Table of Contents

Safety Rules .......................................................................................................................................................... 1

I General .................................................................................................................................................... 1
II Safety Rules for Diesel Engine ............................................................................................................... 1
III Driving & Operation ............................................................................................................................... 2
Chapter I Configuration & Control .................................................................................................................. 3
I Overall parameters .................................................................................................................................. 4
II Diesel engine ........................................................................................................................................... 4
III Transmission system ............................................................................................................................... 4
IV Frame & driving system .......................................................................................................................... 5
V Control system ........................................................................................................................................ 5
VI Hydraulic system..................................................................................................................................... 5
VII Working units .......................................................................................................................................... 6
VIII Filling volume unit: L ............................................................................................................................. 6
IX Instrumentations & electrical system ...................................................................................................... 7
Chapter II Operation of Bulldozer .......................................................................................................................... 10
I Dozing specification.............................................................................................................................. 10
II. Fuel, lubricant and cooling water .......................................................................................................... 11
III Driving & control .................................................................................................................................. 13
Chapter III Running-in and Technical Maintenance ......................................................................................... 18
I Running-in ............................................................................................................................................ 18
II Technical Maintenance after Running-in .............................................................................................. 19
III Technical maintenance of entire machine ............................................................................................. 20
Chapter IV Major Structural Principles............................................................................................................. 22
I Diesel engine ......................................................................................................................................... 22
II Transmission system ............................................................................................................................. 22
III Driving system ...................................................................................................................................... 28
IV Working device and hydraulic system................................................................................................... 30
Chapter V Parking & Storage .......................................................................................................................... 33
I Preparations for Parking & Storage....................................................................................................... 33
II Parking & Storage of Bulldozer in Hanger ........................................................................................... 34
III Parking & storage in the open air .......................................................................................................... 34
Chapter VI Major Faults & Troubleshooting .................................................................................................... 36
I Common faults & troubleshooting ........................................................................................................ 36
II Main faults & troubleshooting of chassis .............................................................................................. 39
III Common faults & troubleshooting of electrical system ........................................................................ 43
VI Electrical System Diagram of Bulldozer ............................................................................................... 45
 Safety Rules

I General
1. In order to prevent accident, the operator must drive the bulldozer carefully.
2. Please read the Operation and Maintenance Manual carefully before bulldozer operation, and perform
running-in, operation and maintenance strictly according to the Operation and Maintenance Manual.
3. The driver should be specially trained, holding a driver license for operation which is to be approved on
time.
4. Select tools according to the Operation and Maintenance Manual, no overloading operation is allowed.
5. The bulldozer is not allowed to be operated with fault, especially shall be shutdown for inspection and
troubleshooting when with no oil pressure, lower/higher water temperature or under abnormal conditions.
6. For the parts lead sealed, the User is not allowed to remove the seal randomly, the inspection and repair
is only performed by the special maintenance personnel on the special equipments as soon as any fault is found.
7. Do not regulate the safety valve in hydraulic system; the regulation is only performed by the special
maintenance personnel on the special equipments where necessary and the open pressure should be in compliance
with the instructions after regulation.
8. Do not operate the bulldozer when experiencing physical discomfort.

II Safety Rules for Diesel Engine

1. Operator should read the Operation and Maintenance Manual of Diesel Engine carefully before start-up,
operation and application, and perform running, operation, application and maintenance strictly according to the
Operation and Maintenance Manual.
2. The diesel engine is not allowed to be operated under overload, and the idle running should not be over
10 minuets.
3. The lead seal on injection pump shall not be removed randomly where applicable, the inspection and
repair is only performed the special maintenance personnel on the special test bench.
4. Do not operate the diesel engine which is in fault, shutdown and inspect for trouble shooting as soon as
the engine is found with extra low oil pressure or no diesel oil pressure or abnormal noise is found inside the
engine.
5. Lubricant for diesel engine should be L-ECD class oil, or equivalent diesel oil with no less than L-ECD
class, which is not allowed to be instead by general diesel engine oil. Do not mix new, old oils and different oils
for application in order to allow the lubricant performance meeting the application requirements, thus protect the
diesel engine from damage.
6. No personnel are allowed to be close to the rotating parts during diesel engine operation. Do not
disassemble the engine during diesel engine operation; take care for safety during necessary inspection and
regulation.
7. Diesel engine should be against fire, no open fire is allowed to be close to the diesel engine.
8. Cut out oil and air circuits during diesel engine racing, to blowout the engine.
9. Reduce load and slow down rotating speed gradually before diesel engine shutdown, and only the
coolant temperature is lowered under 70℃, the engine should be blowout. Do not shutdown accidentally when
the coolant temperature is over high.
10. When the ambient temperature is lower than 0℃, and when the diesel engine is required to be shutdown

1
and stored for long period, the cooling system should be drained out of cooling water or added by coolant as
cooling liquid, in order to protect the engine components from frost crack
11. As the integral closed radiator has 20 MPa inner pressure, special care should be paid when add cooling
liquid during engine operation, to prevent burn.

III Driving & Operation

1. Check the suspension arrangement and surroundings before entire machine startup, check whether any
person or animal is available between the bulldozer and tools, in order to prevent accident.
2. Do not get on and off the bulldozer or perform inspections and maintenance during operation.
3. Please drive the bulldozer in low speed when crossing a sharp turn.
4. When driving through a railway, throttle down and kickdown, keep the driving direction vertical to the
rail, avoiding rail connections.Do not stop on the railway in any case.
5. The driver should adhere to the Locomotive Safety Regulations. The tractor of bulldozer should be
provided with a rigid connector to prevent collision between tractor and bulldozer.
6. Do not load person or heavy weight on the suspension arrangement.
7. Pivot turn should be performed smoothly and steadily only when the suspension arrangement is lifted to
the top. Only the turning process is finished, the bulldozer is allowed to drive in a straight line and lower down the
suspension arrangement into working position.
8. Do not work when the check chain is unavailable or loose.
9. When the suspension arrangement of bulldozer passes through a trench, pot hole, hill, railway and any
other obstacle, slow down the driving speed, the bulldozer is not allowed to be driven when the body is tilted
excessively and the suspension arrangement touches the ground.
10. Do not lift the suspension arrangement or perform adjustment, parts cleaning or other work under the
blade when safety measures are not available.
11. Pay attentions to personal and property safety when maintain the battery.
12. When the ambient temperature is lower than 0℃, and when the water in diesel engine is required to be
drained out of water, screw off the two water drain plugs at bottom of warm air blower to protect the warm air
blower from frost crack.
13. Protect from burn when add water, drain water, discharge oil or be close to high temperature part of
diesel engine.
14. Before electrical system maintenance, remove the earth cable from battery, in order to protect electrical
equipments from damage or danger.
15. When the driver leaves the cab for a short while, the bulldozer should be in Neutral position (i.e.
disengaged) and lower down the suspension arrangement and blade on ground.
16. Pay attention to the fire protection when checking the fuel oil level and injecting oil.
17. Blow out the diesel engine when the bulldozer is shutdown for long time. Bulldozer should be in
Neutral position when parks on a hill, with brake engaged to lock the mechanism.
18. Pay attention to safety when open/close door and window of the cab, in order to protect personnel from
crushed glass.

2
 Chapter I Configuration & Control

Illustration 1-1
1. Ripper 2. Fuel tank 3. Cab 4. Driver’ seat 5. Shift lever 6. Control console 7. Engine cover
8. Exhaust Pipe Stack 9. Blade 10. Guide roller 11. Track roller 12. Carrier roller 13. Driving frame
14. Driving Wheel 15. Track

Illustration 1-2 Overall Dimensions

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I Overall parameters
Model T120N / TS120N
Overall dominions (L×W×H) (mm) 4535×3135×2900 / 4610×3450×2930
Operating weight (kg) 13000 / 13500
Track gauge (mm) 1860 / 2030
Wheel base (mm) 2502
Ground clearance (mm) 368 / 380
Track width (mm) 500 /720
Grounding pressure (kpa) 51 / 36.7
Gear position Theoretical speed (km/h) / towing force (kN)
First gear 2.4 / 94.3
Second gear 3.5 / 67.8
Third gear 6.1 / 51.5
Forth gear 10.6 / 15.1
First reverse gear 3.8
Second reverse gear 7.0

II Diesel engine
Model of diesel engine LR6A3Z-20
In-line, water-cooled, direct spraying combustion
Type of diesel engine
chamber, exhaust turbo-charging
Cylinder Number – cylinder diameter × stroke (mm) 6-105×125
Nominal power / rotating speed (kw/r/min) 93 / 2000
Fuel consumption (g/kw.h) ≤246
Oil consumption (g/kw.h) ≤1.63

III Transmission system

Main clutch Dry, normally engaged, disc spring hold down
Central drive A pair of spiral bevel gear
Steering clutch Multi-plate dry, float brake
Final drive Two pairs of cylindrical gear, float sealing device

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IV Frame & driving system
Frame type Steel plated welded
Suspension Semi-rigid suspension
Tension and buffer device of guide roller Hydraulic tension, spiral spring buffer
Rolled steel section, single grouser, width: 500/720
Track shoe (mm)
pitch span: 171

V Control system
Oil supply control Handle
Main clutch control Mechanical pedal
Main transmission control Mechanical 4F ＋ 2R
Steering clutch control Hydraulic and mechanical
Brake control Mechanical pedal
Multi-way valve control Control lever

VI Hydraulic system
Type Split
CNB E306 (with
Model CNB E463
Gear booster)
Nominal displacement (ml/r) 63 6
Nominal working pressure (MPa) 16
Oil pump
Rotation direction Left
Type Direct-acting slide valve
Model ZL20E－Q8T－04T
Multi-way Nominal working pressure (MPa) 16
valve Working pressure of safety valve (MPa) 16 to 16.5
Four position: lifting, neutral, lowering, floating
Control position
Three position: lifting, neutral, lowering
Model YZQ-C20/54 35-001
Flow (L/min) 14
Hydraulic
booster Pressure (MPa) 4.5+0.5
Max. pressure in hydraulic system
10
(MPa)
Output flow (L/min) 64
Output working pressure (MPa) 16
Hydraulic
Type Steel plate welded, enclosure
Oil Cylinder
Working liquid CA engine oil, #40 for summer and #30 for winter
Fuel filter Strainer

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 Type Split
Open pressure of bypass valve (MPa) 0.02
Model HSGL02-80/55E-3531-960×590
Piston rod diameter (mm) Ø55
Blade
cylinder Hydraulic oil cylinder inner diameter
Ø80
(mm)
Piston stroke (mm) 960
Model HSGK02-120/63E-2401-218×635
Piston rod diameter (mm) Ø63
Ripper
cylinder Hydraulic oil cylinder inner diameter
Ø120
(mm)
Piston stroke (mm) 258

VII Working units

Type Three tips, fixed, four bar linkage
Cutting depth (mm) 400
Ripper
Lifting height (mm) 485
Number of gear 3
Type Fixed and straight
W×H (mm) 3135×970 / 3450×1060
Lifting height (mm) 894 / 907
Blade
Cutting depth (mm) 400
Cutting angle adjustable (°) 55°
Lifting speed (m/s) ≥0.3

VIII Filling volume unit: L

Fuel tank Light diesel oil to GB252-1994 255

Hydraulic oil tank GA grade to GB5323, 30 for winter and 40 for 80

summer
Lubrication system of diesel L-ECD, 30 for winter and 40 for summer 22
engine

Transmission & rear axle SY1103-77, HL-20 for winter and HL-30 for 17
summer

Final drive (complete)
Carrier roller (complete)
Track roller (complete)
Guide roller (complete)
Water tank
SY1103-77, HL-20 for winter and HL-30 for
summer
#26 hypoid gear oil
#26 hypoid gear oil
#26 hypoid gear oil
Cleaning soft water
20
0.36 (maintenance free )
3 (maintenance free )
0.3 (maintenance free )
22

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IX Instrumentations & electrical system

Illustration 1-3 Instrumentations

1. Water temperature gauge 2. Time-of-use register 3. Oil pressure gauge 4. Oil pressure indicator 5.
Preheat indicator 6. Charge indicator 7. Air filter indicator 8. Cooling water temperature indicator

1. Instrumentation & signal

Instrumentation is mainly applied for monitoring the water temperature, oil pressure, working time and other
working conditions of diesel engine.
Time-of-use register: is to timing after startup of engine and normal operation of generator.
Oil pressure gauge: shows the oil pressure during engine operation to the driver.
Water temperature gage: shows the cooling water temperature during engine operation to the driver.
Signal indications are provided for oil pressure alarm, temperature alarm, charging indication, air filter
warning and pre-heater working indication. For the air filter clog warning sensor switch, the warning vacuum
pressure is 6.2 kpa, and the connection is M10×1 female thread. When pressure is over 6.2 kpa, the air filter
warning lamp is ON, warning the driver to shutdown the machine and to maintain the air filter immediately. For
the oil pressure sensor, the warning pressure ≤is 0.08kpa, when the oil pressure is lower than 0.kpa, the oil
pressure warning lamp is ON, warning the driver to shutdown the machine immediately for inspection and repair.
2. Composition of electrical equipments
The electrical system of bulldozer mainly includes: battery, AC generator, start motor, ignition switch, F/R
lamps, warm air blower, instrumentations and sensors, connecting wires etc.
3. Working principle of electrical system
The electrical system is startup online directly through a 24V start motor, with the system voltage of 24V. It
is a single wiring system with minus earth. Press down the main power switch (knife) firstly to connect the earth
cable of battery, then key-in to turn the ignition switch to gear II. The two batteries are operated in series, and
supply power to the start motor with 24V starting power source. Key off as soon as the diesel engine is startup, to
allow the ignition switch back to working position of gear I, thus the entire bulldozer circuitry is powered by the
generator and the two batteries begin charging.
4. Use & maintenance of battery
(1) The bulldozer is provided with 2 maintenance free lead-acid batteries, which are operated in series and

7
modeled to 6-QA-120. The connecting rod should be wiped clean and connected with electric wire during
installation of battery.
(2) Care & maintenance of battery
The battery is free-maintenance type, avoiding frequent electrolyte adding by the User.
When the bulldozer is stored and not in use for a long period, the battery should be dismounted, and charged
once per month with charging current of 10A and charging time of 14 to 16 hours. The battery should be stored
under charge-completed condition, or the long time storage of battery under electricity-lack condition will reduce
the battery life greatly.
Often clean and keep the battery shell roof clean and dry to prevent electricity leakage and to ensure a well
contact between the battery and the connector. Clean out the oxides; apply petrolatum on the battery terminals and
clamp connectors to against corrosion.
Do not cover the battery with tools or other metal works to avoid short circuit and protect the battery from
damage.
(3) Cautions for battery operation
The ignition switch should be maintained at gear I position during diesel engine operation, to allow the
generator supplying electricity to the charging battery.
Do not use the lighting lamps or other electrical equipments for long period after the diesel engine is
shutdown, to protect the battery from discharge which will influence the next startup. The driver should cut off the
main power switch (knife) when leaves the bulldozer. Do not operate the start motor when the battery is seriously
lack of electricity (i.e. electrolyte density is lower than 1.175), or the battery and the start motor will be damaged.
Now, charge the battery before application.
5. Operation & maintenance of generator
The bulldozer is provided with a JFZ2521 integral AC generator, which should be maintained once after each
1000 hours operation of bulldozer. Clean and make the slip ring smooth and tidy. Inspect and replace the carbon
brush when it is seriously worn. Lubricate the bearing with lithium or sodium base grease.
Cautions for generator operation: (1) Do not apply positive-to-ground ignition method to inspect whether the
generator generating power, in order to protect the rectifier diode from damage. (2) V-tape of generator should be
properly tensioned, generally 10 to 15 mm depth can be achieve by pressing the center section of tape.
6. Operation & maintenance of start motor
For the start motor, the model is QDJ27H, rated voltage is 24V, and the rated power is 5.5 kW.
Inspect the commutator and dynamo brush of generator once after each 1000 hours operation of bulldozer,
and use the fine emery paper to grind the serious burn surface of commutator. The dynamo brush should be
replaced when it is over worn or cracked. Lubricate the rotating parts e.g. shaft housing.
The start motor is a short-time duty type, each start should not be over 10 s, time interval between two
startups should be no less than 2 min, when the engine is failed to be startup in sequence for 3 times, stop starting
operation and check out the fault reason. Do not start the engine continuously or for long time period, to protect
the engine and battery from damage.
7. Starter relay
The starter relay (model JN3A-24V) controls the on and off action of electromagnetic switch for start motor
in coordination with the ignition switch, to decrease the current through the contact of ignition switch, thus
avoiding burn through and prolonging using life.
8. Warm air blower assembly
This model is provided with a roof mounted internal-external double circulation type ventilation and heating
device, for which two level speed are available, the high level for large air and heating values while low level for
small air and heating values. The driver may select the levels. Switch between internal and external circulations is
achieved through a switch on upper air outlet of the blower. The air introduced into the Cab from outside is always
cleaned through the air filter in the Cab.
During winter heating, the heating water inlet valve installed on the cylinder cover of diesel engine is always

8
open. Now, the circulating water of diesel engine is used as heating source. In order to drain the water in the warm
air blower thoroughly and protect the blower from frost crack, keep the 2 water drainage plugs at the blower
bottom are removed after the diesel engine is drained out of water in winter to drain the residual water until the
machine is startup at next time. Heating is not required in summer, close the heating water inlet valve to avoid
heating water circulation through the warm air blower; now open the warm air blower switch, adjust the air outlet
to direct the air flow to required direction for ventilation. Furthermore, the warm air blower assembly is also
provided with a cab roof lamp for cab lamping via the switch on lamp.
9. Wiper
The wiper assembly (model ZD2230) composed by a single-speed wiper motor (24V), wiper swing lever and
wiper is used to clean the rain on front windshield improving operator’s visibility in severe environment.
10. Switches
(1) Main power switch: model JK861, is a knife type mechanical switch, which can connect or disconnect
the earthing circuit for the entire bulldozer, up for disconnection and down for connection.
(2) Ignition switch: model JK423K, is provided with two directions, turn to level I in clockwise to connect
the entire bulldozer power supply. Turn the switch to level II for starting the system, release the switch
immediately after the diesel engine is operated, allowing the key re-back to level I position and entire bulldozer
under working condition.
(3) Five-wire rocker switch: is provided with main lighting switch, head lamp changeover switch, working
lamp switch, horn switch and pre-heating switch; when press down any switch, the corresponding indicator is ON
showing the switch is under operating condition.
11. Fuse box
The fuse box (model BX508) is provided with 8 levels to protect the electrical equipments, the dimension
and strand numbers (10A per strand) should be in conformity with the wiring diagram, inspect the fuse for burn
out in time and clear the fault. Do not change strand number, specifications and material of the fuse, or the
electrical equipments may be damaged.
12. F/R lamps: are mainly used for lighting the road conditions in front or at back, which should be protected for
completeness.
13. Working lamp socket
A working lamp socket (model DJ103) is provided on the side plate of battery case, which is mainly used for
lamp installation during inspection at night.

9
 Chapter II Operation of Bulldozer
I Dozing specification
1. Before diesel engine startup, shift lever and power output control lever as well as the distributor control
handle should be at Neutral positions.
2. Before diesel engine startup, keep the suspension arrangements at lowest positions. Inspect the external
fasters, e.g. bolts and nuts to prevent the looseness.
3. Before transporting operation of bulldozer, lift the blade off ground and lock the blade lift cylinder with
a lock pin.
4. Operator is not allowed for approaching the rotating parts or perform disassemble, inspection or
adjustment after the diesel engine is startup.
5. Do not operate the diesel engine which is found with extra low oil pressure or no diesel oil pressure or
abnormal noise is found inside the engine. Shutdown the bulldozer emergently once the situation mentioned above
is found for fault clearing, and do not re-start the engine before troubleshooting.
6. Pay attention to fire protection while checking the fuel oil level and injecting oil.
7. Repair the leakage point on oil tank and tube, while cleaning the oil spots.
8. Bulldozer is operated at night only when provided with complete lighting installations. During dozing
process, work field should be provided with sufficient lighting installations.
9. The tractor of bulldozer should be provided with rigid connector, to prevent collision between tractor
and bulldozer.
10. Throttle down when the bulldozer connects with tools.
11. Observe the driving course and inspect the tack for tools and other foreign matters before start.
12. Do not lean on the door, or stand on the swing or under blade bar, or get on and off the bulldozer during
driving.
13. Do not drive the bulldozer horizontally on a down slop. The bulldozer is not allowed to work on the
slope with a larger than 20°.
14. Shift to lower gear when driving cross any bridge and culvert.
15. When driving through a railway, throttle down and kickdown, keep the driving direction vertical to the
rail, avoiding rail connections. Do not stop on the railway in any case.
16. When the bulldozer is used to fill and level up trench, the blade should not protrude the slope edge, in
order to protect the bulldozer from sliding down the slope.
17. Before diesel engine startup, the distributor handle should be at neutral position.
18. Distributor handle shall be able to return to Neutral position from “lift” and “drop” positions
automatically, or return the handle back to neutral position manually.
19. Operator should always inspect the high pressure tube for completeness, and blow out the diesel engine
and lower down the blade (or ripper) for repair when the tube is cracked.
20. The blade is not provided with reliable support, the operator is not allowed to observe and work under
the blade.
21. The hydraulic oil pump is not allowed for operating without oil when the hydraulic system is without
oil.
22. Do not remove any tube when the hydraulic system is with pressure.

10
 23. The driver should lower down the blade or ripper to ground when leaves or shuts down the bulldozer.
24. Stop and store the bulldozer on level ground as much as possible; or engage gear I (bulldozer head
towards up-slope) or reverse gear I (bulldozer head towards down-slope) via the locking pin of stop brake when
the bulldozer stops on slope. Release the main clutch before driving on slope, and release the brake and steering
handle after the clutch is driven.
25. Pay attention to protection against burnt when remove the water tank cover for water makeup. Water
tank should not be uncovered before diesel engine is cooled, and the cover should be ease off firstly to release
pressure before completely removal. Do not open the water tank cover and water drainage switch immediately
after diesel engine blow out, and the water temperature should be lower down under 70℃ before water tank cover
removal and water drainage.
26. Cut off the main power switch before electrical system maintenance in order to protect the electrical
equipment from damage or danger.

II. Fuel, lubricant and cooling water

1. Fuel
Diesel engine applies light diesel oils for which the national standard GB252-1994 specifies indexes. Select
the number of light diesel oil to the ambient temperature, see table 2-1.
Table 2-1 Diesel Oil Selection to Temperature

Ambient temperature ≥4℃ ≥-5℃ -5℃ to -14℃

Oil number 0 -10 -20

In order to minimize failure rate and prolong diesel engine life, please observe the fuel cleaning rules strictly,
ensure that oil tank is of exclusive use and cleaned, applying airproof oil adding method, the adding oil is settled
for 3 to 7 days before application and taking up level diesel oil in the container.
Pay attention to cleaning during fuel transportation, adding, using processes, in order to prevent contaminant.
Note: Application of fuel which is not settled and filtered may cause tank contaminant, rapidly blocking the
filter, wearing out axial piston pair and oil injection assembly of fuel pump / blocking oil nozzle,
deteriorating engine performance etc.
2. Lubricant for diesel engine
Lubricant for diesel engine should be L-ECD class oil, or equivalent diesel oil with no less than L-ECD class,
which is not allowed to be instead by general diesel engine oil. Correct application o L-ECD class oil and
conformity with the oil using rules may prolong the using life of diesel engine, avoiding cylinder scraping, piston
seizure and other failure.
#30 L-ECD class oil by Dalian Petrochemical, #30 & #40 L-ECD class oils and #30 L-ECD lubricating oil
by Shanghai Gaoqiao Petrochemical Co., #30 & #40 L-ECD lubricating oils by Great Wall Lubricant Co., #10
thickened L-ECD class lubricating oil for low-charged diesel enginee, and lubricating oils to SAE standard are
optional as the lubricating oil for diesel engine. Lubricant should be selected to the temperature during application,
see table 2-2.
Table 2-2 Lubricating Oil Selection to Temperature

Oil number 5W/30 15W/40 40 40

Ambient temperature -25~30 -15~50 10~30 5~50

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3. Oil for hydraulic system
For the hydraulic system, different lubricating oils are selected as the system oil to the weather, see table 2-3.
Table 2-3 Lubricating Oil Selection to Weather

Oil specification Applicable standard & oil number Using time

CA diesel engine oil #30 to GB5323-85 Winter

CA diesel engine oil #40 to GB5323-85 Summer

4. Driving system
Lubricating oils for track roller, carrier roller and guide roller, see table 2-4.
Table 2-4 Lubricating Oil for Driving System

Oil specification Applicable standard & oil number

Hypoid gear oil #26 to Q/SY11069-77

5. Gear oil
Gear oils for transmission, central drive and final drive of the bulldozer, see table 2-5
Table 2-5 Gear Oil for Drive

Oil specification Applicable standard & oil number Using time

Gear oil HL-20 to SY1103-77 Winter in the North
Gear oil Hl-30 to SY1103-77 or 80W/90 to ZBE34006-87 Summer

6. Grease
Different greases are applied to different parts, see table 2-6.
Table 2-6

Grease specification Applicable standard & grease number Using position

Calcium base grease GB492-77 ZN-4 Generator, bearing
Sodium base grease GB491-77 ZG-4 Others

7. Cooling water
Cooling water for diesel engine should be clean soft water, e.g. river water, rain water, snow water etc. The
hard water e.g. spring water or other mineral water used as cooling water where applicable should be softened
before application. (Dissolve and add ammonium nitrate directly to the proportion that 3-4 g ammonium nitrate
for 1 liter water).
Antifreeze fluid with low ice point may be used as coolant in winter, and see table below for the antifreeze
fluid proportion.
The volume of antifreeze fluid differs to the temperature, so the adding quantity to cooling system should be
less than the system capacity by 5-6%.

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 Table 2-7 Antifreeze Fluid Proportion & Ice Point

Ice point Alcohol-water type Glycerinate-water type Glycol-water type

℃ Alcohol weight (%) Glycerinate weight (%) Glycol weight (%)
-5 11.3 21
-10 19.5 32 28.4
-15 26.0 43 32.8
-20 31.0 51 38.5
-25 35.1 58 45.3

Note: Glycol-water type antifreeze fluid is noxious. Pay attention during operation and protect mouth.
Glycol’s boiling point of 197.4℃, then the water in antifreeze fluid is evaporable. Therefore, make up water
after a certain period. Alcohol in the alcohol-water type antifreeze fluid is with low boiling point and is evaporable,
should be added after using for a certain period.
Scale which may be produced in the cooling system after a period using of lubricating oil should be cleaned
out regularly. Generally, the cleaning agent is made by adding 750g sodium hydroxide or 150 g kerosene into 10 L
water and is injected into cooling system for cleaning. Cleaning process: operate cleaning agent in diesel engine
for 5 to 10 min. and shut down the machine when cleaning agent is heated, allows cleaning agent staying in diesel
engine for 10 to 12 hours before re-start the engine, operate the engine with middle speed for 10 to 15 min. and
drain out the cleaning agent, inject water again and operate the engine with middle speed for a while, then drain
out water. Repeat the process above for 2 to 3 times for cleaning the large amount scale.
Main Filling Volume unit L

Fuel tank
Hydraulic oil tank
Diesel engine lubricating
system
Transmission & rear axle
Final drive (complete)
Carrier roller (complete)
Track roller (complete)
Guide roller (complete)
Water tank
Light diesel oil to GB252-1994, 0 for summer and -20 255
for winter
CA grade to GB5323 #30 for winter and #40 for 80
summer
L-ECD class, #30 for winter and #40 for summer 22
SY1103-77 HL-20 for winter and HL-30 for summer 11
SY1103-77 HL-20 for winter and HL-30 for summer 20
Meddle load gear oil or #26 hypoid gear oil 0.36 (free-maintenance)
Meddle load gear oil or #26 hypoid gear oil 3 (free-maintenance)
Meddle load gear oil or #26 hypoid gear oil 0.3 (free-maintenance)
Cleaning (soft) water 22

III Driving & control

Personnel who drive and operate the bulldozer should understand the positions and functions of all the
control mechanisms, as well as start and drive the bulldozer carefully to prevent accident.
1. Startup of diesel engine
(1) Preparation before startup:
i Open the oil outlet on fuel tank.

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 ii Put the shift handle into Neutral position, control handle of multi-way valve in “neutral” position
iii Inspect the cooling water as well as the adding oils for rear axle. Transmission box, final drive and
diesel engine to the standards, and check whether the diesel oil level is between the scales.
iv Vent the air in oil tube circuit before start a new, or repaired or long time shutdown diesel engine, to
allow a smooth startup.
Ventilation method: release outlet screw on diesel engine filter, pump the oil by a hand pump until there is
no blister, vent out air in tube from diesel engine to oil filter, then crew on the outlet on diesel oil filter
while screw off the outlet screw on oil injection pump. Vent air until fuel is free of blister flowing the
same method, then screw on the outlet screw tightly.
v Inspect electric circuit for reliable connection, check whether the battery is fully charged.
(2) Startup
i Throttle control handle of oil injection pump at middle or low gear, the kill button returns to oil supply
position.
ii Connect the main power switch.
iii Step on the main clutch pedal, allow the main clutch disengaged.
iv Key-in the electrical switch and allow the key turning to level II to start the diesel engine, turn the key
back to level I after then engine is startup.
v Diesel engine may be started without any auxiliaries successfully when the ambient temperature is
above -10℃, while be started after adding hot water under low temperature in winter.
vi Starter’s working time should not over 10 s at each application. The minimum start interval should be 2
min. If the startup is failed after three times operation, find out reasons and resolve problems before re-start.
2. Operation of diesel engine
(1) Throttle down immediately after the diesel engine is startup and allow the engine idling, and inspect all
parts operation conditions of the engine then.
(2) Inspect the electrical instrumentations for correct operation.
(3) Increase/decrease speed and load of diesel engine slowly, especially for the diesel engine which is just
started, do not press the accelerator rigidly.
(4) Do not drive until the water is heated above 40℃ in winter.
(5) Do not operate the diesel engine with full loaded immediately after startup, when the water temperature
achieves 60℃, inspect for any abnormal noise and always observe the oil pressure warning indicator.
3. Bulldozer driving and operation
(1) Startup
Check whether all instruments, operating handles and pedals are normal and whether the diesel engine
operates normally.
i Release locking pin of brake pedal to return parking brake pedal.
ii Press the clutch pedal to bottom. Place the gear lever in necessary position. If the gear can not be put in
position and resistance can be felt at gear of gear box, release the clutch slowly and then press it quickly. At this
moment, put into the gear. See illustration 2-1 for gear position of gear lever.

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 Illustration 2-1 Gear Position of Gear Lever
iii Open the throttle and release the clutch pedal rapidly and stably to start up the bulldozer stably. It is
prohibited to release clutch pedal too quickly to avoid parts from damage caused by impact.
(2) Driving
When bulldozer is running, the driver is not allowed to put his feet on main clutch pedal and brake
pedal to avoid the clutch from being in semi-engaged state and the brake from slight braking. When the
bulldozer passes pits and trenches, it is not allowed the main clutch to keep in semi-engaged state to reduce
speed, since this will greatly wear the friction plate of clutch. Let off the gas or place in lower gear position
to pass. Change the gear when the clutch completely disengaged and the bulldozer stops.
During steering of bulldozer, pull the steering arm (right arm for turning right and left arm for turning left)
quickly and stably backwards to the bottom. After steering, return the steering arm quickly and stably. Rapid
steering shall be completed at low speed. At this moment, pull the steering arm to the bottom quickly and stably
and press the brake pedal at the same side to turn right or left rapidly. After steering, release brake pedal first and
then the steering arm. During straight running, driver shall use the steering arm and brake to the minimum to
avoid clutch and brake linings from wear.
Rapid steering can only be completed at the low gear I or the gear II. Rapid steering is prohibited. When
bulldozer makes a turn on soft soil and slip forwards, release immediately the brake pedal and steering arm to
allow bulldozer to run forward in a short distance. Push lever shall be and press the brake pedal again.
When bulldozer operates, select gear position and throttle according to load to operate the bulldozer at full
load or nearly at full load. In this way, the production efficiency of bulldozer can be improved and oil
consumption can be lowered. Operation at overload status is bad for entire machine because of reduction of
revolution, overheating and serious smoke generation of diesel engine. When bulldozer overloads, change into
low gear or reduce load. Never handle overload by disengagement and engagement of clutch.
Watch operation of diesel engine, all instruments and parts at any time when bulldozer is in working
condition. In case of any problem found, stop the bulldozer to check and solve them.
When bulldozer stops temporarily, the driver may not shut down diesel engine, put the gear lever in the
neutral position and let off the gas to allow engine to idly run, but the time is generally less than 10 minutes.
If the idling time of bulldozer is too long, put the flameout rod to shut down the diesel engine. Do not make
the throttle full open suddenly. When the vehicle is parked on a slope, press the brake and use locking devices
rather than putting the gear in neutral position.
(3) Operation
When bulldozer dozes, select the gear position according to situation of soil. Generally, select the gear I.
After put into the gear, put down the bulldozer blade slowly to make it touch the ground surface, engage the clutch
stably, run the bulldozer forwards. Meanwhile, operate the blade to cut into the soil gradually. When the dull
sound can be heard from diesel engine (revolution of diesel engine reduces and more smoke generates), lift
slightly the blade to reduce operating load of bulldozer and restore normal operation.

15
 1) Dozing operation requirement:
i Speed and throttle: The speed of bulldozer shall be slow, since fast speed is difficult to control and hard
to level the ground. Generally, moderate opening of throttle are adopted to spade
ii Put down bulldozer blade to spade: Put the operating lever of controller in “neutral” position to “drop”
position. At this moment, the bulldozer blade is stopped at the place where the ground is touched to be ready for
spading.
iii Nonstop dozing: Bulldozer moves forwards slowly, simultaneously press the handle slightly to force the
blade into the soil and put the handle into “neutral” position after necessary depth is reached to move forward with
soil. The blade is easy to cut into the soil during running. Cut the blade slowly into the soil. Press slightly the
handle by means of “inching” to cut the blade into soil slowly. The blade may be broken if the blade is cut into he
soil too fast and the ground surface is difficult to level.
iv Adjust the blade load according to sound of diesel engine: During spading the sound from diesel engine
can reflect resistance of blade. Notice any abnormal sound. Push slightly the handle by means of “inching” and
adjust lowering and lifting of blade at any time to run the bulldozer stably.
v Adjust the cutting point of blade: bulldozer bumps with the ups and downs of terrain and the cutting
angle varies with bending or lifting of bulldozer body. Thus, Notice lifting or lowering of water tank of diesel
engine during operation. Judge the terrain according to lifting and lowering of machine head and adjust the cutting
position of blade timely.
vi Operate lifting and lowering of bulldozer blade: Since ground surface may be rough and soil is soft and
hard, loose and compact in different parts before the bulldozer, driver shall adjust the blade according to terrain
and soil condition to allow blade to be on the necessary cutting position after the bulldozer arrives at this section.
vii Doze at slope or in pit: If a slope is before bulldozer, when it is estimated can remove this slope, lower
slightly the blade at the moment of arrival to cut into the slope and level it. If slope is too high, lift the blade a bit
to avoid blade from failing to pass because of excessively deep cutting. If a pit is before the bulldozer, lift slightly
the blade at the moment of arrival to push some soil before blade arm into the pit and fill up the pit.
viii use the operating handle and throttle together: if the bulldozer suffers from large resistance and the
diesel engine overloads, i.e. the revolution reduces sharply and black smoke discharges from exhaust pipe. At this
moment, lift the blade immediately to reduce the load and step on the gas to increase power of diesel engine and
pass such obstacle zone.
ix Distance from spading point to stacking point: the distance from spading point to stacking point is
generally about 30 m. If such distance is too long, push to transport stage by stage to improve efficiency.
When bulldozer carries the soil, run along a straight line to allow the soil which leaks from both sides of
blade to form soil ridge along both sides and reduce loss of soil.
After bulldozer carries soil to the dumping point, pull the operating handle to “lifting” position, and lift the
blade, so that the soil falls from the blade.
During dumping, lift the blade high and run a long dumping distance to spread the soil evenly and the track
of bulldozer will compact the thin soil layer to have the effect of compacting in layers.
After the bulldozer dump all soil, push the operating handle to the “neutral” position, fix the blade in
dumping position and return the spading starting point at high speed in reverse gear position to shorten returning
time. If bulldozer is used to level the bumpy ground surface where soil is loose, make blade touch the ground
surface and put the operating handle in “floating” position to run in reverse gear shift to level the ground surface.
2) Dozing precautions
This bulldozer is applicable to dozing, short distance soil handling, site leveling, filling and other works of
projects of class I ~ II soil. For class III or above soil, soil shall be loosened by ripper or by other methods before
the bulldozer is used.
When bulldozer operates, never make sharp turning and turns with large radius as far as possible.

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 Avoid bulldozer from spading as far as when its body tips.
Do not allow to operate at steep slope. When bulldozer tips, oil in oil pan of diesel engine collects at one side
and the lubrication effect is poor, so that relevant parts of diesel engine may be damaged
When bulldozer encounters large resistance during running forwards, do not force it pass the obstacle by
pressing the clutch pedal and release suddenly.
It is not allowed to keep the operating handle of distributor in “lifting” or “drop” position, or else high
pressure hose may easily burst and parts of hydraulic system may be damaged easily.
When many dusts are in dozing yard, shorten the technical maintenance cycle specified in operation and
maintenance instruction of diesel engine according to actual situation. Special attraction shall be given to cleaning
of air filter and oil filter to prolong service life of diesel engine.
4. Stop and shutdown of diesel engine
When bulldozer stops and diesel engine runs, press main clutch pedal, and then press brake pedal. After the
bulldozer stops completely, put the gear lever in neutral position. Lower the dozing blade on ground, release pedal
and let off the throttle to run the diesel engine idly. If bulldozer stops on slope, in addition to above operation, lock
the brake locking pin. If bulldozer stops on the slope for a long time, place an object under the track to prevent
from slipping and serious accidents caused by slipping.
In case of emergency stop, press main clutch pedal and simultaneously put the hand throttle in the lowest
position, and press brake pedal quickly to stop bulldozer as soon as possible. Put the gear lever in neutral position
and release the pedal.
If bulldozer will stop for a long time, after it stops completely, adjust the revolution of diesel engine at 600 ~
800 rpm, and diesel engine runs without load for several minutes. After the temperature of cooling water become
lower than 70℃，pull out the flameout rod to stop oil supply of injection pump of diesel engine. In this way, the
diesel engine shuts down,
Never shut down when the coolant temperature is too high or even the coolant in radiator boils.
It is not allowed to shut down the diesel engine by closing switch of diesel tank to avoid the diesel engine
from difficult startup caused by air entering in oil lines. When ambient temperature is below -5℃, without
antifreeze fluid, the cooling water shall be drained timely to prevent machine parts from crack as a result of
freezing.

17
 Chapter III Running-in and Technical Maintenance

I Running-in
Before using, running-in shall be carried out on the bulldozers newly leaving factory or after overhaul in
accordance with the running-in procedures specified in the Manual. If a bulldozer is put into use without
running-in, the components and parts shall be heavily worn or even cause faults, which will greatly shorten the
bulldozer’s service life.
Operator shall not carry out running-in on the bulldozer until he has been familiar with the control and use
methods.
1. Preparations prior to running-in
(1) Prior to running-in of new bulldozer, inspect the completeness of all parts, to see whether they are in
shortage or damaged.
(2) Inspect the tension of the bulldozer’s external fasteners, and special attention shall be paid on the bolts
or nuts in external important connecting parts, to see whether they are loose, tighten and lock if necessary.
(3) Inspect the track’s tightness to see whether it is in conformity to the specifications.
(4) Add lubricating oil, lubricating grease, fuel, hydraulic oil and cooling water to the bulldozer to specified
values, and inspect for the oil leakage or water leakage, and solve leakage if any.
(5) Before starting, place all control levers in their neutral positions, and inspect whether the travels of all
control devices are standard.
2. Content and procedures of running-in
(1) Idling running-in of diesel engine
The idling running-in of diesel engine lasts for 15 minutes in total. In the first 5 minutes, the engine operates
at idle speed, and then the rotating speed is increased to the middle throttle for 5 minutes’ operation, finally the
throttle is pushed to its maximum position for 5 minutes’ operation.
Note: During the idling running-in, it is required to listen to and observe the diesel engine’s
conditions at any time, pay attention to the water temperature, oil temperature, oil pressure, oil
leakage, water leakage, air leakage etc., especially to abnormal noises, and find out the faults’ reasons
and eliminate if any.
(2) Running-in of hydraulic system
The running-in of hydraulic system shall be carried out at the diesel engine’s rated rotating speed of 2200
r.p.m.. Push the multi-way lever and repeat 20 times, the blade or ripper (for the type equipped with ripper) shall
go up and down steadily, and when lifting ends, the multi-way lever shall be able to return to the “neutral”
position automatically.
Note: Inspect for the oil leakage in all oil pipe connections and all connecting parts during the
running-in, make sure whether the air is absorbed in according to the foam in the hydraulic oil tank,
and eliminate the oil leakage or other faults timely when found.
(3) Deadhead running-in of bulldozer
The deadhead running-in of bulldozer lasts for 5 hours in total.
Deadhead running-in time of bulldozer

Gear I II III IV RI RII

Time (mins) 60 60 60 60 30 30

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 During the deadhead running-in of bulldozer, it is required to carry out smooth rotation at each gear for at
least 10 times, and for the deadhead running-in time at gear I, three times of single breaking sharp turn to the left
and right shall be carried out in addition.
Note: During the deadhead running-in, attention shall be paid to the operating conditions of all parts
and working conditions of all instruments of the bulldozer, and eliminate the abnormal conditions or
faults if any.
(4) The bulldozer’s load in on-load running-in shall comply with the specifications in the following table,
normal technical maintenance shall be carried out in accordance with specifications, and the running-in will last
for 54 hours.

Running-in time at each gear (hrs)

Running-in stage Traction load (KN)
I II III
1 15 3 3 3
2 20 5 5 5
3 30 15 15 /

Attention shall be paid to the following during running-in:

(1) During running-in, maintenance and lubricating shall be carried out in accordance with
specifications and adjust if necessary.
(2) During running-in, it is required to listen to and observe the rotating conditions of all systems and
instruments of bulldozer, and eliminate abnormal conditions timely if any.
(3) After running-in, technical maintenance shall be carried out in accordance with specifications.

II Technical Maintenance after Running-in

Overall technical maintenance shall be carried out immediately after the bulldozer’s running-in and all
lubricating oil shall be replaced.
1. Inspect and clean the diesel engine in accordance with the operation manual for LR6105 series diesel
engine.
(1) Clean the oil pan and replace engine oil.
(2) Replace the filter element of engine oil filter.
(3) Drain out the engine oil in the injection pump and speed regulator, replace & add new oil and clean the
diesel engine’s filter in accordance with specifications.
(4) Clean the oil basin of air filter, replace and add new oil to the specified standard.
(5) Drain out the cooling water, and clean the cooling system with clean soft water.
(6) Inspect the nuts on the cylinder cover, inspect and adjust the valve clearance, and tighten the screws and
nuts in the diesel engine part etc..
2. Technical maintenance of bulldozer after running-in
(1) Drain out the gear oil in the gearbox, rear axle and final drive when it is still hot, clean all drain plugs,
and then add appropriate amount kerosene or diesel oil, traveling for 1 ~ 2 minute(s) at gear I or reserve gear I
(not to turn around as far as possible), drain out the cleaning oil when it is still hot, and then add gear oil to the

19
specified oil level.
(2) Inspect and tighten the screws and nuts at all connecting parts, especially for the tightening of nuts on
the diesel engine cylinder cover, front/rear supporting, connecting parts of gearbox and rear axle, universal joint,
thrust wheel and the connecting parts of frame and rear axle.
(3) Inspect and adjust the clearances of main clutch and small brake, the free travels of main clutch pedal,
rotating pull arm and braking pedal, as well as the axial free movement of driving wheel and tension of track shoe.
(4) Inspect the electrical system’s working conditions.
(5) Inspect and add lubricating grease and lubricating oil.
(6) Elimination of faults found during the bulldozer’s running-in, adjusting and eliminating methods as well
as preliminary conclusions of problems dealt with shall be recorded in the bulldozer’s technical file for reference.
A bulldozer shall not be put into use until running-in and technical maintenance has been carried out.

III Technical maintenance of entire machine

Proper technical maintenance can improve the bulldozer’s reliability and prevent fortuitous accidents in
operation.
Technical maintenance of bulldozer is to carry out periodical inspections on all components and parts and
mechanisms regularly, to see whether they are clean, have sufficient lubricating oil, their motions in normal
condition and make necessary adjustments, thus to avoid premature wear and accidents, to extend the bulldozer’s
service life, improve working efficiency and reduce maintenance costs. Operator shall strictly abide by the
following technical maintenance rules:
1. Shift technical maintenance means to carry out maintenance every 10 ~ 12 hours’ operation, not after a
day’s operation. Clear away the oil sludge and dust inside and outside the bulldozer, if not, it will make the parts’
wear get worse in one hand, and in the other hand, it may cause more severe accidents as a result of its covering
and difficulty to find out existing faults. Clean the oil sludge and dust in the diesel engine and drive part, and
special attention shall be paid on all oil filling ports, lubricating points and oil cups, avoiding bringing the sewage
into the inner cavity of all parts.
Clear away the straws, clods and other sundries in the traveling parts.
2. After every 10 ~ 12 hours’ operation, inspect and tighten the screws and nuts in all parts.
3. After every 10 ~ 12 hours’ operation, inspect the coolant in the water tank, and fill up if insufficient.
4. Inspect whether the engine oil in the oil pan and injection pimp is sufficient, and add if necessary. Note
whether there is water is the oil pan, and diesel in the gearbox, rear axle, final drive and injection pump, and find
out reasons and eliminate abnormal conditions if any.
5. Inspect the track’s sagging degree, and make adjustments if necessary.
6. Inspect whether the electric instruments are in normal condition and all control mechanisms in good
condition, the travel (free total travel) is standard and the hydraulic control levers in normal working condition.
7. Add lubricating grease to all lubricating points.
8. Maintenance of storage battery connection: prior to the maintenance of storage battery connection,
switch off the engine and inspect whether the storage battery connection is clean, clean it with hot water if dirty,
and then paint with petrolatum.
9. Clean the settlings in the sediment bowl of diesel engine.
10. Inspect the tightness of fan belt and make adjustments if necessary.
11. Add lubricating grease to the water pump bearing.

20
 12. Inspect for the deposited oil in the reversing chamber and drain it out if any.
13. Inspect the free travels of main clutch, rotating pull arm and braking pedal, and make adjustments if
necessary.
14. After every 240 ~ 250 hours’ operation, clean the oil pan and replace the stuffing of engine oil tank
cover.
15. After every 240 ~ 250 hours’ operation, clean the engine oil filter and replace the engine oil filter
element.
16. After every 240 ~ 250 hours’ operation, inspect the injection pump pressure and spray quality.
17. After every 240 ~ 250 hours’ operation, inspect and adjust the oil supply advance angle of injection
pump and replace lubricating oil.
18. After every 240 ~ 250 hours’ operation, inspect and adjust the inlet and outlet valve clearances.
19. After every 400 ~ 500 hours’ operation, inspect the tightness of cylinder cover bolts, screw the
tightening torque to the specified torque value if insufficient, and inspect and adjust the inlet and outlet valve
clearances.
20. After every 400 ~ 500 hours’ operation, wash the diesel tank and the diesel. Clean the diesel engine
filter and replace the straining filter element of diesel engine filter.
21. After every 400 ~ 500 hours’ operation, remove the generator, dismount and inspect whether the stator
is in good isolation, clean the bearings, replace lubricating grease and replace the oil seal if necessary.
22. After every 400 ~ 500 hours’ operation, when the bulldozer finishes working and the lubricating oil is
still hot, drain out the lubricating oil in the gearbox, rear axle, end drive, and then inject kerosene or diesel,
traveling 5 minutes forward & backward at gear I or reserve gear I, drain out kerosene or diesel after cleaning,
clean all magnetic plugs and then add new lubricating oil.
23. After every 400 ~ 500 hours’ operation, inspect the hydraulic oil tank and the engagement of large
conical gear.
24. After every 400 ~ 500 hours’ operation, inspect the surface wear of the interconnecting rod of crankshaft
main axle etc., and polish it if necessary.
25. After every 960 ~ 1000 hours’ operation, dismantle the cylinder cover, clean the deposit carbon in the
valve and abrade the valve.

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 Chapter IV Major Structural Principles

I Diesel engine
1. Diesel engine
LR6A3Z-20 diesel engine is a high quality product with features of energy saving, environmental protection,
high efficiency and low energy consumption, and in order to bring power efficiency into full play and extend the
usage life, please use and maintain the diesel engine strictly according to the LR6105 Diesel Engine Manual
delivered with the machine.

Illustration 4-1 LR6A3Z-20 diesel engine

1 - Oil transportation pump; 2 - Injection pump; 3 - Water pump; 4 - Diesel filter; 5 - Diesel settling device;
6 - Centrifugal oil filter;7 - Oil filter

II Transmission system
1. Main clutch
Cautions for maintenance:
(1) Inject grease three to five times to the two places of B showed in the illustration every 8~10 working
hours of bulldozer.
(2) Clean the grease at the oil cup place after maintenance to prevent the slipping of clutch. If there is
grease (lubricating oil) on friction plate, rotate the crankshaft and clean with kerosene or gasoline, and then
unscrew the plug C at the bottom of the clutch housing to release the dirty oil.

22
 Illustration 4-2 T120 clutch
1 - Flywheel; 2 - Driven plate assembly; 3 - Center plate; 4 - Pressure plate; 5 - Disengaging lever bolts;
6 - Disk spring; 7 - Adjusting nut; 8 - Lock nut; 9 - Disengaging lever; 10 - Release bearing assembly;
11 - Clutch housing; 12 - Main clutch shaft; 13 - Fore bearing; 14 - Release fork; 15 - Small brake;

2. Small brake
Adjustment of small brake:
Press down the main clutch pedal until the main clutch is completely disengaged when the clearance between
the disengaging lever plane at the end of the main clutch and the release bearing is 2.5~3.0 mm, i.e. the free stroke
of the pedal is 20~40 mm, at that time, as shown on illustration 4-3, release nut A and turn the bolt B to make the
clearance △=4~ 5 mm, and then lock the nut A.

Illustration 4-3 Smdall brake of bulldozer

23
3. Gearbox
Note: check if the axial clearance of bearings is 0.05~0.1 mm during the assembling and overhaul of the
gearbox, increase or decrease the thickness of one set of adjusting shim for adjustment if the clearance exceeds the
scope.

Illustration 4-4 Gearbox

1 - Shim of adjusting the axial clearance of the two shafts;
2 - Shim of adjusting the center drive imprints;3 - Lock shaft; 4 – Lock pin

24
4. Rear axle

Cautions during using:

The rear axle is connected to the lubricating oil of the gearbox, and the bears and gears apply splash
lubrication. Check regularly whether the oil level is within the standard scope and add oil if necessary during
using, and clean the lumen.

Illustration 4-5 Rear axle

1 - Brake; 2. - Steering clutch; 3 - Large conical gear of center drive; 4 - Large conical gear shaft;
5 - Main shaft; 6 - Disengaging lever of steering clutch; 7 - Brake leverage assembly; 8 - drain plug

5. Center drive
Cautions of adjustment:
(1) The axial clearance caused by the wear of the second shaft cone bearing 1 will result in the changing of
the mounting distance and damage the normal engagement of the gear pair and lead to the early damage.
Therefore, check the axial clearance of the cone bearing during technical maintenance. Make adjustment
accordingly as necessary.
(2) Severe wear of the matching surface of the bearing pedestal of the rear pivot bearing 2 and the rear axle
housing will result in the slope of the second shaft and damage the normal engagement of the gear pair and lead to
the early damage. Therefore, check the radial clearance of the bearing during technical maintenance, and repair or
exchange the bearing when achieves the repair size.

25
 Illustration 4 - 6 Center drive adjustment
1 – 2009 bearing; 2 – 271211 bearing;
A – The second shaft axial clearance adjusting shim; B - The second shaft mounting distance adjusting shim;
C – The mounting distance from the front face of the small cone gear to the center line of the rear axle shaft is
111.5 mm
6. Control mechanism
Adjustment requirements:

(1) The free stroke of the control lever is 20~42 mm;

(2) Full stroke is 170~195 mm.

Illustration 4–7 Control mechanism

1 – Main clutch pedal; 2 – Steering
pull arm;3 – Steering swing arm; 4 -
Adjustable rod; 5 – Lock tooth plate; 6
- Control mechanism support; 7 –
Lock shaft push rod; 8 – Steering pull
rod; 9 - Brake pull rod

26
7. Brake
Brake adjustment:
(1) Release the brake pedal to the top position;
(2) Adjust the rod length to make the brake lever arm to
lean backward of 8°.
(3) Screw the nut 7 exactly and release 6~7 circles, and
then lock;
(4) Tense the brake belt, block the brake pedal on the
locating detent, release the lock nut of the limit adjusting screw
of the brake belt, screw the adjusting screw exactly, release
1~1.5 circles, and then lock with lock nut.

Illustration 4-8 Brake

1 – Triangle plate; 2 – Brake belt lever; 3 – Brake lever;
4 - Brake lever support; 5 – Oil cup; 6 – Oil cup 90°;
7 – Nut; 8 – Sleeve; 9 - Hinge pin; 10 – Pull rod spring;
11 - Brake belt pull rod; 12 – Brake belt long pin;
13 - Brake belt assembly; 14 – Oil cup; 15 – Plug

8. Final driving gear

Operating requirements:
(1) Ensure the good lubrication of gears and bearings.
The upper limit level of the lubricating oil in the final driving
gear shall be at the top position of plug 6, and the lowest
position shall be at the axis position of driving shaft 5.
(2) Ensure the connecting bolt 7 of the driving wheel is
screwed reliably, and the tightening torque is 389~470 N·m.

Illustration 4-9 Final driving gear

1 - Driving wheel; 2 - Float sealing seat; 3 - Float sealing ring;
4 – bearing 46T30220j/6T; 5 – Driving shaft; 6 – Plug;
7 – Bolt; 8 – Driven gear; 9 – Bearing 42613E;
10 - Intermediate shaft gear; 11 – Housing; 12 – Bearing
42608E; 13 – Driving shaft gear; 14 – Bearing 42413;
15 – Driven hub wheel drum; 16 – Bearing 2612; 17 – Plug

27
III Driving system
1. Crawler walk structure

Illustration 4-10 Crawler walk structure

1 - Guide roller; 2 - Supporting wheel; 3 - Track supporting wheel;4 – Tensioning buffer device;
5 - Driving frame; 6 - Oscillating shaft; 7 - Driving wheel; 8 – Crawler;
9 - Equalizing beam and Rubber damping block; 10 – Sliding type guiding device

2. Guide roller
Adjustment requirements:
The clearance after assembling of the guide roller
shall be 0.5 ~ 1.0 mm and the clearance can be adjusted
by shim T1 and T2.

Illustration 4-11 Guide roller

1 - Guide roller axle; 2 - End floating oil seal;
3 - Bi-metallic sleeve sliding bearing; 4 - Guide roller;
5 – Support; 6 - Outer cover; 7 - Oil filler plug;
8 – Adjusting shim; 9 - Driving frame

28
3. Tensioning buffer device

Illustration 4-12 Tensioning buffer device

1. Tensioning oil cylinder assembly 2.Conduit 3. Spring rod 4. Tensioning spring 5. Spring rear support
6. Safety valve 7. Oil drain plug 8. Oil feeding valve

4. Floating oil seal

Floating oil seal is adopted in the supporting wheel, track supporting wheel, guide roller and working device,
and is composed of a pair of float sealing ring casted with special alloy and two special O-rubber seal rings.
Pairs stored and assembled after disassembly to ensure the good seal of the oil seal, and the end surface of
the float sealing ring shall be kept clean to prevent oil leakage after assembly.

Illustration 4-13 Floating oil seal

1 - Fixed seat; 2 - O-seal ring;3 - Float sealing ring; 4 - Oil seal seat

29
5. Combined-type crawler
Adjust the tension of the crawlers on both sides,
check for the loosening of creeper tread bolt and
tighten it timely before working. Clean the broken
stones at the track link and other places to prevent body
injury and parts broken caused by the broken stones
pressed and hit by the crawler.

Notes: every crawler is equipped with a lock track

Illustration 4-15 Combined-type crawler
1 - Creeper tread; 2 - Pin bush; 3 – Lock pin bush;
4 - Lock pin spacer bush; 5 – Right track link; 6 –
Left track link; 7 – Lock track pin; 8 – Lock pin
adapter sleeve; 9 - Track pin; 10 - Creeper tread
bolt
pin (movable pin) that can be easily disassembled, and
the match of the pin and the track link is loose to
perform disassembly.
Measurement of crawler tension: stop the
bulldozer on flat ground, put a straight wood with
length of 1.5 m on the guide roller and track supporting
wheel, and the clearance between straight wood and
crawler shall be 4~5 cm.

IV Working device and hydraulic system

1. Bulldozing device
Note: when the main blade of the bulldozer is seriously worn, release the nut on the fixed bolt of main blade,
remove the main blade, turn around the top and the bottom of the blade and fasten it to further use. Replace new
blade when the angle blades on both sides are seriously worn.

Illustration 4-15 Bulldozing device

1 – Blade; 2 - Fixed bolt of blade; 3 – Welding parts of scraper knife plate; 4 - Welding parts of diagonal rod;
5 - Adjusting screw rod assembly; 6 - Scraper knife arm; 7 - Scraper knife connector

30
2. Ripper
Notes: raise the ripper on top when
the steering of the bulldozer and the ripper
do not work to prevent the broken of
loosening tooth during the travel of the
bulldozer.
Beat out the tooth sharp pin shaft and
replace with new loosening tooth sharp
when the tooth sharp is seriously worn.

Illustration 4-16 Ripper

1 – Support; 2 – Lower connecting rod;
3 – Upper connecting rod; 4 –
Loosening tooth sharp; 5 - Tooth sharp
pin shaft; 6 - Loosening tooth; 7 - Pin
shaft; 8 – Beam; 9 - Oil cylinder

3. Traction equipment
Notes: lock the cotter pin after connecting the traction
machine.
Deploy the machine excess load is forbidden for the
possibilities of damaging traction equipment and accidents.

Illustration 4-17 Traction equipment

1 - Welding parts of traction plate; 2 – Traction pin assembly;
3 - Cotter pin

31
4. Oil line of hydraulic system

Lift Descend
Lift keeping
Descend

Lift keeping Lift Descend

Descend Floating

Illustration 4-21 Oil line of hydraulic system

Hydraulic system schematic diagram of working device

1. Oil tank 2. Filter 3. Oil pump 4. Safety valve 5. One-way valve 6. Control valve of push plate

7. One-way oil compensating valve 8. One-way oil compensating valve 9. Control valve of ripper 10. Overload valve

11. Overload valve 12. Quick-change connector 13. Oil cylinder of ripper 14. Oil cylinder of push plate

32
 Chapter V Parking & Storage
I Preparations for Parking & Storage

The bulldozer should be well prepared for a long-time storage after earthwork operation is completed.

1. Park the bulldozer in a hanger or shed, and/or in the open air if no hanger or shed is available. The
bulldozer must be parked on a high-altitude and dry stand and covered with rain-proof cloth.

2. Separate the hanger and shed or where the bulldozer parked unsheltered a certain space off other
buildings or structures, and set up fire fighting equipments around.

3. Clean the bulldozer completely and conduct technical maintenance applicable for technical
conditions of the bulldozer. Apply lubricant to those surfaces without anti-rust coat to prevent rusting. Touch up
where paint is removed.
4. Parts and attachment tools removed from the bulldozer should be covered and stored in dry places
after being cleaned up.

33
II Parking & Storage of Bulldozer in Hanger
1. Drain the water out of cooling system and the lubricant out of lubricating system, air filter, and speed
regulator of fuel injection pump, transmission system, and running system. While draining the diesel out of the
diesel tank, drain the oil out of the hydraulic system.
2. While stored in a rainy season or damp area, start up the bulldozer and move forward, move to left,
and move to right each for 5 to 10 times as well as move backward, move to left, and move to right each for 5
to 10 times with the gear I, gear II and reverse gear engaged respectively every 40-60 days, to prevent the
clutch disc bonding.
3. Loosen the track and inject lubricating grease into each lubrication point. Plug up the openings in
exhaust pipe and muffler with a wooden plug.
4. If the storage period exceeds one month, rotate the diesel engine crankshaft for several cycles every
12 to 15 days, and inject enough lubricant for lubricating the diesel engine into each cylinder to prevent
cylinder rusting.
5. Clean and wrap the oil sprayer after it being removed, and mark cylinder number for storage. Inject
enough lubricant for lubricating the diesel engine into each cylinder through oil spay hole, rotate for several
cycles, and plug up the oil spray hoe with a wooden plug to prevent dust and damp air from entering into the
cylinder.

To move forward, move backward,

move to left, and move to right each for
5 to 10 times with the gear I and gear II
engaged respectively every 40 to 60
days

Backward Forward

To left To right

III Parking & storage in the open air

The rules below should be followed in addition to those in Chapter II:
1. The stand for parking the bulldozer should be located where rain water and slush are easy to drain off
and arrange drainage ditch around. Loosen off the two water drain plugs at the bottom of warm air blower for
storage in winter, and place the plugs in the tool kit. The two water drain plugs are only fitted on when next
startup to prevent the warm air blower from frost cracking caused by icy water; meanwhile to the best
advantage, hang tag posted “water drain plug removed” after water being drained off the radiator of the warm
air blower.
2. Remove M10×25 fastening bolts (one for left side and one for right side) on brake band stopper for
storage. The bolts are fitted on when next operation.
3. While stored in a rainy period or damp area, start up the bulldozer and move forward, move to left,
and move to right each for 5 to 10 times as well as move backward, move to left, and move to right each for 5
to 10 times with the gear I, gear II and reverse gear engaged respectively every 15-20 days, to prevent the
clutch disc bonding.

34
 Water drained off Water drain
radiator of warm air plug removed
blower

4. Drop down the bulldozer blade and ripper, padded with square lumber (or bricks).
5. The bulldozer should be well covered with rain-proof cloth. Pay close attention that the generator,
starter, adjuster and other electrical elements be unaffected with damp.

35
 Chapter VI Major Faults & Troubleshooting

I Common faults & troubleshooting

1. Diesel engine difficult to start up

Symptoms & Causes Troubleshooting

1. Start motor fails to drive the diesel engine 1.
(1) Battery under voltage, or circuits in loose contact (1) Recharge the Battery, or eliminate loose contact
(2) Start motor gear not engaged with flywheel gear rim (2) Find out causes and eliminate
2. Supply system disabled 2.
(1) Air entering into fuel system (1) Remove air/water out of and fill oil into fuel system
(2) Fuel system blocked (2) Unclog where blocked
(3) Oil sprayer system blocked (3) Inspect oil atomization of oil sprayer, clean and verify
(4) Incorrect oil supply advance angle (4) Adjust oil supply advance angle
(5) Air filter blocked (5) Clean air filter
3. Insufficient compression pressure 3.
(1) Piston ring damaged, cylinder liner worn out (1) Replace piston ring, cylinder liner
(2) Valve leakage (2) Inspect and grind valve
(3) Low final compression temperature (3) Heating

2 Diesel engine not in normal operation

Symptoms & Causes Troubleshooting
1. Air or water entering into fuel system 1. Remove air and inspect water content in diesel
2. Valve spring broken off, or valve clearance misadjusted 2. Inspect valve spring, or readjust valve clearance
3. speed regulator misadjusted or uneven fuel supply of each
cylinder of injection pump 3. Inspect and readjust speed regulator, adjust fuel supply of
4. Cylinder blow-by each cylinder
4. Replace cylinder head shim

3. Diesel engine under power

Symptoms & Causes Troubleshooting
1. Insufficient voltage in cylinder 1.
(1) Valve spring broken off (1) Replace valve spring
(2) Small or no valve clearance (2) Adjust valve clearance
(3) Unsealed valve to leak (3) Grind valve
(4) Piston ring carbonization, or worn out (4) Remove carbon, or replace piston ring
2. Fuel system not in normal operation 2.
(1) Incorrect oil supply advance angle (1) Readjust oil supply advance angle
(2) Oil pump plunger worn out (2) Replace oil pump plunger
(3) Poor oil atomization of fuel injection pump (3) Inspect oil atomization of fuel injection pump, clean or
replace matching parts
(4) Fuel system under supply (4) Inspect whether fuel system blocked or not
3. Filthy air filter 3. Clean or replace air filter element

4. Abnormal noise during operation

Symptoms & Causes Troubleshooting

1. Rash oil supply 1. Inspect and adjust oil supply advance angle
2. Large valve clearance between piston and cylinder liner 2. Replace piston or cylinder liner

36
 Symptoms & Causes Troubleshooting
3. Large clearance between piston pin and bushing to small
end of connecting rod 3. Replace bushing to small end of connecting rod
4. Large valve clearance 4. Adjust valve clearance
5. Large clearance of connecting rod bushing or main 5. Replace connecting rod bushing or main bearing bushing
bearing bushing

5. Abnormal smoke discharge

Symptoms & Causes Troubleshooting
1. Discharging black smoke 1.
(1) Diesel engine overload (1) Reduce load
(2) Poor oil atomization of oil sprayer (2) Clean or replace matching parts of needle valve
(3) Late oil supply (3) Inspect and adjust oil supply advance angle
2. Discharging white smoke 2.
(1) Low temperature of cooling water in diesel engine, water (1) Heat the cooling water, inspect and remove water out of
entering into cylinder cylinder
(2) Late oil supply, poor oil atomization of oil sprayer with (2) Adjust oil supply advance angle, adjust oil spray pressure,
leakage and inspect sealing performance of matching parts of
needle valve
3. Discharging blue smoke 3.
Oil blow-by, piston ring backward fitted, or worn out Refit or replace piston ring

6. Insufficient diesel engine oil pressure

Symptoms & Causes Troubleshooting

1. Oil pressure gauge or sensor damaged, or wires therein 1. Replace pressure gauge or sensor, and inspect circuits
broken 2. Add oil to specified oil level
2. Insufficient oil in oil pan 3. Clean strainer, adjust or replace pressure regulating valve
3. Oil strainer or filter blocked, or pressure regulating valve
on filter offset 4. Adjust or replace pressure regulating valve
4. Main oil distributing passage on cylinder block disabled 5. Replace bearing
5. Large clearance in connecting rod bearing, crankshaft
bearing, camshaft bearing, etc. 6. Inspect and eliminate trouble
6. Oil pump badly worn out, or trouble occurs inside

7. High cooling water temperature

Symptoms & Causes Troubleshooting

1. Water temperature gage or water temperature sensor 1. Inspect and replace parts
damaged, or wires therein broken
2. Insufficient coolant capacity, fan belt loosened 2. Fill up with water, adjust fan belt tension
3. Thermostat disabled 3. Replace thermostat
4. Much filth accumulated inside cylinder head or water 4. Remove filth and clean cooling system
jacket of cylinder block
5. Water blocking ring on cylinder head damaged, water 5. Replace water blocking ring, or repair where leakage
shortage caused by leakage in cooling water circuit occurs

8. Sudden automatic shutdown

Symptoms & Causes Troubleshooting

1. Crankshaft wouldn’t turn over after stopping 1.
(1) Crankshaft locked with shaft bushing (1) Inspect crankshaft and shaft bushing, repair or replace
crankshaft and shaft bushing
(2) Piston locked with cylinder bushing (2) Replace piston and cylinder bushing
2. Crankshaft remains rotating after stopping 2.

37
 Symptoms & Causes Troubleshooting
(1) Air entering into fuel system, or no fuel oil in fuel system (1) Remove air and fill up with fuel oil
(2) Fuel system blocked (2) Clean fuel system
(3) Air filter blocked (3) Clean or replace air filter element

9. Racing

Symptoms & Causes Troubleshooting

1. Speed regulator of fuel injection pump disabled 1. Eliminate troubles, or replace speed regulator
2. Oil supply rod of fuel injection pump jammed in 2. Inspect and eliminate trouble
maximum oil supply position, not returned
3. Oil entering into air intake pipe due to light oil’s 3. Change oil as required, or drain out unwanted oil, and
wrongly-used in oil container, or high oil surface by using clean air intake pipe
oil bath air filter

10. Insufficient oil supply in fuel injection pump

Symptoms & Causes Troubleshooting
1. Diesel filter (for coarse or refined filtration) blocked 1. Clean or replace thick or thin filter
2. Dirty diesel, oil circuit blocked 2. Filter diesel, clean oil circuit as required
3. Inappropriate diesel (specified oil not used) 3. Use clear specified diesel
4. Air entering into oil circuit 4. Remove air (gas)
5. Matching parts of plunger worn out 5. Inspect or replace matching parts of plunger

11. Diesel leakage in fuel injection pump

Symptoms & Causes Troubleshooting
1. Seal gasket to plunger bushing crushing, or gasket 1. Replace seal gasket, and reassemble
damaged 2. Strictly inspect and determine scratching, and replace lid if
2. Filing plane on fuel injection pump lid scratching scratching is not recovered
3. Replace matching parts of plunger
3. Matching parts of plunger badly damaged 4. Replace seal ring or oil transfer pump
4. Uptight sealing among oil transfer pump pushrod, roller
and housing

12. Injector nozzle locked

Symptoms & Causes Troubleshooting

1. Dirty diesel 1. Filter or change diesel
2. Carbonization due to incomplete burning of diesel 2. Remove carbon and clean, or replace matching parts of
injector
3. Long idle operation 3. No idle breaking-in or idle operation

38
II Main faults & troubleshooting of chassis
1. Clutch fault
Failure symptoms Causes analysis
1. Main clutch (1) Frication plate sticks with oil (lubricating
slipping grease overflows, crankshaft rear oil seal
leaks)
(2) Annealing pressure of the belleville spring is
low or the spring has cracks
(3) Clutch levers adjusted are not inconsistent and
no clearance is between clutch lever and clutch
release shaft; it is worn or has no free stroke.
(4) Cover deforms or is serious worn
(5) Friction plate is broken, worn or burnt
Troubleshooting
(1) Check the oil stain source, and Eliminate
the failure, then clean friction plate with
gasoline
(2) Replace belleville spring
(3) Adjust clearance between clutch lever and
clutch release shaft, make sure that heads
of 3 clutch lever in the same plane, with
tolerance less than 0.2 mm. Free stroke is
2.5~3 mm
(4) Repair or replace with new parts
(5) Replace with new friction plate or driven
disc assembly

2. Clutch is pressed to (1) Small brake is adjusted improperly (1) Adjust it as required
the bottom, but it (2) Small brake linings are seriously worn or (2) Replace the brake linings timely
still cannot be damaged
disengaged, and (3) Clearance between clutch lever and clutch (3) Readjust as required
universal joint release shaft, is too large or heads of 3 clutch
continues operates lever in the same plane
(4) Release spring is out of work (4) Replace the release spring
(5) Total stroke of pedal and free stroke are too (5) Adjust the pedal stroke and free stroke
large
(6) Cover of driven disc bends and deforms (6) Repair or replace

2. Gearbox fault

Failure symptoms Causes analysis Troubleshooting

(1) Locking device is adjusted improperly (1) Remove the cotter pin from the locking
pin, adjust the length of the push rod, and
make sure the gears changeable when the
cultch pedal are pressed to the bottom
1. Difficult to put into (2) Small brake linings are seriously worn or (2) Replace small brake
gears damaged
(3) Tooth end is worn and rough (3) Grind tooth end in round shape,. Replace
it if necessary
(4) Main clutch is not completely disengaged (4) Adjust the clearance between clutch lever
and clutch release shaft as required
(1) Tooth of spline shaft are worn and steps (1) Expand the steps. Replace the related
2. Difficult to put off appear parts when they are seriously worn
gears
(2) The same as the above item (2) (2) The same as the above item (2)
Bearing is damaged or the bearing outer ring Immediately stop and check in case of
loosen the bush rings, the front locking nut of shaft abnormal noise found. Eliminate, it, repair or
3. Abnormal gearbox
II loosens, gears are broken replace with new parts according to the
noise
inspection result. Tighten the locking nut as
required
(1) Lubricating oil is deteriorated or insufficient (1) Filled enough oil as required or drain the
4. Hot gearbox old oil, clean up the inner cavity, replace
housing with new oil
(2) Bearing parts of the gear box is damaged (2) Scatter and check, solve the fault

39
 3. Rear axle fault

Failure symptoms Cause analysis Troubleshooting

1. Overheat of rear (1) Improper clearance between bearings or (1) Set it to normal value specified according to
axle housing gears “adjustment of central transmission” or replace
the bearing.
(2) Lack of lubricating oil (2) Add lubricating oil to specified level
(3) Deterioration of lubricating oil (3) Drain original oil. Clean cavity of rear axle
housing with diesel or kerosene and then add
qualified gear oil
(4) Slipping of steering clutch (4) Find causes of steering clutch slipping and
eliminate them
2. Abnormal noise of (1) Gear pair do not conform to (1) Readjust gear pair according to provisions. If
central requirements bearings are seriously worn, replace it.
transmission (2) Clamping bolts of large conical gear (2) Adjust the fastening and locking nuts in
become loose and front end of the 2nd above-mentioned adjustment methods.
shaft is locked.
3. Malfunction of (1) Driving disc bends (1) Level it or replace the driving disc.
steering clutch ( it (2) Driven disc runs out of driven drum (2) Decompose and find the causes and eliminate
can not steer) them.
(3) Free stroke is adjusted improperly. (3) Adjust the free stroke to standard one.
(4) Booster leaks oil or is damaged (4) Replace oil seal or booster.
(5) Friction plate is damaged (broken) and (5) Decompose and replace the damaged driven disc
blocked between driving disc and driven
disc.
(6) 46215 bearing is broken (6) Find causes and replace 46215 bearing.
4. Steering clutch (1) Oil enters in steering clutch (1) Clean with kerosene and eliminate oil leakage
slipping (2) Friction plate is seriously worn or (2) Replace friction plate and readjust stroke of
damaged operating lever (free stroke)
(3) Annealing and deformation of small and (3) Replace springs.
large springs of steering clutch
5. Bulldozer cannot
Brake linings stick to oil, wear is too serious Clean with gasoline respectively, replace brake linings
conduct spot
or clearance is too large. or readjust clearances according to requirements.
steering
6. Steering handle (1) Frequently, it is caused by leaving thrust (1) Reinstall thrust collars as required
cannot be pulled collars uninstalled.
to the rearmost (2) Circlip is not in the slot
position (2) Reinstall as required
(3) Size of driving and driven disc assembly (3) Measure size and replace with qualified driven
exceeds 1050+0.3 mm disc.
(4) 46215 bearing is installed reversely (4) Notice the direction during assembly and correct it.
(5) Cover nuts are not tightened completely. (5) Tighten the cover nuts completely
(6) Locking ring is not in the slot of cover (6) After assembly drilling, install them in nut slots
nuts
(7) Booster stroke is too small (7) Adjust booster stroke (adjust with pull rod and do
not parts in booster)
7. Bulldozer pulls to (1) Free stokes of left and right steering (1) Adjust free stroke of steering clutches to keep
one side. (run with clutches are inconsistent so that one them consistent as much as possible.
large radius) clutch is in semi-engaged status.
(2) Steering clutch leaks oil at final (2) Decompose and eliminate leakage and clean
transmission driving shaft and slips driving disc and driven disc.
(3) Tightness of tracks at both sides is (3) Adjust tracks to keep their tightness consistent.
inconsistent ( large difference)

40
 4. Fault of final transmission device
Failure symptoms Cause analysis Troubleshooting
1. Final transmission (1) Loose connection (1) Tighten the bolts
leakage (2) Seals are worn or damaged (2) Replace seals or apply sealants.
(1) Gear oil is not enough or lubricating oil (1) Add gear oil or drain original oil. Clean housing
2. Housing
deteriorates and add new oil
temperature rises
(2) Bearings are damaged or clearance is (2) Replace bearings or parts
(about 90℃)
too large, or parts are damaged.
(1) Bulldozer suffers from impact of large (1) Pay attention to right use and operation
load and tooth breaks
(2) Bearings are damaged and gear run-out (2) Replace damaged bearings (find causes)
3. Tooth tearing
is large.
(3) Teeth contact of gear is bad and foreign (3) Replace or eliminate
matter gets stuck between gears.

5. Hydraulic hitch system

Failure symptoms Cause analysis Troubleshooting

1. Oil tank has foams (1) Too much oil is in the oil tank (1) Drain excessive oil
and the foams (2) Air enters in oil line (2) Check leaks and eliminate them
overflow from tank
cover (3) Vent in the tank cover is blocked (3) Clean tank cover and fill it.

(1) Oil seals of shaft frame of gear oil pump is (1) Replace oil seals
2. Oil consumption damaged (2) Check leaks and eliminate them
increases (2) Line connection leaks, or the seals are
damaged
(1) Oil in the oil tank is insufficient (1) Add oil to specified level
(2) Operating lever keeps in “ lifting ” or (2) Put operating lever to “neutral” position or
3. Oil temperature rises “lowering” position “floating” position, and put the ripper
too rapid handle in “neutral” position
(3) Filter of oil tank or oil lines are blocked (3) Clean strainer, oil tank and lines. Replace
partly and oil is too dirty oil.

(1) Oil temperature is too low (less than 30℃) (1) Keep oil temperature between 40℃ and
4. Handle of multi-port or too high (over 80℃) 70℃.
valve cannot locate. (2) Slide valve spring of multi-port valve is (2) Replace slide valve spring
broken.
(1) Oil temperature is too low (less than 30℃) (1) Keep oil temperature between 40℃ and
5. Operating lever of or too high (over 80℃) 70℃.
multi-port valve is in (2) Clean, or replace damaged parts
(2) Fuel return valve and puppet valve of
“lifting” position and if necessary
multi-port valve are worn and blocked
cannot return
(3) Opening pressure of relief valve is lower (3) Adjust pressure of relief valve to be 12.75
automatically or
than automatic return pressure Mpa
immediately return
to “neutral” position (4) Pressure of gear oil pump is too low, seal (4) Repair or replace worn parts, or replace
and cannot locate. rings are damaged, or parts of gear oil pump with new gear oil pump
are seriously damaged

41
 Failure symptoms Cause analysis Troubleshooting
(1) Oil tank is lack of oil (1) Inject oil to specified level
(2) Combination lever of gear oil pump is not in (2) Put combination lever to correct position
combination position
(3) Oil temperature is over low (30℃) or over (3) Operate when oil temperature be normal
high (80℃)
(4) Oil line is with air (4) Inspect and troubleshooting
(5) Oil in tank is dirty, filter clogged, oil line (5) Clean oil tank filter and oil line, replace oil
partially blocked
(6) Gear oil pump worn out, with low pressure (6) Repair the worn parts or replace gear oil
pump
6. Ripper dose not lift
or lift slowly (7) Multi-way valve and oil return valve (7) Knock the oil return valve cap slightly with
blocked a wooden hammer or clean the oil return
valve
(8) Multi-way valve, safety valve leaked by oil (8) Inspect and regulate the safety valve
or start pressure is over low
(9) Side valve’s automatic return pressure over (9) Inspect and regulate pressure
low
(10) Compression nut of oil cylinder piston (10) Tighten the tension nut and replace sealing
looses or piston sealing ring damaged ring
(11) Resistance when the ripper lifts out from (11) Bulldozer is driven backwards slightly to
earth is over large reduce resistance
(1) Oil tank is lack of oil (1) Inject oil to specified level
7. Ripper vibrates (2) Oil temperature is over high (80℃) (2) Operate when oil temperature be normal
during lifting and (3) Oil line is with air (3) Check and tighten the connections, vent
lowering down out air
(4) Oil seal of gear oil pump frame damaged (4) Replace oil seal on frame
(1) Oil temperature is over high (80℃) (1) Inject oil to specified level
8. Ripper can not
(2) Seal ring of oil cylinder piston damaged (2) Replace sealing ring
maintain at “lift”
position (3) Multi-way valve and slide valve worn out (3) Replace or repair the parts which are worn
seriously

6. Common failure of driving system

Failure symptoms Causes analysis Troubleshooting
1. Float seal of track (1) Float seal ring broken and not installed in pair (1) Replace
roller, carrier roller (2) O ring twisted, weathered or damaged (2) Replace
and guide roller are (3) Bearing worn out (3) Replace
leaked with oil (4) Oil filler plug on axle end leaked (4) Replace
(1) L/R oscillating axle bent, support oscillating axle hole (1) Repair or replace
worn out (2) Rectify shape and repair
(2) Driving frame distort (3) Repair, replace and adjust
(3) Track link, pin push worn out and track is over (4) Repair or replace
2. Track link failure tensioned
(5) Remove the cap and tighten the bolt
(4) Guide roller, shaft housing. Support worn out or distort
(6) Align
(5) Bolt inside oscillating axle end cap looses
(6) Centers of the three rollers are not in alignment
(1) Joint faces of oil injection valve, discharge valve, (1) Repair or replace
3. Tensioning device safety valve are not sealed or oil circuit is blocked (2) Replace
can not be
(2) Oil cylinder seal ring failure (3) Tighten and adjust
regulated
(3) Fixing bolt looses, relative action is pigheaded
(1) Track tension is over loose (1) Tighten
(2) Inner and outer rims of the three rollers are seriously (2) Repair or replace
4. Track derails
worn out (3) Adjust, repair and align
(3) Centers of the three rollers are not in alignment

42
III Common faults & troubleshooting of electrical system
Failure symptoms Causes analysis Troubleshooting

(1) Battery is dead (1) Charge or replace battery to the

specification
(2) Clean out dirt or oxides
(2) Battery poles is dirty or oxidized
1. Start motor dose not (3) Tighten connector
(3) Cable connector looses, earth cable oxidized
work
(4) Check about circuit
(4) Control circuit for electrical switch etc. break
(5) Replace starter relay
(5) Starter relay damaged
(6) Replace or repair start motor
(6) Short or break circuit inside start motor

(1) Battery is off capacity (1) Charge the battery

(2) Cable wiring contact looses; wiring of start (2) Clean out oxides and tighten the nut
motor is loose or rusted
2. Start motor (3) Commutator surface burnt or with oil spot (3) Grind commutator surface and clean out oil
powerlessly started, spot
can not start the
engine (4) Carbon brush worn out or carbon brush spring (4) Replace and adjust
looses pressure
(5) Main contact of magnetic switch burnt (5) Repair and grind
(6) Short armature wire circuit (6) Repair the failure position

3. Starting motor
continuously
(1) Main contact of magnetic switch is deadly (1) Inspect main contact within the switch,
operate after
bonded smooth and grind the bur on contact surface
releasing the
starting switch

(1) Wrong or break circuit connection, loose (1) Repair circuit

contact
4. Generator dose not (2) Rotor circuit breaks
(2) Repair or replace generator assembly
produce electricity
(3) Commutating diode broken
(3) Replace diode
(4) Regulator broken
(4) Replace regulator

(1) V-belt looses (1) Regulate and tighten the V-belt to the
regulations
5. Charging current (2) Carbon brush contact looses, side ring is with (2) Regulate and clean
for generator is oil spot, insufficient spring pressure
unstable (3) Regulator broken (3) Replace regulator
(4) Battery electrolyte is less or sulfurized (4) Makeup electrolyte or replace battery
seriously

6. Charging current
for generator is over (1) Regulator broken (1) Replace regulator
large

7. Battery is off (1) Plate electrode sulfurized (electrolyte in low (1) Regulate the electrolyte to requirements
capacity and level and incorrect proportion)
difficult to start (2) Wire is loose contacted, or oxidized (2) Tighten the connection and clean out the
diesel engine oxides

43
 Failure symptoms Causes analysis Troubleshooting

(1) Electrolyte contains impurities (1) Inject the electrolyte made by chemical
pure sulfuric acid and distilled water, add
distilled water during using
(2) Wire circuit outside battery is short (2) Inspect for short circuit and trouble
shooting
8. Overlarge self (3) Battery surface is overflowed with electrolyte
discharge or mineral or other substances, allowing the (3) Wipe and clean with or warm water (Note:
positive/negative poles shot out water is not allowed to be leaked into
battery)
(4) Electro-active substance on plate electrode
breaks off allowing the plate short out;
separator warpage makes the positive/negative (4) Replace battery or sent to maintenance
short out. department for maintenance

(1) Connection time from battery to start motor is (1) Connection time is no more than 10 s.
9. Electro-active over long
breaks off seriously, (2) Charging current is over large or charging time (2) Strictly apply the additional charging
electrolyte contains is over long, allowing the plate electrode regulations
brown substance warped
during charging, (3) Add electrolyte with specified weight
battery is off (3) Electrolyte is over weight (4) Tighten fixing bolt of battery
capacity (4) Battery is looses and plate electrode is vibrated
seriously

(1) Orifice blocked, air produced during charging (1) Inspect the orifice and keeps the orifice
can not discharged, inner pressure of battery unobstructed
rises
(2) Check out reasons and troubleshooting
10. Battery shell (2) Battery rapidly discharged, electrolyte
cracked temperature greatly rises, electrolyte and air
(3) Fix the battery solidly
rapidly expanded
(3) Battery looses, and vibrates seriously during
bulldozer driving

(1) Bulb burnt, in poor quality (1) Replace bulb in good quality
11. Lighting lamp dose (2) Fuse burns out (2) Replace fuse
not work (3) Earth cable of lamp fails in contact (3) Clean out the oxides on earth cable
(4) Light switch (4) Replace light switch

12. Instrumentation (1) Instrumentation damaged (1) Replace instrumentation

indication incorrect (2) Sensor damaged (2) Replace sensor

(1) Fuse burns out (1) Replace fuse

13. Entire bulldozer is (2) Earth cable of battery fails in contact (2) Clean out the oxides on earth cable of
out of power batter

(3) Power cable is wrongly connected (3) Connect cable correctly

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 VI Electrical System Diagram of Bulldozer
S/N Code Item Qty
1 6-QW-120T Battery 2
2 JK861 Main power switch 1
3 JF2521A AC generator (28V, 25A) 1
4 WD-3/8M Water temperature sensor (NPT3/8) 1
5 QDJ27H Start motor (24V, 5.5 KW) 1
6 WD140X90T-2 Front lamp (R2, 24V, 50/56W) 2
7 7D2230BA-1 Wiper 2
8 JFT2431 Eletronic regulator 1
9 JN3A-24V Starter relay 1
10 LHT-8A Eletronic monitor of bulldozer 1
11 YL-1/8M10 Oil pressure sensor (NPT1/4) 1
12 61200190040 Air filter clog warning sensor 1
13 BX508 Fuse box 1
14 DFN-3502 Warm air blower 1
15 JK932-002 Warm air blower switch 1
16 JK932-087A Working light switch 1
17 JK932-021 Light switch of F lamp 1
18 JK932-087 Main light switch 1
19 JK423K Ignition start switch 1
20 DZW-2 Rear working lamp 2
21 Roof lamp 1
22 Fan 1

Wire Color Code

Wire color Red Yellow Green Blue White Orange Purple Stone Brown Black
Code R Y G U W O P S N B

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