after the start-up of
the bulldozer. If leakage is detected, find out the possible reason and repair it
promptly.

2. Check each part for looseness of bolts and nuts. If looseness of bolts and nuts is
detected in any parts, especially in air filter, silencer, carrier roller and track shoe,
tighten them promptly.

3. Check the electrical system and all lines.

4. Check and make up cooling water

Open the water adding entry lid (see Figure 5-1) to check the cooling water in the
filter. If no water is observed in the bottom of the filter, add water from the entry to
the lever as shown in the figure. Shut down the engine when adding water. Keep

107
 the engine in idling state for 5min after the water is added. Then check again. If the
water level is not in consistence with the requirement as shown in Figure 5-1, add
water again.

Figure 5-1

Check the cooling system for leakage if the amount of the water added is much
more than normal quantity.
If the water temperature is high, the lid shall be opened slowly to release the water
pressure or the hot water may spurt out.

5. Check the fuel (see Figure 5-2)

Figure 5-2

After the completion of the bulldozer’s work, open the cap and use the oil dipstick G
to check the oil volume. Fill oil from the oil filler F and ensure the tank is filled up. If
the cap is open and the vent hole is blocked, the fuel supplying may stop.
Therefore, regular inspection and dredging shall be conducted.

6. Check the oil pan of the engine for oil volume

Use the oil dipstick G to check the oil volume. Fill oil from the oil filler F in the event
of oil insufficiency. (See Figure 5-3)

108
 The side with “ENGINESTOPPED” of the oil dipstick shall be used if check the oil
volume when the engine is stopped. If checking the oil volume when the engine is
in idling state, keep the oil pressure gauge and water thermometer of the engine
indicating the normal range and use the side with “ENGINEIDLING” of the oil
dipstick.

Figure 5-3

7. Check the volume of oil inside the real axle case, including the transmission and
the torque converter.
Remove the right armrest (see Figure 5-4) and check the oil volume with the oil
dipstick F. Fill engine oil from the oil filler F in the event of oil insufficiency.

Figure 5-4

109
8. Remove water and sediment from the fuel tank
Open the bottom valve of the fuel tank and remove the water and sediment
accumulated on the bottom. In this process, the oil is discharged along with the
water and the sediment.

9. Check the electronic detector (for details see Chapter 8)

10. Check the travel of the brake pedal

When the engine is in idling state, the standard travel of the brake pedal of the
bulldozer is 120-140mm. If the travel is out of the range, adjust the travel according
to procedures given in “Adjustment of Each Equipment”

11. Check the travel of the steering control lever

When the engine is in idling state, if the travel of the steering control lever is out of
its standard travel range, adjust it according to procedures given in “Adjustment of
Each Equipment”.

When the travel of the control lever is in 0-55±5mm, the steering clutch is disengaged.
Pull the control lever further to make the travel within the range of 55±5 - -124±5mm
and the brake is on.

5.3.2 250-hour maintenance

The 250-hour maintenance includes the initial 250 running hours of the bulldozer. The
task is conducted together with the “Daily maintenance”.

1. Add lubrication grease to places as shown in Figure 5-5.

110
111
1 Cool down the fan shaft (one) 2 Tension the wheel (one) 3 Brace (one)
4 Tee (one) 5 Ball joint of cylinder (two, one per side)
6 Bracket of cylinder (four, two per side)
7 Beam of cylinder bracket (four, two per side)
8 Ball joint of tilt cylinder (one) 9 Ball joint of diagonal brace (two)
10 Ball joint of brace (three)
Figure 5-5

2. Check oil volume

Final drive case
Open the plug G to check whether the oil reaches the hole bottom. If not, fill oil
from the hole F.

Figure 5-6

112
 Check oil tank of working equipment
Lower the blade and stop the engine. Check the oil level indicator G 5 min later
(see Figure 5-7).If the level is not between the upper and lower marks of the
indicator panel, fill oil from the oil filler F. This task shall be conducted prior to
the operation of the bulldozer.

Figure 5-7

3. Check the drive belt tightness of the generator

The Figure 5-8 shows the standard tightness. When pressing the belt by finger
(approximate 60N), the belt shall only displace 10mm. If the displacement is over
the value, adjustment is required. Loose the bolt (1) and the nut (2) and move the
generator to achieve the standard tightness.
If the V-belt is worn out or has no margin for adjustment (in addition, the belt has
scar marks or cracks), it shall be replaced promptly. Both belts shall be replaced
together. New belts shall go through 1- hour commissioning. Then check and adjust
their tightness.

113
 Figure 5-8

4. Clean and replace oil filter elements

Clean and replace the oil filter elements of the transmission and the steering clutch.
See Figure 5-9.Remove the bolt (2), cap (1) and elements. Clean the interior of the
filter shell and elements. Replace elements if necessary. After replacement, the
air shall be exhausted. Start the engine and loose the bleeding plug (3). Tight it
immediately after the oil spurts out.

Figure 5-9
5. Check the electrolyte level of the battery
If the level is below the designated height (10-12mm above the pole plate), add
distilled water (see Figure 5-10).If the electrolyte decreases, add weak sulphuric
acid of the same concentration as the electrolyte. In this process, no metal hopper
shall be used. When checking the electrolyte level, the vent hole on the battery
cover shall be maintained as well.

Figure 5-10

114
6 Check the track shoe bolt
Tighten the loosed track shoe bolt with tightening torque of 980-1176N.m

5.3.3 500-hour maintenance

The 500-hour maintenance is conducted together with the 250-hour maintenance.

1. Clean the venting device

Remove the venting device and clean its interior with clean diesel. (See Figure
5-11)

Figure 5-11 (1) Venting Device of the Real Axle Case

115
 Figure 5-11 (2) Venting Device of the Final Drive Case

2. Check the ether start device (if any)

(See Figure 5-12)

Figure 5-12
Remove the ether barrel and check the valve and the control wire. When removing
the ether barrel, clean the valve to prevent dust entering. If damage of
bracket in the valve is detected, replace it. After removal of the ether barrel,
it shall be easy to operate and move the control wire.
When replacing the ether barrel, the following items shall be conducted first.
Check the joint for leakage and tighten the mounting bolt.
Carry out testing in the following sequence

116
 Remove the nylon tube from the spray
Remove the spray
Connect the spray to the tube
Place the control wire in running position. Check each hole of the spray for
spraying 2s later. Place the wire in off position then.

5.3.4 1000-hour maintenance

The 1000-hour maintenance shall be conducted together with the 250-hour

maintenance and the 500-hour maintenance.

1. Add lubrication grease. Add consistent grease to the position as shown in Figure
5-13.

Figure 5-13 (1) Cardan Joint (two)

117
 Figure 5-13 (2) Track Tensioning Device (two, one per side)

Figure 5-13 (3) Diagonal Brace of Bogie (two, each per side)
2. Check the radiator
Remove the mud, dust and leaves from the radiator vane with compressed air
or water. Check the rubber hose at any time. If cracks and aging are detected,
replace the hose promptly. Check the hose clamp for tightness.
3. Replace the oil in the rear axle case, including oil in transmission, torque converter
and bevel gear box, and clean the oil filter. (See Figure 5-14)

118
(1) Discharge oil from oil drain plugs P1 and P2 under the vehicle body. After
discharging, tighten the oil drain plugs.
(2) Open the left base plate. Loose the bolt (1) and remove the cap (2). Then
remove the oil filter mesh (3) and the magnet (4).
(3) Loose the bolt (5) and remove the oil filter of the torque converter along
with the cap (6).
(4) Clean the elements and oil filter removed from the case. Install them in
their original positions. If damage of elements such as oil filter mesh and
magnet is observed, replace the damaged element promptly.
(5) After the replacement of oil filter elements, add engine oil of designated
volume from the oil filler F according to regulations contained in “250-hour
maintenance”.

119
 Figure 5-14

4. Replace the oil in the oil tank of working equipment and clean the oil filter(See
Figure 5-15)

Figure 5-15

120
 (1) Remove the oil drain plug (1) under the oil tank of working equipment.
Loose the oil drain valve (2) to discharge oil. After discharging, tighten the
oil drain valve (2) again.
(2) Loose the bolt (3) from the rear of the oil tank. Remove the cap (4) and take
oil filter elements out from the tank.
(3) Clean the interior and elements of the filter. Replace the damaged
elements promptly. Install elements in their original positions.
(4) After replacement, fill engine oil of designated volume from the oil filler F.

5. Replace the oil in the final drive case (see Figure 5-16)

Figure 5-16

(1) Open the oil drain plug P at both sides of the vehicle body to discharge oil
and then tighten the oil plug again.
(2) Fill engine oil of designated volume from the oil filler F.

121
6. Replace the oil in the running system
Park the bulldozer in flat ground and check the carrier roller, the sprocket and the
front idle for oil volume according to the following procedures. See Figure 5-17.

Figure 5-17

(1) Loose the seal bolt of each wheel slowly. If oil leaks out from the thread, no
oil addition is needed. Tighten the bolt immediately.
(2) If no oil leakage occurs when loosing (even removing) the seal bolt, the oil
is insufficient. Contact the manufacturer immediately.

5.3.5 2000-hour maintenance

The 2000-hour maintenance is conducted together with the 250-hour maintenance,

500-hour maintenance and 1000-hour maintenance.

Add consistent grease to positions as shown in Figure 5-18.

1. Shaft of balance beam (one)

122
2. Shaft of reduction brake (two)

3. Shaft of transmission control lever (three)

123
4. Linkage mechanism shaft of throttle control lever (three)

5. Linkage mechanism shaft of bulldozing plate control lever

124
 6. Linkage mechanism shaft of bulldozing plate control lever （three）

5.3.6 Unscheduled check

1. Replace cooling water

If the cooling water contains antifreeze solution, change the cooling water in spring and
autumn. If not, change the cooling water once per 1000-hour.
Procedures:
(1) Park the vehicle in flat ground and stop the engine. Tighten the venting
device. Open the radiator cap slowly to release the water pressure and to
avoid injury due to hot air when the water temperature is high;
(2) Open three water drain valve (radiator, cylinder block and oil cooler) to
discharge water;
(3) After discharging, clean the equipment with cleaning agent. Follow the
cleaning methods given in the product’s instructions;
(4) After cleaning, discharge the water completely. Close the water drain
valves. Add clean water from the water adding entry to required level;
(5) Keep the engine in idling state and open all water drain valves to discharge
water. At the same time, add water from the water adding entry for cleaning
until the water discharged from the valves is clean. Then close all water
drain valves;
(6) Fill water from the water adding entry to required level again.
(7) Replace the anticorrosive agent in the venting device;

125
 (8) Keep the engine in idling state for 5min and in no-load high-speed state for
5min to remove air from the cooling water;
(9) Add water from the water adding entry according to requirements in “Daily
maintenance” and then tighten the water adding entry lid after the engine is
in standstill for approximate 3min;

2. Check, clean and replace the air filter

If the vacuum indicator of the air filter sounds, the outer filter element shall be cleaned
immediately. In this process, the engine shall be stopped.

Figure 5-19
Remove the cap (1) and the filter mesh of the outer sleeve (see Figure 5-19)
Clean the interior of the filter shell and the cap
Clean the filter mesh of the outer sleeve. Procedures:

Clean it with compressed air. Blow the interior surface along the fold with
dry compressed air (below 0.5MPa). Then blow the exterior surface
along the fold. Finally, blow the interior surface again to make the
interior and exterior surfaces free from dust;

Cleaning of the filter mesh with oil or water is unallowable.

After cleaning, check the filter mesh under the light. If there is any hole damaged,
replace the filter mesh.
Replace the filter mesh of the outer sleeve if it has been cleaned for five times or
used for one year. If the alarm still sounds after cleaning, replace it even
though the cleaning times are less than five.
The filter mesh of the inner sleeve (cleaning is not allowable) shall be replaced
when replacing the filter mesh of the outer sleeve.

126
3. Check running system

(1) Check the track tightness

Park the vehicle in flat ground and place one ruler (see Figure 5-20)
between the sprocket and the front idler. The standard tightness is that the
maximum clearance between the ruler and the track shoe is 20-30mm;

Figure 5-20

(2) Check the clearance of the guide plate of the front idler. If the clearance is
too large, transverse vibration of the front idler and misalignment of centers
of front idler and bogie may be resulted. The clearance A less than 4mm is
considered to be normal range (see Figure 5-21).

Figure 5-21

127
 (3) Check the chain link pitch. Insert wood plate between the track shoe and
the segment sprocket (see Figure 5-22) to loose the track. Measure the
length L of four chain link pitches in the straight line portion taking the point
two segments away from the pin on the wood plate (or with respect to the
king pin) as the start point. 1/4L is equal to the chain link pitch.
Basic chain link pitch: 216mm
Reverse chain link pitch:219.25mm (tight)
221.25mm (limit value)

Figure 5-22

Note: The basic chain link pitch is the value measured after the bulldozer drives forward
while the reverse chain link pitch is the value measured after the bulldozer drivers in
reverse direction.

(4) Check the grouser height

After the track shoe is tensioned, measure the grouser height A in the
middle position of the track shoe (see Figure 5-23):
Basic value: 72mm
Limit value: 25mm

Figure 5-23

128
 (5) Check the outer diameter of carrier roller
Measure the height C between the top and bottom plane of the upper
chain link (see Figure 5-24)
Stop the vehicle when the top plane of the chain link fully contacts with the
outer circle of the carrier roller and measure the height B as shown in
the figure. The outer diameter A of the carrier roller: A=（B-C）*2
Basic value: 222mm
Limit value: 198mm

Figure 5-24

(6) Check each wheel for oil leakage and bolts and nuts for tightness. If any
problem is detected, repair it promptly.

5.4 Wear parts

For wear parts such as filter elements and bulldozer blade, replacement is a must
during the unscheduled maintenance period or when the wear limit is reached.

Wear parts list

129
 Item No. Name Quantity Replacing time

Filter element of the 49-83 Filter element (O ring) 2 250 hours later
steering and （07000-02115） 2
transmission
Filter of oil tank of 175-60-27380 Filter element (O ring) 1 1000 hours
working equipment （07000-05150） 1 later
Air filter 00-7 Filter element assembly 1
Bulldozing plate T21.71-20 Blade edge 3
Blade edge 1
T21.71-19 Blade edge 1
Left cutting blade 3
T21.71-20 Right cutting blade 5
Bolt 3
T21.71-17 Nut 5
T21.71-18 Washer 3
（GB6170） 5
（01643-21845）

Note: Parts as shown in the bracket ( ) shall be replaced at the same time.

5.5 Adjustment
5.5.1 Adjustment of the track tightness (as shown in Figure 5-25)

Figure 5-25

130
Add consistence grease from the oil filler (1) to increase the track tightness. The
adjustment travel limit is S. If the track is still slack when the S is equal to 0, this means
that pins and pin bushings are worn out and their installation positions shall be changed.
Reverse the pins and pin bushings through some angle with respect to their original
installation positions. Reinstall them or replace the track.

If it intends to release the tightness, loose the plug (2) with a single turn to discharge the
consistence grease. Two turns or above shall not be made when loose the plug (2).
Parts other than the plug (2) shall by no means be loosed to avoid the injection of
high-pressure oil, which may cause accident. Drive the vehicle forward or reverse a bit
in the event of abnormality. (See Figure 5-26)

Figure 5-26

5.5.2 Adjustment of clearance between front idlers

(See Figure 5-27)

Figure 5-27

131
When the front idler is under the action of external force, the support (2) moves forward
and backward in the upper part of the bogie frame along the guide plate (3), which leads
to worn-out of the lateral plate (7) and the guide plate (3), transverse vibration and
lateral tilting of the front idler as well as inconsistence of the front idler spacing and the
gauge. Interference of flange of carrier roller and sprocket and edge of segment
sprocket and the chain links will result in fast worn-out. Therefore, clearance between
front idlers shall be adjusted.

1. Adjustment of lateral clearance

Drive the vehicle for 1-2m on the flat ground. If the clearance A (4 places) between
the bogie frame and the lateral plate (7) is more than 4mm, loose the bolt (1) and
remove the spacer a. Adjust the lateral clearance to 0.5-1mm. The thickness of one
spacer is 1mm. (See Figure 5-28).

Figure 5-28
Notes:Loose the bolt (1) no more than 3 turns or it is hard to install the seat (8).

2. Adjustment of clearance between top and bottom

If the sum of the clearance B between the support (2) and the guide plate (3) and
the clearance C between the top and bottom plates and the wearing plate of the
bogie frame is more than 5mm, adjustment is a must. The following are main
considerations:
Remove spacers with appropriate quantity from the position (c) and place them in
the position (b). Adjust the clearance (B+C) to 2mm. In normal conditions, the
clearance C is equal to 0mm. The specific procedures of adjustment are:

132
1. Measure the worn clearance B and subtract 2mm (normal clearance) from B. The
result is the adjustment value δ, that is the δ is equal to B minus 2mm.
2. Loose the bolt (5) until the spring is inelastic.
3. Loose the bolt (1) (no more than 3 turns)
4. Raise the top and bottom guide plates (4) with the lever or the bolt (5) to make the
clearance C equal to 0mm. Remove spacers from the position (c). The thickness of the
spacers shall be equal to the adjustment value δ;
5. Place the spacers removed in procedure 4 into the position b (8 places).The
thickness sum of spacers in the position (c) and the position (b) is equal to the thickness
sum prior to adjustment. The spacers’ quantity before and after the adjustment is the
same. The spacers in both positions have two types: 2mm spacer and 1mm spacer.
Increase and decrease of the total spacers’ quantity may deteriorate the performer of
the spring. Therefore, it is unallowable to increase or decrease the total quantity of
spacers.
6. Tighten the holding down bolt (5)
7. Tighten the bolt (1) with designated tightening torque.
8. Reinstall the lateral plate (7) to their original position.
The maximum adjustment value δ is 6mm.

5.5.3 Adjustment of the travel of reduction pedal

(See Figure 5-29).

Figure 5-29

Place the throttle control lever to the midway of the total travel and press the reduction
pedal to make the clearance A equal to 0mm. In this case, the engine speed shall be
800-900rpm. If the engine speed is out of the range, adjustment shall be conducted
according to the following procedures:

133
Loose the lock nut (1) and adjust the adjusting bolt (2) until the following conditions
occur. The engine speed is within 800-900rpm when pressing the reduction pedal
to make the clearance A equal to 0mm. This means the pedal travel is normal.

Tighten the lock nut (1).

The speed indicator shall be used during the adjustment in order to correctly adjust the
engine speed.

5.5.4 Adjustment of the travel of brake pedal

The brake is of contracting band type. When the brake band lining is worn out, the travel
of the steering control lever and the brake pedal increases and the braking performance
reduces. Therefore, adjustment is required.

The following are procedures:(See Figure 5-30)

Figure 5-30

Remove the rear cover and the brake inspection cover (1)

134
Tighten the adjusting bolt (2) that pulls the brake band tight (until resistance is sensed).
In this case, the brake drum and the brake band contact with each other (see
Figure 5-31).

Figure 5-31

Loose the adjusting bolt (2) with 7/6 turns.

Measure the travel of the brake pedal when the engine is in idling state:
Standard travel: 120-140mm
If the measured value is out of the range, adjust the adjusting bolt (2) again.Turn the bolt
clockwise and the travel of the pedal decreases. Turn the bolt counter-clockwise
and the travel increases.
The size of the adjusting bolt (2) is the marked A as shown in the figure. If the A is below
105mm, adjust or replace the brake band lining.
Make the travels of left and right brake pedals in consistence with each other. The
allowance is 5mm.

135
5.5.5 Adjustment of the travel of steering control lever

The adjustment of the travel of steering control lever for bulldozer is as shown in Figure
5-32. Position the rod (1) in the place 78mm away from the side of the guide block and
make it contact with the plate (2). Push the rod (4) forward to contact the steering valve
rod. Adjust the length of the flexible axle (3). Ensure the rod (1) has no clearance and
the travel of the drive direction rod of the steering control lever is 124±1.0mm.

Figure 5-32

5.5.6 Adjustment of driver’s seat

Freely adjust the height and angle of the seat so that it is convenient for the driver to
operate.

(See Figure 5-33)

136
 Figure 5-33

To-and-fro adjustment of seat

Move the rod (4) to the left and adjust the seat to required position. Then release the rod
(4).
The to-and- fro adjustment value of the seat is 140mm, classified into 7 gears.

Adjustment of seat’s height

Turn the handle (3) to the right and the seat lowers. Turn right and the seat rises.
The adjustment value is 50mm.

Adjustment of backrest
Pull the rod (5) upward and move the backrest to a required position. Then release the
rod (5).

Weight bearing adjustment of seat

Move the handle (2) up and down to align the driver’s weight with the weight metering
scale, thus the optimized state can be ensured.

Direction adjustment of seat

Pull the handle (3) upward and the seat turns right through an angle of 15°. After the
adjustment, place the handle down and lock it.

137
5.5.7 Tilt adjustment of bulldozing plate

The tilt of 500mm of the bulldozing plate can be reached through operating the control
lever. If it intends to increase the tilt further, change the length of the adjusting screw (1)
on the left of the joint between the bulldozing plate and the push rod. After the
adjustment, the maximum left tilt for bulldozers can be 530mm.
Procedures (see Figure 5-34):

Use the adjusting rod (2) to turn the adjusting screw (1). If the length L between the
joints increases, the left tilt decreases while the right tilt increases. If the length L
between the joints decreases, the left tilt increases while the right tilt decreases.

Note: During adjustment, the bulldozing plate shall not contact with the ground.

138
 Figure 5-34

5.5.8 Compensation adjustment of ball joint

Compensation adjustment shall be conducted at the seven ball joints of the bulldozing
plate. The axial clearance shall be less than 1mm (symbol A as shown in Figure 5-35)

Figure 5-35

Procedures:

Loose the bolt and remove the spacer (1). Then tighten the bolt (2) to make the ball
joints having no clearance.

Measure the clearance A and loose the bolt (2).

Adjust the thickness of the spacer (1) and limit the axial clearance within 1mm

After adjustment, tighten all bolts and ensure the ball joint can rotate freely.

139
 Chapter 6 ― Safety Operation Code
and Safe Construction Technology
6.1 Safety operation code
In order to complete the construction with safety, quality and quantity guaranteed, the
driver shall not only understand the structure and operating methods of the machinery
but also be familiar with the performance of the machinery and the safety considerations.
The safety operation code shall be observed during operation, for injury and accident
are caused due to careless.

I. General safety considerations

The driver shall be trained to be familiar with the performance, structure,
maintenance, operating methods and safety operation code of this bulldozer.
Solo driving of the driver is permissible only after he passes the due
examinations.
Personnel other than the driver shall not drive the bulldozer. For trainees,
professional driver shall accompany to give instructions.
Wear safety and protection facilities properly.
The driver, who is overtired or under the alcohol, shall not carry out operation.
Field rules shall be observed to avoid accident.
Keep fuel, grease, antifreeze solution and battery away from heat resources.
When working indoors, pay attention to the clearance between the ceiling,
entry-exit passway and the vehicle. The ground strength shall be sufficient.
When working indoors with poor ventilation, venting devices shall be provided
to prevent personnel from poisoning by exhausted gas from the engine.

II. Prior to operation

Investigate the topography, geology and hazardous locations and determine the
operating methods. Operation can only be conducted after the hazardous
locations are marked or safety measures are taken. For hazardous locations
such as cliff, attention shall be attached to landslide. For places with rockfall
risk, the driver shall wear hardhat. Besides, safe shed and rubber plate shall
be used.
The commanders, if any, shall have unified commands and cooperate with each
other. Driving can be conducted after the driver gets familiar with the signs in
working places. The driver shall be familiar with the storage places for fire
extinguisher, fire fighting facility and first-aid kit and their operating methods so
that he can use them in emergency situation.

140
 Check the sealing parts of the diesel, lube oil and hydraulic system for leakage,
damage and weather all parts are in good conditions. If abnormal condition is
detected, repair shall be carried out.
Check the volume of the diesel and the lube oil. Smocking and approaching of
ignition resources are prohibited when filling oil. Check the oil filler cap for
tightness.
Remove the inflammables such as leaves and waste papers from the engine to
avoid fire disaster.
Adjust the driver’s seat to an optimum position so that it is convenient for driver to
operate.
After starting the engine, check weather each control lever is in neutral position.
After the start-up of the engine, the following shall be conducted prior to operating

Check to see if the instrument indications are all right.

Check to see if the travel of each control lever, pedal and the operation of each rod are
all right (place the transmission control lever in neutral position first)

Carry out trial run in safety place. Check to see if the transmission operation is quick.
The initial stage of the commissioning is low-speed driving. Check to see if the steering
and braking performance of each gear is all right.

Check carefully to see if the gas color exhausted by the engine is all right. Check the
engine for abnormal vibration and noise.

III. During operation

During operation, the driver shall sit on the driver’s seat. Operation of the driver
when he stays in a position far away from the driver’s seat or stands is
unallowable.
During driving, raise the bulldozing plate to a height 400-500mm above the ground
so that the driver has a clear front sight.
Proper operation and running shall be ensured under any circumstance. Over
speed, sharp start-up and crawling are not allowed. Sudden brake and sudden
turn shall be avoided. Keeping the vehicle in idling state for a long time is
unallowable.
Pay attention to pedestrians and barriers. Keep the distance between vehicles.
Check to determine if abnormal conditions of the vehicle exist according to
instrument, sound, vibration, color of exhausted gas and each operating
handle. If any, repair it promptly.
When pulling the breakdown vehicle, one driver shall be provided in this vehicle to

141
 operate the braking or the stop mechanism. Reliable wire rope shall be used
for proper pulling.

Figure 6-1
In the working place, entering of irrelevant personnel is prohibited.

IV. After operation

When parking the vehicle after operation, place the transmission control lever in the
neutral position. Lower the bulldozing plate and ripper on the ground. Lock all
safety bars. Shut down the engine before leaving the cab.
Park the vehicle in designated safety places.
If it is necessary to park the vehicle in slope, fill rock under the track. (see the
following figure)

Figure 6-2

142
6.2 Safe construction technology
The driver shall operate the bulldozer with patience and step by step. He shall be
familiar with the safe construction technologies and keep the concentration so that
safety operation can be guaranteed and damage of machineries and injury of personnel
can be avoided.

Normal operation
When operating the bulldozer in uneven ground, keep it in low-speed state. Shape
transmission and turning at high speed shall be avoided.
Driving over big rock, falling tree or other barriers is unallowable. Such objects shall
be removed by working equipment. If removal is impossible while crossing is
necessary, drive over at low speed to reduce vibration and protect the vehicle
(see the following figure)

Figure 6-3

When operating in water, check the water depth, flow rate and earthiness under
water first. Operating in water of depth over the limit is prohibited. Prior to
operation in water or muddy ground, tighten all drainage plugs. After operation,
remove mud from each part of the bulldozer. Check the oil pan of the engine,
the torque converter, the rear axle case, the hydraulic equipment of the final
drive case and the running system for oil lever, oil leakage and water leakage.
Discharge water in the oil tank if necessary.
Notes:The sprocket and the cooling fan shall not contact with the water when
operating in water.

143
 When passing through the narrow ground, attention shall be attached to the width
and the height of the passway. Commander shall be provided if necessary.
Appropriate lighting facilities shall be provided during night operation. If it is hard to
install lighting facilities, the headlight and work light shall be used to ensure the
safety of operation (see the following figure).

Figure 6-4
When operating in place with mist and smock, great attention shall be paid. If the
operation is affected, stop operating.
When operating around electrical wires, move them to other places. If impossible,
place barriers around them and provide insulation devices. The driver shall
wear rubber shoes or leather shoes to avoid electrical shock hazards.

In order to avoid electrical shock hazards, the following table specifies the shortest
distance between the vehicle and the power supply according to transmission voltage
levels.

Transmission voltage (KV)(quantity Shortest distance (m)

of insulator)
6.6(distribution line) 3
33.0（1-3） 4
66.0（5-8） 5
154.0（10-18） 8
275.0（16-30） 10

144
 When the bulldozer intends to cross one bridge, the bearing capacity shall be found
out and drive the bulldozer across the bridge at low speed after the safety is
ensured.
When the bulldozer intends to cross the railway, it shall be vertical to the railway
and get across at low speed. Turing on the railway is prohibited.

Operation beside the cliff or the roadside

When operating in hazardous locations, it is recommended not to approach the cliff or

the roadside. When driving along the track trace that left during the former operations, if
it is observed that the earth volume is small, drive the bulldozer with great care. (See
the following figure)

Figure 6-5

Operation on the slope

When driving on the slope, the bulldozer shall be driven up and down the slope
in a direction parallel to the slope direction. Oblique driving may result in
turnover or skid.
Before going up and down the slope, appropriate speed shall be selected.
Transmission in the slope is prohibited.

145
 When going down the steep slope or long slope, drive the bulldozer at low
speed and brake the vehicle by means of the engine. Gliding is
unallowable. If the speed is intended to increase, press the brake pedal.
The drive shall pay special attention to pressing speed and travel of the
brake pedal. Lower the bulldozing plate to cut into the ground, so as to
reduce the speed and increase the resistance. There is accelerating
motion trend when going down the slope. Therefore the speed will be
higher than the maximum speed of this low-speed gear when driving in flat
ground. Thus, the driver shall drive the bulldozer with great care when
going down the slope to avoid accident. (See the following figure)

Figure 6-6
Shape brake with the brake pedal in the slope is not permissible.
When driving in the slope, turning shall be avoided. Turing in loose or clay
slope may result in gliding and turnover.
When driving, the objects such as iron plate, falling tree or accumulated leaves
shall be avoided.

If the engine is died in the slope, lower the bulldozer first and park the vehicle. Place the
transmission control lever in neutral position and restart the engine.

Snow removing operation

When conducting snow removing operation in the snow, check the ground for slope
to avoid skid. Appropriate operating speed shall be selected.
The load varies significantly with the quality of the snow. Therefore, when operating,
it shall pay attention not only to skid prevention but also to increase and
decrease of the engine load.
Pay attention to piles buried under the snow during operation.

146
Excavation of hard ground, frozen ground and ditch
Place the bulldozing plate in Tilt position and make the bezel of the tilt blade cut into
the ground. For harder ground, rip the ground with the ripper and excavate with the
blade.

Operation in flat ground

When leveling the surface soil, level the ground with large height difference and
then conduct leveling in the whole area step by step. The operation shall be carried
out at low speed. For the last procedure, place the blade in Floating state and level
the ground at slow astern. For rocky or stony ground, slow astern is unallowable or
damage of bulldozing plate body will be caused.

Dozing
1. It is recommended to use the bulldozer for operations such as dozing, earth
moving and digging if the moving distance is within 80m. If the distance
exceeds the range, it is recommended to use carryload scraper. When digging
the slope, it shall be conducted from up to down, so as to improve the
operating efficiency.
2. When dozing the earth into the cliff, reserve some earth beside the cliff. Push
the earth reserved last time into the cliff and reserve new earth.

Figure 6-7

147
 3. When dumping the earth in the front of the cliff or when the vehicle reaches the
slope top, press the reduction brake slowly and place the transmission control
level in Neutral position to avoid auto-acceleration of vehicle due to load relief
(6-8).

Figure 6-8

Felling and uprooting operations

For trees with diameter of 100-300mm, raise the bulldozing plate to push the tree
for two or three times. Make the bezel of the bulldozing plate cut into the ground to
cut, dig and push the root. After digging out the root, give the root a great impact at
high speed (6-9)

Figure 6-9

148
Construction technology to prolong the lifespan of the running system
The lifespan of the running system varies obviously with the construction
technologies. Therefore, the following items shall be considered one by one:
Select appropriate track shoe that suits the earthiness
Avoid shape start-up, acceleration, braking and unnecessary high-speed operation
and sharp turning
Operate in straight line. Always turning to the same direction shall be avoided. The
turning radius shall be as large as possible.
Remove large rock or other barriers during operation.
During dozing and digging, continuous digging in slope shall be avoided. In this
case, the bulldozer can return to the flat ground and then resume digging.

149
 Chapter 7 ― Common Fault and Troubleshooting

7.1 Electrical
Fault phenomenon Main cause Remedy
The engine runs at a Bad contact The contact clip is loose
high speed, but the light Check and repair broken wires
is dimmed; when the
engine is in operation,
the light is unstable.
Abnormal sound AC motor in bad Replace and repair
happens in the AC motor condition
During engine operation, Bad contact Replace and repair
the pinion makes a
sound when the key is
inserted into the start
switch.
After the key is inserted Bad contact or low Check, repair, charge or
into the start switch, the battery; start switch or replace switches
starting motor does not battery switch in bad
rotate when the key is condition
turned to the start
position.
The engine rotates Bad contact or low Check, repair or charge
slowly during startup battery
Before the engine starts, Bad contact or low Check, repair or charge
the starter gear is battery
disengaged
All the instrument lights Broken wires or fuses Check, repair or charge
are off Low battery

150
7.2 Engine
Fault phenomenon
After the engine stops, the
oil pressure gauge hand
fails to return to “0”
The oil pressure gauge
hand points to the red
range (left)
The oil pressure gauge
hand still points to the red
range (left)
Steam jets from the
radiator pressure valve
The water thermometer
hand points to the right red
range
Though the generator
rotates, the engine fails to
rotate
Frequent fuel stop
The exhaust gas of engine
is in white or clear
The exhaust gas of engine
is in black
Irregular and unstable
engine startup operation
Engine knocking (burning
or mechanical)
Main cause
Oil pressure gauge in bad
condition
Low oil level of oil pan
Bad oil pipe connection or oil
pipe damaged with oil leakage
Oil pressure gauge in bad
condition
Too high oil viscosity or oil
pressure gauge in bad
condition
Cooling water insufficient or
leaked
Loose fan belt
Scale and soil deposited in
cooling system
Water thermometer in bad
condition
Defective radiator
Too large cooling wind on
engine
Low fuel, air entering in fuel
system
Too slow rotation of engine
Water in fuel system
Oil outlet pipe blockage in fuel
tank
Too high oil level in oil pan or
low fuel level
Oil pipe blockage of
turbocharger
Air filter blockage, too high
exhaust pressure
Air entering in fuel system
Bad quality fuels used or
overheat
Internal wear of silencer
151
Remedy
Replace the oil pressure gauge
Fill specified oil
Check, repair or replace oil pressure
gauge
Replace specified oil
Replace the oil pressure gauge
Check and fill cooling water
Adjust, repair or replace
Clean or replace
Replace the water thermometer
Check, repair or replace the fan and
the radiator
Install protective cover
Add fuel, discharge air
Repair in reference to electrical part
Discharge water
Clean oil pipes
Replace specified oil
Check or repair
Clean, replace, check or repair
Discharge air
Replace specified fuel
Replace silencer
7.3 Chassis
Fault phenomenon
Hydraulic torque
converter overheated
After the transmission
control lever is in speed
change, the vehicle
remains immovable or
the is at low speed
The vehicle does not turn
around but runs in
straight line when single
side steering control lever
is pulled
The steering control lever
is heavy
The vehicle fails to stop
when the brake pedal is
Stepped down
Track derail
Abnormal chain wheel
wear
The bulldozing plate rises
slowly or fails to be lifted
Note: for faults other than the above ones, please contact the factory for repair.
Drivers are expected to keep original records such as vehicle operation, maintenance
schedule, fault occurrence and troubleshooting so that the manufacturer could improve
the design and quality.
Main cause Remedy
Loose fan belt Replace the belt
Too high water temperature of Refer to “Engine”
engine
Blockage of oil cooler Clean or replace
Insufficient oil circulation due to Replace the gear pump
gear pump wear
No oil pressure rise in hydraulic Check or repair
torque converter and transmission Check, repair or replace
Poor valve pipe joint fastening, air Check, repair or replace
entry or oil leakage Clean
Gear pump wear or jam Fill specified oil
Transmission oil filter element
blocked
Low oil level in transmission
Steering control lever failure Adjust
Poor adjustment of steering clutch Adjust
and steering brake lever
Poor adjustment of brake pedal Adjust
Too loose track tension Adjust
Too loose or too tight track Adjust
Low hydraulic oil level Fill specified oil
152
 Chapter 8 ― Electrical System

8.1 Electronic monitor

8.1.1 Layout of electronic monitor panel (see the figure below)

8.1.2 Monitoring items

No. Monitoring items Unit Alarm values Alarm levels Remarks

1 Battery voltage V ﹤21 Level I Analog quantity
2 Charging voltage V ﹤25 Level II Analog quantity
3 Fuel level MM ﹤120 Level II Switching value
4 Engine oil level Analog quantity
5 Cooling water level Analog quantity
6 Engine oil pressure Mpa ﹤0.05 Level III Analog quantity
7 Cooling water ℃ ﹥105 Level III Analog quantity
temperature
8 Oil temperature of torque ℃ 120 Level III Analog quantity
converter
9 Hydraulic oil temperature ℃ ﹥105 Level III Analog quantity
10 Air filter HG 625 Level III Analog quantity

153
8.1.3 Alarm modes and functions

The alarm modes and functions are divided into three levels of alarm:

1. Level I alarm: the item indicating lamp (red) blinks alerting the driver.
2. Level II alarm: the item indicating lamp (red) blinks and the main alarm lamp also
blinks, requiring corresponding measures to be taken to eliminate abnormities.
3. Level III alarm: the item indicating lamp (red) and the main alarm lamp blink, and
the buzzer beeps, requiring immediate shutdown to eliminate faults.

8.1.4 System operation

1. Push the start switch of the bulldozer to “ON” position and the system will be in
operating state and conduct self test automatically. The item indicating lamp (green)
and the item alarm lamp (red) will light on alternately. At the same time, the main
alarm lamp blinds, the buzzer beeps and the display indicates “8888” for 3 seconds
(in case of abnormality, the display may not indicate “8888”);
2. After self test, the system may navigate to battery voltage while this item indicating
lamp (green) lights on and the display indicates the battery voltage approximately
24V;
3. At this point, the diesel engine is ready to start (screw the start switch to “START”
position). After the diesel engine starts, the system may still rest on battery voltage,
and various monitoring items come in monitoring status. Now, press “∨” or “∧”,
and you can observe working conditions for various parts according to the
indicating lamps of the corresponding items, e.g. if you want to know the oil
pressure, then press “∨” or “∧” to make the oil pressure indicating lamp (red) light
on and the oil pressure may be indicated on the display;
4. After the diesel engine starts, a system fault may exist if the item indicating lamp
(red) blinks, or the main alarm lamp blinks or the buzzer beeps. In this case, the
error codes may be indicated in the display by pressing “SELF TEST” key and
items in error may be found out according to the error code list. The display may
indicate “8888” in normal state.

154
 Error Code List
Items in error Display value
Broken battery line error 0000
A/D converting to high level error 1111
A/D converting to low level error 2222
※ Broken charging system line error 3333
※ Breaking line under engine 5555
lubricating oil pressure error
Broken line at coolant temperature 6666
error
Broken line at torque converter oil 7777
temperature error
Broken line at hydraulic system oil 9999
temperature error
Normal 8888

Note: broken line alarms with “※” are shielded before the engines is switched on.

The abovementioned system is an old type and the monitoring device panel of new type
is as follows:

155
The alarm modes and functions of new type are the same as those of old type except
the former has no display.

8.1.5 Service of host machine

Because this system is a vehicle electronic monitoring system and onsite service is
impossible, replacing with spare parts shall be the only countermeasure in case any
fault or damage shall occur to this system. Therefore, users are required to get familiar
with the methods this system uses to recognize fault.

Fault recognition and elimination

If there is no optical sound after power on, check there is any 24V power input; if
there is no, check the fuse and the power supply wiring are in good
condition; if the fuse or the power supply wiring is damaged, this fault may
be eliminated immediately.
If the system fails to enter into self test state after power on, press SELF TEST key
again. If the system cannot enter into self test state yet, it may indicate the
monitoring device is faulty and need to be replaced.
The system enters into self test state after power on, however the external buzzer
does not beep. If the buzzer keeps silent after pressing the silence button,
check the connection is in good condition. If no reaction is found after the
broken line is connected, check if the monitoring device output end has no
output. If there is any output, then replace the buzzer.
After startup, the monitoring device should be replaced if there is any lamp on it
failing to light on.
Replacement

Users may ask the factory to replace the equipment. Model, category and specification
should be explicitly indicted to ensure system exchangeability.

8.2 Starting motor

The starting motor part consists of starting motor, battery breaker, electromagnetic
switch, start switch and safety relay.

156
When the start switch (JK406) is in “ON” position, it indicates the bulldozer is in start
state. When the start switch is further turned clockwise to “Start” position, the
electromagnetic switch in the instrument panel is closed, and the pair of contacts of the
electromagnetic switch drives the starting electromagnet on the starter to push out the
gear and energize the starting motor, thus the diesel engine operates (the starting time
is normally 3-5 seconds).

After the diesel engine operates, the display value of each point in the electronic
monitor with three-stage alarm shall be within the allowable range. As a result of diesel
engine operation, the middle point of the engine outputs 12Vdc voltage. At this point,
this voltage drives the safety relay in the instrument panel to contact and the NC contact
of the safety relay open the starting circuit of the starting motor to avoid restart which
may damage the starting motor and the starting flywheel.

8.3 Charging system

The charging system consists of alternating current generator and charging fuse, etc.
The AC generator is a self-rectifying generator equipped with integrated circuit regulator
with 28V output voltage and 35A output current.

Because the generator is an integrate generator, maintenance is normally not

necessary and only belt tension is to be paid attention to.

The charging voltage in the electronic monitor with three-stage alarm only indicates the
output voltage of the generator; therefore, special attention shall be paid to the fuse in
the charging system. Anyway, the generator will not charge after the fuse is blown out
while the charging voltage in the electronic monitor with three-stage alarm may still be
indicated.

8.4 Lighting system

The lighting system of the bulldozer consists of headlight, sidelight, taillight and cab
(canopy) ceiling light, etc. Refer to circuit diagram (Figure 2-80).

157
 Chapter 9 ― Transportation and Storage

9.1 Transportation
During bulldozer transportation, users are required to get familiar with and observe
various road specifications and traffic regulations like transport vehicle on roads and
vehicle restrictions.

When the vehicle runs across a bridge or through a tunnel, the bearing capacity of
bridge or the space size of the tunnel shall be rechecked.

A dedicated loading and unloading platform is preferably built. The following rules and
regulations shall be complied with in case a ladder is used to load the bulldozer to or
unload the bulldozer from a trailer:

(Figure 9-11)
The trailer shall be in braking state and shall be fixed with square timbers at the
tyres.
The ladder shall have sufficient width, length and thickness so that it can bear safe
vehicle loading and unloading. Square timbers can be laid underneath for
strengthening as necessary.
Lay the ladder in right position, then load or unload the vehicle slowly.

 When driving on the ladder, the drive direction can not be adjusted. If it is necessary
to adjust, direction adjustment may be carried out after the vehicle is lowered back to
the ground.

Load the vehicle in proper position in the trailer, then put underneath some wooden
blocks before and after the track. After that, fix it with solid chains or ropes to
avoid any accident due to underway derailment.
Lower down the blade and place various handles to the following positions:

Place the throttle control lever in the idle position, and take off the start key.

Place the transmission control lever in the neutral position.

158
Put the bulldozing plate control lever in the holding position.

Put the brake block rod in the lock position.

 In case the width of the blade head is larger than that of the vehicle, rotate the blade
through an angle or dismantle it and reassemble.

 Antirust measures shall be taken for long distance water transport and rust preventive
oil shall be applied to the cylinder piston rod and other exposed parts.

Figure 9-1

9.2 Storage
9.2.1 Before storage

If the bulldozer is expected to remain used for quite a long time, the following measures
must be taken to minimize service work when it is put into use again.

Do not put each part of the vehicle outdoor by in a dry building after they are washed
and let dry. If it is necessary to place them outdoor, then lay wood plates on the ground
and place the machine on the plates and cover it with canvas.

Before put into warehouse, add sufficient fuel and lubricating oil in the vehicle and
replace engine oil.

Apply a thick layer of lubricating oil on the metal surface (in piston rod position).

For the accumulator jar, remove the lead on the pile head, and cover the accumulator
jar or remove and store separately.

If the ambient temperature is expected to come below 0℃, empty the cooling water in
the engine and radiator, or use antifreeze solution.

Various control levers and pedal are set as follows:

159
 Set the transmission control lever in the neutral position.

 Set the fuel control lever in idle position.

 Set the blade control lever in holding position.

 Set the brake pedal in free position.

9.2.2 In storage

Run the engine once each month and drive the vehicle for a short distance so that the
surfaces of each part of the bulldozer and the engine may be applied with a new oil film
and prevent surface rusting.
When operating working equipment, wipe off the grease on the piston rod of the
hydraulic cylinder.

9.2.3 After storage

After storage (in case the vehicle is not covered or the user fails to conduct antirust
treatment once each month), carry out the following operation before use:
(a) Disassemble the oil drain plugs on the oil pan and other oil tanks, then drain
the mixed water.
(b) Remove the cylinder cover and lubricate each air valve and rocker arm, and
check air valve action.
(c) In order to discharge the air in the hydraulic system, run the engine at low
speed and operate in the following procedures:

Reciprocate each hydraulic cylinder 4-5 times and set the piston in the position 100mm
from the stroke end;
Then reciprocate each hydraulic cylinder 3-4 times till it runs to the stroke end.
 If the engine initially runs at a high speed or the piston runs to the stroke end, then
the mixed air may possibly damage the piston ring gasket.
(d) Operate the engine after it starts up till complete temperature rise occur.

160
 (Annex)
Chapter 1 ― Structural Principle

1. Hydraulic principle

1.1 Lifting hydraulic pipe line of straight blade bulldozing plate

(Figure 1-1 and Figure 1-2)
The lifting hydraulic pipe line of bulldozing plate is installed on the upper part of the
power takeoff together with the working pump (4), hydraulic oil tank (1), hydraulic oil
filter (5), control valve (2) in the hydraulic oil tank as well as the lift cylinder of bulldozing
plate.
1. Hydraulic oil filter
2. Hydraulic control valve
3. Lifting cylinder of bulldozing plate
4. Working pump
5. Hydraulic oil filter

Figure 1-1

161
1 oating 2 Lowering 3 Holding 4 Rising 5 Open pressure

Figure 1-2
1 rking oil pump 2 Check valve 3 Main relief valve
4 Lifting control valve rod of bulldozing plate 5 Oil supply valve for lowering
6 l supply valve for rising 7 Lift cylinder of bulldozing plate
8 draulic oil filter 9 Hydraulic oil filter

1.2 Tilt hydraulic pipe line of straight blade bulldozing plate

(Figure 1-3 and Figure 1-4)
The bulldozer is equipped with bulldozing plate tilting device. The pipe line connecting
the hydraulic oil tank (1) to the tilt cylinder of bulldozing plate goes through the center of
the trust beam so that it can’t be observed.

162
1 hydraulic oil filter 2 Hydraulic control valve 3 Tilt cylinder of bulldozing plate
4 rust beam
Figure 1-3

163
1 rking oil pump 2 Check valve 3 Main relief valve
4 Lifting control valve rod of bulldozing plate 5 Oil supply valve for lowering
6 l supply valve for rising 7 Lifting cylinder 8 Check valve
9 lt control valve rod of bulldozing plate 10 Tilt cylinder 11 Hydraulic oil filter
12 raulic oil filter
Figure 1-4

164
1.3 Control pipe line and system of working equipment (Bulldozer)

Lifting and tilt pipe lines of working equipment consists of the pilot pump (6), the
overflow valve (5), the pilot control handle (4), the hydraulic oil filter (2) and the hydraulic
oil tank (1).
The movement of the pilot control handle in directions of forward, backward, left and
right as shown in the figure can lead to lowering, floating, rising, left tilting and right
tilting of the bulldozing plate.

1 draulic oil filter 2 Hydraulic oil filter 3 Lifting control valve rod of bulldozing plate
4 lot control handle 5 Overflow valve 6 Pilot pump
7 lt control valve rod of bulldozing plate
Figure 1-5

1.4 Main operating valve of working equipment (Figure 1-6)

165
1 fting control valve rod of bulldozing plate 2 Tilt control valve rod of bulldozing plate
3 fting control valve rod of ripper
P port – High pressure oil inlet
T port – Oil drain port
B1 – To main chamber of lifting cylinder
B2 – To minor chamber of lifting cylinder
C1 – To main chamber of tilt cylinder
C2 – To minor chamber of tilt cylinder
F1 – To front oil port of pilot handle of push broach
F2– To rear oil port of pilot handle of push broach
G1- To right oil port of pilot handle of push broach
G2- To left oil port of pilot handle of push broach

166
1.5 Pilot control handle of push broach (Figure 1-7)

P port – High pressure oil inlet

T – Oil drain port
1. owering signal port of push broach 2. eft tilting signal port of push broach
3. sing signal port of push broach 4. ight tilting signal port of push broach
Figure 1-7

Overflow valve (Figure 1-8)

167
P port – Pressure oil inlet
T1 and T2 ports – Overflow ports

Figure 1-8

168