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PD165 User Manual
PD165 User Manual
PD165 User Manual
Precaution:
1. Prior to operation, this Manual shall be read carefully and thoroughly.
Indiscretion and carelessness must be avoided.
2. Information concerning safety of personnel and machines and important
technical specifications in this Manual will be identified and highlighted by
symbols such as △and ★, which require for more attention.
3. The details for the engine operation, maintenance, service and
troubleshooting, please refer to Engine Manual.
Code for Commissioning of New Machine
Although the machine has been carefully adjusted before leaving factory, careful operation is
In case the new machine is in an unreasonable hard engagement state at initiate operation
stage, its potential function may be deteriorated prematurely and lifetime shortened. Therefore,
the new machine should be carefully operated according to the following requirements:
2. Doing 5min idling after starting engine to make it rise in temperature normally and enter
working state;
4. Never doing rapid starting or sharp acceleration and unnecessary emergency brake or
sharp turning;
6. After 250 hours operation, see the table of first 250 hours service and the following contents
for maintenance:
★ When changing oil filter element, check its interior for dirt. If heavy dirty is
accumulated on it, find out the cause before changing as far as possible
Safety Precaution
1. Read the Manual thoroughly prior to start the machine and operate according to the
required order after understanding the structure and rules of the machine.
2. Operator should be trained. Don’t operate the machine when getting exhausted or
3. Always wear work clothes and other protection according to working environment and
object.
6. When adding oil or making any repairs, keep away from fire and don’t smoke.
underground facilities.
8. Before starting, remove all obstacles in the interior of machine, circumference and on
site.
10. Never operate machine not in good condition and unauthorized person should not
sit in cab.
11. After starting the engine, confirm the machine is in good condition, then it is allowed
to operate.
12. Any problem discovered in trial run should be removed in time when found. When it,
even though insignificant, can not be removed in time, the machine could operate
14. Always use handrail and ladder when getting on or off the machine. Never jump on
16. When crossing through hailstone, snow or thick fallen leaves, bush, fallen tree and
rolling rock on a slope, and driving after rain, pay attention to prevent machine from
rolling over.
I
17. When parking the machine, the blade should be lowered to the ground and all the
18. Never operate faulty machine or overload it for safety of machine and yourself.
19. For operation under particular condition see the notice of drive for particular
environment.
★ 20. Type and sort of oil and coolant used for the machine depend upon working
environment and temperature. Please select them according to The Attached table:
★ 21. Antifreeze should not be made up of methanol and ethanol to prevent engine from
trouble. The antifreeze is inflammable and must be kept away from flame.
★ 22. Running water should be used as coolant as much far as possible. Never use sewage
as coolant.
★ 25. Coolant, fuel, lubrication and hydraulic oil should be checked at any time and
supplemented as required.
★ 26. When starting engine, the ambient temperature should be more than -10 ℃. When the
key is turned to starting position the starting time should not be more than 10sec. The
time interval between two starts should not be less than 2min.
II
CONTENTS
VIII
Chapter 1 Outline
1
Item Value
Travel d 2nd 0-6.1 km/h
speed
3rd 0-9.7 km/h
1st 0-4.4 km/h
Revers
2nd 0-7.5 km/h
e
3rd 0-11.9 km/h
Hydraulic torque
3-element, single stage and single phase
converter
Planetary gear and multiple disc clutch, hydraulically
Transmission
Power actuated, forced lubrication
transmis Central drive Spiral bevel gear, I-stage reduction and splash lubrication
sion Wet, multi-disc, spring pressured, manual-hydraulic
system Steering clutch
operated
Steering brake Wet, float brake with hydraulic booster
Final drive Two-step spur gear deceleration, splash lubrication
Swing type of sprayed beam, suspended structure of
Type
equalizer bar, semi-rigidity structure
Number of
2/each side
supporting rollers
Underca Number of thrust
6/each side
rriage wheels
Number of track
37/each side
shoes
Track shoe width 560 mm (standard), 510 mm (optional)
Track pitch 203.2 mm
Transmission setting
Chassis 2.0 MPa
pressure
hydraulic
Steering brake
system 2.0 MPa
setting pressure
System pressure 14 MPa
Type of operating
Gear pump
pump
Hydrauli Flow of operating
c system 240 L/min
pump
of work Type of control
equipme Hand-operated sliding valve
valve
nt Inner diameter Φ110mm× cylinder rod diameter
Lift cylinder
Φ65mm× stroke 1,026mm
Inner diameter Φ160mm× cylinder rod diameter
Tilt cylinder
Φ70mm× stroke 1,236mm
Straight-tilt Angle
Blade width 3,416 mm 4,050 mm
Blade height 1,150 mm 1,050 mm
Max. drop below
530 mm 530 mm
ground
Dozer Max. lift height 1,090 mm 1,110 mm
Max. tilt adjustment 400 mm 400 mm
Max. turn angle of
/ 25°
blade
Cutting angle 55° 55°
Mass 2,332 kg 2,268 kg
Ridger Type Parallelogram, adjustable, removable
2
Item Value
Number of teeth 3-tooth
Pitch 950 mm
Max. loosening
572 mm
depth
Max. lift height 492 mm
Mass 1,850 kg
Min. ground
400 mm
clearance
Min. turn radius 4.5 m
Other
Climbing capacity 30°
performa
Track-center
nce data 1,880 mm
distance
Straight-tilt Angle
Dozing capacity 4.5m3 4.7 m3
Theoretical power
3
Chapter 2 Principle of Structure
The driving force from the engine (1) is transmitted via the flywheel to the drive
case of the hydraulic torque converter (2). The drive case revolves with the pump
wheel and power from the engine turns the turbine wheel with oil according to load
fluctuation to turn the turbine shaft.
Turbine shaft power is transmitted through the universal joint (3) to the input shaft
of the transmission (4).
Select the proper step for the transmission control valve to be mounted on the top
of the transmission housing upon the working requirement so that the gear clutch
selected in the transmission meets and the power will be transmitted via the planet
gear to the bevel pinion(10) at the rear end of the transmission.
The table below lists the running direction, speed level and No. of clutch
transmitting motion:
4
Table 2-1 Variable speed control position and drive path
Forward or reverse Gear speed Clutch engaged (transmission)
1 NO.1 NO.3
Forward 2 NO.1 NO.5
3 NO.1 NO.4
1 NO.2 NO.3
Reverse 2 NO.2 NO.5
3 NO.2 NO.4
5
top to cut off power of steering clutch. The turning radius is determined by the steering brake
(6) mounted on the periphery of the steering clutch brake drum.
Power from the steering clutch is transmitted to the final drive flange, being transmitted under
sequential reduction by way of the 1st pinion (S) →1st gear (T) →2nd pinion (U) →2nd gear (V)
→to turn the sprocket (7).
The revolution of the sprocket drives the track (8) to turn the machine to travel.
2.2 Radiator
Torque
converter oil
Water drain valve
radiator
6
2.3 Power Take Off (PTO)
The P.T.O system is installed on the engine flywheel to complete power output. When engine
Mounting face
of steering
pump
Crankshaft center
Start motor
Steering pump
Hydraulic
transmission pump Operating pump
7
Mount bracket of hydraulic
transmission pump (FAL040) Mounting bracket of
operating pump
Crankshaft center
Crankshaft
center
Rear surface
of cylinder
Fig. 2-5 PTO
Table 2-2 Number of teeth of PTO gear
Code Name Number of Teeth
A PTO driving gear A 41
B Intermediate gear B 52
C Intermediate gear C 35
D Intermediate gear D 37
E Pump driving gear E 61
F Pump driving gear F 35
8
impelled with force against the blade of the turbine and changes its direction toward stator.
The reaction developed at the blade by this action causes the turbine (4) to rotate, and power
is transmitted by turbine shaft (18). The fluid at the turbine is directed from the central part of
the turbine to the stator where its direction is changed, and finally returned to the central part
of the pump.
9
Z direction
Pressure test port of control valve
To oil cooler
To transmission
lubrication
To transmission
case housing
While the fluid flows in the order of pump→turbine→stator → pump as mentioned above,
power is delivered from the pump to the turbine shaft. The pump is idled on the stator shaft (10)
through bearing. Because the turbine is fixed with spline of turbine shaft (18), turbine power is
The stator can change the rotation of the fluid to increase the torque of turbine, which varies
depending on the operating condition. When the load increases, the turbine will be subject to
large resistance torque and automatically decelerate. Therefore, the torque converter can
10
0.75-0.85MPa by this overflow valve. The fluid
from the transmission control valve flows through
port A and the passage A’ in the torque converter Torque converter
housing to the pump. When port A is filled up and case
Transmission
hydraulic pressure to the pump reaches 0.7MPa lubrication
valve
(7kgf/cm2), the fluid compresses spring (22), Transmission Torque converter
control valve pump
pushing up slide valve (21), and flows through
port B into the flow circuit of transmission
Fig. 2-8 Relief Valve
lubrication relief valve. When the slide valve (21)
21. slide valve 22. spring
is pushed up the fluid stayed in the chamber C
flows into the torque converter housing.
Oil temperature
test port
2.4.2 Torque converter regulator valve
This regulator valve, incorporated into the outlet
Oil pressure
test port From torque
circuit of the torque converter, maintains hydraulic converter turbine
Torque
pressure inside the torque converter at 0.2- converter Torque converter
cooler case
0.3MPa (2-3kgf/cm2) to protect the torque
converter and ensure optimum performance.Fluid
from the torque converter flows from the passage
D’ in the torque converter housing to port D until
Fig. 2-9 Regulator Valve
the port is filled up. 23. slide valve 24. spring
When hydraulic pressure in port D reaches
0.3MPa (3kgf/cm2), the fluid compresses spring (24), pushing down slide valve (23), and flows
through port E into the oil cooler circuit. When pushing down slide valve (23), the fluid stayed
at F flows into the torque converter housing. Oil oozing out from between contacting faces of
pump, turbine and stator is drained into the torque converter housing (9) after lubricating each
sliding part.
Universal joint is used to complete power transmission between torque converter and
transmission case. It can ensure for smooth power transmission while coaxality between
turbine output shaft and transmission case spindle axis is within allowance.
12
st rd nd
Forward Reverse 1 3 2
Clutch position
2. No.1 clutch piston 11. No.3 clutch gear 20. Oil seal seat
4. No.2 planetary pinion shaft 13. No.4 Planetary pinion shaft 22. Nut
5. No.2 clutch piston 14. No.4 clutch piston 23. Snap ring
6. No.2 clutch cylinder block 15. No.4 clutch oil cylinder 24. Rear case
7. Snap ring 16. No.5 planetary pinion shaft 25. No.5 clutch planetary carrier
9. No.3 piston cylinder block 18. Stopper pin 27. Snap ring
13
28. No.4 clutch planetary carrier 33. Pin 38. Input shaft
31. No.2 clutch planetary carrier 36. No.1 clutch planetary carrier 41. Bearing cage of input shaft
A. NO.1 clutch sun gear (30 teeth) J. NO.3 clutch ring gear (78teeth)
B. No.1 clutch planetary pinion (21 teeth) K. NO.4 clutch sun gear (41teeth)
C. No.1 clutch ring gear (71 teeth) L. NO.4 clutch planetary pinion (19teeth)
D. NO.2 clutch sun gear (30 teeth) M. NO.4 clutch ring gear (79teeth)
E. No.12 clutch planetary pinion (21 teeth) N. NO.5 clutch sun gear (41teeth)
F. NO.2 clutch ring gear (72teeth) O. NO.5 clutch planetary pinion (19teeth)
G. NO.3 clutch sun gear (30teeth) P. NO.5 clutch ring gear (79teeth)
Planetary gear system (as shown in Fig. 2-13) is composed of three planetary pinion (D)
meshed with sun gear (A) and ring gear (B). Three planetary pinions are supported on the
carrier (C). When the sun gear (A) is rotated and the ring gear is fixed, the planetary gear (D)
and planetary carrier(C) start rotate around the sun gear (A). In the meantime, each planetary
pinion rotates at its own shaft. When the carrier is locked and the planetary pinion rotates at its
14
own shaft, the ring gear (B) is driven in the opposite
15
clutches, the carrier acts as a torque source and transmits torque to No.4 and No.5 sun gear.
the torque of the sun gear (A) drives the carrier (C) in
16
2.6.2 Structure and action of clutch
For locking the ring gear (C) the plate (44) and
piston (2), plate (44), disc (45), pin (33) and piston
(2). The piston presses the plate (44) and disc (45)
disc (45) revolution, thus locking ring gear (C) Fig. 2-19 Clutch engaged
bringing the ring gear (C) in neutral. Fig. 2-20 clutch disengaged
When gear-shift lever is located at the 1st speed, the fluid flows from control valve to the left
side of No.3 clutch piston (10) and pushes the piston (10) to the right. No.3 clutch cylinder
block turning is transmitted to No.3 clutch gear (11). When gear-shift lever is put at 2nd or 3rd
17
speed,the force of spring (29) pushes piston (10)
base (49) port, and the piston (10) presses clutch disc
drainage of check valve and the piston (10) is promptly returned to the farthest left by disc
spring (29).
18
2.6.4 Transmission Path of Each Step of Transmission
Engage No. 1 clutch so that the gear ring (C) of No.1 clutch can be fixed reliably. Engage No.
3 clutch. Connect the carriage (28) of No. 4 clutch with the output shaft through the gear (11)
of No. 3 clutch.
As the gear ring (C) of No. 1 clutch is locked, and the carriage (36) of No. 1 clutch is fixed on
the transmission case (35), neither No. 1 sun gear (A) nor No. 2 sun gear (D) can move.
Therefore, No. 2 planetary gear (E) rotates around No. 2 sun gear (D), and the carriage (31) of
No. 2 clutch rotates in the direction same as No. 3 sun gear (G).
Engagement of No. 3 clutch transmits the motion of carriage (31) of No. 2 clutch to the piston
cylinder (9) of No. 3 clutch, carriage (28) of No. 4 clutch, gear (11) of No. 3 clutch and output
shaft (21).
st rd nd
Clutch position Forward Reverse 1 3 2
Clutch No.
19
2. Forward, 2nd (Fig. 2-25)
No. 1 and No. 5 clutches engage so that the gear rings of them are locked.
As the gear ring (C) of No. 1 clutch is locked, and the carriage (36) of No. 1 clutch is fixed on
the transmission case (35), neither No. 1 sun gear (A) nor No. 2 sun gear (D) can move.
No. 2 planetary gear (E) rotates around No. 2 sun gear (D), and the carriage (31) of No. 2
clutch rotates in the direction same as No. 3 sun gear (G). Meanwhile, drive of carriage (31) is
transmitted to the piston cylinder (9) of No. 3 clutch and carriage (28) of No. 4 clutch.
When No. 5 clutch is engaged, the drive of carriage (28) is transmitted via two paths: one
transmits the drive to No. 4 sun gear (K) and the other transmits the drive to gear ring (M) of
No. 4 clutch, carriage (25) of No. 5 clutch and No. 5 sun gear (N) in order.
Gear ring (M) of No. 4 clutch and carriage (25) of No. 5 clutch are linked to rotate so that both
sun gears (K) and (N) drive the output shaft (21).
Clutch No.
st rd nd
Clutch position Forward Reverse 1 3 2
20
3. Forward, 3rd (Fig. 2-26)
No. 1 and No. 4 clutches engage so that the gear rings of them are locked.
When No. 1 and No. 4 clutches engage, gear rings (C) and (M) are locked. As the gear ring (C)
of No. 1 clutch is locked, and the carriage (36) of No. 1 clutch is fixed on the transmission case
(35), neither No. 1 sun gear (A) nor No. 2 sun gear (D) can move.
No. 2 planetary gear (E) rotates around No. 2 sun gear (D), and the carriage (31) of No. 2
clutch rotates in the direction same as No. 3 sun gear (G). Meanwhile, drive of carriage (31) is
transmitted to the piston cylinder (9) of No. 3 clutch and carriage (28) of No. 4 clutch.
When No. 4 clutch is engaged, the drive of carriage (28) is transmitted to No. 4 sun gear (K)
Clutch No.
st rd nd
Clutch position Forward Reverse 1 3 2
output shaft.
When No. 2 clutch is engaged, gear ring (F) of No. 2 clutch is locked. When No. 3 clutch is
engaged, carriage (28) of No. 4 clutch and output shaft (21) are connected through gear (11)
21
of No. 3 clutch.
When gear ring (F) of No. 2 is fixed, planetary gear (I) engaged with gear ring (F) and
planetary gear (H) engaged with sun gear (G) cannot rotate in fixed position, but around sun
Rotation of planetary gears (I) and (H) is transmitted to carriage (31) of No. 2 clutch so that the
Rotation of carriage (31) is transmitted to the output shaft (21) in the same manner described
above.
same time.
The speed of Reverse 3rd can be achieved as long as No. 2 and No. 4 clutches engage at the
same time.
st rd nd
Clutch position Forward Reverse 1 3 2
Clutch No.
22
2.7 Axle and steering clutch
23
Each steering clutch consists of the following parts:
① Inner drum (5): The inner drum (5) is fixed at the coupling (17) and the coupling is
press-fitted on the spline of bevel gear shaft (15). The inner drum also acts as oil cylinder.
② Bevel gear shaft coupling (17): The coupling makes the fluid from steering control valve
draw into the piston (19).
③ Brake drum (l): The brake drum is bolted to the final drive flange.
④ Clutch discs (4): The inner teeth of clutch disc are engaged with the external teeth of inner
drum (5).
⑤ Clutch plate (3): The external teeth of clutch plate are engaged with the inner teeth of brake
drum (l).
⑥ Pressure plate (2): The pressure plate is fixed at the piston (19) by pin and moved together
with piston.
⑦ Disk spring (20): When the steering lever is put at “Engagement” position, the disk spring
presses the pressure plate (2), clutch plate (3) and clutch disc (4) against the inner drum (5).
Turning the adjusting nut (12) makes the bearing cage (6) move to the left or the right to adjust
the tooth contact surface and gear backlash of the spiral bevel gear pair.
The coupling (17) is press-fitted on the spline of bevel gear shaft (15), then the steering clutch
is fixed at the coupling. The splash lubrication is made by the spiral bevel gear immersed in oil.
The spring (20) in steering clutch makes the clutch disc (4) press against the clutch plate (3)
between the clutch inner drum (5) and the pressure plate (2) to maintain normal contact and
pass the clutch disc (4) turning to the clutch plate (3).
When the steering lever is pulled, the steering control valve serves the function of the fluid
draining into the piston (19). The movement of the piston (19) acts on the pressure plate (2),
so the frictional contact between the clutch plate (3) and clutch disc (4) is eliminated.
When the steering lever is released, the pressure plate (2) returns to the original position
under the force of spring (20), so the frictional contact between the clutch disc (4) and the
clutch plate (3) is restored.
When the left and right steering levers are pulled simultaneously, the left and right steering
clutches are disengaged at the same time. When just the left steering lever is pulled, the left
steering clutch is disengaged. Thus, the power transmitted to the left final drive is shut off, but
the right steering clutch is in a state of engagement, so the machine moves leftward, and vice
versa.
24
⑴ When left steering clutch engaged (Fig.2-29):
Pressure Plate (2) under force of disk spring (20) presses clutch disc (4) and clutch plate (3)
against inner drum (5) and the frictional force between clutch discs (4) and clutch plate (3)
transmits power from the inner drum (5) to the brake drum (1).
Fig. 2-29 Left Steering Clutch Engaged Fig. 2-30 Left Steering Clutch Disengaged
25
steering clutch. After stepping on brake pedal while parking machine, a brake lock handle is
pulled, the brake pedal fixed at brake position and the machine is kept in a state of brake.
One end of brake band (12) is suspended through push block (16) and pin (21) at brake
support (14) and the other end of that through screw (19), adjusting nut (17) and pin (20) at
brake support (14). Two springs make brake band pull wrapped round brake drum even. The
adjusting nut (17) is used to adjust a clearance between brake lining (13) and brake drum.
Forward Center of
bevel gear
shaft
Oil Level
When a steering lever (approx. half of the stroke) at one side is pulled to make machine turn to
this side, the corresponding steering clutch is to be disengaged. Therefore power transmission
to track at this side is disrupted, but the machine will make a gradual turn to this side due to
traction of track, which transmits power. When the steering lever at this side is pulled further,
the hydraulic fluid of steering control valve flows to the brake booster and the brake booster
functions to make the brake band contract the brake drum. Therefore the track at this side is
When a brake pedal is depressed, the brake booster also functions and makes the brake band
27
⑴ Brake operation during forward turning (Fig.2-33)
To brake pedal
contracted in the same steering as the brake drum and fastens the brake drum.
brake drum.
28
2.8.3 Operation of Hydraulic Brake Booster
⑴ When brake pedal is not depressed and steering lever is not pulled (brake not
applied) (Fig. 2-35):
To oil cooler
left. Lever (3) and lever (4) move and apply the
29
⑶ When brake pedal is depressed (brake
applied)
When the hydraulic pressure at port (D) rises, Fig. 2-37 Working principle of booster
20
Final drive employs the two-step reduction method using a spur gear and splash lubrication
Power from bevel gear shaft and steering clutch is transmitted through brake drum to final
drive flange (1), rotating primary driving gear (3) on drive flange.
The primary driving gear engages with primary driven gear (4), rotating the secondary driven
gear (5). Power is further transmitted from the secondary driving gear to the secondary driven
gear (21) with the secondary driving gear, with speed reduction accomplished.
Due to the construction in which the secondary driven gear is bolted on final drive hub (18),
into which sprocket boss (8) is also pressed, so power is finally transmitted to the sprocket.
Final drive case functions as a lubricating oil tank for each gear. The rotating sliding parts of
the sprocket are equipped with floating seals (7) and (15) to prevent entry of dust or mud and
oil leakage.
32
2.10 Undercarriage
2.10.1 Thrust wheel Frame Assembly
1. Idler 2. Track 3. Carrier roller 4. Sprocket guard 5. Track roller (Single flange)
6. Track roller (Double flange) 7. Track roller guard 8. Track roller frame 9. Diagonal
Thrust wheel frame assembly is used to support the total weight of bulldozer and distribute it
over the ground, and turn the driving force transmitted from the sprocket into a pull. The thrust
wheel frame assembly consists of a pair of left and right thrust wheel frames (8), idler (1),
carrier roller (3), thrust wheel (5) and (6). The track (2) around the thrust wheel frame
assembly is driven by the sprocket and guided by a front idler, carrier roller and thrust wheel.
The thrust wheel guard (7) attached on the bottom of each thrust wheel frame is used to
prevent tracks from derailing due to inlaid debris.
33
and sprocket. It is used to:
⑴ Maintain a suitable track tension.
⑵ Absorb the additional force of the idler and track caused by barriers in front of the machine
during running or stone coming into the track.
34
prevent lubrication sharply spraying under high pressure. Although a safeguard is used to
prevent the nipple from flying off, always remember this precaution to guarantee safety.
2.10.3 Idler Assembly
Idler (1) installed in front of each mainframe is supported on idler shaft (3) through support (6)
and bushing (2).
The idler assembly including a seat (the seat is connected with bracket (6)) can slide forth and
back along the thrust wheel frame through support (6), cover (4) and guide attached on the
thrust wheel frame and maintain track turning smoothly.
The lubrication flows to the bushing through oil hole to lubricate the moving surface of bushing
(2). Each end of the bushing is equipped with a floating seal (5) to avoid oil leakage and
35
prevent mud and water from entering.
To improve wearability, the idler should be made of silicomanganese casting and the idler
rolling path engaged with track link subject to induction hardening.
2.10.4 Carrier Roller Assembly
36
2.10.5 Thrust wheel Assembly
Thrust wheels are arranged under the thrust wheel frame at two sides. It functions as evenly
distributing the total weight of bulldozer through thrust wheel over tracks.
Thrust wheel assembly consists of thrust wheel (1), bushing (2), floating seal (4), shaft (5) and
outer cover (3). Thrust wheel is made of particular alloy steel, quenched and tempered.
There are two types of thrust wheels: one type has an outer flange only and the other has both
inner and outer flanges. Thrust wheel bears push load (longitudinal load) and single and
double flanges are alternatively arranged. The oil hole on the thrust wheel shaft is used to fill
lubrication for lubricating sliding surface of bushing. Both ends are equipped with floating seal
to avoid oil leakage and prevent mud and water from entering.
1. Track roller (single flange) 2. Bushing 3. Track roller outer cover 4. Floating seal 5.
37
⑵ Double-flange (Fig. 2-48)
1. Track roller (double-flange) 2. Bushing 3. Track roller outer cover 4. Floating seal 5.
38
2.10.6 Track
1. Dust seal ring 2. Pin 3. Master dust seal ring 4. Master pin 5. Track link 6.
Master pin shaft 7. Bushing 8. Single grouser track shoe 9. Shoe bolt 10. Shoe nut
39
2.10.7 Suspension
⑴ Purpose of Suspension
The suspension is designed to connect the frame and undercarriage system to realize
damping and ensure the machine can swing upwards and downwards on uneven ground.
1. Equalizer bar 2. Center pin 3. Support pin 4. Bushing 5. Dust seal ring
This machine is equipped with a semi-rigid suspension. The equalizer bar (l) is assembled on
the mainframe through center pin (2) with two ends supported on the thrust wheel frame. The
weight of front half of bulldozer is transmitted to the thrust wheel frame through the equalizer
bar because of this construction of equalizer bar, but the vibration from the thrust wheel frame
to the mainframe absorbed by the equalizer bar. The support pin on the thrust wheel frame at
two sides is used to make the main body not too high when bulldozer travelling and operating.
Furthermore, the equalizer bar is designed to rotate around the center pin.
To lubricate the equalizer bar, the mainframe is equipped with an oil cup. The grease is
supplied to the centre pin through a filler pipe and oil hole in the centre pin to lubricate the
sliding surface between shaft and bushing.
40
2.11 Work Equipment
2.11.1 Straight Tilt Dozer
The arched blade (1) is made up of high tensile strength alloy steel
and very rigid enough to bear heavy operation. The cutting edge (2) is
made of carbon steel. Its both ends have cutting edge, so the
opposite end also can be used. The end bit (3) is a casting, which has
excellent wearability and high strength. The push arm (6) is also
made of high tensile strength steel and in box section. Its front part is
connected to the blade through a connection and the rear part
articulated to the thrust wheel frame by means of the trunnion (7). The
push arm moves up and down due to movement of the blade lift
cylinder.
The right side of blade is connected by means of brace and push arm,
41
and the left side of that by means of tilt cylinder (5).
The tilt cylinder (5) is designed to make the blade (I) tilting leftward or rightward to meeting the
special requirement of work.
2.11.2 Angle Dozer
The arched blade (l) is made up of high tensile strength alloy steel and very rigid enough to
bear heavy operation. The cutting edge (2) is made of carbon steel. Its both ends have cutting
edge, so the opposite end also can be used. The end bit (3) is a casting, which has excellent
wearability and high strength. The U-frame (5) is also made of high tensile strength steel and
42
in box section. Its front part is connected to the blade through a connection and the rear part
articulated to the thrust wheel frame by means of the trunnion (6). The push arm moves up
and down due to movement of the blade lift cylinder. The blade is supported on the U-frame
through spheric ringe (9), lower brace (7) and upper brace (4).
Z-view
Lower rod
Fig. 2-53 Ripper
43
The upper rod (3) and lower rod (7) are fixed to the ripper bracket (1) with the pin A and pin D.
The bracket is installed at the rear surface of steering case by nuts. The beam (4) is installed
at the other end of upper and lower rods by pin B and pin C.
The ripper shank (5) is installed on the beam by pin. The point (6) is fixed at the shank .The
bottom of ripper cylinder for lifting and lowering (digging) shank is fixed on the bracket (1) and
the piston rod on the beam (4). For the digging depth of point, the ripper cylinder (2) is
stretched and shortened by the quadric link mechanism (a parallelogram consisting of pin A, B,
C and D) to drive shank (5) up or down and make the all points keep an optimum digging
angle during digging. Depending on ground hardness, one shank or two shanks can be
removed to make the ripper operate in a state of two shanks or one shank.
hydraulic control valve (2), blade lifting cylinder (3), operating pump (4) and hydraulic oil filter
(5) etc. The operating pump (4) is mounted on the top of PTO case. The hydraulic oil in the
hydraulic oil tank flows through the operating pump and becomes high-pressure hydraulic oil,
and then flows into the cylinder (3) after changing direction through hydraulic control valve to
44
1. Hydraulic oil tank 2. Hyraulic control valve 3. Blade lifting cylinder 4. Operating
pump 5. Hydraulic oil filter
Schematic Diagram:
Hold
hydraulic tank (1) to the blade tilting cylinder (3) passes through the center of top push arm (4)
and cannot be seen from outside. The hydraulic oil in the hydraulic tank flows through the
operating pump and becomes high-pressure hydraulic oil, and flows into the cylinder after
changing direction through hydraulic control valve (2) to realize titlting of the blade.
47
⑶ Angle blade lifting hydraulic piping (Fig. 2-58, Fig. 2-59)
The blade lifting hydraulic piping of work equipment consists of hydraulic oil piping (1),
hydraulic control valve (2), blade lifting cylinder (3), operating pump (4) and hydraulic oil filter
(5) etc. The operating pump (4) is mounted on the top of PTO case. The hydraulic oil in the
hydraulic oil tank flows through the operating pump and becomes high-pressure hydraulic oil,
and then flows into the cylinder after changing direction through hydraulic control valve to
1. Hydraulic tank 2. Hydraulic control valve 3. Blade lifting cylinder 4. Operating pump
5. Hydraulic oil filter
48
Schematic Diagram:
Hold
Blade lifting control valve rod 5. Suction valve for lower 6. Suction valve
9.液压油箱
Fig. 2-59 Schematic Diagram of Angle Blade Lifting Hydraulic Piping
铲
49
⑷ Hydraulic piping of ripper (Fig. 2-60, Fig. 2-61)
The bulldozer may be provided with ripper upon user’s request. The hydraulic piping of ripper
consists of hydraulic oil tank (1), hydraulic control valve (2), ripper lifting cylinder (3), operating
pump (4) and hydraulic oil filter (5) etc. The operating pump (4) is mounted on the top of PTO
case. The hydraulic oil drained by the operating pump flows into the ripper lifting cylinder (3)
after changing direction through hydraulic control valve (2) to realize lifting of the ripper.
50
Schematic Diagram:
Lift Lower
1. Operating pump 2. Check valve 3. Main relief valve 4. Suction valve for
ripper lifting 5. Overload valve for ripper lifting 6. Suction valve for lower 7.
10.液压油箱 Fig.
11.液压控制阀
2-61 Schematic Diagram of hydraulic piping of ripper
lever and rotor shaft pulls out the blade lifting valve rod of
2-63)
When the control lever moves rightward, the
left (rise)
descend.
control lever and the ripper control lever are provided with locking devices.
When the locking device presses downward, the motion of link lever and rotor shaft locks the
end of the control lever with the hole of the locking plate so that it cannot move.
The angle blade is provided with stopper to stop the blade control lever from moving leftward
or rightward.
52
2.12.3 Outline of hydraulic control system
Blade lifting
control valve
Blade lifting
control valve
lifting control valve 8. Blade lifting cylinder 9. Suction valve for raise 10.
Suction valve for lower 11. Hydraulic oil filter 12. Hydraulic oil tank
53
2. Straight-tilt dozer with ripper (Fig. 2-66)
1. Operating pump 2. Main relief valve 3. Flow control valve 4. Tilt control valve
5. Tilt cylinder 6. Check valve 7. Blade lifting control valve 8. Blade lifting cylinder
9. Suction valve for raise 10. Suction valve for lower 11. Check valve 12. Ripper control valve
13. ripper cylinder 14. suction valve for ripper raise 15.suction valve for ripper fall 16. ripper
lift overload valve
17. 松土器下降过载阀
Fig. 2-6618. 液压油滤清器
Hydraulic 19.
control system 液压油箱 blade and ripper)
(straight-tilt A. 主安全阀测压口
54
3. Angle dozer (Fig. 2-67)
①raise
②hold
③lower
④float
1. operating pump 2. main relief valve 3. check valve 4. blade lift control valve 5. blade lift
cylinder 6. suction valve for raise 7. suction valve for lower 8. hydraulic oil filter
55
4. Angle dozer with ripper (Fig. 2-68)
blade ripper
①raise ○,Draise
②hold ○,Ehold
③lower ○,Flower
④float
1. operating pump 2. main relief valve 3. check valve 4. blade lift control
valve 5. blade lift cylinder 6. suction valve for raise 7. suction valve for lower
8. check valve 9. ripper control valve 10. ripper lift cylinder 11. suction valve for raise
12. suction valve for lower 13. lift overload valve 14. lower overload valve 15.
hydraulic oil filter 16. hydraulic oil tank A. main relief pressure pickup plug
56
2.12.4 Operating Pump
1. driving gear shaft 2. front cover of pump 3. pump body 4. rear cover of pump 5.
driven gear
To operating pump
1. filling valve 2. lift valve 3. tilt valve 4. ripper vlave 5. oil return valve 6. lift valve rod 7. tilt valve rod
8. ripper valve rod 9. main relief valve P. high-pressure oil inlet T. oil drain A1. to small chamber of lift
cylinder B1. to large chamber of lift cylinder A2. to small chamber of tilt cylinder B2. to large chamber
of lift cylinder A3. to small chamber of ripper cylinder B3. to large chamber of ripper cylinder
Fig. 2-71 Hydraulic control valve
1. bushing 2. gland 3. cylinder head 4. cylinder 5. piston rod 6. axle bushing 7. nut
8. bushing 9. gasket 10. bushing 11. dust seal 12. shield 13. back-up ring 14. slipper
seal 15. back ring 16. wearing ring 17. piston 18. valve seat 19. piston valve
Fig. 2-72 Blade lift cylinder
58
Technical Parameter Unit: mm
59
2.12.9 Ripper cylinder
back-up ring 12. slipper seal 13. back ring 14. wearing ring 15. piston
⑴ General
Hydraulic cylinder is a device, which converts fluid energy into mechanical energy for
straight-line movement. There are oil ports at both head (piston rod end) and bottom end of
cylinder. If the oil enters at the head end the piston moves towards the bottom and the oil at
the bottom is drained to the tank. In the same way, if the oil enters at the bottom end the piston
moves towards the head and the oil at the head is drained to the tank.
The piston, therefore, can be moved in two directions. This type of piston is called a
60
double-acting piston.
② Piston valve
The piston valve (Fig. 2-75) is installed in the
the piston valve opens to let the oil on the high high-pressure oil
pressure side flow to the low pressure side. In Fig. 2-75 piston valve
2-77).
If the piston rod is removed quickly and is suddenly stopped when it reaches the end of its
If more oil is sent to the cylinder, the pressure in the circuit will rise too high and oil will start to
When the piston reaches its stroke end every time, the operation of piston valve is as follows:
and as a result, the pressure in the cylinder Fig. 2-78 working principle
piston valve
rises and pushes the piston rod to the right.
62
head or bottom end of the cylinder.
gasket
③ Cylinder head dust seal
a. There are two types of cylinder head. One is
mounted on the cylinder (Fig. 2-80) with bolts as
piston
shown in the figure. The other has a thread and rod
inside the cylinder from leaking through the gap Fig. 2-80 cylinder
wearing ring
The piston (Fig. 2-81), which slides inside the cylinder, is piston
fitted with piston rings (Fig. 2-82) to prevent oil from
Fig. 2-81 Piston
entering low pressure side through the piston from the
back ring
high pressure side.
slipper ring
If hydraulic pressure is applied from the other side, the
back-up ring
back ring changes shape and the slipper seal is pushed
against the cylinder to prevent oil leakage.
In addition, both the piston and the cylinder are made of
steel, so they will scratch each other if they slide directly
in contact. To prevent this, the piston is fitted with a wear
ring made of bakelite with a cloth filling.
63
2.12.11 Torqflow Hydraulic System
The principal components comprising the torqflow hydraulic circuit are the strainer (1), torqflow
pump (2), oil filter (3), transmission control valve (4), torque converter relief valve, torque
converter (5), torque converter regulator valve , oil cooler (6) , transmission lubricating relief
valve and torque converter scavenging pump etc. (Fig 2-83).
Oil in the transmission case is sucked up to torqflow pump through strainer (1), and supplied
to transmission control valve (4) through oil filter (3). The transmission control valve is divided
into the modulating relief valve group and the torque converter relief valve group. The oil
relieved to a pressure of 2MPa (20kgf/cm2) from the modulating relief valve is supplied to
torque converter relief valve.
The torque converter relief valve is set at 0.75-0.85 MPa (7.5-8.5kgf/cm) and controls oil
pressure to be fed to the torque converter .The oil delivered through this valve is then directed
to the lubrication circuit. The oil is then directed out of the torque converter and to torque
converter regulator valve.
The regulator valve is set at 0.2-0.3MPa (2-3kgf/cm2) and maintains the torque converter
inside pressure. The oil of 0.2-0.3MPa (2-3kgf/cm2) supplied by the regulator valve is directed
through oil cooler (6) where it is cooled to transmission lubricating relief valve.
64
The lubricating relief valve is set at 0.12MPa (1.2kgf/cm 2) and supplies oil to all sliding parts of
the transmission and PTO.
Oil used for lubricating torque converter or oil oozing out of each contacting face of the
converter is returned from the converter to the transmission case by means of scavenging
pump.
Principle of variable speed circuit (Fig. 2-84):
st
No. 3clutch (1st speed)
No. 4clutch (3st speed) setting pressure
No. 5clutch (2 speed) setting pressure 0.75-0.85MPa
0.2-0.3MPa
1. Transmission case 2. Strainer 3. Torqflow pump 4. Filter 5. Modulating relief valve 6. Quick return valve 7. relief
valve 8. speed valve 9. Forward-reverse valve 10. Torque converter relief valve 11. Torque converter 12. Torque
converter regulator valve 13. Oil cooler 14. Lubricating relief valve 15. PTO case lubrication 16. Transmission
lubrication 17. Torque converter case 18. Strainer 19. Scavenging pump A. Plug for transmission modulating relief
pressure (ZG 1/8) B. Plug for transmission 1st speed clutch pressure (ZG 1/8) C. Plug for torque converter relief pressure
(ZG 1/8) D. Plug for torque converter regulator pressure (ZG 1/8) E. Adapter for torque converter oil temperature
66
2.12.12 Torqflow pump
1. Drive gear shaft 2. Pump front cover 3. Pump body 4. Pump rear cover 5. Driven gear
67
2.12.13 Transmission control valve
The transmission control valve consists of modulating relief valve and reducing valve (Fig. 2-87).
Z-view
speed lever
to torque converter
reverse
forward
from oil pump
2 speed
3nd speed
1rd speed
from A from B
neutral
st
68
1. Stopper 2. Valve core (B) 3. Valve core spring 4. Valve core (A) 5. Modulating relief valve spool 6. Modulating
valve spring (Large) 7. Modulating valve sleeve 8. Modulating valve spring(Small) 9.Side cover 10. Reducing
valve spool 11. Piston 12. Stopper 13. Reducing valve spring 14. Sleeve 15. Quick return valve 16. Stopper 17.
Directional valve spool 18. Spool 19. Sleeve 20. Cover 21.Speed valve spool 22. Valve body 23. Speed valve
body 24. Speed valve spool detent pin F. To Forward clutch R. To Reverse clutch ⑴ To 1st clutch ⑵ To 2nd clutch
⑶ To 3rd clutch
Fig. 2-87 Transmission control valve
F-R valve
quick return forward clutch
from pump valve reverse clutch
clutch with oil is called “filling time”. When the gear shift lever (engaged) modulating time (sec.)
oil pressure at a suitable rate to the set valve, causing the clutch to engage smoothly (point D).
69
⑵ Working principle (Fig. 2-89)
① When machine moving forward at 1st speed (Point
A in the curve) (Fig 2-90)
The modulating relief valve functions as a relieve
valve. The hydraulic oil from torqflow pump flows into
reducing valve through the oil port (e) of quick return
valve (15).
The hydraulic oil via centre hole of quick return valve
flows through throttle (g) to the right side of
modulating sleeve and pushes the modulating sleeve
(7) to the left.
Another hydraulic oil circuit from torqflow pump flows into the piston valve (2) through the
throttle (f) of quick return valve to push the regulating relieve valve (5) to the right. When the
modulating relieve valve (5) is pushed to the right and the modulating sleeve (7) to the left, the
modulating spring (6) and (8) are compressed so that they are in a state of balance. Under this
circumstance the hydraulic oil is released and flows to the torque converter.
② Immediately after shifting the gearshift lever to 2nd speed (point B in the curve) (Fig 2-91)
Immediately after a speed change, oil from pump
flows into clutch pack and fills up clutch. Quick return
valve (15) moves to the left by the oil flow to port (e).
At the same time valve (5) and sleeve (7) are returned
by the force of spring (6) and (8) and oil of chamber (c)
flows to drain port (a), and oil of chamber (a) flows to
drain port (b).
70
When the clutch piston is filled up with oil, the oil pressure
of port (c) through orifice (f) in the quick return valve (15)
rises. Under the force of the oil pressure of port (c), the
modulating valve (5) moves to the right. This causes port
(i) to open, thus connecting the torque converter circuit to
the relief (Fig 2-93).
On the other hand, the oil passing through the center hole
of quick return valve (15) flows into port (a) through orifice
(g).
After filling port (a), the oil pressure rises and the
pressurized oil pushes modulating sleeve (7) to the
causing spring (6) and (8) to compress.
As the oil pressure increases gradually, the oil pressure of
each port increases too, causing modulating sleeve (7) to
move to the left. And then modulating valve (5) continues
to move to the left and closes torque converter relief port
(i), causing spring (6) and (8) to compress (Fig 2-94).
④ When pressure is rising and oil pressure rise is completed (Fig 2-95)
When closing the torque converter relief port (i), the oil
pressure of port (c) rises again, and pushes modulating
valve (5) to the right to open relief port (i), causing
spring (6) and (8) to compress so that the oil pressure of
the circuit increases.
As result, modulating valve (5) continues to move to the
right and left and increase the pressure until modulating
sleeve (7) strikes valve body (j). When this happens, the
oil flows to relief port (i) and the oil pressure ceases to
rise, so that the relief pressure reaches the set pressure
of modulating valve: 2MPa (20kgf/cm2).
71
2. Reducing valve
Reducing valve (10) is equipped in the circuit between quick return valve (15) and speed valve
(21), and keeps the oil pressure on the 1st clutch at 1.25MPa (12.5kgf/cm2). When this
pressure is reached, the 1st clutch circuit is closed. (Fig. 2-87)
In the “Neutral” position, the oil from the pump works on the
1st clutch when the engine is started. This is to shorten the
time to fill cylinders Forward and Reverse with pressurized oil,
which assists machine starting. When the gear shift lever is
shifted to Forward-1st speed position, enough oil is supplied
by the pump to fill Forward cylinder. When the lever is then
shifted from Forward-1st to Foeward-2nd position, the oil is
supplied to only 2nd clutch cylinder as Forward clutch is
already full. Thus the modulating time is shortened (Fig.98).
Fig. 2-98 Principle of reducing valve
72
2.12.14 Transmission filter
73
2.12.15 Transmission lubrication system
1. Transmission lubrication chart (Fig. 2-100)
74
2. Lubricating relief valve (Fig. 2-101)
1. Valve body 2. Cover 3. Spring seat 4. Spring 5. Lubriating relief valve spool
6. cover 7. bushing 8. bushing 9. cushion
75
2.12.16 Steering clutch and brake piping
The hydraulic steering system mainly consists of strainer (1), steering pump (2), steering filter
(3), steering control valve (4), brake booster, relief valve and oil cooler (5). (Fig. 2-102)
1. Steering strainer 2. Steering pump 3. Steering filter 4. Steering control valve 5. Oil
cooler
Fig. 2-102 Steering clutch and brake piping
The hydraulic oil inside the steering case passes through magnet strainer (1) and is sucked up
by steering pump (2). From here it passes through steering filter (3) and flows to steering
control valve (4), brake booster and relief valve.
The oil relieved by relief valve [set pressure: 2MPa (20 kgf/cm 2)] flows to the oil cooler by-bass
valve.
If the oil pressure in the oil cooler by-pass valve exceeds the set pressure of 1.26MPa
(12.6kgf/cm2), due to reason such as clogging of oil cooler (5) or the lubrication system, the oil
is relieved to the steering case.
When the steering lever is pulled halfway, the oil flowing to steering control valve (4) flows to
steering clutch. When the steering lever is pulled fully, the oil flows to the steering clutch and
brake booster. This disengages the steering clutch and at the same time actuates the brake.
76
2.12.17 Hydraulic system of steering clutch and brake
1. Schematic diagram of hydraulic system of steering clutch and brake (Fig. 2-103)
1. Steering strainer (magnet type) 2. Steering pump 3. Steering filter 4. Relief valve 5. Oil
cooler by-pass valve 6. Oil cooler 7. Steering control valve 8. Brake valve 9. Brake booster
10. Left steering clutch 11. Right steering clutch 12. Steering case
A. Plug for relief valve pressure (ZG1/8) B. Plug for left steering clutch pressure (ZG1/8)
C. Plug for right steering clutch pressure (ZG1/8) D. Plug for left brake booster pressure
(ZG1/8)
E. Plug for right brake booster pressure (ZG1/8) F. Plug for by-pass valve pressure (ZG1/8)
Fig. 2-103 Principle of hydraulic system of steering clutch and brake
77
2. Structure of hydraulic system of steering clutch and brake (Fig. 2-104)
Engine running, both steering levers are not pulled and both brake pedals are not depressed:
78
2.12.18 Steering pump
1. Structure (Fig. 2-105):
1. Driving gear shaft 2.Front pump cover 3. Pump body 4. Rear pump cover 5.
Driven gear
2. Technical Parameter:
Model: CB-Hd40
Type: gear pump
Delivery: 40 ml/r
Rated pressure: 4MPa (40kgf/cm2)
79
2.12.19 Steering control valve
1. Structure of steering control valve (Fig. 2-106A, Fig. 2-106B)
The steering control valve includes two steering valves (12) and controls the oil line to left and
right steering clutches, left and right brake valves (20) and oil line to left and right brake
boosters.
80
2. Pipe 3. Brake valve body 4. Bolt 5. Shim 5. Lever
82
Under the action of adjusting bolt (8), the shaft
(17) moves rightward and pushes the brake valve
rod (20). In such case, chamber E and chamber
H are cut off and chamber D and chamber E are
connected. The hydraulic oil flows into the brake
booster through chamber E. (Fig. 2-112)
The hydraulic oil flowing to chamber F through
the orifice (b) pushes the piston (22) and the
reacting force pushes the brake valve rod (20)
leftward. The spring (18) is compressed. The
brake valve rod (20) cuts off the oil circuit from
chamber D to chamber E. The system pressure
and the force of spring (18) are balanced. (Fig.
2-113)
If the steering rod is further pulled, the spring (18)
will be compressed further. In such case, the
spring force rises and the oil pressure balanced will rise with the spring force. The brake acts.
⑸ When the steering rod is pulled to the end (steering
clutch disengaged; brake applied):
The shaft (9) moves rightward until touching the
stoppers (G) and (H). After that, the shaft (9) cannot
move rightward any more and the steering valve rod
(12) cannot move further. Under the pushing force of
the adjusting bolt (8), the shaft (17) can move
rightward to push the brake valve rod (20). (Fig. 2-114)
However, even if the shaft (9) reaches the terminal of
the travel, shaft (17) has not reached the terminal
of the travel. Therefore, the hydraulic oil flows into
chamber (F) through the orifice (b) pushes the
piston (22), and the reacting force pushes the
brake valve rod (20) leftward and compresses the
spring (18). The brake valve rod (20) cuts off the
hydraulic oil from chamber D to chamber E. The
Fig. 2-115 Principle of steering control valve
system pressure and the force of spring (18) are
balanced. When the steering rod is pulled to the end, the force of spring (18) reaches the max.
value. The circuit pressure balancing with the force of spring (18) also reaches the max. value
1.67MPa (16.7kgf/cm2). The brake process is completed and the brake band holds the brake
drum. (Fig. 2-115)
83
⑹ When the steering rod is recovered (steering
clutch engaged, without brake):
Shaft (9), shaft (17), brake valve rod (20) and
steering valve rod (12) all return to their original
positions under the action of the spring force. In
such case, the steering valve rod (12) cuts off
the oil circuit from chamber A to chamber B and
connects chamber B and chamber G. The
hydraulic oil in the steering clutch is then
drained to the steering clutch case through Fig. 2-116 Principle of steering control valve
84
2.12.20 Steering relief valve
85
2. Working principle of steering relief valve (Fig. 2-118):
The hydraulic oil from the steering pump
of the bypass valve. In such case, the hydraulic pressure is kept to 2MPa (20kgf/cm 2). The oil
circuit pressure rises if the oil cooler is blocked. The hydraulic oil in chamber D will push the
bypass valve rod (2) along the arrow to connect chamber C and chamber E. The hydraulic oil
will be drained to the oil tank and the hydraulic pressure will become 1.26MPa (12.6kgf/cm2).
86
2.12.21 Steering strainer
87
2.12.22 Steering filter
1. Structure (Fig. 2-120):
1. Cover 2. Spring 3. Spring guide 4. Valve 5. Spring 6. Bracket 7. Element 8. Filter case
2. Working principle:
The hydraulic oil from steering pump flows into the case via the inlet. After being filtered by the
element (7), it is fed to the inlet of the control valve from the outlet. If the element (7) is
seriously blocked, the valve (4) will open when the front-rear pressure different of it reaches
0.3MPa (3kgf/cm2).
88
2.13 Control system
2.13.1 Engine control
A fuel lever is installed on the dashboard. Decelerator pedal is equipped in the front of right
foot. When the decelerator pedal is depressed, the absorber prevents the fuel control lever
from moving. When machine arriving at the top of a slope, or when dumping dirt from a cliff,
the travel speed will increase suddenly when unloaded. Slow down the engine speed by
depressing the decelerator pedal.
idling
full speed
89
2.13.2 Transmission control
1. The transmission control lever system consists of transmission control lever and safety
switch to ensure the engine may be started and the speed may be switched only in neutral
position. (Fig. 2-122)
⑴ Transmission control lever
When moving the gear shift lever from the “Neutral” position to 1st, 2nd or 3rd position, each
part moves in the direction shown by the arrow, resulting in pulling the speed valve spool (4).
The transmission control lever is mounted on the left control frame to realize three kinds of
speed (F, R) of the dozer. There is only one transmission control lever.
When the gear shift lever moves from the forward position to the reverse position, each part
moves in the direction shown by the arrow, resulting in pulling the F-R valve rod (5).
safety lever
1. Gear shift lever 2. Safety lever for gear shift lever 3. Transmission control valve 4. Speed
valve lever 5. Forward-Reverse lever F. Forward position R. Reverse position N. Neutral
position
Fig. 2-122 Transmission control
90
To engine oil pressure indicator
To charging indicator
safety switch
connected disconnected
To engine R
disconne
connected cted
disconne
cted
disconne
cted
disconne
Terminal (magnetic field) R
cted
To battery
neutral
brake
release
91
2.14 Electrical system
The electrical system is used to complete the tasks such as starting of dozer, operating
condition supervision of diesel engine and working lighting to reduce the work volume of the
operator and improve the operation comfort.
The electrical system mainly consists of battery, DC starting motor, AC generator, starting
switch, neutral switch, rocker switch set, lights and various instruments, sensors and
connecting conductors.
Working principle of electrical system:
The electrical system is a DC 24V system using single-wire negative earthing system. The
starting motor is started directly in electrical manner. Two batteries in parallel feed the starting
motor with 24V power. The circuit of battery is connected through the relay. The starting switch
is used to start the diesel engine. When the diesel engine is started, the starting motor stops
working. The whole system will be fed by the generator. Meanwhile, two batteries will be
charged.
2.14.1 Starting Group
1. The Starting Group is composed of starting motor, battery relay (power switch) and
starting switch.
2. When starting switch is set to “On” position, the battery relay is switched on to make the
battery negative pole be connected with the unit body. It means that the machine is in normal
starting state.
3. When the starting switch is turned clockwise to “Start” position further, the electromagnetic
coil on the starting motor is turned on and the gear pushed out, at the same time, the starting
motor switched on to make the diesel engine operated (the starting time normally is within 3-5
seconds).
4. After diesel engine running, the output voltage at generator midpoint is connected to the
timer to accumulate operating time of the diesel engine.
5. To stop the diesel engine, the starting switch must be counterclockwise turned to the end
(automatic reposition). At this time, the stop electromagnet above starting motor is attracted to
close the throttle at the oil spray pump, so the diesel engine stops.
2.14.2 Charging Group
1. The Charging Group is composed of AC generator and volt gauge etc.
2. The AC generator is the self-rectified one with an integrated circuit regulator. The output
voltage is 28V and the output current is 50A.
3. The generator is a maintenance-free one due to its integration. Just pay attention to the
tension of the generator belt, which drives the generator.
4. The volt gauge will indicate the output voltage of the generator after the engine is started.
2.14.3 Lighting Group
The lighting of machine is composed of front lamp, rear lamp, ceiling lamp and gauge lamp,
which are controlled by the light switch on the instrument box (ceiling lamp in the cab is
provided with switch).
92
Schematic diagram of electrical system (Fig. 2-125):
Fig. 2-126
The fuse box is used to protect the electrical equipment. Its specification shall meet the
requirement of the circuit diagram. If the fuse is burn out too many times (or burn out after
being replaced) during working, check it immediately to eliminate the failure. Before replacing
the fuse, disconnect the starting switch. If the fuse is eroded, white powder is visible, or the
fuse is loosened from the base, replace it with the one having the same capacity. Do not
change the specification and material of the fuse, or the electrical equipment may be
damaged.
94
Specification and control circuit of fuse: (Fig. 2-127)
Fig. 2-127
2.14.6 Other Group
The dozer is provided with horn (Fig. 2-128), fan (Fig. 2-129), front and rear windscreen wiper
and lighter etc.
95
2.15 Fuel supply system
Fuel tank is located at the rear part of machine. The fuel is injected into the fuel tank via filter
screen. The dipstick can be seen after filler cap removing. The fuel flows into fuel pump and oil
filter via the fuel tank. The fuel shutoff valve and the water drain valve are installed in the rear
of the oil tank.
1. Oil tank 2. Fuel filter 3. Dipstick 4. Water drain valve 5. Fuel shutoff valve 6. (PT)
96
Chapter 3 Instrument, Switch and Control Device
3.1 Arrangement of instrument, switch and control device (Fig.
3-1, Fig. 3-2, Fig. 3-3, Fig. 3-4 and Fig. 3-5)
⑶
⑷
⑺
⑵ ⑻
⑼
⑽
⒇
4. Blade control lever 9. Brake lock
lever 10. Blade lock lever
⒀
1. Accelerator control lever 2. Steering ⑿ ⒁
control lever (left) 3. Steering control lever
⑾ ⒂
(right) 7. Transmission lock lever 8. Gear
shift lever 20. Horn switch
Fig. 3-1 Instrument, switch and control
⒃
⒅ ⒄
device
11. oil pressure gauge 12. water temp. gauge
13. volt gauge 14. torque converter oil temp.
gauge 15. timer 16. lighter 17. starting switch
18. electrical control switch group 1
Fig. 3-4 Instrument, switch and control device
⑸
⑹ (21) ⒆
5. decelerator pedal 6. brake pedal 19. electrical control switch group 2 21. ceiling lamp switch
Fig. 3-3 Instrument, switch and control Fig. 3-5 Instrument, switch and control device
device
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3.2 Operation of instrument, switch and control device
3.2.1 Starting switch
There are four positions on this switch: FLAME OUT, OFF, ON and Start. (Fig. 3-6)
OFF:
The key insertion position is OFF position and all of the
circuits are disconnected at this time.
ON:
Turn the key to ON position. In such case, the battery
relay is connected. The negative pole of the battery
connects to the relay bond. The power is on. Charging,
lighting and various instruments connect with the power.
Connect corresponding switch upon need.
START:
When the key is turned from ON to Start position, the engine is started. When the key is
released, it will be returned to ON position automatically。
★The time for key to stay at Start position should not be more than 10 sec.
FLAME OUT:
When the key is turned from ON to FLAME OUT position,
the engine is stopped.
3.2.2 Instrument
1. Oil pressure gauge (Fig. 3-7): The range of oil pressure
gauge is 0-10 bar (approx. 0-1MPa). It indicates the
pressure of engine lubricating oil. When the engine is
running, the normal working range is 3.15-4.85 bar.
★For cold start, sometimes the pressure is low. In such case,
preheating will be required.
Fig. 3-7 Oil pressure gauge
If the oil pressure is too low or too high, turn off the engine
immediately and check it. The work can be recovered only when the indicator is in the normal
range.
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2. Water temperature gauge (Fig. 3-8):
The range of water temperature gauge is 40-120℃. It
indicates the temperature of cooling water of the engine.
When the engine runs normally, the temperature range is
80-100℃. If the temperature is too high, reduce the speed of
the engine so that the indicator goes to the normal position.
Stop the engine and inspect the water level if necessary.
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3.2.3 Electrical control switch group
Using of switch in the electrical system is relatively simple. All the switches are provided with
clear marks. Operate them as required. The rocker switch shall be subject to the printed figure.
Press the side with mark to start and release it to close.
1. Electrical control switch group 1 (Fig. 3-12): mounted on the instrument box
⑴ instrument lamp switch
④ ⑤
⑵ front lamp switch
⑶ rear lamp switch
① ② ③
⑷ ether start switch
⑸ warm air switch Fig. 3-12 Control switch group 1
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3.2.6 Brake lock lever
When parking, the brake pedals are stepped on and the lock lock
lever is placed in Lock to lock the brakes.
After parking, the brake pedals must be locked. (Fig.
3-16) unlock
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3.2.10 Transmission lock lever
Lower the lock lever to lock it at neutral position.
When stopping the machine for a period of time, be
sure to turn the gear shift lever to Neutral and set it at the
unlock
lock position. (Fig. 3-20)
lock
3.2.11 Blade control lever
Fig. 3-20 Transmission lock lever
The control lever normally is located at the hold position ”2”.
To raise the blade, pull the control lever to the position “l”; To
lower the blade, push the control lever to the position “3”.
When push the control lever further to the position “4”, the
blade will be in floating state.
When operate straight-tilt blade, pull the control lever to the
“A” position to make the blade tilt right; pull the control lever
Fig. 3-21 Blade control lever
to “B” position to make the blade tilt left. (Fig. 3-21)
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2. Backrest
Pull up the lever in the spindle so that the
backrest will move towards the seat surface
automatically. To adjust the direction, apply
some force to the backrest. When the
backrest comes to a proper position, release
the lever to lock it automatically. Step
adjustment from 30° to 120° to the seat
surface is allowable.
3.Forward and backward adjustment
Pull the right rod under the mattress outward
to adjust the seat to the desired position
forward and backward. Then, release the rod.
Fig. 3-23 Operator seat
The seat will be locked automatically. The
adjustment range is ±75mm.
4. Load carrying
Turn the handle in front of the damp system to effect stepless load carrying adjustment. The
dial window is located on one side so that the operator can adjust to the optimal condition
suitable to his/her weight. Stepless adjustment from 50Kg to 130Kg is available.
5. Seat height
The seat is provided with manual adjustment through lifting. Lift the mattress along the height.
One-way circulation and three-step adjustment are provided. The range of adjustment is 30mm
per each step.
6. Waist support adjustment
The waist adjustment knob on the left of the back is used to adjust the curve of the waist
support so that the backbone of the operator can fit with the back for the most comfortable
adjustment.
7. Armrest
Adjusting knob is provided in the armrest. Turning the knob manually may effect stepless
adjustment. The armrests can be flipped up when unnecessary.
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Chapter 4 Operation
4.1 Check before starting
★ Check before starting must be customarily carried out. Never neglect and be careless of it,
because it is concerned in person and machine safety.
4.1.1 Check for oil and water leakage
Check the machine around for oil and water leakage and such abnormality, especially check
the connections of high pressure hoses, hydraulic cylinder, final drive, thrust wheel, carrier
roller floating seals and radiator for tightness. If any leakage and abnormality are found out,
remove them.
4.1.2 Check for bolt and nut
Check the bolt and nut for tightness and retighten them if required. Particularly check the bolts
of air cleaner, sprocket segment, engine hood and track shoe.
4.1.3 Circuit check
Check electrical wire for breakdown, short circuits and loose terminals.
4.1.4 Cooling water level check
Remove the radiator cover “1” (Fig. 4-1) to check the water level. Add cooling water if it does
not reach the desired position.
When cooling water is too warm, loosen the cover “1” slowly to release the internal
pressure, then open it to prevent hot water from spraying.
Fig. 4-1 Check cooling water level Fig. 4-2 Check fuel level
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4.1.6 Oil level check of engine oil pan
Oil level should be between high and lower markets of the oil dipsticks “G”. (Fig. 4-3)
★ Oil should be added from the filler “F” if required, but oil level should not be over higher
marker. (Fig. 4-4)
★ Oil type should be in accordance with ambient temperature. Please select it according to
attached table: Sort and Consumption of Fuel, Coolant and Lubricant (See the attached table).
★ When checking oil level, the machine should be parked on the horizontal ground. The
check must be carried out 15 minutes later after engine stop.
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4.1.9 Check for travel of brake pedal
The standard travel of brake pedal is 95-115mm. In
case the travel is more than 115mm or the brake is
defective, please adjust it according to content of
the adjustment section. (Fig. 4-8)
Fig. 4-8 Travel of brake pedal
★ The machine should be thoroughly checked, adjusted Fig. 4-10 Check for instrument
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3. Transmission gear sift lever is at the neutral position “N” (Fig. 3-19).
4. Transmission lock lever is at the lock position (Fig. 3-20).
5. The blade is on the ground and the lock lever is at the lock position (Fig. 3-22).
4.2.2 Starting engine
1. The fuel control lever is placed in low idling position (front end) (Fig. 3-17).
2. The starting key is set from OFF to START. The starting motor will drive the engine. After
starting engine release the key to make it return to ON position automatically (Fig. 3-5).
★Do not leave the key in Start position for more than 10 seconds.
★Restart the engine after 2 minutes when the previous start is failed.
★Observe the oil pressure gauge indicator after starting to decide whether the engine has built
up the lubricating oil pressure.
★When fuel is exhausted, it should be added before starting engine. Then the element of oil
filter should be full of fuel to make the air removed from the fuel system and restart engine.
★For cold start, see the “Cold weather operation”.
3. Preheat and check is required after starting engine.
⑴ Run engine at low speed and make sure the pressure gauge shows green range.
⑵ Pull fuel control lever to make middle-speed idling of engine for about 5 minutes.
⑶ Run the engine under load when the water temperature indicator is in the green area.
⑷ Check all gauges for proper operation.
⑸ Check for normal coloration of exhaust and any abnormal noise or vibration.
⑹ Check for oil and water leakage.
★ The process from (1) to (3) is called preheating. If the engine is cold and the engine oil
pressure is out of the required range after starting, wait until it falls into the required range and
then continue preheating.
★When preheating is over, avoid accelerating the engine abruptly.
★ When the engine has run for more than 20 minutes without load, apply load to it, or it may
run at low temperature, resulting bad burning, serious wear of moving parts, or even oil
accumulation in the turbocharger, which may cause oil leakage from the bottom of the turbine.
4.2.3 Operation of machine running
See Fig. 3-1, Fig. 3-2 and Fig. 3-3:
1. Unlock the lock lever (7), (9), (10) and release the blade control lever (4), brake pedal (6)
and gear shift lever (8).
2. Push the blade control lever (4) to the lift position “1” to raise the blade 40-50cm off ground.
3. Raise the ripper to the highest position (if any).
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4. Pull the fuel control lever (1) to increase the engine speed.
5. Push the horn button (20) to sound the horn.
6. Move the gear shift lever (8) to the desired shift to start machine.
★Step down the decelerator pedal when starting to reduce the engine speed for impact damp.
When start at sharp gradient, drive the engine at full speed, keep stepping down the brake
pedal, push the gear shift lever to 1st position, and slowly release the brake pedal so that the
dozer will move slowly.
★ If the gear shift lever does not move from the position, due to the action of the relief valve,
the dozer will not move even if the engine is started. In such case, push the lever to N position
and then to the desired position.
7. Gear shift of machine forward and backward
★ The machine can change speed during running, so no stopping will be required when
changing speed.
★ To change speed during running, step down the decelerator pedal. Change the speed after
the speed falls down to avoid impact which will cause damage to the machine.
8. Left/right turning (Fig. 4-12)
Pull left/right steering lever halfway backwards so that the left/right steering clutch disengages
and the machine turns slowly to the left/right.
9. Left/right pivot turn (not allowed in usual condition) (Fig. 4-13)
Pull left/right steering lever to the end backwards so that the left/right steering brake acts and
the machine makes a left (right) pivot turn.
108
10. Running on ramp
When running on a ramp, the longitudinal gradient shall not exceed 30° and no reverse is
allowed when creeping.
Neither gear shift nor passing through barrier is allowed on sharp ramp.
The machine running on ramp may suffer from lateral sliding easily, so drive the machine
at low speed in straight line. Never drive laterally on large ramp.
When falling gradient, pull the gear shift lever to the low-speed position and apply brake
with the engine. If the engine has overspeed, reduce the speed using the brake pedal.
★ When starting on sharp ramp, firstly step down the brake pedal, pull the gear shift lever to
“1” position and meanwhile release the brake pedal.
★ Do not stop the machine on a ramp unless in special condition. If it is unavoidable to stop
the machine on a ramp, the head shall face the downward side and the brake pedal shall be
locked. In case of large gradient, insert the blade into the earth to prevent from gliding of the
machine.
11. Turning on ramp
Pull left/right steering lever halfway backwards so that the left/right steering clutch disengages
and the machine makes a small turn leftward/rightward. (Fig. 4-14)
Pull left/right steering lever to the end backwards so that the left/right steering brake acts and
the machine makes a large turn leftward/rightward. (Fig. 4-15)
Fig. 4-14 Small turn on ramp Fig. 4-15 Large turn on ramp
In case of turning during gliding by right of the weight of the machine, the machine shall
turn opposite when the steering lever is pulled halfway.
Try to avoid turning on the ramp.
Do not turn on soft earth or clay soil.
Do not make pivot turn at high speed.
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4.2.4 Running in water
Before going into the water, investigate the water depth and the condition of soil under
the water to prevent from accident due to too-deep water or being trapped in earth.
★ The carrier roller shall not be covered with water and the cooling fan shall not touch the
water.
★When working in seawater or other corrosive water, wash the machine with clean water after
finishing the work.
4.2.5 Running in desert
When running in desert or other flying particles, try to seal the machine and clean the air filter
from time to time.
★Provide desert-type air filter if necessary.
4.2.6 Stopping machine
See Fig. 3-1, Fig. 3-2 and Fig. 3-3:
1. Pull back the fuel control lever (1) to decrease engine speed (Fig. 3-17).
2. Move the gear shift lever (8) to the Neutral position (Fig. 3-19).
3. Depress the brake pedal (6) and lock it by lock lever (9) (Not locked for temporary stop) (Fig.
3-15 and Fig. 3-16).
4. Lock gear shift lever (8) by lock lever (7) (Not locked for temporary stop) (Fig. 3-20).
5. Turn blade control lever (4) to lower position “3” to make blade on the ground (Fig. 3-21).
6. Press the blade lock lever (10) to the lock position to lock the blade control lever (4) (Fig.
3-22).
7. When ripper is provided, descend the ripper onto the ground and then lock the ripper control
lever.
8. Stop engine:
★ Run engine at low speed for 5 min. and cool down the engine, then stop it. Otherwise, the
engine lifetime will be shortened.
Turn the starting key to FLAME OUT position; after the machine is stopped, take off the key.
4.2.7 Running under cold weather
It is difficulty to start engine due to too low temperature and freezing cooling water etc. It is
harmful to the engine. So the following measures should be taken:
1. The oil and water are selected according to the attached table: “Sort and consumption of
fuel, coolant and lubricant”.
⑴ Replace the lubricating oil of each device with specified low-viscosity oil;
⑵ Use light oil which is 5℃ lower than the ambient temperature for fuel;
⑶ Add antifreezing agent into the cooling water.
110
2. When temperature is lower than 0C, the appropriate antifreeze should be selected
according to the lowest temperature in order to prevent cooling water from freezing.
⑴ Use standard antifreezing agent. Do not use the one containing methanol or ethanol, or it
may cause failure of the engine.
⑵ Prior to adding antifreezing agent, completely drain the water in cooling system and clean
the inside. Fill the antifreezing agent after removing the scale deposit.
Antifreezing agent is inflammable, so avoid any possible fire.
Generally, antifreezing agent contains antirusting agent which includes alkali. Try to avoid
skin and eye exposure.
★ When the weather becomes warm, drain the antifreezing agent (excl. permanent
antifreezing agent), and fill clean water after washing the cooling system.
⑶ Following measures shall be applied when no antifreezing is provided:
a. The starting temperature of the engine thermostat is 79℃. Usually, even in cold season,
circulating water in cooling system is cold when the engine is running. Freezing may occur if
the water in radiator is standstill. In such case, the thermostat shall be removed and
meanwhile pay attention to the value of water temperature gauge. Keep the water temperature
normal.
b. After finishing the work each day, the cooling water in oil cooler, radiator and engine body
shall be drained completely to prevent from frost cracking of the machine.
★Water drained for freezing prevention is anticorrosive and can be reused next time.
c. Anticorrosive tank (if any) shall be removed after finishing the work each day to prevent from
freezing. Close the inlet and outlet valves of the tank. Seal the orifice. Wrap it with cloth. Place
it in warm place to prevent from freezing.
3. Particularly pay attention to that the snow and water on the piston of hydraulic cylinder
should be cleaned away; otherwise the cylinder may be damaged due to freezing.
4. When temperature drops, the battery ability may decrease. It normally makes the charge
capacity reduce and the electrolyte freeze. The charge level of battery should be kept to about
100 and isolated to prevent low temperature.
★ The relation between specific gravity of electrolyte and rate of charge is shown in the
following table.
Fluid temp.
20℃ 0℃ -10℃ -20℃
Charge rate
100% 1.28 1.29 1.30 1.31
90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
111
★ If the electrolyte level drops, add distilled water in the next morning before operation to
prevent fluid from freezing at night.
panel handle
To reservoir
112
Chapter 5 Digging and Pushing
Select reasonable machine and equipment, adjust the equipments to requirement and apply
right operation method according to pushing job, can prolong machine lifetime and reduce
operator’s labor and raise working efficiency.
PD165Y-2 Bulldozer is designed for ordinary operating condition.
Blade is divided into straight-tilt blade and angle blade which are used for different terrain and
working object. Ripper is optional according to customer.
Its valid distance per trip should preferably be 70 meters at maximum. If longer, use of scraper
is more economical.
5.2 Leveling
Uneven ground surfaces remaining after digging
can be leveled off by the following methods (Fig.
5-2):
⑴ Operate the machine at low speed with the
blade fully loaded with soil and uneven ground is
Fig. 5-2 Leveling
filled and cut by advancing machine.
⑵ A flat finished surface is also possible by slowly
backing the machine with the blade fully “floating”.
★ However, avoid this on rocky ground, as it may
damage the blade.
113
★ During earthmoving, try to avoid sharp starting, emergency brake and sharp turning as far
as possible.
raise
lower
1. When the handle is placed at (1) (raise position), the blade is raised.
2. When the handle is placed at (2) (hold position), the blade is stopped and held at this
position.
3. When the handle is placed at (3) (lower position), the blade is lowered.
4. When the handle is placed at (4) (float position), the blade can be floated up and down.
5.4.2 Straight-tilt blade operation
Straight-tilt blade operation (Fig. 5-5):
When the handle is placed at A or B, the blade will tilt right or left. The remaining four places
are similar to angle operation.
114
5.5 Blade Adjustment
5.5.1 Level adjustment for angle blade
In case of single-side pushing, adjust the blade to 25°:
(Fig. 5-6)
115
5.5.2 Vertical adjustment for angle blade
1. Raise blade 40-50cm off ground and place a wood under the pushing frame (Fig. 5-7).
2. Loosen the setting bolt (l) (Fig. 5-11).
3. Insert the adjusting lever into hole A on the upper support lever (2) and turn the adjusting
lever to lengthen or shorten the upper support lever (2).
Right tilt of blade: right side shortened and left side lengthened; left tilt of blade: left side
shortened and right side lengthened.
4. When tilting to the desired height, fix the blade with bolt (1).
116
5.5.4 Cutting angle adjustment
The standard blade cutting angle () is 55.
The arm length (L) can be adjusted to the optimum length by lever (1) according to different
soils (Fig. 5-14).
117
7. Working along a slope machine moves down hill.
118
Chapter 6 Maintenance and Service
6.1 Precaution
To prolong machine lifetime, assure person-machine safety, raise working efficiency and
increase economic coefficient.
In addition to reading the requirement concerned mentioned in “Safety Notice”, operator and
serviceman must also observe the following precautions.
1. Serviceman must be familiar with the machine structure, performance,
assembly-and-disassembly procedure, technical requirement and precaution before handle it.
2. For difficult service and maintenance item, the best way is to consult the manufacturer if you
can not handle it.
3. Routine maintenance should be made before machine starting and after each shift. Before
maintenance park machine on the horizontal ground, lower blade and lock out locking device,
then make maintenance.
4. For maintenance with engine operated, two persons are required to incorporate. One
person sits down in cab and the other makes maintenance. Be careful that your body never
contacts moving parts.
5. Before maintenance, the place around maintenance part should be thoroughly cleaned and
washed, especially the place around filler, filter, fitting and case cap cleaned to prevent dust
from entering oil.
6. Keep in mind that high pressure exists in hydraulic circuit. Before you add oil, drain off oil
and make check and maintenance, release the pressure first.
7. Pressure release procedure is as follows: lower blade and ripper on the ground, shut down
engine and set the control lever of hydraulic system to each shift gear 2-3 times in succession,
then slowly loosen oil cap or pipe connection.
8. Before oil change drive machine to make oil temperature rise to 30C-40C, then drain off it.
Use clean oil and grease.
9. Oil check and change should not be carried out on site in dust cloud. Otherwise dust could
enter oil.
10. Never handle electric system, wearing raincoat or in rain.
11. Be careful that spray hot water may hurt person when checking and adding cooling water.
12. Remove air from oil circuit after oil filter element and strainer are replaced.
13. Never add oil with screen of filler removed.
14. Before gearbox maintenance empty your pocket. Be careful that dropping spanner and nut
etc. into the gearbox may result in trouble.
15. Oil must be kept away from fire and never replace lighting with fire.
16. Thoroughly wash parts surface before O-ring, gasket or other seals are changed and then
they should be assembled carefully.
119
In order to make you thoroughly know and master maintenance items and content in different
6 Check oil level in engine oil pan Check and supply 4.1.6
120
No. Item Content Section
Lubrication 6.6.1
Lubrication 6.9.4
122
6.2 Description of service per 50h
Fuel tank
Loosen the valve at bottom of fuel tank to drain off impurity and mixture of oil and water.
123
3. Cylinder support (Lubricate 4 points) (Fig. 6-3)
4. Cylinder support shaft, Lubricate 2 points (Fig. 6-4)
124
6.4.3 Change of steering filter element
2. Remove bolt (1) and cap (2), then pull out filter element (3) from the case (Fig. 6-8).
3. Clean case interior and the removed parts. A new filter element is used when required. After
refresh oil into the case, fix the cap (2) with bolt (1).
4. After assembling the filter element, loosen the air plug (4), start the engine until the oil
2. Dismount bolt (1), remove cap (2) and pull out filter element (3) from filter (Fig. 6-9).
3. Clean the case interior of filter and the removed parts from it, then assembly a new filter
element. After filling oil, tighten bolt (1) and close cap (2).
4. After changing filter element, loosen air plug (4) and start engine until no air bubble appears
and oil overflows from the air plug (4), then tighten the air plug (4).
125
6.4.5 Battery electrolyte level
The machine is provided with maintenance-free battery which requires no service and
maintenance in general (Fig. 6-10).
The charge indicator A of battery shall be always green or the open-circuit voltage shall
be 12.45V or higher.
126
6.4.8 Radiator and heat sink
Loosen bolt (1), open radiator guard (2) and clean heat sink of
mud or other things with compressed air or vapour (Fig. 6-13).
★Check the belt for damage or other defect.
★Check the clamp for looseness.
of the track.
127
6.5.4 Breather
1,000
128
2. Pin shaft of diagonal brace track brace (2 points) (Fig. 6-19)
track brace
3. Track tension cylinder (2 points) (Fig. 6-20)
129
7. Replace the filter element of transmission as required in the content of service per 250h.
8. Fill the specified amount of oil through inlet “F” (Fig. 4-31).
9. Refer to the inspection item and confirm the specified oil level.
★Amount of changing oil: 52L
3. Remove the strainer bolt ① to take off the cover ② and take
out the spring ③ and screen ④ (Fig. 6 -23).
Remove oil injection plug (F) at two sides first, then take out
drain plug (P) and retighten the drain plug after draining off oil.
An amount of oil is added from filler (F). (See the description of
service per 250 hours.)
130
6.6.5 Hydraulic tank and filter
Change hydraulic oil and wash the filter (Fig. 6-26):
1. Lower blade on the leveling ground and stop engine. Turn blade control lever
forward-backward and left-right each for one time, then slowly loosen cap of filler (F) and take
out the cap after removing air from case.
2. Loosen off drain plug (P) under the hydraulic tank and empty the tank, then retighten the
drain plug.
3. Remove bolt (1) and take out cap (2) and the filter element. Wash the removed parts and
change for new filter element.
4. Fill new oil to the indicated oil level from filler (F) (see the description of service per 250
hours).
Lubrication of thrust wheel, carrier roller and guide roller (Fig. 6-27):
1. Park the machine on the level ground. Check thrust wheel, carrier roller and guide roller for
oil consumption one by one.
2. Slowly loosen the sealed bolt. If oil leaks, tighten it immediately.
3. If there is still no oil leak after the bolt is loosened off, it means that the oil is too small.
Consult with manufacturer about it in time.
Fig. 6-27 Lubrication of thrust wheel, carrier roller and guide roller
6.6.7 Anticorrosion device
Anticorrosion device (if any) shall be replaced as required in the manual of engine.
131
6.7 Description of service per 2,000h
Maintain according to service per 50, 250, 500 and 1,000 hours at the same time.
1. Engine intake and exhaust device
Wash engine intake and exhaust pipe and check sediment in pipe and check pipe for damage.
Change it when required (See the engine operation manual for detail).
2. AC generator
⑴ Provide the generator with maintenance each time when the machine has worked for
1,000h. Carefully clean the slip-ring to make it smooth and clean. Check the carbon brush. If it
is seriously worn, replace it.
⑵ Apply lithium base or sodium base grease to the bearing.
Precaution of using generator:
★ Do not check whether the generator works normally through positive-to-ground strike, or the
rectifier diode may be broken.
★ The tension of V-belt of the generator shall be proper. Generally, the center section of the
rubber belt can be pressed down by 10-15mm.
★ If machine often operates at night, repair it once every 1,000 hours (See the engine
operation manual for detail).
3. Starting motor
The starting motor shall be provided with maintenance each time when the machine has
worked for 1,000h. Check the commutator and electric brush. If the surface of commutator is
seriously burn, polish it with fine sand paper. The electric brush shall be replaced immediately
if it is seriously worn or broken. Apply lubricating oil to moving parts such as bearing.
4. Engine throttle clearance
Adjust throttle clearance (For detail see the engine operation manual).
5. Engine damper
Check rubber surface of damper for crack and fracture. Change it if any.
132
6.9 Service when required
Check and maintain the following places ifrom time to time.
6.9.1 Track tension
Due to different operating conditions and soil conditions, the tension of track shall be detected
from time to time upon the change of wear so that it will remain in standard tension condition.
Detection and adjustment shall be carried out in the condition same as the operating condition:
1. Inspection and repair (Fig. 6-28)
Park the machine on level ground (do not apply
brake when going forward). Place a straight bar on
track between carrier roller and guide roller. The
measurement should be made at middle position.
If the distance between the bar and grouser is
20-30mm, it means that the tension is suitable.
Fig. 6-28 Track tension
Make proper adjustment if the tension is out of the
standard.
2. Adjustment (Fig. 6-29)
① To increase the tension, fill the grease through
pressurizing with the oil lubricator ①. To decrease the
tension, loosen the oil lubricator ① counterclockwise by
1 turn to drain the grease.
The high-pressure grease in the cylinder may be
Fig. 6-29 Track tension
injected. Never loosen the oil lubricator ① by more than
1 turn. In such case, do not loosen other parts. If the
grease does not overflow smoothly, move the machine
slightly forward and backward several times.
② If the track is still loose after filling grease, it means
the pin sleeve is seriously worn. Reverse or replace the
pin sleeve.
★The injected grease can make the adjusting clearance
Fig. 6-30 Track tension
“S” to 0. If this limit is reached, but the track tension is
still not enough, it means that track pin and pin sleeve are worn out seriously and they must be
changed (Fig 6-30).
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6.9.2 Air filter
For specific maintenance of air filter, please refer to the use and maintenance manual of diesel
engine.
1. Inspection (Fig. 4-9)
When the sight glass of maintenance indicator of the air filter is red, it means the air filter
element is blocked. Turn off the engine immediately and wash or replace the element.
2. Clean and change external filter elemen (Fig. 6-31)
① Remove bolt, cap and external filter element.
② Clean filter case interior and cap.
③ Clean and check filter element and assemble it (See Section 6.9.2.4 “Clean external filter
element”).
★ When the external filter element was cleaned 6 times or used for one year to time limit, it
should be changed at the same time together with the internal filter element.
★When sealing washer (5) and wing nut (4) are damaged, they must be changed at the same
time (Fig.6-32).
★ With just cleaned external filter element, if the sight glass is still red, the internal and
external filter elements must be also changed together even if the external filter element is
cleaned less than 6 times.
★Check and tighten fixed nut of internal filter element.
3. Change internal filter element
① Remove cap and external filter element and take out
internal filter element.
② Seal air inlet to prevent foreign matter entering into the
engine pipe.
③ Clean case interior of air filter.
Fig. 6-33 Clean external element
④ Tighten a new internal filter element to connector by nut.
⑤ Assemble external filter element and cap.
★Absolutely do not reassemble the used internal filter element.
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When cleaning and changing filter, do not start engine.
4. Clean external filter element (Fig. 6-33)
① Cleaning with compressed air: Blow the interior of the external filter element with dry
compressed air (less than 0.7MPa) along the internal wrinkle, and then blow it along the
external wrinkle. Finally do the interior repeatedly until it is cleaned.
When using compressed air, wear safety goggles and the other safety protection.
② The following several methods are in need of spare filter element.
Using tap water: Use tap water of the pressure less than 0.3MPa to flush the inside and
outside crease of the element repeatedly. Check when it is dry.
Using detergent: Use warm solution containing neutral detergent to clean the element and
flush it with clean water. Dry it.
⑴ Shut down engine and tighten vale of anti-corrosion device (if any).
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⑵ Slowly loosen off filler cap (1) of radiator (Fig. 4-1).
Be careful that spraying hot water will hurt person.
⑶ Open the drain valve (Fig. 2-3) at the bottom of the radiator to drain the cooling water.
⑷ Close the drain valve and fill tap water from the inlet until the water level approaches the
inlet.
⑸ Run the engine at high speed, and open the drain valve until water is trained off and stop
the engine 10 minutes later.
★During flushing, adjust flow of added water to make radiator full of water.
⑹ After rinsing, drain off water and then close drain valve.
⑺ Clean cooling system once more with detergent according to its instruction.
⑻ After cleaning with detergent water, drain off it, and then close the drain valve and fill up
cleaning water (running water).
⑼ Run the engine at high speed and open all drain valves to make water pass through cooling
system until cleaning water is drained off from drain valve.
★ During flushing, adjust water flow to make injecting water capacity equal to draining water
capacity and radiator full of water.
⑽ After water thoroughly becomes clear, shut down the machine, and close drain valve.
⑾ Change filter element of anti-corrosion device and open its valve (if any).
⑿ Add cleaning water until it overflows from water filler.
⒀ Run the engine at low speed for 5 minutes and then at high speed for 5 minutes to exhaust
cooling system of air (Water filler is open at this time).
⒁ Stop the engine and wait for 3 minutes, then supply water to the indicated level, finally
tighten water filler cap.
6.9.4 Lubrication
Apply the lubricating oil to the place showed by the arrow:
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Fig. 6-35 decelerator pedal shaft
4. 2 places at blade control lever shaft (Fig.6-36)
★When end bit, cutting edge, bolt and nut are worn out
or damaged, they must be changed in time and blade
body must not be damaged (Fig. 6-37).
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6.9.9 Change fuse
The fuse is mainly used to protect the electrical parts and conductors. When the fuse is burn
out or oxidized or loose from the bracket, it shall be replaced.
Replace the fuse with the one having the same specification.
6.10 Adjustment
6.10.1 Adjust brake pedal travel
When brake disc is worn out, the brake pedal travel will increase. At this time the clearance
between brake drum and brake disc should be adjusted.
When the standard clearance between brake disc and brake drum is 0.3mm, the pedal travel
is 95-115mm (Max. travel: 115mm) (Fig. 4-8).
2. Remove the brake case cover (1). Tighten the adjusting Fig. 6-38 Rear cover
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6.10.2 Adjust guide roller clearance
The cover (2) is clamped on left and right guide roller
bracket with a clearance of 0.5-1.0 to side face of
track frame to force idler move along track roller frame
guide. Therefore, when guide roller moves, the cover
(2) will be worn to expand its left-right swing or incline.
This will cause idler to depart from track, or master
link and guide roller to be worn unevenly. To avoid
those accidents, adjust the clearance between cover
(2) and track roller frame.
Fig. 6-40 Guide roller clearance
Adjustment of guide roller clearance (Fig. 6-40):
1. Let the machine move 1-2m on the level ground, then measure the clearance “A” between
cover and track roller frame (at four places: left, right, inside and outside).
2. If the clearance is more than 4mm, loosen bolt (1), remove cover(2), take away some
gaskets (3) and adjust each side clearance to 0.5-1.0mm (the thickness of each gasket (3) is
1.0mm).
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3. Calculate the outside diameter of thrust wheel (dimension A).
A= (B—C)×2
When close to the repair limit, immediate repair shall be done to extend the service life.
6.10.5 Battery
The machine is provided with maintenance-free battery which does not need frequent supply
of electrolyte. For long-time shutdown, remove the battery and charge the battery once every
month with 10A for 14-16h. Store the battery in full condition, or its service life will be
shortened. In addition, keep the top of the battery case clean and dry to prevent from current
leakage. Keep good contact of the battery and the terminal. Remove any oxide. Apply geoline
to the terminal and connecting head of the battery to prevent from rust. Never put any tool or
other metal substance on the battery, or short circuit may occur and the battery may be
damaged.
Note: The above lubrication is designed for operating temperature from -20℃ to 40℃. Other
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6.12 Measure pressure of hydraulic system of pan
1. The machine is provided with a centralized pressure gauge for hydraulic system on the left
② ④ ⑥
① ③ ⑤ ⑦
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Chapter 7 Troubleshooting
The following may not remove all trouble, but it is useful to give a reference to troubleshooting.
★Engine troubleshooting (For detail see the operation manual).
7.1 Engine
7.1.1 Oil pressure gauge still shows red range when speed is raised after
engine is started
1. Check whether the oil sump has sufficient oil, and supply oil to the indicated oil level if
necessary.
2. Check whether the oil filter element is blocked, and replace it if necessary.
3. Check whether the oil pipe or connector is badly fixed or has oil leakage due to damage.
4. Replace the pressure gauge.
7.1.2 Vapour is sprayed from top pressure valve of radiator when water
temperature gauge pointer stays in red range
1. Supply cooling water and check for water leakage.
2. Adjust fan belt tension.
3. Replace the cooling water and wash the inside of the cooling system.
4. Clean or repair heat sink.
5. Change thermostat.
6. Tighten radiator cover or change its sealing lining.
7. Tighten radiator cover or change its sealing lining.
7.1.3 Water temperature gauge pointer still stays within red range when
engine operates
1. Change thermostat.
2. Change water temperature gauge.
7.1.4 Starting engine operates, but engine is still not started
1. Supply fuel.
2. Check fuel system for air introduction.
3. Change spraying pump and nipple.
4. Check throttle clearance.
5. Check engine compressive force.
★Refer to relevant part of electrical system (See engine operation manual).
7.1.5 Engine emits white or blue exhaust gas
1. Adjust the oil sump to the specified capacity.
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2. Change with specified fuel.
Check the intake side of the fuel pipeline for air leakage.
Change alternator.
7.2.3 Starting motor will not run when starting switch key is turned to Start
1. Check circuit.
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7.2.5 Starting motor runs, but engine runs slowly
1. Charge the battery.
2. Change the starting motor.
7.2.6 Starting motor gear is disengaged before starting engine
1. Check and repair the circuit.
2. Charge the battery.
7.3 Undercarriage
7.3.1 Oil pressure of torque converter does not rise
1. If oil pressure of transmission is normal, check oil pipe of torque converter and connection
for leakage.
2. If oil pressure of transmission drops excessively, check or change transmission oil pump.
3. If oil pressure of transmission drops excessively, add oil into transmission.
4. If oil pressure of transmission drops excessively, clean and change transmission oil strainer
and filter, clean oil coolant and etc.
7.3.2 Torque converter overheats (Oil temperature pointer stays within red
range)
1. If water temperature is normal, clean oil coolant.
2. If water temperature rises excessively, see Engine and Item 7.3.1.
7.3.3 When gear shift lever is placed at high shift, machine can not start or
speed can not increase
1. Add oil into steering case.
2. If the oil pressure of torque converter does not rise, refer to 7.3.1.
3. If oil pressure of transmission is normal, check or change related clutch seals, plates and
discs in transmission.
4. Check, repair or change steering gear pump.
7.3.4 When pull steering control lever at one side, machine stops, but it
does not steer or engine speed changes
1. Check and adjust steering clutch.
2. Repair steering oil pump and pipe leakage part.
3. Change steering pump.
4. Adjust steering linkage.
7.3.5 When pull steering control lever at one side, machine moves in
straight line, but does not steer
1. Refer to 7.3.4.
2. Adjust the brake.
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7.3.6 Steering lever is inflexible or the control is difficult
3. Check and repair the hydraulic control valve and operating pipeline.
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Chapter 8 Transportation and storage
8.1 Transportation
8.1.1 Precaution for operation of machine
When driving the machine, observe all the highway rules and the traffic regulation, such as
land transport vehicle and vehicle restriction regulations etc.
1. Take necessary protective measures and obtain the license of road access in accordance
with corresponding road transportation laws.
2. Cheek the load limit of bridge and the space size of tunnel before passing through bridge
and tunnel.
3. When running on spread road, use platform trailer to transport in order to protect the road
surface. For short-distance running, cushion shall be used to protect the road surface.
Pitch road is very soft in summer. Special attention shall be paid.
8.1.2 Method for loaded transport
1. Use special platform for loading.
2. When using ladder to load/unload the machine on the trailer, following rules shall be
observed:
⑴ (Fig. 8-1)Apply reliable brake to the trailer. Stop the
wheels with wood pad. The ladder shall be placed in
accord with the center of the machine and reliable fixture
shall be provided. Fig. 8-1 Loaded
thickness to support machine safety load and unload. It could be strengthened underneath by
square wood if necessary.
⑵ The ladder shall be placed in proper direction. Then,
load/unload the machine slowly and smoothly (Fig. 8-2).
When running along the ladder, the running
direction can not be adjusted. If direction adjustment is Fig. 8-2 Loaded
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⑷ Fall down the working device. Place each control lever to the position described below and
take off the starting key:
Place the accelerator control lever in idling position.
Place the gear shift lever in neutral position and lock it.
Place the blade control lever and ripper control lever in hold position and lock them.
The brake lock lever is placed in “Lock” position.
★ If the blade width exceeds trailer width, the blade should be angled or disassembled and
separately shipped.
8.2 Storage
8.2.1 Before storage
To place the machine in storage for an extended period, the following measures must be
followed to minimize maintenance when reusing:
1. Thoroughly wash the machine and park it indoors in a dry place. Don’t park it outdoors.
In case it is indispensable to store the machine outdoors leave it on flat ground with wood
plated and cover it with canvas.
2. Lubricate, grease the machine and replace with new oil before storage.
3. Uncovered part of piston rod should be slightly applied with oil.
4. Conductor at the terminal of battery should be removed and the battery covered or removed
and separately stored.
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5. When you estimate that the ambient temperature will fall down below 0℃, add the antifreeze
Blade control lever and ripper control lever are set to holding position and locked.
Start the engine once a month and move the machine for a short distance, so that new oil film
will be formed over the surface of all movable parts and engine components.
When operate working equipment, wipe off the grease on the cylinder piston rod.
After storage (if the machine is kept without cover or the rust preventive operation once a
1. Remove the drain plug on oil pan and other oil tank to drain the intruded water.
2. Remove the cylinder head, lubricate the valves and rockers and inspect the valve action.
3. To expel air from hydraulic system, turn the engine at low speed and operate as follows:
a. Each cylinder should move back and forth 4-5 times and piston stops at 100mm far from the
stroke end.
b. Next, each cylinder should move back and forth 34 times and move to the stroke end.
★ If the engine operates at high speed at the beginning or the piston moves to the stroke end,
4. If the engine operates at high speed at the beginning or the piston moves to the stroke end,
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Chapter 9 Operation and maintenance of ripper
During machine running raise ripper, insert pin into pin hole at lower part of shank and lock
There are three gearshifts for ripper control handle: “Hold”, “Raise” and “Lower”.
★ Slowly lower ripper. Never fast drop it on the hard ground to prevent shank tip from
damaging.
1. Adjust depth: The ripping depth can be adjusted using three pin holes (A) on ripper shank.
Pull out split pin (1) and take out pin (2), then adjust dipping depth (Fig.9-1).
Pull out pin (3) as showed by the arrow for replacement (Fig. 9-1).
9.3 Troubleshooting
1. Supply oil.
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